Cardboard is a loose term that covers two different materials: corrugated board for shipping and protection, and paperboard for retail cartons. TBPB makes custom cardboard boxes in either with no minimum order, and we beat any written quote on matching specs.
Corrugated or paperboard: the first decision
Corrugated has a fluted layer between two flat liners, which gives it stiffness and cushioning. Paperboard is a single thin sheet, folded and glued into a carton. Corrugated survives shipping; paperboard looks good on a shelf and prints crisply. Plenty of orders use both: a printed paperboard carton for the product, packed inside a corrugated shipper. If your product goes straight to the customer in a parcel, start with corrugated. If it sits on a store shelf, start with paperboard.
Flute size and board weight
- E-flute: thin and smooth, prints well, suits lighter products and retail-style mailers
- B-flute: more crush resistance, a common choice for general shipping
- Double wall: for heavy or tall items and stacked pallets
- Paperboard folding carton: usually 16 to 24 pt, for lighter products and shelf display
Thicker is not always better. A heavy board costs more to ship and can make a small box feel clumsy. Match the board to the weight of the contents and the shipping route.
Sizing a cardboard box
Measure the product, then add clearance. For a paperboard carton, about 1/8 inch per side is the usual starting point. For corrugated shipping, add room for padding on every side, and remember that inside dimensions are what count. Always give the length first, then width, then height, measured with the opening facing up. A wrong order of dimensions is the most common cause of a box that does not fit. A foam insert or a paperboard divider can keep items from shifting.
Print and finish
Corrugated can take simple one or two color print, or a full-color litho-laminated surface. Paperboard takes CMYK and Pantone with aqueous, matte or gloss coating, soft-touch lamination, foil and embossing. If you want a printed outer box that opens well, look at tuck top boxes, and for shelf-ready products with a hanging slot, hang tab boxes.
Next step: send product dimensions and a quantity, even one, and TBPB draws the dieline and quotes it.
Frequently asked questions
Is there a minimum order for custom cardboard boxes?
No. TBPB has no minimum order, so you can order one box as a sample or thousands for a full run. Send the size and artwork and we quote the exact quantity.
What is the difference between corrugated and paperboard?
Corrugated has a fluted middle layer between two liners, giving it strength and cushioning for shipping. Paperboard is a single sheet used for retail cartons. Corrugated protects; paperboard prints cleaner and looks better on a shelf.
Which flute should I choose?
E-flute is thin and prints well, good for lighter items. B-flute resists crushing and suits general shipping. Double wall is for heavy or tall loads. Tell us the weight and route and we recommend the build.
How do I measure for a cardboard box?
Measure the product, then add clearance: about 1/8 inch per side for a paperboard carton, and more padding room for corrugated shipping. Give length, width and height in that order, measured as inside dimensions.
Can I print on corrugated boxes?
Yes. Corrugated takes simple one or two color print or a full-color laminated surface. For the sharpest color, paperboard cartons print better. Many brands print a paperboard carton and pack it in a plain corrugated shipper.
Do I need inserts?
If the product can slide or is fragile, yes. Foam or paperboard inserts hold items still and reduce damage in transit. Send us the product and we design the insert with the box.
More Cardboard Boxes
See the full Cardboard Boxes range, or explore related options with no minimum order and our best-price guarantee:
