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The Lifecycle of a Corrugated Box: From Raw Materials to Recycling

May 14 2024 Learn More

Corrugated packaging is one of the most sustainable and versatile materials in the supply chain. From its origins as raw paper fiber to its end-of-life recycling, every stage of a corrugated box’s lifecycle plays a critical role in minimizing waste and reducing environmental impact.

Sourcing Raw Materials

Corrugated board begins with kraft and recycled paper fibers. Most corrugated materials today are made from a mix of virgin pulp (from sustainably managed forests) and recycled content. In fact:

  • All corrugated paper contains a minimum of 60% recycled content.
  • Packaging can be recycled up to 6 times before the fibers break down.
  • All uncoated corrugated paper is 100% recyclable.

Manufacturing & Customization

Once the paper fibers are processed into linerboard and fluting, they are combined into single-wall, double-wall, or multi-wall corrugated board. These boards are then converted into custom-sized boxes, trays, and mailers for various industries.

R&L Packaging specializes in:

  • Die-cut mailers and retail-ready boxes
  • Custom-printed packaging for branding and engagement
  • Moisture-resistant and freezer-grade packaging for food applications

Local Manufacturing Benefits

For customers ordering from R&L Packaging in British Columbia, Alberta, or Washington, sourcing locally has significant sustainability advantages:

  • Reduced CO2 emissions from transportation, compared to imported or long-distance shipments.
  • Faster lead times and just-in-time inventory solutions to reduce unnecessary stockpiling.
  • Locally built packaging supports regional businesses and strengthens supply chain reliability.

Distribution & Real-World Use

Corrugated boxes are engineered to withstand logistics challenges, whether by truck, rail, or air freight. Factors like stacking strength, humidity exposure, and temperature extremes impact packaging durability.

  • Meat & seafood industries require moisture-resistant coatings or wax-alternative materials to maintain structural integrity in cold storage and transit.
  • Produce and agriculture industries rely on stackable, high-strength trays and HSC boxes to protect fresh fruits and vegetables.
  • E-commerce brands utilize custom mailers with inside printing to enhance the unboxing experience while ensuring product safety in transit.

End-of-Life & Recycling

After a box has served its purpose, the recycling process closes the loop. Recycling corrugated packaging helps minimize landfill waste and reduces the 28% of municipal waste that comes from packaging. Even reducing plastic waste by 1% makes a huge difference in sustainability efforts.

Recycled fibers go back into the paper-making process, continuing the cycle up to six times before becoming compost or biofuel. Choosing corrugated over plastic-based alternatives helps companies meet eco-friendly packaging goals while maintaining durability and affordability.

Choose Sustainable Packaging with R&L

At R&L Packaging, we prioritize sustainability, strength, and efficiency. Whether you need custom corrugated solutions for retail, food, or e-commerce, we offer local production, high-recycled-content materials, and tailored designs to optimize performance while reducing environmental impact.

đź“© Get a Quote TodayContact Us or email Sales@RLPackaging.ca to get started!

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