Willcox patented the first processes for producing corrugated paper. However, it was not until 1894 when Robert Gair invented the modern corrugated container that it really took off. Gair developed automated processes and machinery that allowed corrugated containers to be produced on a large commercial scale.
Over the next few decades, it continued to evolve as automation improved and new advancements were made. In the 1920s, wax-based adhesives replaced the previously used starch-based adhesives, making the containers stronger and more weather-resistant. Single-wall and double-wall corrugated board began appearing on the market in the 1930s. By the 1940s, it had largely replaced wooden boxes in the shipping industry due to its advantages of being lighter, cheaper, and more durable.
Advances in technology in the late 20th century, such as the development of color printing, brought even more innovations to it. Packaging could now be customized with colorful graphics and messaging to attract customers. Additional improvements continue to be made today, focusing on sustainability, print resolution, and new production techniques. 3D printing technology is also being explored for its potential applications in its manufacturing.
Types
There are several main types of corrugated packaging based on construction:
- Single-wall - A single inner fluted corrugated sheet bonded between two flat linerboards. It offers protection but less strength compared to double-wall. Used for lighter goods.
- Double-wall - Two outer flat linerboards are bonded to an inner corrugated layer. This provides greater protection and support. Most commonly used type.
- Triple-wall - Has three corrugated layers with two inner medium corrugated sheet. Offers maximum strength for heavy products. Mainly used for industrial packaging.
Corrugated boards also differ based on flute profile and corrugation density. Common flute profiles include A, B, C, E, and F flutes. Higher corrugation density leads to higher strength at the cost of higher material usage. Packaging types may also be waxed or laminated for moisture or grease resistance.
Advantages
Some key advantages that have contributed to Corrugated Packaging becoming a popular choice across industries include:
- Strength and durability - Properly designed corrugated boxes can withstand impacts and weight of stacked products during transportation and storage.
- Lightweight - Being made of paperboard, it is significantly lighter than alternatives like wood. This reduces freight costs.
- Sustainability - Corrugated is one of the most recycled materials in the world with over 95% recovery rate in the US. It uses renewable paper fibers as raw material.
- Versatility - Corrugated packaging is available in a wide range of sizes and strengths to accommodate various product types. Custom print and design options allow branding through packaging.
- Barrier properties - Wax, lamination and special coatings can be applied to corrugated to provide moisture, water, grease or puncture resistance.
- Cost-effectiveness - Compared to alternatives, it has a lower material and production cost per unit. The supply chain is also well-established.
Applications in Different Industries
Given its versatility and advantages, it finds use across multiple industries for both shipping and retail applications:
- Consumer goods - Used for shipping and storing food, beverage, home care and other products. Custom designs attract customers in stores.
- Industrial goods - Protect heavy machinery, auto and electronics components. Special grades provide strength for bulky or oddly shaped goods.
- Pharmaceuticals - Provide tamper evidence, impact protection, and controlled ventilation for medications and medical supplies.
- Fresh produce - Perforated liner material allows airflow to prolong freshness of fruits and vegetables during shipping.
- E-commerce - Easy to assemble mailers and express packaging designed for home delivery of online orders.
- Retail - Shelf-ready displays,POP displays, endcaps help merchandise products attractively on retail shelves to boost sales.
The corrugated packaging industry has grown steadily at around 3-4% annually over the past decade. Growth is expected to continue driven by factors like increasing e-commerce, demand from emerging economies, and further penetration inAsia-Pacific and Latin American regions.
Technological innovations are also helping expand applications and efficiency of corrugated packaging. Some areas receiving focus include development of new barrier coatings, advances in printing resolution, introduction of RFID and smart labels, implementing automation withmachine learning in plants. Sustainable initiatives aim to reduce material usage through lightweighting and use more recycled content and renewable materials.
With its versatility, sustainability credentials and continuous innovations, corrugated packaging is poised to remain a packaging solution of choice for shipping and storage needs across industries worldwide for the foreseeable future. Its advantages will keep driving its demand even as new formats like flexible packaging gain popularity for certain products.
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