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All About Boxes The Basics We have included this section to help you select the proper style and type of box to meet your packaging and shipping needs Measurements Box sizes are measured by using inner dimensions unless otherwise specified The size of your contents actually determine the inner box dimensions Domestically within the United States those dimensions are listed in the following sequence Length L x Width W x Depth D Internationally the dimensions are stated as Length L x Breadth B x Height H Dimensions are based on the opening of an assembled box Looking at the opening the longer of the two sides is considered the length The shorter of the two sides is the width The side perpendicular to the length and width is the depth of the box Exceptions are bookfolds bin boxes divider bins where width precedes length depth of the measurement sequence How To Measure A Box The Quick Way Looking at the opening of the box measure the longest or length panel first Using a tape measure place it in the bottom of the box approximately one inch from the back wall and measure from left to right Repeat the process for the shorter width panel Then folding a side flap inward until it is perpendicular to its vertical side wall place the tape measure at the end of the flap and extend it downward until it rests on the inner flap at the bottom of the box see illustration This exercise will give you the depth dimension of the box One piece die cut boxes such as the mailer style with a tuck in top do not have flaps when assembled but the measuring procedure is basically the same For the box depth use the inside back panel as it has a visible score line crease separating back panel from lid For the width of a die cut box measure between the score lines found on the inside of the top or lid And of course for the length of the box place your measuring rule on the bottom of the box approximately one inch from the back panel Measure from left to right Box Construction What you need to know The Manufacturer s Joint is where the two ends of the side panels meet to form the box At that point the panels are fastened together with tape staples or glue This description applies to regular slotted shipping cartons RSCs The side panel thickness and content weight determine the type of seal used for the manufacturer s joint For example glue is used for most single wall boxes but staples are found in some double wall and in most triple wall boxes In contrast die cut boxes are one piece panels scored and folded together They do not have a manufacturer s joint Box Strength The strength of a corrugated box starts with its material A corrugated sheet consists of two major components linerboard and medium Linerboard is the flat paper that covers both sides of the sheet and the medium is the fluted or arched paper found between both liners The flute when anchored to the linerboards with a starched based adhesive resists bending and pressure from all directions When placed vertically on its ends the flutes form vertical columns capable of supporting considerable amounts of weight Flutes come in five basic heights and shapes the most common are B Flute used for die cut boxes and C Flute used for RSCs B flute is compressed and appears thinner but don t be fooled It is made with more paper to provide stronger side wall protection from blows and punctures C flute is taller with more air space but offers enhanced stacking strength For excellent graphic reproduction consider E flute The amount of virgin pulp fibers and the length of those fibers in a corrugated sheet substantially contribute to box strength For example the difference between a 200 test box and a 275 test box is that the latter has more pulp fibers in its corrugated linerboard The 200 test box is rated to hold up to 65 lbs of box and contents while the 275 box can hold up to 95 lbs A 350 test box is rated to hold up to 120 lbs of box and contents The following chart shows Bursting Test and Edge Crush Test performance standards of corrugated box liners based on the combined weight of a box and its contents Look for the Manufacturer s Stamp A way to be sure that the material of the box that you re purchasing meets industry standards is to look for the Manufacturer s Certification Stamp usually printed on one of the bottom flaps of the box The stamp identifies the material as singlewall doublewall or triplewall It also certifies the Mullen Bursting Test most common is 200 lbs per square inch or the Edge Crush Test ECT 32 lbs per inch The Mullen Test measures the bursting strength of the corrugated linerboard while the Edge Crush Test measures linerboard stacking strength The 200 lbs Mullen box and the 32 ECT box are comparable in stacking strength But that is where the similarity ends The Mullen Test box is better suited for the protection of heavier contents while the Edge Crush Test box provides lighter weight cartons with good stacking characteristics When in doubt as to which box to use always select the Mullen Test box because the construction of the linerboard cannot be altered For example 200 Mullen Test linerboard must be made of 42 per square inch basis weight paper and the medium or flute paper cannot be less than 23 per square inch basis weight What is the difference between ECT and Burst Solution ECT Edge Crush Test and Burst sometimes called Mullen ratings for corrugated board are based on two completely different tests