Everything You Need to Know About Corrugated Packaging

A box is just a box, right? Well, that’s true until it gets destroyed in transit and your product is destroyed alongside your brand’s reputation. With corrugated packaging, manufacturers can utilize a dynamic solution essential for protecting products, boosting brand visibility, and achieving sustainability goals.

In this guide, discover how these materials are customized to meet specific needs. The right kind of packaging is more than just a container. It’s the foundation to your entire supply chain strategy.

1. What Is Corrugated Packaging and Is It Necessary for My Product?

2. What Are the Benefits of Using Corrugated Packaging Products?

3. How Are Corrugated Materials Used Creatively Across Different Industries?

4. What Are the Advantages of Using Corrugated Packaging in Your Supply Chain?

5. How Does Corrugated Container Packaging Improve Inventory Management?

6. Can Modern Brown Box Packaging Boost the Customer Experience?

7. What Should You Expect from a Corrugated Container Company?

8. What Questions Should I Ask a Corrugated Container Company?

9. How Does York Create Its Corrugated Sheets for Packaging?

1. What Is Corrugated Packaging and Is It Necessary for My Product?

Corrugated packaging is a significant component in the product supply chain. It is distinguished by its unique structure — a central fluted corrugated sheet sandwiched between two flat linerboards. This design provides remarkable durability and cushioning while offering significant flexibility in printability and structural design. Given its versatility, corrugated packing can be used in a vast range of applications, from heavy-duty shipping boxes to intricate retail display packaging. The material’s inherent strength protects products during transit while its lightweight nature reduces shipping costs.

There are several types of flutes, and York manufactures the following:

• C-flute: Features 38 flutes per foot and is the standard choice for brown boxes and shippers. It’s valued for its thickness and strength.

• B-flute: Contains 47 flutes per foot, offering a smoother surface that is preferable for graphic packaging and display components.

• E-flute: Has 90 flutes per foot with a thinner profile, ideal for applications requiring high graphic quality, making it suitable for direct printing.

Source: York

But is corrugated packaging necessary for your product? It depends largely on the specific packaging needs of the items you are shipping or displaying. For instance, if your product requires a high level of protection or if it’s frequently handled through complex distribution channels, corrugated packing might be your ideal choice. Furthermore, corrugated materials bring numerous environmental benefits. They contain large percentages of recycled fiber and are fully recyclable, which is significant in a world that continually demands sustainability. Plus, the customization in size, shape, and style helps cater to whatever your specific needs are.

Tip: York Container can provide our customers with 100% recycled corrugated board to help meet sustainability goals.

2. What Are the Benefits of Using Corrugated Packaging Products?

The benefits of corrugated packaging products go far beyond just providing a quality container for shipping and display. This type of packaging offers distinct advantages in terms of cost-effectiveness, customization, and sustainability. Here’s a breakdown of each key benefit:

Cost-Effectiveness:

Through design flexibility and durability, corrugated packaging can be tailored to meet specific needs without a significant increase in cost. Plus, the durability means less of a need for replacements due to damage. And, with some well-designed corrugated boxes, they cut down on space and transportation costs. The ability to withstand rigorous conditions also leads to minimizing the risk of in-transit damage.

High Customizability:

The tailored design solutions of corrugated packaging allow it to be customized to different shapes, sizes, and strengths based on the product’s requirements. Further, for products that need extra care (such as electronics or perishable goods), corrugated packaging offers extra protective adaptions such as inserts or specialized coatings.

Improved Sustainability:

Corrugated packing is predominately made from renewable resources and can itself be recycled. Using recycled corrugated materials not only helps the environment but also boosts a brand’s image while adhering to increased sustainability requirements and regulations.

“Manufacturers and retailers of fast-moving consumer goods continue to innovate new packaging formats to improve circularity, particularly focusing on recycled content.”

- David Feber, Via McKinsey “Sustainability in Packaging 2023”

3. How Are Corrugated Materials Used Across Different Industries?

Leaders at manufacturing and distribution companies must think beyond the traditional uses of packaging. With corrugated materials, numerous creative avenues can be taken, showcasing their extensive use across various industries. The versatile packaging options not only protect products during transportation but can significantly boost brand visibility on store shelves. The goal is to appeal directly to consumers through customized, visually engaging designs that resonate with their preferences and values.

