This article is an in-depth guide to how cardboard boxes are made.
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A cardboard box is a container designed for shipping, crafted from layers of thick paper exceeding 0.01 inch (0.25 mm) in thickness. The term "cardboard" extends to describe various types of sturdy paper products used to manufacture boxes. This category includes diverse forms like corrugated and chipboard boxes.
Cardboard containers take on various shapes and sizes, created by stylishly folding, cutting, and shaping sturdy layered paper sheets.
Part of the recycling industry, chipboard boxes are formed from recycled cardboard, paper remnants, and sawdust into strong panels. Although they resemble cardboard, chipboard is made from recycled content compressed and adhered to form dense sheets.
Engineered for strength and protection, cardboard boxes are lightweight yet durable enough to securely house items. They are perfect for storing and transporting goods such as clothing and toys, as their solid sides offer effective impact resistance.
Cardboard sheets are also applied as separators or cushioning within larger, sturdier containers.
Cardboard boxes are popular due to their recyclability, making them a cost-effective option compared to other types of containers. The layers of paper in cardboard can be shredded, treated, and transformed into new rolls for producing recycled paper or chipboard.
About 90% of all products are shipped using cardboard boxes, with over 88% being manufactured from recycled materials. Creating new cardboard boxes from raw materials requires substantial energy and numerous trees. Conversely, using recycled materials for cardboard box production substantially cuts down on energy usage and keeps these materials out of landfills, reducing the risk of harmful toxin release.
Cardboard boxes are essential packaging solutions used across a multitude of industries including retail, shipping, e-commerce, and food & beverage. These boxes come in a vast array of shapes, sizes, and structural designs to accommodate varying product dimensions and protective needs. Most commonly, cardboard boxes are manufactured from either corrugated cardboard or paperboard made from recycled paper or virgin tree pulp. This eco-friendly manufacturing helps reduce environmental impact while maintaining the performance and strength that cardboard packaging is known for. The resulting board is created by layering, treating, and pressing pulp to develop a robust, high-quality packaging material.
The process of manufacturing cardboard boxes begins with resilient paper grades sourced from tree fibers, such as hardwood or softwood varieties. Through a series of intensive treatments, these raw fibers are converted into the tough and flexible starting material required for box production. The chosen material affects key properties like burst strength, crush resistance, and recyclability, which are critical for modern packaging requirements.
Pulping is the foundational step in producing paper for both corrugated cardboard and paperboard. In this process, raw materials such as wood chips or recycled paper are broken down into cellulose fibers—collectively referred to as paper pulp. The main objective is to remove lignin and impurities while preserving the integrity of the cellulose fibers, ensuring the desired balance of flexibility and strength for packaging applications. The pulping stage can utilize chemical, mechanical, or biological methods, each requiring significant water usage—averaging about 26.4 gallons (100 liters) per kilogram of paper produced.
Mechanical pulping mechanically separates cellulose fibers using stone grinders and water. This method delivers a high pulp yield and minimal environmental impact, but results in lower long-term fiber strength, making it less optimal for heavy-duty corrugated box manufacturing.
Chemical pulping combines heat, pressure, and chemicals to dissolve lignin and separate the wood fibers, creating higher-quality paper with excellent durability and resistance properties, often used for premium cartons and corrugated liners.
After pulping, the raw pulp may appear dark due to residual lignin. To produce high-quality white or light paperboard, the pulp undergoes a bleaching process. Dependent on the desired brightness and whiteness, manufacturers use delignification, oxidation, and reduction techniques to achieve uniform color and remove impurities, ensuring the finished packaging is suitable for printing and complies with industry food safety requirements.
Once cleaned and refined, the fibers are further processed—flattened and fibrillated—to enhance inter-fiber bonding and board strength. Fillers such as clay and calcium carbonate are often added to increase opacity and printability. The mixture is now ready to be formed into paperboard using highly specialized paper machines.
The paper machine utilizes wire meshes and felt belts to dewater and dry the pulp. As the pulp flows through shaping, pressing, and heated drying cylinders, any remaining moisture is removed, producing strong, supple sheets ready to be wound onto large mother rolls for further processing and conversion into packaging.
