What is difference between cardboard box and corrugated box?

1. What are cardboard box?

Cardboard boxes are usually made from cardboard, which is a heavy paper material. This category covers a wide range of paper-based sheets, such as cardboard and cardstock. Sometimes, people refer to “cardboard” in everyday terms, even including the outer layer of corrugated cardboard.

Cardboard is often used in lighter application scenarios such as product packaging, retail boxes, etc., especially if there is a high demand for cosmetic presentation. Cardboard is usually single-ply and is sometimes laminated for strength.

Cardboard is a type of cardboard and is generally used for less heavy-duty applications, like the backing of note books or lightweight packaging.

2. What are corrugated box?

Corrugated boxes are unique in that they are made from multiple layers of cardboard, with a layer of corrugated paper with a unique “corrugated” shape in the center, flanked on either side by flat, laminated paper. This corrugated middle layer gives the box excellent rigidity, strength and cushioning properties, making it ideal for many heavy-duty applications.

The corrugated board, the heart of the paperboard, has a wave shape that greatly enhances the strength and compression resistance of the paperboard, effectively resisting extrusion from the outside world.

Facing papers are located on both sides of the corrugated board, and depending on the use of the box, they can be printed with graphics or left blank.

3. Differences between cardboard boxes and corrugated boxes

1) Strength and Durability

Because of its three-layer structure, a corrugated box is much stronger than an ordinary cardboard box. The rigid support formed by the corrugated paper between the sheets enables the carton to effectively resist extrusion, puncture and tearing, and is particularly suited to coping with the pressures of transportation and handling, especially in busy warehouse environments.

In contrast, ordinary cardboard boxes are weak and prone to bending or tearing. Single-layer cardboard offers limited protection for the contents and is only suitable for the transportation of lightweight or low-value products that do not require much protection.

2) Different Uses

Based on its high strength and durability, corrugated boxes are widely used in moving, e-commerce and logistics distribution. For fragile, heavy or high-value items such as furniture, electrical appliances, electronic equipment, glassware, machinery, etc., corrugated boxes provide additional protection while facilitating handling.

Cardboard boxes, on the other hand, are more suitable for packaging lighter, less fragile items that do not require much protection, such as cereals, snacks, clothing, shoes, and stationery such as envelopes, notebooks and folders.

3) Transportation Distances

When shipping products over long distances, it’s important to make sure the goods are well protected during transit. Corrugated cardboard boxes are a better choice for long-distance transportation, as their internal corrugated layer adds strength and rigidity to the box, allowing it to withstand the stresses of transportation, handling and stacking.

During transportation, products are often subjected to a variety of bumps, vibrations, temperature changes, humidity and rough handling. For long-distance transportation, the corrugated layer of corrugated boxes acts as a shock absorber and provides superior protection.

4) Sustainability

While both plain and corrugated cardboard can be recycled, corrugated boxes perform better in terms of sustainability. Corrugated boxes are more durable and can withstand the stresses of the warehouse environment, and therefore need to be replaced less often. In many cases, corrugated boxes can be recycled and reused many times, saving both resources and costs.

5) Cost

On the face of it, corrugated boxes are usually more expensive than cardboard boxes due to their more complex construction. However, the additional protection provided by corrugated boxes can reduce product damage and save costs in the long run. In addition, some corrugated boxes can be reused many times, reducing costs over time.

Plain cardboard boxes are relatively inexpensive, but are more susceptible to damage, which can lead to additional costs for returns, replacement products, and customer dissatisfaction.

4. Advantages and Disadvantages of Cardboard Boxes and Corrugated Boxes

Advantages of Cardboard Boxes

• Light weight: Cardboard boxes are significantly lighter in weight than many other packaging materials, which not only reduces transportation costs, but also makes them easier to handle.
• Cost-effective: Due to their affordable price, cardboard boxes provide businesses with a cost-effective packaging solution, especially when purchased in bulk.
• Versatile: cardboard boxes can be customized to fit a variety of product sizes and shapes, making them suitable for a wide range of application scenarios.
• Protective effect: despite their light weight, cardboard boxes are resistant to dust, dirt and minor impacts, ensuring that items are delivered in good condition.

Disadvantages of cardboard boxes

• Poor durability: usually lacks the structural reinforcement needed to carry heavy loads or long-distance transportation.
• Limited protection: compared to corrugated cartons, they are less effective in shock absorption and cushioning due to the absence of an internal corrugated structure.

