FAQ

Frequently Asked Questions

Box basics Order Basics Sustainability

Box basics

History of Corrugated Boxes

As people discover more about corrugated boxes, they quickly see that there’s nothing “basic” about them. Each box consists of three layers of paper, offering endless combinations. But don’t worry—that’s where we come in. We’ve designed this page to provide clear, easy-to-understand information to help you get familiar with the fundamentals of corrugated cardboard.

Do you provide design services?

Yes, we offer these services at an additional hourly or flat rate, depending on various factors. To help reduce costs, you can also provide your own artwork and/or drawings.

Cardboard Box Types

Regular Slotted Containers
The most common box style with flaps of equal length. Ideal for shipping small items like cups, mugs, and books.

Corrugated Trays
Trays designed for easy handling and visibility of products. Ideal for food and beverages, such as bottled water and snacks.

Half Slotted Containers
Boxes with one set of flaps and an open side for sliding over items. Ideal for large and heavy products like refrigerators.

Die Cut Custom
Custom boxes made to specific requirements with full-color options. Ideal for unique products like cosmetics, toys, and gifts.

Full Overlap
Boxes with overlapping outer flaps for extra durability. Ideal for heavy items needing additional support, such as washing machines.

Roll End Tuck Top
Unglued, foldable boxes suitable for narrow items. Ideal for packaging vitamins, coffee, and tea.

Corrugated Board Strength

Board strength determines how robust a box needs to be. To assess the required strength, consider:

The type of products being packaged
The total weight of the box
The size of the box
How the box will be stacked, stored, and transported

R&L Packaging offers two customization options for box strength: choosing the flute type and using the edge crush test.

Corrugated Box Construction

R&L Packaging offers two types of cardboard construction:

Single Wall: The most common type, consisting of one layer of your chosen flute type. Suitable for most applications, with options ranging from 23ECT to 44ECT.
Double Wall: Also known as ‘heavy duty,’ this construction features two layers of flutes (typically one layer of B and one layer of C), providing about 35% more strength than single wall. Ideal for heavy or large items, with options ranging from 44ECT to 61ECT.

Flute Types

Flute Type	Flutes/Foot	Thickness	Advantages
B Flute	42-50	1/8″	Good cushioning, stacking, and printing
C Flute	39-43	11/64″	Good stacking strength and crushing resistance
E Flute	94	1/16″	Excellent crush resistance and printing surface
BC Flute	Double Wall	1/4″	Suitable for very large and heavy items

Corrugated Box Flute Types

Corrugated flutes are the wavy layers in a corrugated box that provide strength and rigidity. They run parallel to the box’s depth, offering stacking strength and insulation against temperature changes.

B Flutes: 42-50 flutes per foot, 1/8″ thick. They offer strong stacking and crushing resistance, ideal for canned goods and displays.
C Flutes: 39-43 flutes per foot, 11/64″ thick. A balanced choice providing cushioning, stacking, and printing properties, suitable for glass, furniture, and dairy.
E Flutes: 94 flutes per foot, 1/16″ thick. Thin profile for space-saving and excellent crush resistance, best for die-cut custom boxes.

Types of Printing Methods

Flexo Line
Basic printing method for corrugated materials.

Flexo Process
Uses four colors for high-quality graphics and photo images.

Flood Coated
Applies solid color coverage, often used for retail packaging and displays.

Label Laminate
Attaches printed sheets to corrugated surfaces for glossy, photo-quality images, suitable for smaller runs.

Screen Print
Directly applies graphic images to corrugated packaging.

Litho Laminate
Similar to label laminate but requires higher minimum quantities (10-20K).

Preprint
Uses pre-printed rolls for linerboard, similar in quality to Flexo process.

Edge Crush Test

The Edge Crush Test measures the ability of corrugated board to withstand stacking or crushing forces. It determines the force needed to crush the board when standing on its edge, helping estimate the container’s compression strength.

Construction Types and Load Limits

Construction	Edge Crush Test (ECT)	Maximum Suggested Load Limit (lbs)
Single Wall 23ECT	23	20
Single Wall 26ECT	26	35
Single Wall 29ECT	29	50
Single Wall 32ECT	32	65
Single Wall 36ECT	36	75
Single Wall 42ECT	42	80
Single Wall 44ECT	44	95
Double Wall 48ECT	48	100
Double Wall 51ECT	51	120
Double Wall 61ECT	61	140

Information & Resources

There’s much to discover about corrugation and cardboard boxes. Here are some recommended links for more information on the topic.

