Cardboard is one of the most widely used materials used in modern packaging worldwide. This article will explore what it actually is, where it comes from, and what makes it so special for a product packaging option.
Let’s jump in!
What is a Cardboard?
Cardboard is a collective term used to describe paper-based material used for packaging. In the packaging industry, it mainly refers to paperboard and corrugated fiber board, each serving a different purpose.
Let’s have a look at both:
Paperboard
The paperboard is a thick, strong lightweight material made from wood pulp. In terms of weight and strength, paperboard sits somewhere between the regular paper and thicker, heavier cardboard. It is a versatile packaging material with application across many industries. Those include, but are not limited to pharmaceuticals, food & beverage, cosmetics, and electronics.
In the packaging industry, there are four-commercial grade paperboard types commonly used, namely:
- Solid Bleached Sulfate (SBS):
SBS is a bleached chemical pulp-board supplied as a white sheet. It is used for packaging with excessive printing needs, or applications needing clean surfaces for food-contact safety. It’s a popular choice in the confectionery and cosmetics industry, where print quality and food compatibility plays a key role.
- Folding Box Board (FBB)
The FBB is a multi-ply construction that combines different pulp layers. It has an excellent stiffness-to-weight ratio, making it the perfect choice that suits most retail cartons that need a combination of strength, light weight, and printability. Some of its most common applications include cereal box packaging, pharmaceutical cartons, and basic retail packs.
- Coated Unbleached Kraft (CUK)
It contains unbleached kraft as a base with coating on top for better printability and moisture control. It is highly durable with a signature, natural look often preferred by brands with minimalist brand identity. It has excellent tear resistance, making it one of the best, but of niche choices for packaging design.
- Coated Recycled Board
The CRB combines recycled fibres with surface coating for better printability. Although a generally eco-responsible and budget-friendly option, it is relatively less stiff compared to boards made from non-recycled materials. With no significant practical advantages over non-recycled paperboard, brands choose this when using recycled material is the only goal.
Corrugated Fiberboard/Cardboard
On the other hand, corrugated cardboard include a layer or layers of “fluted” material sandwiched between two flat liner boards. Its light weight, high durability, and optimal cushioning ensures the product inside stays protected on long transit routes where serious bumps and shocks are imminent.
When choosing corrugated cardboard, you’ll often come across two options, single-wall corrugated cardboard, and double-wall corrugated cardboard.
Let’s understand the difference:
- Single-wall corrugated cardboard: A single-wall corrugated cardboard is just what it sounds like. It features a single fluted layer between two flat liner sheets on each side. It’s a versatile packaging option that works great for a wide range of everyday products. Moreover, it’s light weight and better strength usually makes it the most secure option for most standard shipping situations.
- Double-wall corrugated cardboard: The double-wall corrugated cardboard includes two fluted sheets sandwiched between flat liner sheets. They provide better protection compared to single-wall corrugated cardboard, serving as a standard packaging option for fragile and heavy items. For longer and difficult transit routes, they serve as a better option, although expensive.
Where Does Cardboard Come From?
In the simplest words, cardboard comes from trees. But for our more curious readers, the trees are actually cut into chips. These chips are then transferred to mills where they are converted into a soft, mushy pulp through certain mechanical and chemical methods. This pulp is then pressed, which becomes paper upon drying. These layers of paper are then joined together using glue, turning them into a thick, sturdy material that we call cardboard.
How is Cardboard Made: A Step-by-Step Breakdown
Cardboard making is a long process with many steps involved. Let’s have a look at each, one by one:
Pulping
This is the first and most important step. Here, the wood chips are converted into soft, mushy pulp by dissolving lignin through various mechanical and chemical methods. Lignin is basically a natural polymer found in wood that holds the wood fibers together, mainly responsible for its rigidity.
Purification of Raw Material
The purification process involves removing residual dirt, contaminants, and remaining glue/lignin from the obtained pulp. This step is extremely important to ensure the obtained paper has a clean, light color.
Bleaching
Bleaching is not mandatory and is usually done when the demand is specifically for white, clean, and premium-quality paperboard.
Here, the pulp is put through further purification and refinement. The whole process of bleaching is generally divided into multiple stages namely ClO₂ treatment, alkaline extraction, and peroxide bleaching. The exact sequence of these stages may differ based on the pulp type and required brightness level. However, in standard practice, they follow each other in the exact way as described.
In the ClO₂ treatment stage, the remaining dark lignin structures are broken down. This is then followed by the extraction stage, where these broken-down lignin structures are dissolved and washed away. It is followed by adding a chemical named hydrogen peroxide, which brightens the pulp color further.
Forming and Pressing
Once the pulp is purified, the rest of the process is carried through a massive machine called the Fourdrinier machine. The Fourdier machine is commonly used to form continuous paper sheets through forming, pressing, and drying sections.
Corrugation
To make corrugated cardboard, the sheet is passed through corrugating rolls to create flutes. It is then sandwiched between two flat sheets and glued. This turns it into sturdy corrugated cardboard that’s then used for making custom packaging for different kinds of products.
Cutting and Shaping Cardboard
The cardboard sheets made are generally huge in shape. Therefore, they are cut, shaped, and folded to make custom packaging of different shapes and sizes based on demand.
Why Cardboard Is Considered an Ideal Choice for Packaging:
First things first, cardboard makes for an excellent packaging option due to its rigidity. However, there’s more to why it’s considered an ideal choice for packaging. Following are just some reasons:
- Versatility: Cardboard is extremely versatile with a wonderful array of uses. It can be turned into any shape and can be manufactured in any size. Moreover, the branding and visual customizations are as limitless as your imagination
- Cost-Effectiveness: Cardboard is one of the cheapest packaging materials for businesses that sell products in bulk. Even the highest-quality cardboard will cost less than hard plastic or wood, making it an ideal choice for product packaging.
