How are cardboard boxes designed? And what material is used to make them

Cardboard boxes are shipping containers made of heavy-duty material. They are also frequently used for product packaging across the retail sector. You can use cardboard as a generic descriptor for multiple types of solid firm papers used to produce these packages. Construct and design them to ensure protection during transport and shipping. Learn the manufacturing and designing process of these cardboard boxes:

Initial Manufacturing of Paperboard for Cardboard Boxes

Pulping Process

The pulping process is used to create the paper for the paperboard. But, first, bleach the pulp to purify it and change its colour. Whether pulp or recycled cardboard, this bleaching process purifies the raw materials. In the case of recycled cardboard boxes, bleaching extracts any chemicals from the cardboard.

Pass the pulp through a series of blades designed to flatten the fibres. It creates the fibrillated ends to assist the bonding process in making the paper stronger. Also, add fillers to increase the density of the pulp and make it opaque. The paper machine dries the pulp by forcing it through rotating wires and belts to remove the water. Before placing it on giant paper, rolls use high temperature and pressure to extract any remaining moisture.

Paper board Construction

Paperboard builds in layers of pulp that you spray in water onto a mesh screen to form a mat. The spraying of the pulp slurry onto the mat builds up the fibres. Besides, mix each grade or type of paperboard carefully to match the requirements to meet its grade standards.

Coating Paperboard

Send the finished and dried paperboard for further processing, where you can coat it with a polymer. In preparation for the coating process, add a starch solution to bind the fibres to the surface and add durability to the board. Before applying the coating, press the paperboard between steel rolls to equalize the board’s density and surface. Next, apply the coating to smooth its surface. Then dry and reel it onto a steel core, cutting the long reel to different widths. The finished product has a smooth, waxy texture similar to the consistency found on a juice or milk carton.

Availability of Different Materials

Corrugated Board

To make cardboard storage boxes sturdier, use corrugated boards. It consists of many layers of paperboard. It has a fluted inner layer, and this layer joins between two outer layers and serves as a separator. However, both layers are made of different kinds of pulps. The flute contains a thinner type of paperboard while the other is of sturdier material. Besides, you can get it in single, double, and triple-wall cardboard.

Paper Liners

Another material to make custom cardboard boxes is paper liners. You can build them from hardwood trees that have short fibres. Hardwood trees probably include birch, sycamore, chestnut, and oak. Most modern box manufacturers use recycled paper, which is inexpensive and has an abrasive texture. Tensile strength and are suitable for cardboard boxes for moving long distances. Referred to as test liners, you can broadly use paper liners in manufacturing.

Kraft Paper

You can make Kraft paper from softwood trees with long fibres, such as bamboo, pine, spruce, and oak. The long fibers make it tear and burst-resistant. To make cardboard boxes with lids durable and sturdy, use this material. It makes them solid and thicker. Also, it adds quality to these packages, and you can easily recycle them.

The Final Designing of Cardboard Boxes

Bending or Folding

The folding machine folds the cardboard gift boxes and other types of packages along the score lines. Stitching or glue connects the sections to form the completed box. You can use hygienic glue, an essential feature for cartons for the food industry. Use staples for containers for heavy-duty applications and form a tighter seal.

Adding Flaps and Handles

Cut the handles and flaps into the paperboard sheets by die cutters or a trimmer hat to perforate the sheets and score them. The die trimmers’ sharp blades cut out the flaps’ shapes and score the sheets for folding. Although trimmers and cylinder die cutters are the most suitable method, you can also use simple die cutters for shorter production runs.


In most cases, custom cardboard boxes may need information printed on them. So, you can use it to identify products, advertising, or other relevant information regarding the box’s contents and function. Printing on the packaging is a process you must carefully complete to avoid crushing flutes or the cardboard. Feed rolls send the cases into the printing machine. Besides, you can apply a broad range of colours and designs to them with their printing plates.

Inspection of Boxes

To do is inspect the cardboard boxes wholesale before shipping to consumers. Then, compare each box to the template used to build it. All manufacturers pay attention to their final products to ensure that the containers live up to the organization’s standards and the high-quality materials they use.

To conclude, cardboard boxes are an excellent, cost-effective solution for various packaging and storage needs. They offer a surprisingly high level of protection to the products kept inside. Also, they are incredibly versatile and environmentally friendly. You can find these containers for commercial and industrial uses. They are popular for retail packaging because you can easily design them to offer a great aesthetic look to your products.

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