Custom corrugated boxes are a versatile solution for many packaging projects. Corrugated is the most frequently used shipping material in the United States and offers a practical balance of protection, cost and customization. Boxes range from simple slotted shippers to die-cut mailers and retail-ready displays.
Corrugated board is made from layers of paper. In single-wall board, a fluted layer sits between two flat liners. Together, these layers provide strength and protection while keeping the structure relatively lightweight.
Start by deciding whether corrugated is the right packaging material for your product. The sections below then walk through box styles, board grades and flute profiles, order quantities, lead times, and printing options. Common questions are answered near the end of the page. If you would like help evaluating your options, use the contact form to connect with our team.
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The three factors below determine whether corrugated packaging is the right solution for your next project.
Product Characteristics
The product’s weight, fragility, dimensions, and shape help determine the right packaging material. Heavy or fragile products often benefit from a corrugated box’s protection. Soft goods or non-fragile products sold through e-commerce are common exceptions.
Does the product have protruding parts, easily scratched surfaces, or multiple pieces or accessories packed together? These details help determine whether the box alone provides enough protection or needs inserts, dividers, or cushioning to secure the product and separate components.
Logistics and Transit
Consider how the product will be stored, distributed and handled before it reaches the customer. The corrugated shipping box design and board strength can depend on several factors such as shipping distance, shipping method, and how many times the packaging gets handled during the distribution process. A parcel moving through a sorting network can face more individual handling than a pallet moving dock to dock. Does the packaging get distributed through multiple channels? If so, design the corrugated box for the most demanding conditions it will encounter.
Branding and Customer Experience
What brand perception are you trying to convey to your customer? Is there a way to improve your customers’ unboxing experience? How do you want the customer to first interact with your product? These are some of the questions you should be asking when considering the branding and unboxing experience for your packaging. Corrugated offers printing options for both retail and e-commerce packaging. When presentation is the priority, a folding carton may be a better fit, with a corrugated master case providing protection during shipment to the store.
Every packaging project has its own requirements. Involving our team early can help identify design constraints and avoid costly changes after key decisions have been made. Visit our custom packaging overview page to evaluate other packaging options. Our guide on choosing the right packaging material walks through key variables in more detail.
Most corrugated packaging is built from a standard set of box styles. We have grouped them below based on the main styles: slotted containers, die-cut boxes, and retail displays. It may seem like there are hundreds of structural options, but most corrugated projects begin with one of the styles below. The diagram for each style shows its length (L), width (W), and height (H). Box dimensions are always given as inside dimensions, so measure the inside usable space, not the outside of the box. Need to measure an existing corrugated box style? Check out our guide on How to Measure a Box.
Slotted shippers are formed on standard equipment with a glued, taped, or stitched joint. A cutting die is not typically needed to produce this type of box, which makes it a great option if you need multiple sizes or plan to change sizes in the future. Slotted shippers are a great low-cost option and the default for most shipping applications.
RSC (Regular Slotted Container)
Description: All flaps are the same length. The two outer flaps are each half the box width and meet at the center to get taped closed. Efficient box style with minimal manufacturing waste.
Best Fit For: Default choice for most products.
FOL (Full Overlap)
Description: Like an RSC, but the outer flaps overlap each other across the full width of the box. The doubled corrugated board adds stacking strength and edge protection.
Best Fit For: This style can add strength to the ends of the box without needing to increase the overall corrugated board strength. Boxes less than 4″ wide are often FOLs because it can be difficult to close an RSC with small outer flaps under 2″.
HSC (Half Slotted Container)
Description: An RSC with only one set of flaps, which saves board where a closed top is not needed.
Best Fit For: Open bins and trays, especially larger ones sized to a pallet footprint. An HSC turned upside down can also be used as an inexpensive lid option.
5PF (Five Panel Folder)
Description: A scored blank with a fifth panel that wraps around to form the closing flap. End flaps overlap for additional strength.
Best Fit For: Large, long, or awkward items. Great option for products that are difficult to load into RSCs or FOLs. Place the product on the flat 5PF, then fold the box around it and tape it closed.
Die-cut folders and corrugated mailers are custom designed to fit your product and require a cutting die to produce. Gluing is typically not needed, which removes a manufacturing step. Customers choose them over a slotted shipper when they want better presentation, or a box that closes without needing tape.
REFT (Roll End Front Tuck)
Description: The side walls roll over and lock into the bottom of the box, creating additional strength due to the multiple layers of corrugated board. The locking flap tucks into the front panel, often with self-locking tabs called radius tabs or cherry locks.