Paperboard is constructed by uniformly layering pulp onto a wire mesh or screen, where it forms a fibrous mat. This multi-layering process increases paperboard stiffness, providing resistance to crushing and piercing—essential features for robust packaging and shipping boxes. Different grades of paperboard, such as solid bleached sulfate (SBS) or coated unbleached kraft (CUK), are blended as needed to meet varying performance and branding requirements.
Following mat formation, a multi-stage water removal sequence begins. About 20% of water drains via gravity, followed by mechanical dewatering through sponge rollers, and culminating in heated drying tunnels that reduce overall moisture to approximately 5%. This ensures the finished board maintains consistent dimensional stability and optimal machineability for box production lines.
The paperboard is then cut and slit into various roll widths, allowing manufacturers to create boxes of all sizes, from small cosmetic cartons to large shipping containers or display packaging. Custom roll sizes enable precise conversions to suit customer needs, product protection standards, and machine compatibility.
With the drying process complete, paperboard can be upgraded by applying a polymer or clay coating to enhance surface quality, printability, and barrier properties. Melting and extruding polymer pellets, or applying clay-based slurries, provides a smooth, glossy, and sometimes water-resistant finish as seen on beverage cartons, food packaging, and luxury retail boxes. Prior to coating, a starch solution further strengthens the fibers, supporting structural integrity during forming, folding, and usage.
To maximize the uniformity of the coating, the board is first calendared between steel rollers, smoothing its surface and achieving consistent thickness and density. The coating is applied to one or both sides based on end-use requirements, then dried, rewound, and slit according to customer or application needs. Sheets or rolls are tailored to fit die-cutting and converting machines, with a final surface comparable to milk cartons or high-end product displays.
This added finish helps improve box printing, resistance to moisture, and visual appeal—features critical in consumer goods packaging and branding.
Once coated or uncoated paperboard is ready, it is delivered to box manufacturing facilities where it undergoes conversion into a variety of corrugated boxes, shipping boxes, folding cartons, and custom packaging solutions. At this stage, additional features such as die-cut handles, ventilation holes, flaps, or tamper-evident seals may be added in line with customer or regulatory specifications. Score lines facilitate easy folding and accurate shaping based on standardized or custom box styles like RSC (Regular Slotted Container), die-cut mailers, or display cartons.
Conversion equipment and methods vary by manufacturer, depending on run size, board grade, design complexity, and end-use environment—for example, heavy-duty packaging for industrial supplies versus lightweight retail gift boxes.
The mother rolls of paperboard or corrugated board are shipped to box plants, with widths matched to the box blank size and required production throughput, ensuring efficient material use and minimized waste during box forming.
Kraft paper, named after the German word for "strength," stands as the gold standard for corrugated box liners and packaging solutions requiring outstanding toughness. Sourced from softwood trees like pine, spruce, or fir, Kraft paper’s long fibers provide high tear and burst resistance—making it suitable for demanding shipping, industrial packaging, and e-commerce applications. The paper's color spectrum ranges from brown to yellowish, influenced by tree species and regional growth conditions.
Kraft paper is attached to both sides of the fluted corrugated medium to form single-wall corrugated board, providing superior stacking strength, crush resistance, and protection against environmental factors. Higher-end constructions may include double-wall or triple-wall designs for custom heavy-duty packaging or export cartons. Flute size and shape may be selected to optimize cushioning, compressive resistance, and printing surface for branding or labeling purposes.
Due to its unique surface texture and porosity, Kraft paper offers excellent print quality for retail displays, shipping labels, and brand messaging. Designers value its natural, rustic appearance—suitable for eco-friendly packaging, luxury gift boxes, and personalized presentation boxes.
Unlike smoother white paperboard, Kraft paper’s distinctive look, tactile feel, and environmental advantages provide packaging engineers and marketers with versatile solutions for both functional and visual requirements.
Chipboard—also known as greyboard or paperboard—is a dense, rigid packaging material produced entirely from recycled paper, wood residues, and sawdust, making it a sustainable choice for eco-conscious packaging. Used widely in making folding cartons, slip sheets, notepad backings, and point-of-purchase displays, chipboard offers impressive versatility. Its construction begins by mixing waste fibers and sawdust with adhesives (typically urea formaldehyde), then compressing and heating the blend to form tough, solid panels. Chipboard’s cost-effectiveness makes it a popular option for lightweight, high-volume retail cartons and shipping pads.
