Corrugated paperboard, also known as corrugated fiberboard or corrugated cardboard, is a packaging material made of flat outer layers and a fluted inner layer. The terms differ slightly based on the materials used—paper or fibers—offering structural strength and durability.
“Cardboard” is a broad term covering various heavy paperboards, including corrugated fiberboard, which features a fluted layer between flat layers, created through the corrugating process. Its rigidity and strength make it ideal for shipping, retail, and storage applications.
The thickness of corrugated material generally depends on two of its components, which are flutes and liners.
Fluting types measure the board callipers (thickness in inches) Each category has its own thickness and different sizing of the flutes in terms of height and frequency (the distance between the waves) of the flutes.
The A-flute design is widely valued for its excellent cushioning and stackability. Featuring approximately 36 flutes per foot and a ¼-inch height, it offers robust strength, making it a top choice for packaging and shipping fragile items.
Type B flute offers distinct advantages, including superior crush and dent resistance, enhanced protection, and suitability as a partition for heavier loads. With a ⅛-inch height and approximately 49 flutes per foot, it provides greater packaging stability compared to A flute.
C-flute, with a thickness of 11/64 inches and approximately 39 flutes per foot, is an excellent choice for packaging and shipping. Its durability withstands handling and transportation rigors, offering high compression and crush resistance while providing an ideal surface for printing and labeling.
E-flute offers excellent crush and bending resistance, enhancing efficiency. Its nearly flat surface ensures smooth, high-quality printing, while its thin, lightweight structure saves space. With a thickness over 1/16 inch and approximately 90 flutes per foot, it’s a preferred alternative to traditional paperboards for packaging delicate items like ceramics, cosmetics, and glassware.
F-flute, designed for retail consumer goods, is the thinnest flute type at 1/32 inch with approximately 125 flutes per foot, offering enhanced rigidity. Using less fiber, it’s ideal for point-of-purchase displays, jewelry, cosmetics, shoe boxes, and food clamshell containers.
Each flute type boasts excellent compression, strong stacking ability, robust crush resistance, and high flexural rigidity.
It is not only the flutes that matter but also the exterior layer, known as “flat liner boards,” which prides itself on the strength and durability of the corrugated board. These liners come in various forms, which are:
1- Kraft liners that are subcategorized based on color and their contents.
2- Test liners
3- Chip liners
This wall type consists of three layers bonded between four layers of linerboard. Its robust structure ensures high compression resistance and excellent stacking stability.
Kraft paper rolls are typically processed through corrugators to create the characteristic zigzag pattern of flutes. These flutes are then bonded with layers of linerboard using adhesive to form corrugated boards of varying calipers. The addition of each flute and linerboard layer results in distinct types of corrugated boards, such as single-face, single-wall, double-wall, and triple-wall, each offering unique strength, cushioning, and stacking properties suited for diverse packaging needs.
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