Advantages of corrugated boxes

• Good protection: corrugated boxes are stronger than ordinary cardboard, providing stable cushioning for products during transportation and handling. In addition, it can effectively protect against moisture and bacteria, which is especially important for food packaging that requires long-distance transportation.
• Customizability: Corrugated box packaging can be easily customized to meet specific business needs, providing customized solutions that meet unique requirements.
• Cost-effective: Corrugated boxes are one of the most affordable packaging options, requiring low labor costs and fewer manufacturing tooling requirements.
• Beneficial for branding: Customized branding on corrugated boxes increases the visibility and professionalism of a company. This element of personalization can make packaging designs stand out, foster customer loyalty and promote repeat business.
• Sustainability: Made from 70-100% recycled materials, corrugated boxes are environmentally friendly and easy to recycle and reuse, making them a sustainable packaging solution for businesses.
• Lightweight: Its lightweight nature helps reduce transportation costs, making it ideal for transporting heavy items without compromising safety.
• High flexibility: corrugated boxes are available in a variety of sizes and layer configurations (single, double or triple) to accommodate a wide range of products, making them highly versatile in the packaging market.

Disadvantages of Corrugated Boxes

• Higher Costs: Corrugated boxes are usually more expensive to produce than regular cardboard boxes due to the additional materials required and more complex manufacturing processes.
• Weight issues: in some cases, corrugated boxes may be heavier than cardboard boxes, which may increase transportation costs

5. Common Types of Corrugated Boxes 

1) Standard Slotted Box (RSC)

The standard slotted box is the most common type of carton due to its efficient design. This type of box has four folds at each end, each half the width of the box. When folded, the outer folds (usually longitudinal) meet in the center to form a strong and balanced carton structure. Because its contents are completely closed, the standard slotted box is often used for transportation.

2) Half Slotted Box (HSC)

The Half Slotted Box is similar to the Standard Slotted Box, but it only has a fold at one end and remains open at the other. Its fold size is also half the width of the carton, when folded in the middle of the joint, usually fixed with tape or staples. Because there is only one set of folds, the half-slotted box allows the user to quickly access the contents of the box.

3) Full Overlap Slotted Box (FOL)

Unlike standard slotted boxes and half-slotted boxes, full overlap slotted boxes have longer folds that completely overlap when folded. This overlapping design provides additional protection at the top and bottom of the box. Because of their durability, full overlap slotted boxes are commonly used in heavy-duty applications such as industrial equipment, machinery, and automotive parts.

4) Die Cut Boxes

Die cut boxes are used in application scenarios that require a high degree of customization. Engineers will design the carton according to the customer’s needs and then use custom cutting dies to produce the final product. This process enables intricate designs to be realized and provides products with snug-fitting packaging, making it a truly tailor-made solution. Die cut boxes are suitable for a wide range of products and are commonly used in e-commerce and retail packaging.

5) Telescoping Boxes

Telescoping Boxes consisted by two parts: An outer structure and an inner structure that slides within it, creating an expansion effect. Since this type of carton can expand up to three times its original size, it is ideal for packaging large, long or oddly shaped items such as pipes, machinery and appliances.

6. Industry Applications for Corrugated Boxes

1) E-Commerce

E-commerce retail sales continue to soar and are expected to continue to grow. This has had a profound impact on packaging demand, especially in secondary and tertiary packaging. Secondary packaging refers to the outer packaging of primary packaging, which is used to combine multiple packages; tertiary packaging is used for bulk handling, storage and distribution.

Corrugated boxes are considered the backbone of the e-commerce supply chain. Brand owners and marketing organizations work together to resize cartons, enhance the consumer’s unboxing experience at home through high-quality graphic design, and explore better ways to communicate brand values.

2) Marketing & Printing industry 

Inkjet and offset printing technologies have opened up a multitude of new opportunities for the packaging and printing industry. Advances in substrates, inks and decorating technologies have transformed plain corrugated board into containers with high-quality graphics and printed decorations.

Marketing teams can get creative and utilize corrugated boxes to enhance brand image and add premium elements to cartons. Stacker-turners help turn goods over for printing and handle large quantities of goods quickly and safely.

3) Packaging for the Food Industry

Corrugated boxes are ideally suited for packaging food products. It offers a number of important advantages, including high security, effective resistance to bacterial infection, extended product shelf life, protection against mold and rot, and traceability.

As cardboard boxes in food distribution are usually used only once and then discarded, their easy recyclability is also a key factor in choosing corrugated boxes.