Best Fit For: E-commerce mailers that open from the front, with a height less than their width or length. Deeper boxes waste board in any roll-end style, so an Indestructo works better for those situations.
RETT (Roll End Top Tuck)
Description: Like the REFT, the side walls roll over to double up the corrugated material and lock in the bottom of the box without needing tape or glue. The lid tucks into the top, often with side flaps that fold over for product security and cushioning.
Best Fit For: A shallow box that opens from the top, with the inside of the lid available for print. Tall or deep boxes waste board because the rolled ends run up the full height and back down.
Indestructo Mailer
Description: A roll-end box with multiple overlapping layers of corrugated on the sides and ends. The extra layers add crush and edge protection. The blank uses less board in deep or cube-shaped sizes. The Indestructo often costs less per unit than a standard roll-end mailer for certain sizes.
Best Fit For: Heavy, dense, or fragile items in a box deeper than 4 inches, or with a height close to its width (such as 8 x 4 x 4″). Outside that size range, this box style can actually use more board, so a roll-end mailer or RSC could be a better solution.
Auto-Bottom (Auto-Lock or Crash-Lock)
Description: A die-cut box designed like a folding carton, with pre-glued bottom panels that snap into a locked flat base as the box is squared up. Auto-bottoms commonly use a tuck-top, although other top closures are available.
Best Fit For: Fast assembly at the pack station because the bottom locks as the box is opened. This style can cost a little more per box but may reduce assembly and fulfillment labor.
1-2-3 Bottom (Snap-Lock)
Description: Similar to an auto-bottom, but the interlocking bottom panels need to be folded up in a 1-2-3 step process. This style is used when the size of the box isn’t a great fit for a typical auto-bottom box, or for smaller volume projects when a cheaper unit price is preferred over faster assembly. Various closure options are available for the top of the box.
Best Fit For: Lower-volume or hand-assembled programs where assembly speed at the pack station is less important. Unit price is typically less than auto-bottom.
OPF (One Piece Folder)
Description: A die-cut blank with a flat bottom, end flaps, and side flaps that fold over and meet to form the top. It wraps tightly around a shallow product and adds very little bulk.
Best Fit For: Flat, low-profile items such as books, prints, plaques, or framed pieces, about 3 inches deep or less. Deep or heavy items get little structural support from a folder and should be packed in an Indestructo or RSC.
Retail-ready packaging is shipped to the store and goes on the retail shelf or floor with little or no repackaging. The design depends on the product’s size, shape, and weight and the retailer’s display requirements.
Perforated Die-Cut Shipper
Description: An RSC with a perforated top section that the retailer tears away to create a simple display. Adding the perforation makes it a die-cut RSC, so it does require a cutting die.
Best Fit For: A low-cost option for a shelf-ready box when a torn edge on the display is acceptable.
Die-Cut Tray with Lid
Description: A die-cut tray holds the product and an inverted HSC acts as the lid. Once the display arrives at retail, the lid is discarded and the tray displays the product inside.
Best Fit For: Cleaner, more consistent shelf presentation. The perforated RSC often doesn’t rip cleanly and exposes a raw edge of corrugated. This option presents the product in a clean, die-cut tray which is typically printed.
Club-Store Pallet Displays
Description: Quarter-pallet and full-pallet trays designed for warehouse clubs. When the product is self-supporting, such as corrugated master cases of chip bags or plastic jars of peanuts, a 3-inch high tray is enough because the display only has to contain the product. When the product is not self-supporting, such as family-size chip bags or pouches of jerky, a 3-inch lip full-pallet tray with vertical U-pads carries the load, with the flute running vertically.
Best Fit For: Warehouse club programs that ship on a quarter or full pallet and go straight to the floor. A self-supporting product needs only the tray. A product that is not self-supporting puts the load on the display, and U-pads or stackable club-store trays are added.
Club-Store Trays
Description: Full trays that fold up with sidewalls and stack directly on each other. There are usually four, six, or eight club trays per pallet layer. The stacking strength comes from the trays themselves, so the display does not need additional components to help with strength.
Best Fit For: Product that is not self-supporting. One repeated tray provides all stacking strength for the pallet display. Uses more material than pallet display trays but is simpler to assemble.
Corrugated board is described by three separate specifications: wall construction, flute profile, and board grade.
Wall construction refers to the number of fluted layers in corrugated board. Single wall has one fluted layer between two flat liners. Double wall has two fluted layers, and triple wall has three, with liners separating the layers. The choice depends on the product’s weight and the protection required.
