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Cardboard Boxes

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Cardboard boxes are used as shipping containers in countless households and industries. The term ‘cardboard box’ refers to multiple types of paper boxes, such as corrugated boxes and chipboard boxes. A cardboard box is made from heavy duty paper with a thickness as low as 0.01 inch (0.25 mm). Various types and shapes of cardboard boxes are made by folding, cutting, and shaping layers of this heavy-duty paper. Read More…

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Leading Manufacturers

St. Charles, IL  |  630-384-1130

Stocking a full line of 200# (NOT 32ect) readily available stock boxes. Specializing in custom corrugated boxes, Larsen Packaging Products, Inc. is a one-stop manufacturer and distributor of a wide range of corrugated items including heavy duty stitched seam triple wall gaylord-type cartons. We’re also a distributor of over 30,000 shipping supplies including a full line of 2000+ stock corrugated boxes & mailers available for next day delivery. Vendor managed inventory & blanket order fulfillment are also value-added programs provided to our local clients, upon request.

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Larsen Packaging Products, Inc. $$$

Pennsauken, NJ  |  856-486-0006

At Deluxe Packaging, our goal is to always create a cost-effective solution for you and to service you better than anyone else. We offer a full array of high quality corrugated boxes in a variety of shapes, sizes, materials, and features. Deluxe Packaging has a proven track record in custom packaging design and timely delivery.

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Deluxe Packaging, Inc. $$$

Burr Ridge, IL  |  866-572-9938

Packaging Design Corporation is a leading single-source provider of corrugated boxes and more. Packaging Design specialize in creating customized packaging to help you sell your product. Founded in 1968, Packaging Design is family-owned and operated focusing on quality, innovation and total customer satisfaction. Let Packaging Design be your provider for quality packaging solutions.

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Packaging Design Corporation $$$

Houston, TX  |  800-306-8326

For more than 20 years, we have been the leading box manufacturer here at Herman Packaging. We always put our customers first and work hard to find them solutions. We guarantee high-quality products and services with our dedication and expertise.

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Herman Packaging $$$

Beloit, WI  |  800-393-7917

Corrugated boxes are the industry standard! All cartons are constructed from strong 200#/32ect, kraft corrugated (unless otherwise noted). Order in bundle or bale quantities. 100`s of sizes to choose from! All boxes ship and store flat to save space. Corrugated boxes are all 100% recyclable. Protect your large shipments with cargo containers! Makes a great master pack for smaller boxes. Protect irregularly shaped shipments. Many standard air freight containers available. Easy to pack.

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Western Container Corp. $$$

Milwaukee, WI  |  800-926-6100

At Associated Bag, we have built a reputation among many industries by providing a broad range of high-quality corrugated boxes and exceptional customer service. Our 6-month quote guarantee is unequalled in our industry, giving our customers the flexibility to order whenever the time is best for them.Our line of boxes include corrugated shipping boxes, insulated boxes, and more. Contact Associated Bag today!

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Associated Bag $$$
placeholder image Larsen Packaging Products, Inc. Deluxe Packaging, Inc. Packaging Design Corporation Herman Packaging Western Container Corp. Associated Bag

Cardboard boxes are designed to protect interior materials and products from any damage during the shipping process. These boxes can also be used as dividers and padding in much larger boxes. Another important factor that makes cardboard boxes ideal is that they can be economically and easily recycled.

Cardboard Boxes

Classification of Cardboard Boxes

Cardboard boxes are classified into two broad categories.

Paperboard Boxes

Paperboard is a type of standard paper that is somewhat thicker, measuring 0.010 inches (0.25 mm). The thickness and rigidity of this paper makes it suitable for creating boxes. Paperboard boxes are made by pulping, separating hard and soft wood, and making fibers through both mechanical and chemical treatments. Examples of paperboard boxes include shirt, gift, toiletry, and food boxes.

Corrugated Boxes

Corrugated boxes are made by layering paperboard, with two outer layers of paperboard and one inner layer made of soft pulp to provide a rippled shape. Corrugated boxes are more durable than paperboard boxes and are often used for shipping purposes. Pizza boxes and moving boxes are two examples of this type.

Manufacturing Process

The manufacturing process for cardboard boxes consists of the following steps:

Turning Trees to Paper

  • The pulp for making paper is extracted from trees such as pine, chestnut, etc.
  • Two types of liners are used in making cardboard boxes: a test liner and a kraft liner.
  • The test liners are made from hardwood or recycled paper, giving them an abrasive surface.
  • The kraft liner is made from softwood trees and has a smooth finish with high resistance to tear and burst.


