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How are cardboard boxes designed & what material is used to make them?

One of the finest packaging is cardboard boxes that are equally popular among every single business using packaging for their products. They are popular because of their flexibility which allows transforming them into any shape. This trait also benefits in getting these boxes in desired sizes and designs. On the other hand, cardboard material offers complete safety to fragile products against physical, biological, and environmental factors.

A brand face no refusal for including custom options like embossing, foiling, die-cut windows, scoring, perforation, or PVC sheets. Moreover, the addition of handles or any other desired custom options is also easier because of the modern production equipment. Bonding between cardboard and printing is of no doubt. Businesses can get their desired design print over these boxes without any color variation or ink fading issues. CMYK color schemes eliminate all such issues and make the design catchy.

Witnessing the presence of cardboard boxes is quite common nowadays in the retail stores for every second product. But, have you ever wondered as a business or consumer about processes these boxes go through to reach your hands. There is an interesting process that works behind from the very start of material selection to their production. Knowing about these factors will help you make a purchase decision for this packaging for your upcoming startup or running business. Moreover, you would know about the best attributes of this packaging if you are a common product buyer. So, let’s know all about it.

Material selection for cardboard boxes:

The first step toward designing cardboard boxes is a selection of the raw material for the production of cardboard. Understanding this stage is necessary before delving into further details regarding their production. Traditionally, pine, fir, spruce, and other softwood trees are the preferred choices of packaging firms. The softwood of these trees is perfect for these boxes as they would have more flexibility and burst resistance.

Tensile and durable fibers are a major factor behind this phenomenon that dry wood is unable to offer. However, some common consumers and innovative brands consider it a way of deforestation. Therefore, they can enjoy alternate and eco-friendly options in this regard. Wood chips are a byproduct and have to go to waste or burn stations otherwise. But it is easy to recycle them for creating paper. Apart from it, mushrooms, corn starch, and bamboo pulp are also organic options.

Pulp and paper making process:

The paper and pulp preparation stage comes after getting the raw material for cardboard boxes from different options. The pulping process involves separating lignin from the fibers by cooking the wood shavings at high temperatures. Cooking these wood shavings in sulfate solution is the cause of the traditional brown color of this material. Pulp is squeezed then with the help of beaters which are machines used for this purpose.

Squeezing the pulp and soaking it is what makes cardboard a perfect option for printing without any ink-spreading issues. Paper is formed in the paper-making machine from this pulp. Paper is rolled over the rollers, and all humidity is eliminated further with heated rollers. It then becomes ready for shipment to the main manufacturing units of the packaging firms, where the true magic happens.

Fluting process of boxes:

A major difference between the cardboard box packaging and common boxes is their ability to protect items. This protection comes from the special flutes created inside the walls of this packaging. Fluting make sheets corrugated, which provides extra resistance against influencing factors. A wavy layer of cardboard is created using the fluting machine. Next, a corrugator or fluting machine presses the paper between two rigid rollers and blasts it with hot steam.

This shapes the waves of the flute. Meanwhile, another roller applies glue to one side of the flute, and then the liner is attached to it. The same process repeats for pasting the other liner to the remaining side. This wavy layer sandwiched between the liner sheets creates an air cushion that provides extra strength. Brands can even ask packaging firms to use double or triple wall flutes to enhance items’ safety.

Product-specific design customization:

Now, the stage is set to use these prepared fluted sheets to produce cardboard boxes wholesale. The design of this packaging is always according to the products placed inside them. Such design becomes more attractive and useful to fulfill business and product needs. For example, food businesses or bakeries can customize them with designs related to the product.

A bakery can get a cake box in a round or square shape according to requirements. Similar is the case with other businesses. Structural changes in the box with customization make a brand distinctive from others. The custom options like installation of die-cut window, logo embossing, foiling, and scoring become a top choice in this regard. Moreover, the addition of handles is an additional option for brands that they use to provide customer ease.

Printing of the desired design layout:

These boxes are manufactured flat and shifted to the printing sections inside a firm. They are printed with the desired design layout by fetching the file into printers. All innovative brands nowadays prefer the use of digital and offset printers for the printing of cardboard boxes. This design layout also plays a vital role in making the packaging look different from rivals.

Displaying the branding elements like brand name, slogan, and web address increases the number of customers engaging with the products. Display of imagery regarding the inside products further benefits in raising product visibility. These mentioned printers work under the CMYK color scheme, which is a mix of four colors. Ultimately, a brand can get the desired design print with higher accuracy.

It was all about the cardboard boxes and the ways followed in their production and printing mechanism. Every single step involves the use of technological advancements to achieve perfection. The abundance of custom options and choices for raw material selection increases their worth more. A business using these boxes sees quick results with increased sales volumes.