- Eco-Friendliness: Cardboard is widely recyclable and reusable when it is free from non-paper coatings and contaminations. It not only helps the packaging suppliers keep the costs down, but also helps brands like you reduce your carbon footprint.
- Durability: Cardboard boxes provide excellent protection to the products inside due to multiple layers of sheet. This is especially true for corrugated cardboard packaging. The middle layer between the straight sheets in a corrugated box makes a springy layer. This layer acts as a shock absorbent, making it an ideal choice for even the bulkiest items.
Different Shapes and Sizes of Cardboard Shipping Boxes
Cardboard boxes come in different sizes, shapes, and forms. Following are some of the most common dimensions you’ll see for different types of cardboard boxes:
Common Corrugated Box Dimensions
- 8” x 8” x 8”
- 12” x 12” x 12”
- 16” x 12” x 10”
- 18” x 18” x 18”
Common Mailer Box Dimensions
- 9” x 6” x 2”
- 10” x 8” x 4”
- 12” x 10” x 5”
Common Folding Carton Dimensions
- 3” x 2” x 5”
- 4” x 4” x 8”
- 6” x 2” x 9”
Cardboard Box Size Chart For Different Products at a Glance
| Product Type | Cardboard Box Dimensions in Inches | Cardboard Box Dimensions in cm | Cardboard box dimensions in mm |
| Jewelry Box | 3” x 3” x 1” | 7.6 x 7.6 x 2.5 cm | 76 x 76 x 25 mm |
| Lipstick Box | 1” × 1” × 5” | 2.5 x 2.5 x 12.7 cm | 25 x 25 x 127 mm |
| Perfume Box | 3” x 3” x 6” | 7.6 x 7.6 x 15.2 cm | 76 x 76 x 152 mm |
| Candle Box | 4” x 4” x 5” | 10.2 x 10.2 x 12.7 cm | 102 x 102 x 127 mm |
| Shoe Box | 13″ × 7″ × 5″ | 33 x 17.8 x 12.7 cm | 330 x 178 x 127 mm |
| Phone Cases and Chargers | 6″ × 6″ × 2″ | 15.2 × 15.2 × 5.1 cm | 152 x 152 x 51 mm |
| Mugs, Glassware, and Gift Items | 6″ × 6″ × 6″ | 15.2 × 15.2 × 15.2 cm | 152 x 152 x 152 mm |
| Large Home Goods/ Bulk Products | 18″ × 18″ × 12″ | 45.7 × 45.7 × 30.5 cm | 457 x 457 x 305 mm |
| Soap Box | 4” x 3” x 1.5” | 10.2 x 7.6 x 3.8 cm | 102 x 76 x 38 mm |
The Future of Cardboard Boxes: What to Expect
Cardboard boxes are already widely used in the shipping industry. However, just like anything, these boxes are going through continuous innovations as we speak. That said, here are some trends you will see rising in the coming years:
- Micro-Fluting: This technique involves making a very thin fluted layer between the two flat liners. This makes cardboard boxes more lightweight while still preserving its protective qualities. With reduced material usage, micro-fluting successfully bridges the gap between structural performance, eco-friendliness, and excellent printing quality for retail packaging.
- Biodegradable Barriers: Barriers or coatings are commonly applied on corrugated boxes to protect them against moisture. However, what’s used mostly today are petroleum- or plastic-based coatings. As the world moves towards eco-friendliness, we are going to see a huge surge in the use of plant-based coatings.
- Closed-Loop Circularity: Although cardboard is already very environmentally friendly, manufacturers are trying hard to achieve closed-loop circularity. As of now, there has been a significant improvement in industrial recycling rates, with the carbon footprint of cardboard manufacturers steadily decreasing.
Ready to Upgrade Your Packaging?
Your packaging doesn’t just protect your product. It’s your first introduction to your customers. Therefore, it should be as good as the product itself. At SoonPak, we provide custom cardboard packaging solutions to businesses of all sizes. From branding to quality, our cardboard boxes are designed to ensure your first introduction to your customers is a uniquely curated experience with bespoke designs. Contact us today to get a free quote. We would love to help you take your packaging and branding to the next level.
FAQs
Is it cardboard paper or wood?
Cardboard is a specially engineered material made from paper pulp. This pulp is made from wood chips that are treated with various mechanical and chemical methods, turning them into pulp that’s later converted into paper.
Can cardboard get wet?
Even when treated with a water-resistant coating, excessive exposure to water can severely compromise the structural integrity of cardboard boxes. Therefore, it’s important to keep all your cardboard boxes far from moisture if you want to protect your belongings.
What is cardboard really made of?
Cardboard is made of wood pulp or, sometimes, recycled paper fibers, which are mixed with water and other chemicals and then pressed into sheets with a special machine. These sheets are then glued together to make sturdy packaging boxes.
Is cardboard 100% recyclable?
As long as they are not lined with non-paper coatings, most cardboard boxes are highly recyclable. Although this is not true for cardboard boxes that use plastic film or any other extra embellishments.
Why is cardboard brown?
Cardboard brown is made of unbleached brown wood pulp which contains a natural compound called lignin. The presence of lignin in the pulp gives the cardboard its signature earthy color.
Final Thoughts
Cardboard has always been one of the ideal choices for shipping and packaging boxes, and it is here to stay. It serves as an eco-friendly alternative to all the other options, with reliable protection that gives it an edge. Besides, it’s highly cost-effective, making it perfect for brands to save profit margins. We hope this article helped you understand what cardboard is, where it comes from, and how it’s going to evolve in the future. See you with another informative piece.
