Corrugated fiberboard—commonly known as corrugated cardboard—is one of the most widely used and versatile packaging materials in the world. From shipping boxes to product packaging and retail displays, corrugated fiberboard is the go-to choice for businesses looking for durability, cost-efficiency, and sustainability.

Whether you’re an e-commerce brand, a manufacturer, or a packaging designer, understanding the structure, types, and benefits of corrugated fiberboard is crucial to making the right packaging decisions.

Definition: What Is Corrugated Fiberboard?

Corrugated fiberboard is a multi-layered paper-based material consisting of a fluted (wavy) inner layer sandwiched between one or two flat linerboards. This structure creates a strong, lightweight material that offers excellent cushioning, compression resistance, and stacking strength.

It is used to manufacture:

• Shipping cartons

• Mailer boxes

• Product displays

• Custom printed retail packaging

• Protective packaging inserts

Structure of Corrugated Fiberboard

Corrugated fiberboard is made up of three core components:

1. Linerboard – The flat outer surfaces (inside and outside) of the board. Made from kraft or test paper.

2. Fluting (Corrugation) – The arched, wave-like paper in between the linerboards. This creates air pockets that provide strength and cushioning.

3. Adhesive – A starch-based glue that bonds the fluting to the linerboards.

The combination of these layers gives corrugated board its signature rigid-yet-lightweight properties.

Types of Corrugated Fiberboard by Wall Configuration

Corrugated fiberboard comes in different wall types depending on the number of layers:

1. Single Wall (3-Ply)

• One fluted layer between two linerboards

• Most common for shipping boxes and retail packaging

• Lightweight and cost-effective

2. Double Wall (5-Ply)

• Two fluted layers, three linerboards

• Greater strength and crush resistance

• Ideal for heavy items or stacked shipping

3. Triple Wall (7-Ply)

• Three fluted layers, four linerboards

• Used for industrial parts, machinery, and bulk shipments

• A strong alternative to wooden crates

Types of Flute Profiles

Flute profiles refer to the size and thickness of the corrugation. Each flute type has its own characteristics.

Some boards combine flutes (e.g., BC Flute or EB Flute) to optimize both protection and printing.

Corrugated vs. Cardboard: What's the Difference?

Cardboard is a generic term often used to refer to any paper-based packaging material. However, corrugated fiberboard is a specific type of cardboard made with fluting and liners, giving it enhanced structural properties.

Benefits of Corrugated Fiberboard

1. Lightweight yet Strong

Thanks to its fluted core, corrugated fiberboard offers excellent strength-to-weight ratio, making it ideal for shipping without adding extra freight cost.

2. Customizable

It can be die-cut, folded, printed, laminated, and coated to suit a wide range of packaging needs—from minimal eco-packaging to luxury retail boxes.

3. Eco-Friendly

Corrugated board is:

• Made from recycled content

• 100% recyclable

• Biodegradable

• Reusable for secondary storage

4. Cost-Effective

Compared to plastic or wood, corrugated fiberboard is inexpensive to produce and ship, offering significant savings for businesses.

5. Printable and Brandable

With high-quality printing techniques (like flexographic, lithographic, or digital), corrugated packaging becomes a marketing tool that showcases your brand story and product info.

6. Excellent Protection

It absorbs shocks and vibrations, protects from moisture (with coatings), and resists compression—making it perfect for e-commerce and retail logistics.

Applications of Corrugated Fiberboard

Sustainable Trends in Corrugated Packaging

With growing environmental concerns, corrugated fiberboard is leading the way in sustainable packaging solutions.

• Brands are moving toward uncoated kraft finishes for a natural look.

• Water-based inks and recyclable coatings are now widely used.

• Innovations in recycled fluting and renewable fiber liners are helping to close the loop in packaging waste.

Choosing the Right Corrugated Fiberboard

When selecting corrugated packaging, consider:

• Product weight and fragility

• Shipping method (air, freight, dropship)

• Storage conditions (humidity, stacking)

• Branding and display requirements

• Sustainability goals

Work with packaging specialists to determine the best flute profile, wall type, and board grade for your needs.

Conclusion:

From protecting fragile electronics to showcasing artisanal baked goods, corrugated fiberboard is the unsung hero of modern packaging. With its strength, versatility, eco-friendliness, and printability, it's no surprise that corrugated boxes move more than 90% of all shipped goods worldwide.

As brands seek to balance function, sustainability, and style, custom product packaging stands out as the smart, scalable solution.