Corrugated Cardboard

Buy corrugated cardboard and use it as packaging all-rounder when shipping goods

Corrugated cardboard is one of the best-known representatives among packaging materials and is suitable as a package and transport material, as outer packaging and as padding and filling material. The cardboard is extremely robust and tear-resistant, environmentally friendly and recyclable, and is available in different variants. The number and length of corrugations and the way it is constructed increase its strength and stability. At the same time, corrugated cardboard provides excellent cushioning functions, protects goods during transport and storage on pallets, and is also ideal for boxes when moving.

Corrugated board is made from the raw material paper and, as a versatile pulp product, is one of the most widely used packaging materials around the world. Approximately 80 percent recyclable waste paper and 20 percent virgin fibers from broken and thinned wood are used in its manufacture, making the material extremely environmentally friendly and fully recyclable. In addition, no bleach is used in the manufacturing process, which is why corrugated board is brown. This is also environmentally friendly and sustainable. Corrugated products consist of one or more layers of corrugated paper glued between cover paper.

Why corrugated board is one of the most important achievements for modern logistics

Corrugated paper was first patented in England in 1856 by Edward Ellies Allen and Edward Charles Healey, who used it as a liner for hats. For packaging purposes, the American Albert L. Jones received the patent for the new type of cardboard in 1871. He worked corrugations into textiles with a pleating machine and, instead of fabric, pushed cardboard over the rollers, which provided good insulation protection for delicate goods thanks to its corrugated shape. As the movement of goods increased, so did the demand for and types of production of this versatile cardboard packaging.

In modern logistics, corrugated cardboard is now an indispensable tool and is also the first choice for shipping and moving. Not only does the material score points for its light weight, versatility in use, flexibility and simultaneous stability, it is also produced in an environmentally friendly and inexpensive manner. The suitability of the material is determined according to the FEFCO standard. This internationally valid code can be used for standardization and description of various shipping packages.

How a high-quality end product is created in the corrugator and why it is brown

Corrugated board is produced in corrugated board plants and, in its simple form, always has three layers. The cardboard is composed of a corrugated layer surrounded by two layers of paper. The whole is fixed by glue. The composition of the paper layers follows a simple physical principle. The pressure generated during shipping and transport is absorbed by the corrugation and evenly distributed to the packaging and outer paper and cardboard layers. This makes the material many times stronger and suitable for heavier weight of goods, while being light and thin itself. Since corrugated cardboard is made of paper at the same time, it is not rigid, but flexible, which makes it ideal as a filling material, for example, in the form of cardboard shredder or roll corrugated cardboard with C flute.

Corrugated board material is available in different flute structures and flute combinations, which are adjusted to the requirements and change the material in strength and stability. The more corrugation levels there are and depending on which corrugation structure the material has, the characteristics change so that an insulating component is also added.

The different types of corrugation - from double corrugation to C flute

The corrugation is the characteristic feature of the material and determines its functional properties. It provides the cavities, the high stiffness and stability, and has a shock-absorbing effect. The decisive factor is the shape of the wave arc, which in turn is determined by the wave pitch and wave height. The height is determined by the type of wave in the vertical spacing, the pitch represents the horizontal spacing of the wave troughs. Here, the larger the flute, the greater the buffering effect and stackability, while the smaller the flute, the smoother and firmer the plane, which is also printable.

A distinction is made between common types of flutes based on their structure. Wave A represents the coarse wave with a wave height between 4 and 5 millimeters and a wave pitch of 7.9 to 10 millimeters. Wave C is the medium wave with a wave height of 3.1 to 4 millimeters and a pitch of 6.5 to 7.9 millimeters. Shaft B is the fine shaft with a height of 2.2 to 3.1 millimeters and a pitch of 4.8 to 6.5 millimeters. Shaft E is the fine or mini shaft, where the height is 1 to 1.9 millimeters and the pitch is 2.6 to 3.5 millimeters. The maxi shaft and the mini shaft can be perfectly combined to provide several protection and steaming properties. High protection is provided by the A and C flutes, which are also frequently used for multi-flute designs. Multiple plies provide increased load capacity while providing good cushioning to protect the packaged goods.

The packaging and construction types defined by the FEFCO standard are based on the corrugated shape and structure of the corrugated board. The FEFCO code is divided into four digits, where the first two represent the design and basic type, and the last two represent the subordinate design. It is also possible to combine different types of boxes. Code 01 includes commercial rolls and sheets of corrugated roll board and corrugated blanks. Code 02 defines folding boxes made from a blank that can be unfolded. The basic types range from form-fitting boxes to firmly glued boxes and interior fittings such as dividers, pads or inserts. In total, the FEFCO standard distinguishes nine different basic types. When buying corrugated board, it is therefore important to ensure that the product also complies with the FEFCO Standard.

Why single and double wall corrugated board are the most important corrugated cardboard types

The single flute corrugated form is the base and has a fluted web enclosed by an outer and inner paper layer. If the number of corrugations increases, another intermediate cover and corrugated sheet are added. The cover paper is either testliner or kraftliner. Testliner is made of recovered paper, while kraftliner is stable paper with virgin fibers. The corrugated web is usually stiff and air-permeable and glued with a starchy glue. This increases the stability of the plies whenever force is applied. Variations differ in the height and length of the corrugation.

If the material is glued on one side, it is roll corrugated board, which is excellent as a filling material. It consists only of a cover paper and an open corrugated web. In addition to this and single face corrugated board, there is double face corrugated board and multi-layer corrugated board. Double wall corrugated board is double fluted, in which two fluted webs glued together on one side are enclosed by cover paper and there is another smooth layer between the flute levels. Double wall corrugated board then has multiple flute webs with a smooth paper layer sandwiched between each.

The type of corrugated board determines the stability and load-bearing capacity of the packaging. If corrugated board is single wall, it offers more flexibility and is malleable, but also has disadvantages such as lower resistance. If corrugated board is double flute, it can be combined with different types of flutes, for example, a composition of a coarse and fine flute or a maxi and mini flute. A coarse flute has a greater flute height and better cushioning capacity. The fine flute protects against mechanical forces and also provides a better base for printing due to its smooth design. Accordingly, there is a lot to consider when ordering corrugated board.

Why double fluting provides more protection during transport

Since single face corrugated paperboard is still very flexible, it is excellent for rolling and thus serves as a filling material in the form of cardboard shredder, roll corrugated paperboard or corrugated board blank. It provides good cushioning, allows filling of voids and stabilizes goods during shipping. Roll corrugated cardboard at the same time forms a popular intermediate layer on pallets to separate goods from each other and provide a buffer. When moving, this type of outer packaging is often used to protect fragile items and stabilize them for transport.

In addition, the single-wall product is suitable for shipping light goods, while the multiwall version is more robust, shock-resistant and resilient, has higher edge crush and puncture resistance, and provides sufficient protection for heavy and bulky goods.

There are also differences in design and structure. The one-sided version of the material has a regular corrugated structure, is pliable and flexible, and lends itself to various uses, including as outer packaging. If corrugated cardboard is 2-corrugated it is more rigid and has better damping functions. Double wall corrugated board always has two flute layers and three face papers, which are standardized according to DIN 55468.

What are the most important quality features and how are they tested?

Strict quality standards apply, especially in the logistics, packaging and shipping sectors, and these are guaranteed by various test procedures and tests. The test procedures are carried out under standardized laboratory conditions and are often applied during the development phase of production. Based on these standards, the DIN 55468 standard applies, which corrugated board packaging must meet in order to be suitable for sale, shipping and storage.

Important quality characteristics relate above all to puncture resistance, bursting strength and edge crush resistance. However, the test also includes the total weight per unit area and the weight of the individual layers. In addition, the thickness of the board is measured in accordance with DIN EN 20 534, which gives an initial indication of the quality characteristics of the material. For storage, the measurement of storage stress and stacking crush resistance applies. The most important test methods for corrugated board quality testing include the ECT, BCT and RCT.

The ECT (Edge Crush Test) is one of the most informative tests and concerns edge crush resistance. It tests at what maximum weight the material can withstand and what stacking strength it has. The ECT determines the overall strength of the packaging material and the high-edge crush resistance of corrugated board. The test method provides information on the maximum force at which the material can be stressed with a precisely defined length and height, or more precisely, the maximum resistance with which the corrugations can withstand a force acting in the same direction of the corrugations. The edge crush resistance is designated by the letters R, specified in kilonewtons per meter (kN/m) and performed with a compression testing machine.

Another quality characteristic is bursting strength. It is tested according to DIN 53 141 in a procedure to determine the resistance that a circularly clamped corrugated board sample offers to a uniformly increasing pressure before the material gives way and is damaged. In this BCT (Box Compression Test), the value is given in kilopascals (kPa) and determined according to a hydraulic principle. Glycerine is used as the pressure-transmitting medium.
For use on pallets, the stacking crush resistance plays an important role and can also be determined using the BCT. It indicates the force that corrugated board can absorb and remove as packaging without buckling. This value is simultaneously dependent on other components, including the air humidity and inherent moisture of the material.

The ring crush resistance, determines according to DIN 53 124 with the RCT (Ring Crush Test) the crush resistance of a strip of corrugated board material, which is formed into a ring and standardized in width and length. The test is performed in a compression testing machine in which the specimen is clamped between two plane-parallel plates. The value is given in kilonewtons per meter and is used to determine the paper quality, durability and sustainability of the end product.

In addition, the flat crush resistance is tested with the FCT (Flat Crush Test). This test is carried out on the finished product in accordance with DIN 23 035 exclusively for single-sided and single-flute board. A circular sample is taken and placed between two compression plates. The material is pressed until the flute collapses. The highest value is the flat crush resistance, which is also given in kPa. This test is not performed for double corrugated board.

The answer to the question "Where can one order a corrugated board product and what must be considered?"

If one wants to order corrugated board, sustainability and quality are key purchase criteria. Manufacturers guarantee the properties of the material through the testing procedures. When purchasing, it is particularly important to pay attention to which type is useful. This depends on the intended use. Single corrugated board, which is flexible, malleable and stable, is sufficient as padding and filling material. It is environmentally friendly and has excellent insulating properties. At the same time, single-ply material is load-bearing and suitable for shipping light goods. If the weight of the goods is heavier, you should buy double wall corrugated cardboard, which are more robust and load-bearing and remain the right choice even for bulky goods.

Properties such as edge protection, bursting strength and crush resistance should be taken into account when buying cardboard boxes and packaging materials that are intended to ensure safe transportation. Manufacturers provide this information in the product description of their cardboard boxes, which also includes information about the corrugation type, construction and corrugated paper thickness.

If you are wondering "where to buy corrugated cardboard?" then we have the answer: right here in our online store! We offer you different corrugated products, so you can buy double corrugated, as well as roll corrugated or cardboard shredder. We are here for you and will be happy to advise you professionally and reliably if you have any questions. Just use our contact form or give us a call.

Corrugated board is available in single wall and double wall with different advantages

As one of the most popular packaging materials, corrugated carton has many advantages in terms of material properties, stability, strength and sustainability. It is environmentally friendly, can be fully recycled and is also largely made from recycled waste paper. At the same time, production is efficient, CO2-optimized and environmentally friendly. Since the material has many cavities due to its corrugated shape and texture, it has a damping and insulating function. Better than solid board, especially the double corrugated product reduces heat flow, so the packaging is also suitable for temperature sensitive goods. This can be an important criterion when buying double corrugated board. However, it depends on the application whether double flute should be present in the corrugated board or whether the single flute counterpart is used.

Corrugated board can be printed in any form and allows a colorful design or the printing of a logo or motif. Other advantages to buying corrugated cardboard come from the fact that it is strong, but at the same time malleable, easy to combine, and slip and scuff resistant. This makes it versatile in use, including for shipping, logistics and storage. The material is water repellent, insulating, oil resistant, flame retardant, anti-static and good as cushioning and filling material for fragile goods.

Corrugated board as filling material

Not only is the corrugated paper product the ideal material for cartons and packaging, but it is also ideally suited for cushioning goods or as a filling material for stuffing cavities. In this way, the cellulose derivative prevents damage to or punctures in the packaging. Corrugated board as a filling material is divided into roll corrugated board, corrugated board blanks and cardboard shredder.

Roll corrugated board

Roll corrugated board offers optimum protection for surfaces, corners and edges of objects and is at the same time flexible and rollable and stable and rigid. It is single ply, usually with cover paper on one side, and available in a variety of roll widths for cushioning. To provide a high quality product, our roll corrugated C flute is used. This simple flute allows for efficient cushioning and shock absorption. Corrugated cardboard can be folded, wrapped and cut to size and is ideal for packaging glass, small parts, ceramics and other fragile goods. The material has disadvantages when it comes to protecting bulky goods or irregular surfaces. Here, corrugated roll cardboard is more difficult to adapt. On the other hand, it serves well as a filling material and all-round packaging.

Corrugated board blanks

Another variant for padding are corrugated board blanks. They serve as intermediate layers on pallets and provide protection, separation and cushioning. Corrugated cardboard blanks simplify stacking on pallets without damaging the goods. The blanks are standardized and available in different sizes, so that they can be adjusted to the intended use and the goods to be shipped. The blank made of corrugated cardboard material is much stronger and more stable than other paper blanks, while remaining lightweight and suitable for multiple levels. This provides sufficient protection for stacking and sorting of goods. Used for corrugated board blanks both single and double wall material. The material can also be used in cartons to reinforce the bottom or to create partitions.

Cardboard shredder

Papp Schredder is one of the most environmentally friendly and inexpensive filling materials and replaces bubble wrap or Styrofoam. It is used to fill the voids in cardboard boxes and to completely pad packages when ordering so that goods are not damaged or shift. Corrugated cardboard scraps are used for the production of cardboard shredders. The cardboard is fully recyclable and climate neutral. The high quality of the filling material enables optimal cushioning and padding. In addition, Papp Schredder can be used several times and is well suited for frequent shipping. Papp Schredder also has a homogeneous visual effect, since in most cases it is just as brown as the outer packaging. The material is light and flexible and easy to dispense, so nothing is wasted. The shape allows a perfect fit to the goods.