corrugated shipping boxes

Corrugated shipping boxes are corrugated board cartons made for transit, where a parcel may travel by van, sorting centre and courier network before reaching its destination. They are specified for strength and stacking, as well as for size, so goods arrive intact even after a long route and repeated handling.

Why corrugated shipping boxes need a strength specification

A shipping box is not just a container. It is a structural part of the delivery. In transit, boxes are stacked, pressed, tilted and sometimes dropped, and the box must resist those forces without collapsing onto its contents. Corrugated board gives that resistance through its fluted layer, which cushions shocks, and its liners, which resist tearing and crushing. Strength ratings help buyers compare boards, and one common measure is edge crush strength, which relates to stacking performance. A higher rating generally suits heavier loads and higher stacks, but the right rating depends on product weight, box size and the route.

Size and strength interact. A large box with a light product may need only single wall board, because the load is spread and the stack pressure is modest. A small box with a heavy product may need stronger board, because the weight concentrates on a small base. A tall box may need extra care, because stacking pressure and side pressure act differently on tall panels. Specifying a shipping box by size alone, without weight and stacking details, risks a box that looks right but fails in transit.

Single wall and double wall shipping board

Single wall board, with one fluted layer, suits most courier parcels and light to medium goods. It keeps parcel weight down and folds and tapes quickly. Double wall board, with two fluted layers, suits heavy goods, fragile goods, export loads and parcels that will sit at the bottom of a high stack. It also suits goods that will travel a long distance with several handling stages. Triple wall board suits industrial freight, but it is rarely needed for standard courier parcels. Choose the wall type by testing the heaviest order, not the average order.

Flute choices for shipping

C flute board, about 4 mm thick, is a common shipping choice because it balances cushioning, stacking strength and print quality. B flute board, about 3 mm thick, gives good crush resistance in a thinner profile and suits die cut shipping boxes. E flute board, about 1.5 mm thick, suits presentation shipping boxes where print and a slim profile matter. A flute board, about 5 mm thick, gives the most cushioning among single wall options and suits fragile goods. The flute should match the product, because a thin flute on a fragile product and a thick flute on a light product both waste the advantage of corrugated board.

Sizing, packing and sealing for courier transit

Measure the product with any protective wrap, sleeve or insert, then choose a shipping box whose internal size sits just above the packed product. A snug fit stops movement, which is the main cause of transit damage. Fill gaps just enough to prevent shifting, and avoid overfilling that forces the lid up. Place heavy items at the bottom, wrap fragile items separately, and use dividers where items could collide. A shipping box should close flat, seal fully and feel solid when lifted by one edge.

Sealing is critical for courier work. Tape the centre seam fully, from edge to edge, and tape the bottom seam with the same care as the top, because the bottom carries the load. Use tape that adheres firmly to board, and avoid a single short strip across the middle of a heavy box. For high value or tamper sensitive goods, a full tape seal or a printed tape gives a clear sign if the box has been opened. Label the box on the largest flat panel, clear of seams and tape edges where possible, so the label stays legible through sorting.

Stacking, palletising and warehouse handling

Stack shipping boxes with the heaviest boxes at the bottom and the lightest at the top, and align edges so weight passes straight down through the walls. Avoid overhanging a pallet edge, because an overhanging box loses support and crushes more easily. Keep boxes dry, because damp board loses a large part of its stacking strength. If boxes will be stored for a long period, check the bottom boxes regularly for bowing or crushing, and rotate stock so older boxes do not sit under new stock indefinitely.

Protecting goods against vibration and drops

Courier transit involves vibration as well as impacts. A product that sits loosely in a box will vibrate against the walls and may scuff or loosen over a long route. A snug fit, a fitted insert or a small amount of gap filling stops that vibration. For fragile goods, add a layer of cushioning around the product itself, not just in the corners of the box. Test a packed box by shaking it gently: if you hear or feel movement, add fitting or filling until the product stays still.

Custom printed corrugated shipping boxes

Print on a shipping box can be simple, such as a logo and handling notes, or full, with artwork across the outer panels. Simple print suits warehouse and courier cartons where labelling and handling matter most. Full print suits brands that want the delivery to feel like part of the product experience. Keep print clear of tape seams where possible, and keep handling notes legible, because a shipping box will be handled by people who have not seen the brand before. You can check current parcel format limits on the Royal Mail UK parcel and letter services page when planning a box that may also travel by post.

For custom printed orders, artwork approval comes first, and production follows after final artwork is approved. Corrugated lead times after final artwork approval are 12 to 15 working days. These are production lead times, not a promised delivery date, so allow time for artwork checks and for the courier service itself when you plan a range launch or a busy season. To start, request a custom quote and a quote will confirm the specification, quantity and print details for your exact shipping needs. You can also browse the full shop, read delivery information, learn about the team, and view corrugated packaging boxes for related options.

Recycling shipping boxes after delivery

Corrugated shipping boxes are widely recyclable through household and commercial cardboard recycling. Recipients can flatten the box, remove tape and labels where practical, and place it with cardboard recycling. A sturdy shipping box can also be reused for storage, moving or a return before recycling, which extends its useful life.

Testing a shipping box before a full run

Pack the heaviest and most fragile products in the range, seal the boxes, stack them as they will be stacked in transit, and check for crushing, seal failure and movement inside. Drop a test pack a short distance onto a firm surface, as a courier parcel might be dropped, and inspect the contents. A specification that survives that test is ready for regular dispatch.

Frequently asked questions about corrugated shipping boxes

What is the difference between a shipping box and a mailer box?

A shipping box is usually a transit carton specified for courier strength and stacking, often in a regular slotted style. A mailer box is usually a folding presentation carton for postal delivery. Many orders suit either style, but a shipping box is the better choice for heavy, fragile or bulk freight.

When should I choose double wall shipping boxes?

Choose double wall board for heavy goods, fragile goods, high stacks, export loads and long courier routes. Single wall board suits most light and medium courier parcels.

How do I stop goods moving inside a shipping box?

Choose a snug internal size, use inserts or dividers where needed, and fill gaps just enough to stop movement. Shake a test pack gently: if the product moves, adjust the fit or filling.

Are corrugated shipping boxes recyclable?

Yes, corrugated board is widely recyclable through household and commercial cardboard recycling. Flatten the box and remove tape and labels where practical before recycling.

How do I order custom printed corrugated shipping boxes?

Use the quote page to share sizes, weights, board specification, print ideas and quantities. You will receive a quote based on your specification, and production follows after final artwork approval.