How Corrugated Boxes Are Manufactured

We all know that our favorite product is packed inside a packaging usually made from kraft paper or cardboard sheet. But, have you ever wondered how these boxes are transferred from the factory to the warehouse? These small product packagings arrive at the warehouse in a container known as corrugated boxes. You might have read somewhere that cardboard boxes are sturdy and can withstand the worst of climate conditions, and this is true.

The thing to know here is that corrugated boxes are way stronger and more securer than cardboard boxes, no wonder why every big industry prefers corrugated boxes wholesale above any other available option. These containers won’t enhance the look of shelves in the stores, but they will make sure that the product that will enhance the look of the shelf arrives at its destination without suffering any damage.

These boxes are the core of the packaging industry because when custom boxes weren’t introduced, these boxes were the undisputed boxes in the world, and they still are. In this blog, you will read about how corrugated boxes are manufactured.

Without any further ado, let’s get started.

The Tree:

Corrugated boxes are made from 100% natural and recyclable material, and this is one of the main factors why every industry prefers these boxes. The benefit of using eco-friendly packaging is that it will reduce the carbon footprint. The trees used for the manufacturing of corrugated boxes are softwood trees such as pine trees. The reason behind this is that pine trees have longer fiber which can help create a smooth finish for these boxes.

The color of the cardboard sheet will depend on the wood you use. For example, silver birch trees will make dark color sheets, and spruce will make a typical light brown color. If you feel bad that trees will be cut down for making corrugated boxes, then know that these boxes are used to reduce the carbon footprint, which is very harmful to the forests.

The Pulp:

Finding a quality tree is vital, and making the fiber out of it is crucial. If you look closely at cardboard or corrugated boxes, you will see some thin and long particles, those particles are called pulps. A tree is broken down, and the pulps are made. Some companies use the technique of grinding the wood against a stone, and some use chemical methods.

Companies like to use chemicals like sodium sulfate to make the pulps more firm. Using the right amount of chemicals is vital because if a company uses excessive chemicals, there are chances of a carbon footprint.


After finding the suitable tree and making pulp from it, now comes the time when companies move to the corrugation part. After the pulp is dried, companies start to make cardboard sheets. For corrugated boxes, two pieces of liners and a whole bunch of fluted cardboard are required. The fluted cardboard is filled in between the two liners to ensure that the corrugated boxes are not vulnerable.

Rolls of the paper are made when dried pulp is passed through a roller, which flutes the paper. The level of fluting depends on the quality you are looking for, more fluting is done when companies manufacture high-quality boxes.


Once the whole work of making the pulp and making sheets from that pulp is done, the time comes for the cutting of the sheets. The cutting of the boxes depends on the size requirement. Many machines are programmed to cut the cardboard depending on the production demand.

Then the card is sent to a trimmer. The trimmer is designed to deal with aspects that a machine can’t handle. A trimmer can add handles and cut flaps that are needed for the assembling part.


The assembly of the boxes will depend on the requirements of the client and the market. For making the boxes robust, glue and stitching are used to fold sections jointly to secure the box. Specific machinery can construct boxes for you on demand.

These machines are designed to ensure that there is as little waste as possible. After the boxes are made, the squandered material can be used again in the machines to make more boxes, so you see, there is not much waste.

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