Corrugated mailer boxes are the perfect packaging solution for shipping lightweight items. They are sturdy, crush resistant, and fold flat for easy assembly without tape, glue, or staples.
Mailers are ideal for e-commerce and subscription businesses. They also provide an excellent way to showcase a brand aesthetic. Choose from various styles, including indestructo tuck or easy fold options.
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Corrugated Board
Paperboard, also known as corrugated fiberboard, is a sturdy material that can endure the rigors of shipping and storing. It is a versatile packaging option with different thicknesses, flute types, and colors. It is also available with various coatings and finishes to ensure your product remains secure and attractive.
The ruffled fluting of the corrugated medium is what gives it its exceptional strength. The arches in the fluted pattern are glued together, which allows them to keep their shape while resisting pressure from all directions. Inventors of the corrugated medium borrowed an architectural principle that has been around for thousands of years. An arch with the proper curve is the most substantial way to span a distance, and the inventors of the fluted paperboard took that concept to create this durable material.
During manufacturing, the paper-based corrugated medium is heated, moistened, and formed into its fluted pattern on a “corrugator.” Then it is joined with flat liner boards to make the finished product. The liners may be bleached white, mottled white, or colored and can be printed.
C-Flute is the most common type of flute for corrugated cardboard and is known for its good compression strength and stacking resistance. E-Flute is a thinner version of C-Flute with a smooth surface ideal for high-graphics printing. Both can withstand the edge crush test (ECT), which applies force perpendicular to the edges of the box until it buckles.
Corrugated Liner
Many corrugated mailer boxes exist, but each one is expected to have a lid, top, sides, bottom and inner space. This is due to the essential attributes of the material and its ability to be shaped, folded, and processed. The design of a box can be changed by adding or removing flaps, slots, and folds and applying different coatings, treatments, and adhesives.
Corrugated is an environmentally-friendly material that works well for most industries. It is easy to customize with graphics and surface printing, making it an excellent choice for packaging products and building brand loyalty. It’s also a cost-effective option, mainly when used in bulk shipping.
Containerboard is a term for the paperboard components (liner board and corrugated medium) that make up a corrugated box. It can be made of virgin or recycled fibers. The edge crush test measures the force to compress the on-edge combined board. It’s a primary factor in determining the compression strength of a completed box and is required by some carrier classifications.
Corrugated Slotted or Full Overlap
Corrugated packaging is designed to provide a safe and secure shipping method for any item. They can accommodate any size or shape and can be customized with a company’s logo. This helps to build brand recognition, as it adds to a professional image for the business. It can also withstand various climatic conditions, including moisture, temperature changes, and vibrations.
There are many types of custom boxes, each with a unique design and specific needs in mind. However, all boxes have a few essential attributes and expectations that they must meet to be functional. These include a lid, top, bottom, sides, and inner space. These attributes lead to the creation of various box styles, each with benefits and uses.
Regular Slotted Container (RSC)
The RSC, the most common type of corrugated box, comprises three pieces joined together to form a box. This box is highly resistant to rough handling in transit and has a large, flat bottom that provides excellent support for products and items.
The center special full overlap slotted container (CSSFC) is similar to the RSC, except the outer flaps come within an inch of a complete overlap when closed. The overlapping of the outer flaps makes this box stronger and more resistant to harsh environments.
Loose Fill
Whether you’re a large, global brand that mails packages to your customers worldwide or an independent e-commerce business that sends out a few orders each week, it is essential to use proper packaging materials for shipping. After all, if you use a too-small box for your product, it could crush during shipping. Similarly, if you ship your product in a package that is too heavy, it can cause damage to the item and its packaging.
Corrugated shipping boxes are a durable and affordable option for your products and can help ensure your packaging is as safe and secure as possible. However, choosing a suitable packaging material for your product, including void fill, is essential.
A foam pad is an excellent void-fill solution that offers an affordable, lightweight, and versatile product. It can be used as a layer of protection to separate items within a box or to provide additional cushioning in an already well-packaged shipment.
A regular slotted container (RSC) is a type of box made from a single sheet of corrugated board that is scored and slotted, allowing it to be easily folded. It has flaps that extend from the side and end panels. The inner flaps are cut to different lengths, and the outer flaps overlap when closed to give a double thickness of corrugated at the top and bottom of the box.