More About Boxes

Why is Corrugated Cardboard so popular?

Aside from polythene packaging, corrugated cardboard is amongst one of, if not, the most popular form of packaging and shipping.

  • Very lightweight, saving shipping costs.
  • Environmentally friendly, 100% recyclable.
  • Simple to use and very durable.
  • Quick to assemble, nothing complex.
  • Can be customised into different grades, fluting profiles that cater to your business’ needs.
  • Can be printed on to increase brand exposure.

There are several reasons why corrugated board is so popular, with the first being that it is very lightweight, which is a huge factor in saving shipping costs. Being environmentally friendly is a huge factor in modern day business. Consumers are aware of the need for products that can be recycled, which brings us to its next benefit. Corrugated cardboard is very much recyclable as the material used is from a sustainable source. This means fewer resources are required for future production of corrugated boxes. Other benefits of corrugated cardboard are the simplicity of use and durability. Packaging can be a time-consuming process if you do not have the right packaging products, however with corrugated cardboard; it is quick to assemble, and not to complex. Corrugated board can come in different grades, and fluting profiles that cater to your business’ needs, this also influences durability of your cardboard. Cardboard is more than simply single wall or double wall, white or brown, the durability of your cardboard is heavily determined by the board grade, and the corrugated fluting profile. In the next section, this will be outlined to give you a greater understanding of corrugated cardboard.

You often see cardboard described for example as: 125K – BC – 125T.

In the corrugated cardboard industry, the first part of this sequence indicates the outer liner. The number is used to represent the gsm of the liner, 125 grams per square metre.

The two letters in the middle represent the fluting profile. BC Flute is double wall and is approximately 6mm thick.

Lastly, the numbers at the end of the sequence represent the inner liner, being 125 grams per square metres.

Here is a rough guide to the different types of board grade.

125 - Light

150 - Medium

200 - Heavy

300 – Very Heavy (Export Level)

K = Kraft – Contains virgin fibres

T = Test – Fully recycled liner

L = Test Liner 2 – Not used very often

WK = White Kraft


Fluting Profiles

E Flute = Single Wall – Approximately 1mm thick

B Flute = Single Wall – Approximately 2.5-3mm thick

C Flute = Single Wall – Approximately 4mm thick

BC Flute = Double Wall – Approximately 6mm thick

EB Flute = Double Wall – Approximately 4mm thick


When receiving bespoke orders for boxes, most will simply ask for single or double wall, by asking the customers the relevant questions, you can gauge what sort of board grade or fluting profile they require. If a customer wishes to have white kraft, it is generally 10% more expensive than brown.

After the board grade is determined, we need to know the quantity as this will affect the price, the more boxes ordered, the cheaper the unit price. The square meterage of the order increases the raw material needed, the price breaks are at 200, 500 and 1000 sqm.

There are also many different box styles that are defined by the European Federation of Corrugated Board Manufacturers (FEFCO). FEFCO codes are simple and recognised internationally, it is a substitute to long descriptions.

Popular box styles include:

Packing box – most common style of box

If the flaps meet in the middle (0201)

If the flaps overlap one another (0203)


Packing Wallet (0401)

For extra protection can be upgraded to (0403)


Pizza Box Style (0426) – die cut box, lock over front


Die Cut Box (0427) – lock over both sides


Die Cut Box (0470) – Alternative style to 0427, more depth


Self-locking tray (0422) – Used for packing tins, cans or jars


Taped Close Tray/ Base & Lid (0301) – Cheaper alternative than 0422



We work with internal dimensions, and we follow the format of: Length x Width x Height (Depth)

Length = the longest side of the box opening

Width = Shorter side of the box opening

Height (Depth) = How tall is the case looking into the box from above


If dimensions given are external, by providing us the box style and grade, we can take away the thickness of the board.

Die cut boxes requires the blank size. This is done by measuring the box when flat. Start with the flute direction as the first dimension.


 To find out how to order bespoke boxes, please click here.