How is Corrugated Made

Everyone uses corrugated boxes. You would be hard-pressed to exist in today&#;s society and not have some kind of contact with them. But have you ever thought about how they are made? To make corrugated boxes, you need three main materials: paper, steam, and adhesive. The process begins with paper.

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Paper is used to make the two main components of corrugated fiberboard:

1. The linerboard&#;used as the outer facings

2. The medium&#;fluted paper that is attached to the linerboard to produce combined board in a continuous web

Multiple choices exist when it comes to paper types and thicknesses for corrugated board. Make sure you determine the goals for your package and work closely with your box plant and/or paper supplier to see the paper characteristics you need to reach those goals.

For more than 100 years, corrugated boxes have reigned as the go-to method of packaging for product transportation. In today&#;s market, corrugated materials are used to display, promote, and package just about every product on earth. Whether it&#;s food, toys, office supplies, computers, clothes, furniture, or electronics, everything we buy has traveled some distance to reach us and will typically have been protected by a corrugated container from its original point of manufacture.

Benefits of Corrugated

The origins of the corrugated paper manufacturing process can be traced back to shipping and packaging operations in the 19th century. Today, it is used throughout most of the world during transit from the manufacturer all the way to the point of sale, or direct to the consumer&#;s home. Some of the extensive benefits of corrugated include its:

• Minimal weight

• Practicality

• Usefulness

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• Sustainability

• Recyclability

• Design and merchandising appeal

In addition to these practical and environmental benefits, corrugated also offers limitless design possibilities and merchandising appeal to consumers. Even when the destination has been reached, corrugated can be recycled and used for the same purpose all over again.

Innovation in the Corrugated Industry

Corrugated manufacturers continue to improve their corrugated paper manufacturing process and products to adapt to changes in distribution systems, the needs of retailers, and consumer demands. This includes finding ways to build stronger paper that&#;s lightweight and water-resistant.

To remain versatile in the face of these ever-changing demands, corrugated facilities have equipped themselves with machine-automated technology that enables them to make an astounding $23 billion annually in the United States alone. As populations increase and the demand for products continues to grow, corrugated is likely to remain the best option for transporting products and materials safely all around the world.

The Corrugated Paper Manufacturing Process

The process for making corrugated boxes involves six steps that begin with sustainable timber harvesting and finish up in a specialty carton plant like the one used by FGS. To understand this process with a simple illustration, you can take a piece of paper and add waves in it (known as flutes). Glue the fluted paper to layers of strong linerboard and hey presto &#; you&#;ve got a tough piece of combined board that can take a beating while protecting even the most fragile of contents on the inside. 

The production of commercial corrugated is a little more involved than the example above, involving specialized machines and customization. Find the details of each step of the corrugated manufacturing process below:

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