Ask someone what’s the difference between corrugated boxes and cardboard boxes, and you’ll likely get a confused look.
To most people, corrugated boxes and cardboard boxes are the same types of boxes. In fact, many use these two terms interchangeably.
But here’s the thing: they’re not the same. They’re two completely different materials, with two different purposes.
Shopping packaging carton
In 2018, nearly 1.9 billion people purchased goods online. By 2021, that number is expected to reach 2.14 billion. While there are plenty of in-store shoppers, the meteoric increase in online shopping over the years has led to the expectations around shopping changing — even for retailers with physical locations.
Whether customers are buying from online sources like Amazon or are ordering online from brick-and-mortar retailers, every consumer expects their products to arrive quickly — and in good condition.
Have you considered the kind of packaging you're using to ship your products? It's an important decision because it could be the difference between a one-time customer and a lifetime customer.
What Are the Differences Between the Two Materials?
While both cardboard packaging and corrugated packaging look similar and might seem to accomplish the same tasks, they're actually quite different in structure and purpose. So when it comes down to corrugated vs cardboard, which should you be using to satisfy your packaging needs — and those of your customers? Your choice of corrugated vs cardboard will make a significant impact on customers' impressions, so it's important to understand the differences between the two shipping container types.
cardboard carton
A cardboard carton is made of thick paper stock or heavy paper-pulp. This material is used to make a variety of products such as small containers, product packaging, and even structural support for less rigid items like notepads, inserts that keep clothing items like button-up shirts from losing shape in their packaging, and more. Products can be shipped in containers made of cardboard, but it presents a risk to retailers as the material provides little protection and also requires extra material such as bubble wrap to ensure the products inside stay safe.
Corrugated cartons
Corrugated cartons are made up of a few layers of material rather than just a single sheet. The three layers include an inside liner, an outside liner, and a medium that goes between the two, which is fluted. Corrugated is a resilient material that is also light weight — an important consideration for those shipping a significant number of packages. These containers will remain sound even when exposed to shocks, moisture, and sudden temperature changes. While no container is invincible to excessive force or prolonged and harsh conditions, corrugated provides a higher level of assurance that your products will move from your warehouse to their final destination in great shape.
Corrugated Boxes
Corrugated boxes are often mistakenly called cardboard boxes, even though they’re made of different materials.
Corrugated box sheets are made of three different layers of paperboard: an inside liner, an outside liner, and a type of fluted corrugated sheet in between. This design creates a strong and stable material that can withstand an impressive amount of force relative to its weight.
Because of its high strength-to-weight ratio, corrugated boxes make the perfect packaging solution for shipping or transporting medium-sized and large items. They’re widely used in product shipping and transport, being used to deliver everything from medium-sized goods to large household appliances.
Corrugated boxes are available in a variety of fluting designs and flute profiles, providing different sizes, thickness, and load capacities. This makes corrugated boxes versatile packaging solutions, with different varieties designed for different needs.
Cardboard Boxes
Unlike corrugated boxes that are made of multiple sheets of paperboard, cardboard boxes often use a single sheet of heavy-duty paper or paperboard.
Compared to corrugated boxes, cardboard box sheets are noticeably thinner and lighter. These sheets, however, also come in a variety of strengths and hardness.
Cardboard boxes are commonly used for packing and transporting small or light items (think cereal boxes, boxes for perishable food, small toys, board games, and other similar items).
Because of its softer material, cardboard boxes can be bent or shaped more easily than corrugated boxes. It’s not unusual to see cardboard boxes in different shapes, and they can even be moulded to follow the shape of the item that it’s holding.
Does the Difference Matter?
In most cases, using one term for the other won’t cause much harm. Many people refer to corrugated boxes as cardboard boxes, and it works out fine in most cases. After all, there’s no cardboard police who will come and take you away for calling a box by the wrong name.
However, there are instances when using the right term will help everyone avoid confusion and expenses.
For example, if you’re shipping products or valuable items to another location, then you’ll need to use the right type of box to deliver it. This is especially true if other people are packing your items for you. If they end up using the wrong type of box, then it could result in damaged goods or higher costs of delivery. In cases like this, using the right term will help you avoid confusion and potential expenses.
Remember: if strength and carrying capacity are what you’re after, then corrugated boxes are likely what you need. For small and lightweight items, a cardboard box is likely better and more cost-effective.
So, while using one term for the other might be alright in most cases, knowing the difference between the two at the right time and situation will prove to be helpful.
When to Use Corrugated vs Cardboard
When used in the proper circumstances, both cardboard and corrugated cartons can be useful as packaging options. For example, cardboard is an efficient option when packaging lightweight products such as light clothing or thinner items (hence the cardboard-style media mailers you'd find at the post office). Depending on the item, it should be understood that the product will be subject to handling and that this won't result in damage. Carefully consider if cardboard is the right shipping material for your products.
Corrugated is used more often for packing and shipping items due to its strong and durable nature. Whereas cardboard and other materials are not impact-resistant, corrugated can withstand the rigors of moving from a warehouse to a mail processing center and ultimately to a delivery vehicle. The ability to provide cushioning for the contents inside is a significant advantage — even if the product itself is already packaged or wrapped.
If your product or brand also makes use of custom shippers or packaging, corrugated may be a better choice as it allows for just as much customization as cardboard while offering more rigidity. Die-cuts, custom opening folds and flaps, and other customization enable more unique design without risking the product contained within.
Another way corrugated packaging is used over standard cardboard material is for food packaging. This is due to the sustainability and cleanliness that it provides throughout the transportation process that brings produce to store shelves. And with the rise of online grocery shopping and meal services, companies are also using corrugated containers lined with insulating material to protect perishable goods in addition to dry ice used to keep contents cool. Learn more about why you should use corrugated packaging.
Benefits of Corrugated vs. Cardboard Boxes
Now that you understand the differences between a corrugated box vs. a cardboard box, let’s take a look at the benefits of each. Both corrugated and cardboard are useful for many applications. When it comes to shipping, however, corrugated is the clear choice. Explore the benefits of corrugated and cardboard boxes and when to use each style.
Why Is Corrugated Cardboard Popular?
The benefits of corrugated packaging include:
- Enhanced protection: Its multi-layered design provides a stable cushion that keeps products safe during transportation and handling. Corrugated also provides a durable barrier between your products and any outside moisture, keeping them dry on the road.
- Customization options: Corrugated board can be customized in a number of ways. From thickness and size to coatings, adhesives, graphics and shapes, businesses can tailor almost every aspect of corrugated board to suit their product and brand.
- Cost-effective: Its lightweight, customizable design makes corrugated board one of the most cost-effective options. There’s no need for costly labor, expensive tools or unnecessary bulk. Corrugated boxes can also be recycled and reused if needed.
What to Ship in Cardboard Boxes
Use standard cardboard shipping boxes for:
- Light clothing
- Small containers
- Structural support for non-rigid items that need inserts to retain their shape
- Cereal boxes
Keep in mind that cardboard is not recommended for shipping, as it does not offer the level of protection and durability needed to keep your items safe.
Note: Food-safe primary packaging should be used so that it does not come in direct contact with the corrugated shipping box.
What to Ship in Corrugated Boxes
Use customizable corrugated mailer boxes to package:
- Any items that need to be shipped
- Heavyweight items
- Retail displays
- Food, including perishable goods and delivery items like pizza