Though "chipboard" and "cardboard" are sometimes used interchangeably in everyday language, professionals distinguish between them—chipboard relies solely on compressed, recycled paper and is used for rigid, non-corrugated boxes; while corrugated cardboard consists of fluted or layered construction for added cushioning and stacking strength. Chipboard is offered in several thicknesses and densities, making it suitable for specialty packaging, box dividers, inserts, and book covers—providing reliable protection with a lower environmental footprint.
The chipboard production process starts with collection and sorting of waste paper and other fiber-rich scrap. These are shredded into fine powders, dried, and mixed with adhesive resin. The mixture is then pressed and heated to form dense, uniform panels that are cut and finished for various packaging uses. Depending on its source, chipboard may appear brown (kraft-colored) or gray, with white-coated variants available for premium print or display applications.
Primary raw materials for chipboard manufacturing are post-consumer recycled paper, scrap cardboard, packaging waste, and sawdust from wood processing industries. All these components are ground and refined into small granules or fibers as an initial stage before blending with adhesive binding agents.
The recycling process utilizes industrial shredders or chippers to pulverize raw scrap into a fine, uniform consistency, preparing it for efficient resination and panel formation. This precise size reduction ensures strong bonding and consistent density, both crucial attributes for sturdy chipboard packaging.
After shredding, the material is thoroughly dried to remove excess moisture, which could otherwise weaken finished board integrity. The dried particles are then combined with a synthetic resin—often urea formaldehyde—to ensure optimal adhesion and rigidity, producing durable chipboard panels perfect for folding cartons, binding covers, protective pads, and end caps.
The adhesive-fiber blend is poured into molds or onto conveyor systems, then subjected to intensified heat and pressure to compact the particles into smooth, robust sheets. The rigorous quality standards applied in this process deliver chipboard with the consistent thickness and resilience demanded by automated packaging lines.
With a fully recycled composition, chipboard is a recognized sustainable packaging material. It provides excellent product protection at a lower cost compared to corrugated boards, making it a preferred choice for point-of-sale packaging, subscription boxes, and flat mailers. Its flexibility in thickness and density enables a wide range of applications across industries, maintaining product safety from distribution through delivery.
Chipboard’s strength is mostly determined by its thickness, measured in "points"—each point equals one thousandth of an inch. This allows for precise selection according to packaging requirements, product weight, or display needs.
During box production, flaps, handles, and locking features are carefully die-cut and scored into paperboard sheets. High-speed trimmers and die cutters use precision blades and rubberized surfaces to ensure smooth, accurate cuts without tearing the board. Depending on production volume and box design, advanced rotary or flatbed die-cutters may be used for long runs, while simpler presses handle custom or short-run packaging projects.
In all cases, strict quality measures are applied to maintain consistent sheet thickness for automated folding, gluing, and packaging operations. Scrap offcuts and trimmings are efficiently collected and recycled—further supporting the sustainability of modern box manufacturing.
The folding process, often conducted on automated flexo-folder-gluer machines, bends scored sheets into the intended box shapes. Box joints are completed using either eco-friendly adhesives or industrial staples, depending on the box’s application—food-safe glue for packaging in the food and beverage sector, and heavy-duty staples for shipping industrial parts or heavier consumer goods. This seamless process ensures boxes retain structural integrity during transportation and handling.
After assembly, boxes are squared, stacked, banded, and made ready for final inspection or shipment to customers needing reliable primary and secondary packaging.
Many cardboard and corrugated boxes require custom printing—including brand logos, barcodes, product information, and handling instructions. Flexographic (flexo) printing is the most common printing technology in the packaging industry due to its versatility, speed, and ability to handle a wide range of inks and substrates. The flexo process uses flexible photopolymer plates to transfer ink onto paperboard as it is fed through the press, allowing for high-volume, cost-effective production of custom-printed cartons and retail packaging.