Association of Independent Corrugated Converters
The Packaging Association of Canada
Fibre Box Assocation
Canadian Paper Packaging Assocation
European Flexography Industry Association
European Federation of Corrugated Board Manufacturers
ISO 3037:2007-03, Corrugated fibreboard – Determination of edgewise crush resistance

How should I measure a box?

Always measure the interior dimensions of your boxes. Enter the dimensions in the following order:

Length x Width x Height

Measurements should be in inches. If your dimensions are in centimeters, divide the numbers by 2.54 to convert them to inches.

For example, a box measuring 16″ x 11″ x 8″.

What does the description “short-flap” or “full-overlap” mean?

Most of our boxes are “Regular Slotted Cartons” (RSC). These are the most commonly used cartons, featuring top and bottom flaps that meet in the middle and are ready for taping. This versatile design is suitable for a wide range of packing applications.

Short-flap boxes have shorter flaps on each side, leaving a gap in the center.

Full-overlap boxes have lengthwise flaps that match the box’s width, folding over each other to provide additional strength and protection for the top and bottom of the box.

Order Basics

Do you ship or deliver?

We can ship boxes across Canada and the United States. Additionally, customers have the option to pick up their orders directly from our Abbotsford warehouse. Orders exceeding $1,000 often qualify for free shipping within the Lower Mainland.

What are accepted payment methods?

R&L Packaging accepts payments via cheque, bank draft, or e-transfer. Please note that we do not process payments through credit cards at this time.

Where are the cardboard (corrugated) boxes made?

Our corrugated box products are 100% made in Canada and all of our corrugated box materials are sourced from either Canada or USA only.

What are the payment terms?

For new customers, we require an initial deposit of 50-75%, depending on the complexity of the project. The final payment must be completed in full before we proceed with shipping.

How long does a custom order take?

We usually require 2 weeks to complete a custom order. For repeat orders, the turnaround time is typically 1-2 weeks.

Do you offer bulk discounts?

Yes, bulk orders for pallets or skids of cardboard boxes are eligible for a volume discount.

Do you sell to retail or wholesale?

We sell to both retail and wholesale/business customers. For our stock cardboard boxes (standard sizes), we can accommodate very small order volumes.

Sustainability

Are your cardboard boxes recyclable? Are your products environmentally friendly?

Yes, corrugated packaging is an eco-friendly option with high recyclability. It boasts the best recycling rates among packaging materials, as many communities have established recycling programs similar to trash collection.

Corrugated packaging is also easily customizable, which helps minimize material waste. After use, these boxes can be either reused or easily broken down and recycled.

The corrugated industry leads in recycling, with many boxes containing 70% to 100% recycled materials. Corrugated fibers can be recycled up to 25 times, making it a sustainable choice.

Are cardboard boxes considered environmentally friendly?

Yes, corrugated cardboard boxes are environmentally friendly. They decompose easily and are recyclable. Companies seeking to adopt eco-friendly practices and reduce their carbon footprint are encouraged to use them.

Between cardboard and plastic, which is more eco-friendly?

Corrugated cardboard boxes are typically more eco-friendly than most plastics. They are fully recyclable, tear-resistant, and cost-effective, providing a sustainable packaging solution that is kinder to the environment.

Is creating corrugate energy-efficient

Manufacturing corrugated packaging from recycled materials uses less energy compared to producing it from new materials. Many manufacturers also utilize locally sourced materials, reducing fuel costs for transportation. By choosing corrugated boxes, your company can conserve energy and allocate it to other needs.

Using corrugated materials also minimizes the resources needed for new packaging and requires less energy to process than many other materials.

How does a companies brand strengthen when partnering with a sustainable products?

Green business practices and marketing are not just trends; they reflect a growing commitment to sustainability. As eco-friendly options expand, companies are increasingly focusing on sustainable sourcing and packaging. Choosing sustainable packaging enhances your company’s image and aligns with modern consumers’ values.

Consumers want assurance that their purchases are environmentally responsible. They appreciate transparency and seek out products that reflect their values. Highlighting your use of corrugated packaging in your marketing can showcase your commitment to sustainability and resonate with eco-conscious buyers.

Does saving the earth save you money?

Sustainable corrugated packaging is both cost-effective and budget-friendly. Transitioning to more eco-friendly packaging options can often result in cost savings. Corrugated materials are durable, providing excellent protection for your products.

Cardboard is generally less expensive than many alternatives, especially when using recycled materials. Additionally, its lightweight nature reduces shipping costs and helps lower fuel emissions.

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