How to Choose the Right Corrugated Board

Which board grade is right for you?

Not all corrugated packaging is the same and picking the right type can make all the difference in protecting your products and reducing costs. With so many board grades and constructions available, each designed for a specific purpose, selecting the right solution can quickly become confusing. We wanted to make it easier for you to understand the choices available and what is best for your individual needs.

Understanding Corrugated Material

Corrugated material is a versatile and durable packaging solution made by combining layers of paperboard. It provides excellent protection during transit and storage while offering flexibility in design and presentation. The process begins with flat sheets of paper, which are then processed through a corrugating machine to create ridges, known as flutes, between layers. These flutes add strength and cushioning to the board, ensuring it can handle various weights and impacts.

Construction and Types of Corrugated Board

1. Single Wall Corrugated Board

Single wall is the most common type of corrugated board, consisting of three layers: a liner (outer layers), a medium (fluted layer), and a liner again. It is ideal for lighter packaging needs and provides good protection for fragile goods. For example, a single wall board typically has a strength rating of B or C flutes, which provide a good balance between durability and flexibility.

2. Double Wall Corrugated Board

Double wall board consists of two fluted layers sandwiched between two outer liners. This construction is suited for heavier and more fragile items, offering enhanced protection and durability. Double wall is often used for industrial goods, electronics and products that require extra impact resistance.

Flutes Explained

Flutes are the ridges formed between the layers of corrugated material and come in different sizes and shapes to serve various packaging needs.

A Flute: The largest flute, offering excellent strength and cushioning. Ideal for heavy-duty industrial applications.
B Flute: Amongst the most commonly used types of cardboard used for packaging applications. Exceptionally versatile used in both die cutting and regular case-making processes. It gives good all-round performance in all types of packaging.
C Flute: A balanced option that provides good cushioning and stiffness, suitable for a wide range of uses.
E Flute: A finer flute, known for a smooth finish and better dimensional stability. Often used for lighter consumer goods.
BD Flute: Around 4.3mm to 4.8mm thick, BD flute combines B and D flutes into a double walled material.
BC Flute: This double wall material combines both B and C flutes together. This gives a good all round performance, making it common for producing shipping boxes that offer a higher level of transit protection.

Choosing the Right Corrugated Solution

Selecting the appropriate board grade, construction and flute type helps your packaging meet both your protective needs and environmental standards. Corrugated boards provide not only durability but also sustainability, as according to FEFCO, corrugated board is one of the most recycled materials in Europe, with an impressive 89% recycling rate. This ensures that the majority of corrugated products are recovered and reused, contributing significantly to a circular economy, helping businesses reduce waste, lower carbon footprint, and meet increasing demands for eco-conscious operations.

Additionally, many boards are biodegradable, breaking down naturally without harming the environment, a win-win for businesses and the planet.

Ribble Packaging

At Ribble Packaging, we offer bespoke cardboard packaging solutions for businesses of any size. With our central UK location, we provide efficient national delivery, ensuring your packaging needs are met promptly. Our process includes the use of an onsite corrugator with a state-of-the-art Fanfold down-stacking facility. Supported by our onsite conversion plant, we also offer case-making and die-cutting capabilities to create the perfect packaging solution for your business.