In the food and beverage industry, corrugated packaging ensures the hygienic and sturdy containment of goods which is important for maintaining freshness and safety standards. But beyond that, it’s a branding opportunity. Just look at how Starbucks uses corrugated materials to keep their product fresh while broadcasting their brand. Remember, 30% of people say they are more likely to share pictures and videos of packages they receive on social media if the packaging is visually appealing.

Source: York

Meanwhile, the pharmaceutical industry benefits from the durability and reliability of corrugated materials. That protects sensitive medical products during shipping and handling. Moreover, in consumer goods, these materials allow for highly customized packaging solutions that cater to specific product dimensions and marketing needs, minimizing waste and improving logistics.

In essence, creative use across industries comes down to these three benefits:

• Protecting consumer goods

• Saving warehouse space

• Being easy to customize

The widespread application of corrugated materials also shows their role in sustainability efforts within these industries. Made predominately from recycled content and being fully recyclable, corrugated packaging aligns with the increasing consumer desire for environmentally responsible products. (85% of buyers want their products to be sustainable!) This helps companies reduce their ecological footprint while improving customer loyalty.

4. What Are the Advantages of Using Corrugated Packaging in Your Supply Chain?

Corrugated packaging offers significant advantages for integrating into your supply chain. It can boost efficiency, flexibility, and sustainability. Here’s how:

• Speed to Market and Production Flexibility: The durability and lightweight nature of corrugated packaging means that goods are protected yet easy to handle. The versatility here allows for these packaging solutions to be rapidly produced to meet urgent demands.

• Total Control of Material: With corrugated packaging, companies have control over the materials used and the overall production volume. This control fosters demand-based production strategies and ensures minimal material delays or supply chain disruptions.

• Comprehensive Fulfillment Solutions: Space utilization, inventory management, and product visibility challenges are serious and can lead to costly and unnecessary mistakes. However, they can be addressed with customized fulfillment strategies such as customized countertops and floor displays to promotional materials and graphic packaging.

With corrugated material solutions, companies meet the growing consumer desire for efficiency and sustainability. This readiness prepares manufacturers to quickly respond to supply chain disruptions and adjust to changes or better inventory management.

5. How Does Corrugated Container Packaging Improve Inventory Management?

Corrugated container packaging can significantly enhance inventory management. This type of packaging allows for quicker adjustments in production schedules, which helps products move rapidly from production to the consumer. The agility here reduces the time products spend in inventory and accelerates the entire supply chain process. Additionally, corrugated packaging is lightweight and durable. This means handling and logistics are that much simpler.

Moreover, corrugated container companies offer advanced control over the production process, which ensures consistent quality and supply. This tight control minimizes disruptions to allow for more predictable and accurate inventory management. The use of integrated technology — such as QR codes — helps for precise tracking and management of products through the supply chain.

Through this innovative package design, corrugated containers can transform traditional inventory management into something more efficient, responsive, and controlled. This helps companies navigate the dynamic needs of modern markets.

“The fusion of robust supply chain logistics and cutting-edge technology forms a potent defense against escalating threats. By investing in tech and methodologies, leaders can unlock substantial opportunities for bolstering resilience against supply chain disruptions.”

- Brian Enright, Forbes

6. Can Modern Brown Box Packaging Boost the Customer Experience?

It might seem simple, but modern brown box packaging can havetransformative benefits on the customer experience. The key here is to provide efficiency, accuracy, and precision without calling attention to it. Remember, the best customer experience is an unnoticed customer experience.

Receiving packaging that arrives on time, in the right quantity, and with the appropriate specifications such as type and print quality might seem minor. However, these variables are pivotal in maintaining supply chain efficiency and upholding your brand reputation. There is a direct correlation to the customer experience.

