When it comes to packaging, understanding the differences between various materials is essential for businesses and consumers alike. Two commonly used materials are corrugated and cardboard. In this blog post, we’ll explore what corrugated cardboard is, explain how it differs from regular cardboard, and discuss the advantages of using corrugated boxes for various applications.

What is Corrugated?

Corrugated cardboard, also known simply as corrugated, is a type of material made up of multiple alternating layers. It consists of a wavy, fluted sheet glued to one or more liners. The most common construction is the fluted sheet between two liners. This structure makes corrugated thicker and more durable than cardboard. The fluted layer adds strength and cushioning, enhancing overall durability and impact resistance.

The structural characteristics of corrugated board are based on four variables: 1) the strength of the corrugated medium, 2) the height and number of flutes per foot, 3) the strength of the liners, 4) the number of walls: single, double, or triple.

Corrugated is the preferred choice in the shipping and packaging industry, commonly used for packaging electronics and various consumer goods. If you have ever ordered something online, chances are it arrived in a corrugated box.

What is Cardboard?

Cardboard is a general term used to describe thick, paper-based material. The most common type is paperboard (also known as chipboard)—a single layer of thick paper that is easy to cut and bend.

Its flexibility makes cardboard an ideal choice for arts and crafts, greeting cards, and notebook covers. It is also widely used in retail packaging, such as boxes for cereal and other food products, board game boxes, tissue boxes, etc. Cardboard is best suited for lightweight items that require minimal protection.

What is a Corrugated Sheet Made Of?

A corrugated sheet consists of multiple layers:

Liner Boards: The thin facings on the outside and inside of a corrugated board.

Fluted Mediums: The wavy inner arches that are attached between the liner boards with adhesive.

These elements work together to enhance strength and durability, making corrugated an ideal packaging material.

Flute Designation	Flutes per Linear Foot	Flute Thickness (in)
A-Flute	33+3	3/16
B-Flute	47+3	1/8
C-Flute	39+3	5/32
E-Flute	90+4	1/16

Corrugated Board Styles

Single face: Consists of one layer of fluted material attached to a single sheet of linerboard. This style is not used for outer packaging but is ideal for interior cushioning and protecting items during shipping.

Single wall: Made with one fluted medium sandwiched between two sheets of linerboard. This is the most commonly used corrugated board and comes in a variety of strengths.

Double wall: Features two layers of fluted medium (B-flute and C-flute, see below) between three sheets of linerboard. This style is built for extra strength, making it suitable for holding or stacking heavier items or for products that need more protection during transit.

Triple wall: Composed of three fluted mediums (two layers of C-flute and one layer of B-flute, see below) between four sheets of linerboard, this is the most durable corrugated board. It is often used for large, heavy-duty bin-style boxes in industrial applications.

Most Common Flutes

A-flute is the thickest type of corrugated board, measuring about 3/16 inch in thickness. It offers excellent cushioning and compression strength, making it ideal for packaging fragile or delicate items that need extra protection during shipping. It provides superior protection and is often found in packaging for heavy or sensitive equipment.

B-flute corrugated board is approximately 1/8 inch thick and is often used for smaller cartons and retail packaging. The flatter surface of B-flute holds printed graphics well and folds easily into detailed shapes, making it a popular choice for die-cut designs.

C-flute is the most widely used type of corrugated board, measuring about 5/32 inch thick. It balances strength and printability, making it suitable for standard shipping boxes and packaging applications that require both durability and branding.

E-flute is much thinner than B-flute and C-flute, at about 1/16 inch thick. It is commonly used for smaller cartons and high-end retail packaging. Because of its closely spaced flutes, E-flute offers an excellent print surface and is great for custom graphics. A familiar example is the pizza box, which is often made from E-flute.

What is a Corrugated Box?

A corrugated box is a shipping container made from corrugated cardboard. These boxes come in various shapes and sizes, making them versatile for different packaging needs. They are widely used for shipping, storage, and transportation due to their ability to withstand pressure and protect items from damage. Corrugated boxes are not only sturdy but also lightweight, making them an efficient choice for logistics.

Benefits of Corrugated Boxes

• Strength and Durability: Corrugated boxes can hold heavier items without bending or breaking.
• Cost-Effective: They are generally more affordable than other packaging options.
• Eco-Friendly: Made from recyclable materials, corrugated boxes can be reused and recycled, reducing environmental impact.
• Customizable: These boxes can be tailored to fit specific dimensions and branding requirements.

Important Differences: Cardboard vs. Corrugated

While both cardboard and corrugated cardboard are used for packaging, there are key differences between the two materials:

	Cardboard	Corrugated
Structure & Composition	Flat and smooth, made from a single layer of thick paper with no fluted layer	Fluted structure, with a wavy, fluted layer that adds strength and cushioning
Durability & Protection	Best for lightweight products that do not require much protection	Much stronger, offering better protection against impacts and rough handling during transportation, making it a good choice for protecting fragile items
Uses	Often used for lightweight items, such as stationery, retail packaging for small consumer products, arts and crafts, playing cards, etc.	Primarily used for shipping heavy or fragile items, consumer packaging, retail displays, and other things that require protection during shipping
Cost	Typically cheaper due to its thinner construction, simpler manufacturing process, and lower material usage	Higher cost due to its multilayer structure, which makes the manufacturing process more complex

While cardboard may be sufficient for light-duty packaging, corrugated is the better choice for most applications. Due to its superior construction and durability, Abbott-Action only uses corrugated for all packaging and displays. Corrugated boxes provide superior strength and protection, making them the preferred choice for e-commerce shipping.

Abbott-Action has an ownership position in NewCorr Packaging, our corrugated supplier. This relationship ensures that Abbott-Action receives the exact type of high-quality, corrugated material in a timely manner to meet the needs of our customers.