and measure different properties of the material Burst tests use hydraulic pressure behind a flexible diaphragm Increasing the pressure causes the diaphragm to expand through a circular opening A sample of board is clamped across the opening and the diaphragm forces through due to increasing pressure until it bursts the sample Test level is maximum pressure in pounds per square inch psi ECT uses a small sample of board compressed between two platens which are aligned perpendicular to the flute direction Test value is the maximum force to collapse the board in pounds force per inch of specimen length So the two tests measure different properties ECT measures primarily top to bottom compression strength while burst measures primarily puncture and tear resistance Corrugated grades are based on these tests When a test is applied to a sample then the results allow us to assign a grade So a particular run of board is not intrinsically ECT or burst the designation only refers to how it was tested board may be designed to optimize one or the other test results however If a run is designed to be graded ECT and then is graded ECT and marked accordingly we typically call it ECT grade board But the sample run could also be graded burst Grade is just a classification system and there happens to be two systems Accordingly it is not typically possible to tell the difference between ECT and burst grades as all board can fit into both grading systems Carrier rules now allow for grading by either system The ratings are ALTERNATES but not EQUIVALENTS No equivalency exists or is implied between the grading systems For example while 32 ECT is an ALTERNATIVE to 200 burst 32 ECT is not EQUIVALENT to 200 burst In fact we would expect that 200 burst would test about 38 ECT and that 32 ECT would burst test at roughly 150 If you re primary concern is crushed boxes and stacking problems consider specifying in terms of ECT If it s containment strength and puncture resistance consider specifying in terms of burst If you need both specify both Flutes The Flute describes the structure of the wave shaped cardboard material that makes up a board s corrugation Flutes come in several sizes known as flute profiles The standard profiles range from A flute the largest to F flute and below microflutes A flute 33 flutes linear foot B flute 47 flutes linear foot C flute 39 flutes linear foot E flute 90 flutes linear foot F flute 128 flutes linear foot Generally larger flutes provide greater strength and cushioning while smaller flutes have better printability and foldability Flute profiles can be mixed and matched within the same piece of combined board to manipulate printability compression strengths cushioning strengths and the total thickness of the board For instance CE double wall gets its durability from its C flute layer while the E flute gives it a smoother printing surface A Flute A Flute the original flute is the highest flute size and therefore when combined with an inner and outer facing is the thickest With 36 flutes to the foot A Flute makes the most of corrugated s cushioning and stacking properties for fragile and delicate items Because A Flute offers excellent stiffness qualities and short column crush resistance it has application across a broad range of customer uses 36 Flutes Foot 1 4 B Flute B Flute the second flute size adopted by the corrugated industry has lower arch heights than A and more flutes per foot 50 This means that the medium contacts and supports the liners at a greater number of points providing a stiff flat surface for high quality printing and die cutting and with excellent crush resistant properties B Flute is also preferred for high speed automatic packing lines and for pads dividers partitions and other forms of inner packing Complex die cuts and beverage trays are excellent applications for B Flute as are can cases wrap around blanks glass to glass packs and slipsheets B Flute is generally combined with light weight liners but can be used with heavier facings if the need arises 49 Flutes Foot good puncture resistance less space consumed in warehouse uses canned goods displays C Flute C Flute came along next to split the difference between A and B Flutes With 42 flutes per foot it s thinner than A flute thicker than B and offers good cushioning stacking and printing properties C Flute is by far the most widely used flute size An estimated 80 of today s corrugated containers are made of C Flute board 41 Flutes Foot good stacking strength good crushing resistance very common uses glass furniture dairy E Flute E Flute has the greatest number of flutes per foot at 94 which gives it the greatest crush resistance and the flattest surface for high quality printing applications The thin board profile of E Flute it is one fourth the thickness of C Flute reduces box size and saves storage space Because of its thin profile and excellent cushioning properties E Flute can often substitute for conventional folding cartons or solid fiber containers Examples of E Flute applications include boxes for cosmetics fragile glass and ceramic items and delicate instruments Another growing end use is for pizza boxes where the retailer wants a cost effective container with good graphics and excellent product protection 95 Flutes Foot light weight strong alternative to paper board superior printing surface excellent for custom die cut boxes uses displays point of purchase boxes F Flute F Flute the newest flute is just a little more