Flute profile is the size of the arches that are sandwiched between the flat liners and determine the overall thickness of the corrugated board. The most commonly used corrugated flutes in the United States (in order) are C, B, and E flute.
Board grade is determined by the paper weights used for the liners and fluting medium. Together, these components give the board its strength rating, measured by either the Edge Crush Test (ECT) or the Mullen burst test. These ratings are used to specify the appropriate board grade for your corrugated packaging.
Our guide to corrugated fluting basics goes deeper on each wall construction and flute profile.
Double-wall board can combine different flute profiles, such as BC or EB. EB has the finer E flute on the outside for boxes where print quality matters.
Board strength is rated two ways. ECT (Edge Crush Test) measures the board’s resistance to edgewise compression, which helps assess stacking performance. The required rating depends on the box design and application. The everyday single-wall shipping grade is 32 ECT. Mullen is a burst test, specified when burst strength through the box wall is the priority. Our Mullen vs ECT comparison covers how the two relate.
To select the right corrugated grade, consider the product’s weight, shipping method, and the conditions the package will encounter throughout its journey. These factors help determine the appropriate wall construction and flute profile. Retail packaging that needs a smooth, high-quality print surface may call for E flute, while tall stacks or demanding pallet patterns may need a stronger board grade than the product’s weight alone suggests. Understanding how the package will be handled, displayed, and distributed across each sales channel is essential to making the right choice.
PAX has no hard minimum order quantity (MOQ) for custom corrugated boxes. The practical order size depends on your budget and the box design. For most projects, roughly 500 to 1,000 units makes economic sense. Smaller runs of 50 to 100 can work for large, heavy-duty double-wall boxes protecting higher-value products. It often makes sense to weigh the packaging cost against the protection and value the custom design adds.
Production setup costs are spread across the order, so larger runs generally have a lower setup cost per box. A design that requires a new cutting die also has an initial tooling charge. We identify applicable setup and tooling costs in the quote. If custom production does not fit the budget or quantity, we will recommend a stock box.
We develop the structural design and provide a dieline for your artwork. Once you approve the structure and supply artwork on that dieline, we confirm any print plate costs. We then need your purchase order to begin final proofing.
For new projects, production lead time starts after we receive your purchase order and final artwork proof approval. Making any required cutting die and print plates is included in that lead time. For reorders, the lead time starts when we receive and confirm your order. Timing depends on material availability and the production schedule.
| Print and converting method | Typical production lead time |
|---|---|
| Unprinted RSC | 2 to 3 weeks |
| Printed and/or die-cut (plates or dies required) | 2 to 4 weeks |
| Litho-laminated | 3 to 4 weeks |
| Digital, smaller quantities | About 2 weeks |
Lead times exclude delivery unless local delivery is specifically included in your quote. For new projects, allow additional time before production for structural design, artwork preparation and proof approvals.
The best printing option depends on your artwork, order quantity, liner and budget. Common choices include direct flexography, flexography on a white liner, litho lamination and digital printing. White-liner flexography uses the same print process as direct flexography, with a different printing surface. Our packaging printing guide explains the main processes and their trade-offs.
Direct Flexography
Direct flexography uses printing plates to apply ink directly to corrugated board. It is a common choice for shipping boxes with logos, text and one or several colors. It can be an economical option for straightforward artwork. Print quality depends on the artwork, liner, colors and press.
Flexography on White Liner
A white liner gives flexographic printing a brighter background than brown kraft. Depending on the liner grade, a smoother or coated surface can also improve the appearance of detailed artwork. This option can suit shipping boxes that need a stronger retail presentation.
Litho Lamination
Litho lamination combines a printed paper sheet with a corrugated structure. Artwork is printed by offset lithography and then bonded to the corrugated board. It is a useful option for detailed images, photography and retail presentation. The additional lamination step affects cost and timing.
Digital
Digital printing transfers artwork to the printing surface without printing plates. It can suit short runs, multiple artwork versions, and variable information. Modern digital systems also produce finished commercial packaging. Cutting and finishing may still require tooling.
Finishing Options
Functional options include hand holes, carrying handles, perforations, tear strips and peel-and-seal closures. The seam that joins the box body can be glued, taped or stitched, depending on the design. Decorative finishes are available for some constructions, although PAX does not typically specify them for corrugated projects. If foil, spot UV or embossing is central to the design, we can review the construction and suitable packaging options, such as folding cartons or rigid setup boxes.
AF&PA reports that 70–75% of cardboard in the United States was recycled in 2025. “Cardboard” is the association’s own term for that stream, and the figure is reported as a range under its updated methodology. This industry recycling rate is different from the recycled content of an individual corrugated box.
