Custom corrugated boxes are printed cartons made from fluted board, built for shipping, storage and bulk transport. TBPB makes them to your exact dimensions with no minimum order, and the price-beat guarantee applies if you bring a written quote for the same specifications.
What the flute does
Corrugated board is two flat sheets of linerboard with a rippled medium glued between them. The ripples, called flutes, act like tiny arches and carry vertical load. The flute size sets the thickness and the personality of the board. E-flute is about 1/16 inch thick and prints cleanly. B-flute is about 1/8 inch and gives better cushioning and crush resistance. Double-wall board layers two flutes for heavy items. Thicker board protects more, but it also takes more room and costs more to ship.
Matching the board to the product
Start with weight and fragility. A box of lightweight apparel does not need the strength of one carrying glass jars. Start from the longest route the carton will take, and the stack height in the warehouse. If the box will sit under others for weeks, choose stronger board than the contents alone suggest. Boards are often described by strength tests such as edge crush resistance. If you need a particular rating, tell us in your quote request and we will match the board to it.
Sizing and style
Measure the product and add room for protection, usually an inch or more on each dimension if you will use void fill, less if you will use a fitted insert. Oversized boxes cost more to ship and let the product move. The regular slotted style is the common shipping shape, with flaps that meet in the middle. Die-cut styles can assemble without tape and give more room for branding. Corrugated can be printed on the outside, the inside, or both, with kraft or white liner.
When another box is a better fit
If customers will see the box first, a self-locking mailer box gives a better opening experience than a plain shipping carton. For a natural brown look, the kraft mailer boxes keep the board visible. For protection inside the carton, add custom foam inserts. For high-volume e-commerce, see the ecommerce mailer boxes. The wider corrugated boxes category lists the range.
Printing on corrugated
Corrugated takes ink differently from paperboard. The fluted surface is less smooth, so fine detail and photographs print a little softer, and brown kraft liner darkens colours. For crisp, bright print, ask for a white liner or a coated top sheet. Logos, bold type and flat colours reproduce well on any liner. Plan your artwork for the board you pick, and tell us if colour accuracy matters so we can discuss the options.
Shipping mistakes to avoid
The most common failure is a box that is too big. The product slides, the corners take impact, and the carrier charges for dimensional weight. The second is a box that is strong on paper but sits wet in a humid warehouse, because corrugated loses strength as it absorbs moisture. Store boxes flat and dry, and avoid stacking pallets higher than the board was designed for. Pack a few real orders into samples and drop-test them before you commit to a large run.
- Flute: E-flute, B-flute, or double wall for heavier goods
- Liner: kraft brown or white, printed outside, inside or both
- Style: regular slotted, tuck-front, roll-end, die-cut
- Print: one-colour logo or full-colour CMYK, Pantone match
- Inserts: corrugated dividers, paperboard or foam
- Quantity: no minimum order
Send the product dimensions, weight and a quantity, even one, and we will draw the dieline and quote it. If you ship regulated goods, labelling and hazard requirements are your responsibility, and TBPB prints the artwork you supply.
Frequently asked questions
What are custom corrugated boxes?
Custom corrugated boxes are cartons made from fluted board, cut to the size of your product and printed with your branding. The flutes give the board strength and cushioning, which makes corrugated the standard choice for shipping, storage and bulk transport.
Is there a minimum order for custom corrugated boxes?
No. TBPB has no minimum order, so you can order a single sample or a pallet. Send the product dimensions, weight and quantity and we will confirm the board and quote it for your exact product.
What is the difference between E-flute and B-flute?
E-flute is about 1/16 inch thick and prints sharper, making it good for lighter goods. B-flute is about 1/8 inch and gives better cushioning and crush resistance for heavier items. Double-wall board adds more strength for heavy cargo or long routes.
How do I choose the right box size?
Measure the product, then add room for protection. Allow an inch or more per dimension if you will use void fill, or less with a fitted insert. An oversized box costs more to ship and lets the product move, so aim for a snug fit.
Can I print on the inside of a corrugated box?
Yes. Corrugated can be printed outside, inside or both, on kraft or white liner. Inside print adds cost, so use it where it supports your brand experience. A simple one-colour logo on a kraft exterior is the most economical choice.
Can you match a board strength rating?
Often yes, if you give us the requirement. Boards are commonly described by edge crush resistance and burst ratings. Tell us the rating or the product weight and shipping route in your quote request, and we will recommend a board and construction that fits.
More Corrugated Boxes
See the full Corrugated Boxes range, or explore related options with no minimum order and our best-price guarantee: