Corrugated boxes are one of the most common packaging materials used by packaging businesses throughout the world to ship and store their products. They are made of corrugated paperboard which has three layers: an internal liner, an exterior liner and a fluting medium. This form of paperboard provides excellent protection for products during shipment and storage. In this post, you will learn the science behind corrugated boxes and how they keep things secure.
What is Corrugated Packaging?
Before we can discuss the special strength of corrugated boxes, we must first define them. Corrugated boxes are made of numerous layers of material, with a fluted layer sandwiched between two flat linerboards. This combination lends corrugated boxes their distinctive rigidity and capacity to handle heavy loads, impacts, and environmental stresses.
Unlike standard cardboard which is made up of a single layer of paperboard, corrugated boxes provide superior protection which makes them the preferred choice for shipping and storage in a variety of industries, including e-commerce, food, electronics, automotive and pharmaceuticals.
Factors That Affect Box Strength
Custom corrugated boxes offer a very high strength-to-weight ratio. This ratio represents the box’s ability to support a significant amount of weight relative to its own mass. The strength-to-weight ratio is directly influenced by the thickness and weight of the liner paper, as well as the flute size used. As a result, the box can withstand both bending and crushing forces.
1. The Fluting Medium: The Key to Corrugated Boxes’ Strength
The corrugated substance produces a sequence of arches within the two layers of smooth material. This design adds significant strength to the box by equally dispersing weight throughout its surface. The most crucial part of corrugated boxes is the fluting medium which gives the box its rigidity and strength. It is composed of a number of arches that are compressed between the two liners to form a number of columns that are capable of bearing large loads without collapsing.
Because of the air circulation provided by these channels, the boxes are under less pressure and are less likely to collapse. The primary element that gives a corrugated sheet its cushioning qualities is its flutes.
2. The Effect of Quality of Box Liners
In addition to the fluting medium, corrugated boxes can be lined with a variety of cushioning materials such as foam or bubble wrap. These materials add an extra layer of protection to fragile products, reducing the risk of damage.
Corrugated box liners also contribute significantly to the box’s strength and protection. They are often composed of Kraft paper, a high-strength paper derived from wood pulp. The quality of the liners determines the box’s strength and durability. Higher-quality liners are more resistant to crushing and tearing, making them perfect for transporting big or delicate items. The thickness of the liners also influences the strength of the box. Thicker liners safeguard the contents within the box and last longer during delivery and storage.
3. Cushioning Effect
Products are subjected to a variety of external pressures during transportation and handling including collision and vibration which can cause damage or even destruction. Corrugated boxes use cushioning to protect their contents from these forces.
The fluting medium in corrugated boxes functions as a shock absorber, absorbing and decreasing energy from external forces. When a box is subjected to impact or vibration, the fluting medium compresses which absorbs the impact energy and reduces the force transmitted to the products inside.
4. Compression Strength
Corrugated boxes also prevent things from being crushed or deformed during transportation and handling. Heavy products or boxes placed on top of each other might crush or deform a box, causing damage to the contents. The fluting medium in corrugated boxes has high compression strength, allowing the box to withstand heavy loads without collapsing or deforming. The arches in the fluting medium form a series of columns that can withstand heavy loads without collapsing, making corrugated boxes ideal for shipping bulky items.
5. Stacking Strength
Corrugated boxes have exceptional stacking strength, allowing them to be piled on top of one another without collapsing or deforming. This is critical for firms that need to keep a large number of products in a limited location.
Corrugated boxes’ stacking strength is also due to the fluting medium. The arches in the fluting medium form a network of channels that allow air to move between the boxes alleviating pressure and helping to keep them from collapsing.
6. Moisture Resistance Effect
Moisture may be extremely damaging to many things, particularly those that are sensitive to water, such as electronics, food and medications. Corrugated boxes can be treated with moisture-resistant coatings to protect the contents from moisture damage.
There are several types of moisture-resistant coatings that can be applied to corrugated boxes. Some coatings are applied to the surface of the box, forming a barrier that prevents moisture from entering. Other coatings are applied to the fluting medium, resulting in a moisture-resistant layer throughout the box.
7. Customization Effect
Corrugated boxes are very adaptable so they can be tailored to the precise requirements of the products being sent. Customization enables firms to design packaging that is fitted to the specific needs of their products.
Customization choices include different sizes, shapes and printing methods. Some products may require a box of a specific shape or size to fit securely inside. Custom printing can also be utilized to generate branding and marketing materials, increasing the value of the package beyond its protective functions.
8. Sustainability and Eco-Friendliness: An Additional Strength
One of the primary benefits of corrugated boxes is their environmental sustainability. Corrugated boxes, which are made primarily from renewable resources like wood pulp and recycled paper, have a significantly lower carbon footprint than many other packaging materials.
Additionally, corrugated boxes are extremely recyclable which makes them an environmentally beneficial solution for both businesses and consumers. The ability to recycle and reuse these boxes helps businesses achieve their sustainability goals, decrease waste and attract environmentally conscious clients.
Final Thoughts
A corrugated box’s strength goes far beyond its outside surface. Although they have long been a mainstay of the packaging sector, corrugated boxes are being propelled into the future by developments in materials science, design engineering and sustainability. In order to satisfy today’s packaging requirements, corrugated boxes are versatile, strong and eco-friendly, making them ideal for delivering electronics, food and delicate products.
