Question 1

What corrugated flute types do you offer?

Accepted Answer

We offer a full range of corrugated flute types to match different protection and performance requirements. E-flute (1.5mm thickness) is the thinnest option, ideal for retail packaging, mailer boxes, and products requiring excellent print surface quality. Its fine corrugation produces a smooth surface for high-quality printing.

B-flute (3mm thickness) provides moderate cushioning and stacking strength, making it versatile for both shipping and retail applications. It offers a good balance between protection, weight, and cost.

C-flute (4mm thickness) is the most common shipping box material, providing excellent crush resistance and stacking strength for warehouse storage and transportation. It is the standard choice for general shipping boxes.

Double-wall construction combines two layers (typically B-C or E-B flute) for maximum protection of heavy or fragile items. We also offer specialty constructions including triple-wall for extremely heavy loads and micro-flute for premium retail packaging.

Question 2

Can corrugated boxes be custom printed?

Accepted Answer

Yes, we offer multiple printing methods for corrugated boxes. Flexographic printing (flexo) is the most common method for corrugated, offering good quality for text, logos, and simple graphics at economical pricing. It is ideal for shipping boxes with basic branding.

Offset printing on corrugated provides significantly higher print quality, approaching the level of paper box printing. This method is ideal for retail-ready corrugated packaging and e-commerce mailer boxes where visual impact matters.

Digital printing is available for short runs and variable data printing, offering full-color capability without printing plate costs. This method is cost-effective for quantities under 1,000 boxes or when multiple design versions are needed.

For premium e-commerce experiences, we offer interior printing that creates branded unboxing moments inside corrugated mailer boxes. Full-color interior graphics transform a functional shipping box into a memorable brand experience.

Question 3

What sizes are available for custom corrugated boxes?

Accepted Answer

We manufacture corrugated boxes in virtually any size, from small product boxes (4x4x2 inches) to large industrial containers (48x40x36 inches). Standard RSC (Regular Slotted Container) boxes are available in dozens of stock sizes for immediate production.

Custom dimensions are produced to match your specific product measurements. We recommend allowing 0.5-1 inch of clearance around products for void-fill materials, plus additional space if foam inserts or custom packaging elements will be included.

Specialty shapes beyond standard rectangular boxes include hexagonal, triangular, telescoping, and full-overlap designs. Die-cut boxes can incorporate features like auto-lock bottoms, display windows, carry handles, and dispensing openings.

Our box design team can help optimize dimensions for shipping efficiency, ensuring your boxes fit standard pallet configurations and maximize truck utilization.

Question 4

What is the minimum order for corrugated boxes?

Accepted Answer

Minimum orders for corrugated boxes depend on the type and complexity. Standard RSC boxes with single-color printing start at 250 units. Custom die-cut boxes typically require 500+ units due to the die-cutting tool investment.

Printed mailer boxes with full-color exterior and interior graphics have minimums of 500-1,000 units depending on box size and print complexity. Digital printing can accommodate smaller quantities at higher per-unit costs.

Tooling costs for custom box designs include die-cutting tools ($150-$500 depending on size and complexity) and printing plates ($100-$300 per color). These are one-time costs retained for future orders.

For businesses with regular corrugated needs, we offer inventory programs where pre-produced boxes are stored at our facility and shipped in scheduled batches, reducing per-order logistics costs and ensuring consistent supply.

Question 5

Are your corrugated boxes environmentally friendly?

Accepted Answer

Yes, corrugated cardboard is one of the most environmentally friendly packaging materials available. Our corrugated boxes use a minimum of 30% recycled content, with options for up to 100% recycled material depending on strength requirements.

Corrugated cardboard has one of the highest recycling rates of any packaging material, with over 90% of corrugated boxes being recovered for recycling in the United States. The material can be recycled 5-7 times before fibers become too short for reuse.

We offer FSC-certified corrugated materials sourced from sustainably managed forests. Printing uses water-based and soy-based inks that are compostable and recyclable along with the corrugated material.

For brands requiring documented environmental credentials, we can provide sustainability certifications, carbon footprint calculations for packaging, and assistance with environmental claims and recycling instructions for consumer-facing packaging.

Corrugated Cardboard Box

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