The Making of Corrugated Boxes

Cardboard boxes appear everywhere in our world. They help us store our belongings and ship packages of all sizes. Many people have handled a corrugated box before, but probably never really knew how they were made. Here is a quick look at how these containers are made using a simple process of heat, glue and paper.

1. Corrugated box manufacturer, starts the process by designing the size and shape of the box. Once they have the size figured out, they can start thinking about how the box will function. Details regarding how the box opens or closes and how durable it is during shipping will determine how it is constructed.

2. Recyclable materials are fed through a machine in which the material is formed into three layers; two flat layers and a corrugated centerpiece. These layers combined make what we refer to as cardboard. In order to shape the layers, the machine uses steam heat, then glues them together to make a cardboard sheet.

3. Next, the machine cuts the cardboard to the desired length. The numbers of cuts used on the corrugated board vary depending on the size of the box. After the machine cuts the board, it is stacked and sent to a trimmer.

4. The trimmer cuts flaps and handles into the cardboard. The blades cut each piece with exact precision for a uniform set of corrugated boxes. A conveyor belt catches the trimmings and ships them to recycling. The trimmings can be recycled up to six times.

5. Once the flaps and handles are in place, the cardboard box shape takes form after the connecting edges are glued down. The finished product is loaded on pallets and prepared for printing.

6. The print added to the corrugated board will vary depending on the initial design. Some boxes receive only basic text printing, while others have elaborate designs applied to them. Special applications such as high-gloss, matte and moisture resistant finishes complete the process for most boxes.