than half the thickness of E Flute and is the newest growth segment in the corrugated industry The idea behind the new flute originally developed in Europe is to make packages with lower fibre content With F Flute converters can reduce the total amount of fibre in the packaging thereby creating a more rigid box with less solid waste going into landfills In Europe F Flute is being used for specialty packaging point of purchase displays jewelry and cosmetic packages and shoe boxes In the U S the McDonald s Big Mac clamshell in F Flute has received great attention Dairy Queen too is using the F Flute clamshell for its Ultimate sandwich and its hot dogs 128 Flutes Foot 1 32 Types of Corrugated Materials Single WallDouble WallTriple Wall Single Face Sheet A corrugated medium with a linerboard facing adhered to one side It can be manufactured in sheets or rolls Single face is principally used as a wrapping material and occasionally for interior packing or padding Single Wall Corrugated A corrugated medium with a linerboard facing adhered to both sides It is also referred to as Double Face This popular and versatile 3 ply construction is converted into a wide variety of containers and packaging components most popular wide range of strengths Double Wall Corrugated Two corrugated mediums with a linerboard facing adhered between them and to both sides This 5 ply construction is most applicable for packing heavy items where high rigidity and protection is required made up of B and C Flutes extra padding and strength great for stacking heavy items Triple Wall Corrugated Three corrugated mediums and four linerboard facings This 7 ply construction is used where large container sizes are involved such as pallet packs made up of two layers of C Flute and one layer of B Flute very strong and crush resistant excellent for storage and transit To vary the look of your corrugated box you have the following choices in outside liner grades Kraft Naturally brown in color The most commonly used and least expensive liner 3 White Mottled white with underlying kraft showing through Provides a cleaner look and better printability than kraft 1 White Bleached bright white Offers very good printability but easily soils during transit Premium Grades Surfaces have a bright white clay coating minimizing porosity so printing inks sit up on the surface Gives excellent printability as colors are more vibrant and lower absorbency improves registration However because of the high hold out ink rub can be a problem Litho printed labels for labels laminated onto corrugated boxes When What Box to Use When to use a single wall 200 test box when the box and contents weigh less than 65 lbs This weight limit works fine for multiple light weight items in a box or for a masterpack box where individual boxes are packed tightly in organized rows and stacks If a single heavy item is to be shipped in a single wall 200 test box we recommend a weight limit of 45 lbs or an upgrade to a 275 test single wall box Simply apply common sense and always err on the conservative side Box Styles Regular Slotted Carton RSC Also called shipping boxes RSCs are the most commonly used boxes They are usually kraft brown in color have four flaps on the top and bottom and the side walls are sealed at one corner known as the Manufacturer s Joint This design is highly functional for most packing applications Multiple Depth Carton MDC The same box design as an RSC but with horizontal scores creases at selected depths along all four side walls This feature gives you depth flexibility when packing a box A Multiple Depth Carton can be several boxes in one Half Slotted Carton HSC A variation of the RSC the Half Slotted Carton has only one set of flaps The opposite side of the box is completely open allowing it to slide over an item Envision the use of the box turned over so that the flaps are on the top The covered item is usually attached to a pallet or other type of surface that serves as a separate bottom Full Overlap Slotted Carton FOL With a Full Overlap Slotted Carton all length flaps are also equal to the width of the box The flaps actually fold over one another to provide added strength and protection to the top and bottom Five Panel Folder FPF A Five Panel Folder actually resembles a shallow depth box when assembled It is a one piece box with an over lapping top and over lapping end panels The functional design is also economical Snap Bottom Carton SBC Available with tuck in top or with RSC style top flaps shown Also referred to as an auto bottom box The bottom of the box snaps into place without tape for quick assembly Best suited for light weight products Full Telescope Design Carton FTD A two piece box with a separate lid that fits over a bottom tray Half Telescope Design Carton HTD Two half slotted cartons with one box slightly smaller to enable it to be inserted into the other box Offers the ability to adjust the height or length of the box to fit your needs Especially suitable for large heavy items For depth flexibility with smaller items visit the Multiple Depth box section of this web site Two Piece Carton With Separate Lid CSL Die cut box with open top and tray style lid Similar to a File Storage Box but without the hand holes on either end See File Storage Boxes section of this Web Site if you are looking for a box to store paper files Double Cover Carton DC This style of box is frequently used for tall or large heavy items A three piece box the Double Cover Ca