Printing is performed with careful control to maintain the original caliper (thickness) of the paperboard, preserving its protective qualities. Advanced machines blend and register colors precisely, supporting bright graphics, clear text, and consistent branding for retail shelf appeal or logistics compliance.
The final step in quality packaging production is a meticulous inspection process. Sophisticated sensors check glue lines, flap alignment, and box dimensions against production specifications. Visual inspection by trained staff ensures boxes are free from defects—such as incomplete scoring, off-center printing, or weak adhesive bonds. This rigorous quality control prevents costly shipping mishaps and upholds the high standards demanded in packaging for pharmaceuticals, electronics, consumer goods, and food distribution.
Through these advanced processes, cardboard and chipboard packaging remains central to global supply chains, product protection, and brand presentation. High standards in design, materials, production, and inspection ensure the end result: durable, cost-effective, and sustainable boxes that deliver products safely and effectively from manufacturers to end-users.
Paperboard is a favored material for retail packaging because it can be easily shaped, designed, and customized to enhance the visual appeal of a product. Well-crafted paperboard creates a strong first impression for customers, serving as the primary method for presenting and showcasing products.
The advantages of paperboard are categorized by different grades, which can vary based on the manufacturer. Understanding these grades is crucial for selecting the appropriate paperboard that meets the specific needs of a product and company. The quality and cost of paperboard grades can vary significantly.
SBS (Solid Bleached Sulfate) is a high-quality, bright white paperboard known for its premium finish. Both sides of the board are coated with clay, resulting in clear, crisp, and vibrant printing. SBS is valued for its superior quality, derived from its use of hardwood fibers, while its internal layers are made from softwoods or a mix of soft and hardwood fibers.
SBS paperboard is produced using sulfate pulping of virgin hardwood, making it suitable for food contact, highly foldable, and strong enough for frozen applications. Its numerous advantages make SBS the most expensive among paperboard grades.
CUK (Coated Unbleached Kraft) is crafted from unbleached virgin Kraft fibers, giving it a distinctive brown color. It primarily uses softwoods, like pine, with some hardwood fibers in the top layer to provide a smooth surface for printing. The long, robust pine fibers contribute to CUK's excellent strength and tear resistance, making it well-suited for beverage containers and heavy-duty packaging for tools and laundry detergents.
CUK's durability also makes it resistant to moisture. It is the strongest of the paperboard grades, widely used, and more affordable compared to SBS.
UUK (Unbleached Uncoated Kraft) is a natural brown paperboard made from a mix of softwood and hardwood fibers, including recycled fibers. It offers high strength at a lower cost. However, its texture is not suited for detailed printing or intricate designs. UUK is well-suited for storing hardware in damp environments and for applications requiring heavy-duty performance.
CRB (Coated Recycled Board) is composed of recycled fibers with a top layer of white fibers and a clay coating. This grade includes several variations such as CCN, WLC, Duplex, GB, and CCNB. CRB is a low-strength paperboard, making it suitable for lightweight products like chips, crackers, cereal, and snacks.
URB (Uncoated Recycled Board) is produced from recycled newsprint and paper. It is a thick grade of paperboard often used for setup boxes or dividers. URB is the most cost-effective paperboard grade, offering excellent value for the money.
FBB (Folding Box Board) is a multilayer paperboard made from a combination of chemical and mechanical pulps. Mechanical pulp is sandwiched between layers of chemical pulp, with the top ply consisting of bleached chemical pulp. This low-density material provides high stiffness and ensures product safety with its virgin fiber composition. The blend of mechanical and chemical layers results in strong, rigid sheets that, when fully coated, allow for crisp and high-resolution printing.
Despite its many advantages, FBB has the lowest strength among paperboard grades. However, variations in coatings and treatments can enhance its strength, making it somewhat competitive with SBS. One of the notable features of FBB is its excellent foldability; boxes with attached lids can be opened and closed smoothly without damaging the score lines.
While paperboard is one of the most common forms of cardboard, it is not the only type. Cardboard is an exceptionally versatile material available in various forms, allowing for customization to meet specific and specialized requirements. Its flexibility enables adjustments in strength, weight, width, and functionality to suit a wide range of applications.