Recycled content varies by board grade and supplier. If your project has a recycled-content target or requires FSC-certified material, tell us when you request a quote so we can confirm the available options and documentation.
PAX designs with both corrugated and foam inserts. Foam can be appropriate when a product needs cushioning or a fitted shape that the proposed corrugated design cannot provide. When a corrugated insert meets the protection requirements, it can eliminate a separate foam component and simplify material sorting. We evaluate the complete package before recommending a change.
Sustainable Project Example: A customer was shipping a handheld electronic device in a roll end front tuck (REFT) corrugated mailer with a foam insert. PAX redesigned the insert in corrugated board, securing part of the device between two board layers and leaving protective air space around the product. The revised design removes the foam component, and the corrugated insert ships and stores flat. The redesigned package passed the customer’s ISTA 3A testing.
Start with the product’s dimensions, protection needs and shipping route. Choose a box size and board grade that meet those requirements, then assess each coating or finish for a clear purpose. Compare material use, packing time, storage and recyclability alongside cost. True value is created when cost-saving solutions and sustainability converge. Our guide to sustainable paper packaging options compares corrugated, folding cartons, and rigid setup boxes.
To quote custom corrugated boxes for shipping, send the product dimensions and weight, order quantity, shipping method and delivery destination. Tell us about fragile areas, any inserts, where the product will be sold and when you need the boxes. Include print and finishing requirements if you know them. If you already have packaging, send a sample or specifications and identify whether the dimensions are inside or outside measurements.
Custom corrugated box pricing depends on size, board specification, print coverage and method, order quantity, tooling and finishing. Setup charges can have a larger effect on the per-box cost of a short run because they are spread across fewer units. Larger orders generally reduce the price per box by spreading setup costs across more units.
You do not need to choose a box style before contacting us. Our sales team gathers the product, shipping and presentation requirements, then works with our packaging engineers to develop the structure. We review the proposed design with you before finalizing it for production.
After you approve the structure, we provide a dieline showing the box panels, cut lines, folds and glue areas. Structural approval typically uses a physical unprinted sample, although a drawing may be sufficient for some projects or minor adjustments. Your designer places the artwork on our dieline and sends it back so we can confirm any print plate costs. Final proofing begins after we receive your purchase order.
For CMYK printing, we typically provide a physical printed proof that serves as the color reference for production. For PMS colors, we typically provide an ink drawdown showing how the ink will look on the selected corrugated liner, such as kraft or mottled white. You review and approve the applicable color reference before production.
If timing requires skipping the physical color review, we confirm that decision with you before proceeding. Color may differ from your expectations, and any further adjustments would be made on a subsequent production run. Our guide to PMS vs CMYK for packaging covers the difference between the two.
Select the test plan for the product and its shipping route. Our customers usually start with a trial shipment to get quick initial feedback on the package’s performance. Controlled lab testing is another option that evaluates the package under a defined procedure. ISTA 3A is a common option for parcel packages up to 150 lb; pallet and freight routes may require other tests. Eligible FedEx business account holders can receive basic testing at no charge. Confirm retailer or carrier requirements with the testing lab beforehand.
Amazon’s Ships in Product Packaging (SIPP) program qualifies eligible products to ship in their own packaging without an added Amazon box or bag. Testing and packaging requirements depend on the product and enrollment route. Some items qualify for self-testing, while fragile products generally require a specific lab-testing route. Confirm the current requirements for your marketplace and selling arrangement before finalizing packaging.
Corrugated board is a paper-based structure with fluted material bonded to flat liners. Single-wall board has one fluted layer between two liners; double-wall board adds another fluted layer and liner. “Cardboard” is a broad everyday term that can also mean the unfluted paperboard used in folding cartons.
Send product dimensions, weight, quantity and any current packaging specifications or photos. Our team can recommend a corrugated design or discuss another material if the application calls for it.
Reviewing the packaging design can reveal savings that comparing quotes for the same specification may miss. Across 100 projects over eight months, PAX compared the price of its redesigned packaging with what customers were paying their existing suppliers. On packaging built from two or more components, the redesign averaged a 12.3% cost reduction.
PAX Solutions is based in Osseo, Minnesota, and works with customers across the United States.
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This video shows how different types of corrugated packaging are produced in an actual production setting. Our customers have found it helpful to see how the packaging is made when working through the decisions on this page. Packaging design and styles, corrugated wall and flute construction, and printing options are easier to understand once you have seen the manufacturing process.
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