4) Corrugated displays for office supplies and stationery

When shipping office supplies, especially paper, items can be damaged. Corrugated packaging and cushioning materials ensure safe transportation.

Corrugated display racks are also often used when selling stationery. Corrugated cardboard is strong enough to withstand the frequent interactions of consumers with the displays. As products may be taken in and out on a daily basis, there is a need for a display that is stable and can hold products safely.

5) Textile and Luxury Goods Industry

When shopping online, consumers expect to receive products that are well-packaged and undamaged. Customer satisfaction is the key to customer retention, so designing beautiful corrugated boxes has become an important part of a textile company’s work.

Thanks to numerous online unboxing videos, consumers buying textiles, shoes and bags expect a memorable unboxing experience. The fashion industry has partnered with the marketing and packaging industry to engage with customers through carton design, thin paper, hang tags and flyers. Brand recognition and design are critical in luxury packaging, which is why mechanical equipment is indispensable.

6) Corrugated Boxes for Electronics

For electronics packaging, the key is to ensure that the product is intact. Technology products contain many delicate components, such as screens, which can be easily damaged if the packaging material is not strong and lacks cushioning. Therefore, corrugated boxes combined with protective materials are ideal for the transportation of electronic products.

7) Healthcare

Fragile medical devices are susceptible to damage due to improper packaging and are often mishandled. Because they are both fragile and require good hygiene, they need to be handled with care and packaged in rigid materials that are bacteria-resistant and able to prevent contamination, while following specific protocols.

The use of corrugated boxes by pharmaceutical companies ensures that patients receive the medicines they need under optimal conditions.

8) Batteries and Hazardous Materials Industry

There are numerous guidelines and regulations to consider when transporting batteries and other hazardous materials. Containers used in these industries need to be clearly labeled with their contents and pass a series of tests, such as drop tests, vibration tests and pressure tests, to ensure that hazardous materials do not pose any danger.

Durable and waterproof, corrugated cardboard is rigid and can withstand temperature changes. These cartons have proved to be very suitable for these products provided that they are properly marked for UN transportation.

9) Corrugated Cartons for Heavy Goods

Heavy-duty shipping cartons are particularly strong and durable, with double or triple corrugated construction, providing extra protection to keep products safe and resistant to weather changes, vibration, and possible dropping or rough handling.

Weather changes and torn cartons are among the risks businesses can face when shipping heavy items. Double corrugated boxes are a good investment, providing the right protection and cushioning to ensure that products arrive at their destination in the best possible condition.

10) Corrugated Packaging for the Military Industry

Transporting military supplies means meeting a range of documented and practical needs. Some items may be extremely fragile and require sturdy containers; others are heavy; and still others must be able to withstand humid environments or high temperatures. Corrugated boxes used in the military industry need to pass a number of tests and provide detailed descriptions of the contents.

7. How to choose the right transportation box for the product?

Product Size

The primary factor in choosing the right shipping box is the product size. This helps in determining the perfect size for a customized corrugated box. The first thing to decide is whether the product will be placed directly into the corrugated box or whether the product will be packed in a box before being placed into the corrugated box. Once this is determined, accurately measure the dimensions of the product or the inner box and design the custom corrugated box to be 1 inch larger than the measurements so that there is enough room to pack the product. At the same time, avoid choosing a carton that is too large to ensure that the product is secured inside the box.

Product Weight

Measure the weight of the product to select the appropriate packaging carton. If the product weighs less than 20 pounds, a plain cardboard box may be suitable. For products weighing more than 20 pounds, corrugated boxes must be selected. Depending on the size of the box, corrugated boxes can carry products from 20 to 120 pounds. For heavier products, double or triple corrugated boxes may be used, with a capacity of up to 300 pounds.

Number of Products to Ship

The number of products to be shipped is also an important factor. If only a single item is being shipped, you can simply use a product box. However, if you are shipping multiple products, a larger corrugated box is more appropriate. Considering these factors will help in finding the best box for transporting products.

Cardboard boxes and corrugated boxes each have their own unique characteristics in the packaging and transportation world. Cardboard boxes are lightweight and low-cost, making them suitable for packaging lightweight, non-fragile items, while corrugated boxes are the preferred choice for the transportation of heavy, fragile or high-value items owing to their outstanding strength, durability and versatility. Both also have their advantages and disadvantages when it comes to sustainability and cost-effectiveness. In addition, understanding the common types of corrugated boxes and their applications in different industries, as well as how to choose the right box for transportation based on product characteristics, can help us make more informed decisions for efficient, safe and cost-effective packaging and transportation.

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