Honeycomb cardboard is both lightweight and durable, featuring two outer panels that provide stability and strength, along with a broad surface area. Its robust nature makes it an excellent alternative to wood or plastic pallets. Honeycomb cardboard can be produced in various strengths and sizes, offering an exceptional strength-to-weight ratio. In door manufacturing, it serves as a filler for door cavities.
Available in various thicknesses, honeycomb cardboard can be shaped into sturdy and resilient boxes with corners reinforced by multi-ply cardboard. Its unique structure provides impact resistance, enhancing its durability.
Honeycomb cardboard comes in different configurations, with cell sizes ranging from 0.32 inches (8 mm) to 0.86 inches (22 mm) and honeycomb heights from 0.23 inches (6 mm) to 4.1 inches (104 mm).
Gray paperboard is a robust type of paperboard made from recycled paper pulp, characterized by its gray color. Known for its rigidity, it is commonly used in applications such as pad backing, rigid boxes, cartons, and bookbinding. The surface of gray paperboard is gray, with inner layers often appearing brown or gray as well.
Its strength arises from the manufacturing process, which does not involve adhesives or glues. Instead, the layers or plies of gray paperboard are bonded by the long fibers of the board, which are pressed together using heavy steel rollers.
Gray cardboard, similar to gray paperboard, is produced from recycled paper and cardboard. It features a smooth surface with excellent rigidity and is slightly thicker than gray paperboard. The increased thickness of gray cardboard makes it a suitable substitute for laminated cardboard.
Cardboard boxes are the preferred option for packaging, storage, and product display due to their adaptability. They offer excellent protection and security for products while maintaining an attractive appearance.
Cardboard boxes come in various designs to suit every packing need, making them integral to innovations in packaging and shipping processes. Their versatility has driven advancements in how products are packaged and transported.
RSC (Regular Slotted Containers) are standard shipping boxes with flaps of equal size that align when closed, allowing them to be taped and secured. The end flaps fold inward without meeting, while the side flaps fold inward so their edges align for taping and securing.
FOL (Full Overlap) cardboard boxes are similar to RSC boxes but with one key difference: the long outer flaps overlap when folded inward. This design enhances the box's strength when stacked and provides additional edge protection, making it more resilient to rough handling.
FTD (Full Telescope Design) boxes feature a design where one section fits into another, with the cover fully enclosing the box body. The flaps are secured with staples or tape. This design offers excellent compression strength, making it suitable for stacking heavy or large items.
Snap bottom boxes have a similar upper structure to RSC boxes but with a distinctive bottom design. The flaps are cut and shaped to fold over each other and snap into slots to lock securely. This feature allows for quick and easy assembly of the box.
A one-piece folder cardboard box is designed from a single sheet that folds along pre-scored lines to create the box. The bottom of the box is a flat piece with four sides and attached flaps. When folded, these flaps raise the sides to form a rectangular shape. As with RSC boxes, the end flaps are shorter and do not meet, while the side flaps either overlap or align at their edges based on the specific box design.
One-piece folder cardboard boxes are typically used for shipping individual items like iPads, books, video games, and other flat or thin objects. Their flat surface is perfect for printing logos, images, and instructions, making them a versatile choice for various packaging needs.
The self-locking cardboard box, also known as the RELF (Roll End Lock Front) die-cut box, resembles the one-piece folder but with distinctive features. It consists of a single piece of cardboard that is scored to fold into shape. The sides have long flaps attached, and the ends are made from double-width, equally scored sections.
To assemble a self-locking box, the sides are folded upward, and their flaps are aligned with the scoring on the box's ends. The double-wide end sections are then folded up, with one part of the end overlapping the extended flaps. This configuration is secured by slots in the box's base and tabs on the end pieces.
The lids for self-locking boxes are created in a similar manner, resulting in telescoping lids that fit over the folded box. The innovative design of self-locking boxes eliminates the need for tape or glue to secure the sides; only tape is required to seal the box.
Another variation of the self-locking or RELF die-cut box features a lid attached to one of the long sides with extended flaps. As with other self-locking boxes, it is assembled by folding the sides and positioning the flaps. The lid on the long side folds up, with flaps sliding into place inside the box and engaging with the self-locked edges.