  • This process ensures that the wood chips pulped are clean enough to use.
  • Two types of pulping involve mechanical pulping and chemical pulping.
  • In mechanical pulping, the paper is ground with a stone to convert the wood into cellulose fibers.
  • This stone is sprayed with water to remove the lignin from the fibers.
  • Mechanical pulping is a low cost process that offers higher output.
  • Chemical pulping is done by cooking the wood to reduce it into cellulose fibers.
  • Two chemicals, sulfate and sulfite, are used to create the strongest and best quality paper.
  • That strengthened paper is called kraft paper, which can be brown or sometimes bleached to white.


  • Fluted cardboard is a wavy piece of paper between two liners.
  • The fluted paper gives strength to the board and reduces damage from impact.
  • The cardboard’s waves are created when the sheet is put in a corrugated roller machine (corrugator).

Production and Bending

  • After going through the corrugator, the papers are steamed in high heat and pressed together.
  • One side of the flute is glued to the carton, and the two liners are then adhered to the walls of the carton.
  • The boards are cut according to size and fed to the trimmer.
  • The trimmer precisely cut the edges of the box and feeds it into the bending machine.
  • The bending machine then bends the fold and shapes the box accordingly.

Storage and Distribution

  • The completed and shaped cardboard boxes are stored at a secure and dry place.
  • They are then distributed or sold to the customers accordingly.
  • Sometimes customers demand printing on the boxes; this is also completed before dispatch.

Types of Cardboard Boxes

Cardboard boxes come in the following types:

Honeycomb Cardboard

Honeycomb cardboard is durable, lightweight, impact resistant, and strengthened. It has two outside panels with a large surface area. These are used as fillers in door manufacturing.

Gray Paperboard

It is a thick gray paperboard made from recycled paper. It is used in many applications due to its stiffness. Gray paperboard is used in making pad backing, rigid boxes, cartons, and bookbinding.

Gray Cardboard

Gray cardboard is made from recycled paper and cardboard. It is smooth, stiff and slightly thicker, which makes it ideal as a replacement for laminated cardboard.

Slotted Container

These boxes are used for shipping purposes; both flaps of the box are of equal size for proper closing.

Slotted Container Cardboard Box

Full Overlap Slotted Container

This box follows the same pattern as that of slotted containers, with one difference – the outer long flap overlaps when bent inward. This pattern provides additional strength to the box during rough handling.

Full Telescope Box

This box has separate sections, and one section fits inside the other one. The flaps are taped, and the top section completely covers the whole base. This box is ideal to use for heavy items.

Full Telescope Box

Snap Bottom Box

The upper part of these boxes are the same as that of slotted containers, but the flaps are cut and shaped in a way that they fold over each other.

One-piece Folder

It is a single unit that folds along the line to form a box. These boxes are ideal to use for shipping items such as ipads, books, video games, etc. Printing can also be done on these boxes.

Self-locking Box

The flaps of self locking boxes are extended and can be locked easily without using tapes or glue. There is also a large lid that slides into self locked edges.

Self Locking Box

Applications of Cardboard Boxes

  • Cardboard boxes are used to protect sensitive technologies from damage.
  • They are widely used in making boxes for bakeries, beer, retail displays, notebooks, paper pads, takeout food and many more.
  • Chipboards are also used in furniture as a structural component to provide stability and support.

Cardboard Box Informational Video


Corrugated Box Power Pages

Cardboard Boxes

Cardboard Boxes

A cardboard box is a shipping container made of thick heavy duty paper known as paperboard, which is more than 0.01 inch or 0.25 mm thick. The term cardboard is used as a generic descriptor for various types of solid firm papers used to produce boxes...

Corrugated Boxes

Corrugated Boxes

A corrugated box is a disposable container whose sides are made up of layers of material that include an inside layer, outer layer, and middle layer. The middle layer, between the outer and inner layers, is fluted, which are rigid wave shaped arches that provide cushioning...

Plastic Corrugated Boxes

Plastic Corrugated Boxes

A plastic corrugated box is a disposable container with three layers of material consisting of an inner layer, an outer layer, and a middle layer on its sides. Corrugated plastic is known by various names, including polyflute, flute plastic, twin wall plastic, and corflute...

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