Over the past decade, the trend in brown box packaging has focused on minimizing the use of materials. By decreasing the volume of packaging, manufacturers can lower both material costs and logistical expenses. Additionally, using less material in packaging supports environmental sustainability. That said, these efficiencies must be balanced to avoid compromising the protection of packaged goods. Overly reducing material usage or selecting lower-quality materials to cut costs leads to damaged goods during transit, negatively impacting the customer experience. Don’t forget: the condition of the packaging often forms the first impression of a brand.

“A McKinsey survey of ten countries found that consumers see sustainability as increasingly important, and the vast majority of consumers say they are willing to pay more for sustainable packaging…”

- The third wave of biomaterials: When innovation meets demand, Via McKinsey, 2021

7. What Should You Expect from a Corrugated Container Company?

As manufacturers, it’s very important to make the right choice when it comes to a packaging partner. A reliable corrugated container company should offer extensive industry expertise, ample production capacity, innovative ideas, and a strong track record of delivering on time and within specifications. These elements are essential for getting your product to market effectively.

Here’s what you should expect from a leading corrugated container company:

• Initial Consultation and Customization: Expect a thorough consultation process where the company will want to understand your department's needs and the specific challenges or goals for your packaging.

• Collaborative Design Process: Be prepared for a detailed dialogue and possibly multiple meetings to discuss the product’s distribution, transportation, and specific requirements.

• Production and Delivery: Once the design is finalized, expect the company to schedule production well in advance, with regular updates and scheduling meetings to keep the process on track.

• Sustainability Considerations: A competent provider will regularly consult with retailers to understand and meet their packaging preferences, particularly concerning sustainability.

• Ongoing Support and Feedback: Post-delivery, the relationship should continue with ongoing support, including quality checks, performance reports, and opportunities for feedback.

Finding the right corrugated container company isn’t just a working relationship. Instead, think of it as a true partnership. First impressions matter, and the way your product looks and feels is a significant variable in your business potential.

8. What Questions Should I Ask a Corrugated Container Company?

In modern manufacturing, the goal is to find a delicate balance between efficiency, supply chain resilience, and sustainability. When assessing a corrugated container company, you must consider several key factors to ensure you’re aligned on your goals. A mixup here can lead to significant obstacles in operations and, even worse, reputational damage.

Here are five questions to ask a corrugated container company to determine if they can meet your packaging needs:

1. How Can a Corrugated Container Company Help Our Company Become More Sustainable?

2. What Sustainable Packaging Materials Do You Use, and How Are They Sourced?

3. What Certifications Do You Have?

4. How Do You Report on Packaging Operations & Sustainability Efforts?

5. Do You Use Automation to Improve Your Packaging Efficiency?

While these are the most common questions to ask, you may have more. Learn what you should expect from a corrugated container company. Or, you can watch the video below to learn about the packaging process. 

9. How Does York Create Its Corrugated Sheets for Packaging?

York produces corrugated sheets using at least three layers of paper, including an inner liner, a fluting medium, and an outer liner, with paper weights varying from 23 to 69 pounds. This variety helps meet various performance requirements by combining different paper weights for packaging efficiency and customization.

Source: York

Having a range of paper options — including standard kraft and specialized white linerboards for detailed printing — means we can customize right on-site. Our team responds quickly to urgent production needs.

Key aspects of the production process include:

• Die-Cutting Techniques: York uses both rotary and flatbed die-cutting methods. Rotary die-cutting is faster, and capable of handling up to 10,000 sheets per hour. Flatbed die-cutting, while slower, offers more consistent precision, beneficial for complex designs.

• Automated Assembly: To streamline the final assembly process, York utilizes automated machinery such as case erectors and formers. These machines sort, stack, bundle, and palletize the packaging.

• Sustainability and Efficiency: The entire process underscores York’s commitment to sustainability by prioritizing the use of recycled materials. This aligns with environmental goals while supporting our clients’ needs for cost-effective and responsible packaging solutions.

York Is Your Partner in Corrugated Packaging

Innovation. Sustainability. Passion. That’s the York Container Company's mission.

As you navigate the complexities of your packaging requirements, consider York not just as a supplier, but a strategic partner committed to improving your operations and impact. We’d love to discuss your goals and challenges. Reach out to our team for tailored packaging solutions that drive your business forward.