The examples of boxes mentioned here represent just a small portion of the diverse range used in supply chain and shipping processes. Cardboard manufacturers continuously innovate and design new boxes for specialized and unique applications. Moreover, these manufacturers are always available to assist customers in designing boxes that meet their specific needs perfectly.
Chipboard's versatility in various sizes and thicknesses contributes to its extensive use. It can be shaped and customized to suit a broad array of applications. Primarily, chipboard is utilized for packaging commercial and industrial goods.
Chipboard's durability makes it an ideal packing material for sensitive technical equipment, offering protection against vibrations and impacts that could damage electronic components during transport. It provides essential structural integrity and stability.
In the bakery industry, chipboard is used for boxes to safeguard baked goods from damage. Its strength and flexibility also make it a suitable material for cake boards, as it does not absorb moisture.
Chipboard is commonly used for tissue boxes, ensuring they remain intact and do not collapse during shipping.
Beer cases often use chipboard due to its ability to support the weight of a case, which can exceed 20 lbs (9 kg), making it a robust choice for packaging.
Retail displays benefit from chipboard's lightweight yet sturdy nature. It provides the necessary strength and resilience to withstand frequent handling while presenting products attractively.
Chipboard is also used as backing for pads of paper, offering the right balance of strength and flexibility to support the paper. It is also commonly found as backing in picture frames and shipping envelopes.
In furniture manufacturing, chipboard serves as a structural component, often covered with wood or veneer. It is used in the sides and backs of chairs and couches, adding stability and support.
Its resistance to moisture makes chipboard a preferred choice for fast-food packaging, as it prevents sogginess and helps retain the food's flavor and aroma.
The diverse applications of chipboard, as illustrated above, showcase its versatility. Its ability to be customized in various shapes and sizes makes it suitable for a wide range of demanding uses.
The advent of the cardboard box during the first industrial revolution marked a significant shift in the packaging sector. Introduced by Sir Malcolm Thornhill in 1817, this innovation arrived in the United States in 1895 and quickly became a staple for packaging.
By the early 20th century, smaller cardboard boxes, made from lighter paperboard, became popular for packaging breakfast cereals. This trend grew rapidly, and today, cardboard boxes are prevalent in the packaging of a vast array of products.
Despite being composed primarily of paper and starch, cardboard boxes are remarkably sturdy, flexible, and resistant to moisture. They are perfect for shipping, safeguarding, showcasing, and organizing products of various shapes and sizes. With the right surface treatment, these boxes can feature an extensive range of prints, including vibrant graphics, innovative designs, and engaging images.
The swift popularity of cardboard boxes can be attributed primarily to their affordability, which is significantly lower than previous packaging options. These boxes can be produced to suit any company's budget, making them an economical choice for enhancing brand visibility. The reduced cost of cardboard boxes is linked to the inexpensive labor and materials used in their production. Furthermore, more than 80% of cardboard is recyclable and reusable, contributing to its cost-effectiveness.
In the 21st century, sustainability has emerged as a crucial focus in industry and manufacturing, aiming to protect our environment for future generations. Cardboard boxes align perfectly with these sustainability goals because they can be recycled and repurposed into new boxes at the end of their lifecycle.
The cardboard packaging sector stands as one of the most significant industries in the U.S., valued at over $60 billion. This industry emphasizes its commitment to utilizing domestic raw materials and employing American workers for its production processes.
Engineers and designers have consistently pushed the boundaries of cardboard box usage through creative and functional designs. By leveraging various types of paperboard and cardboard, manufacturers have developed solutions tailored to diverse shipping, packaging, and storage needs.
The growing popularity of cardboard is largely attributed to its recyclability. Unlike many other materials, cardboard doesn't often end up in landfills. Waste management companies have established specialized processes to sort cardboard, allowing it to be collected, bundled, and sent to manufacturers for recycling.
Among the countless everyday items, cardboard boxes stand out as exceptionally eco-friendly. More than 80% of all cardboard manufactured is recyclable without limits. Manufacturers are able to repurpose any type of cardboard to produce items that match the quality of new products. The endless recyclability of cardboard, without loss of quality, makes it an ideal choice for environmental conservation and sustainability.
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