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This article will give a detailed discussion of plastic
It is expected that after reading, one should understand the
Plastic Corrugated Boxes: What They Are, How They Work,
and Considerations in Choosing the Appropriate Corrugated
How Plastic Corrugated Boxes are Manufactured
Different Types of Plastic Corrugated Boxes
Applications, Advantages, and Disadvantages of Plastic
And much more…
Chapter One: Plastic Corrugated Boxes: What They Are, How They
Work, and Considerations in Choosing the Appropriate Corrugated
The reality is that moving goods to numerous locations puts too
much strain on cardboard boxes. They rip easily, are prone to
leak, and may expose products to chemicals, moisture, and dust,
which can quickly harm stock and impede production from various
manufacturing components being exposed to these harmful
conditions. Corrugated plastic boxes are an effective, reusable
alternative that conserves time, money, and resources.
What They Are
A plastic corrugated box is a disposable container with three
layers of material consisting of an inner layer, an outer layer,
and a middle layer on its sides. Corrugated plastic is known by
various names, including polyflute, flute plastic, twin wall
plastic, and corflute. There are three layers of polypropylene
plastic substrate found in corrugated plastic. These plastic
containers provide good protection when storing, handling,
stacking, and transporting goods. They are composed of
high-quality polyethylene or polypropylene and commonly range in
thickness from 2mm to 25mm (nearly an inch). These plastic
corrugated boxes are 100% recyclable and reusable for reduced
waste and greater savings. They are resistant to chemicals,
dust, and water. In addition, they are lightweight to facilitate
transportation and handling.
How They Work
Plastic corrugated boxes are an attractive alternative for
packaging because of their material and sturdiness. As a result
of their construction, corrugated plastic boxes rank among the
market's most portable, shock-absorbing, and lightweight plastic
products. With a neutral pH, polypropylene is an incredibly
durable thermoplastic polymer that can resist various
environmental temperatures, weather, and usage circumstances for
extended periods. They are there to protect the products being
transported or stored. Plastic corrugated boxes reduce the
damage of any internal items from the external environment if
there happens to be an impact during transportation. They are
excellent at shielding products from moisture. Plastic
corrugated boxes also function extremely well maintaining their
support structure when storing or carrying heavy objects.
Considerations in Choosing the Appropriate Plastic Corrugated
When looking for a packaging solution that goes with their
product, people want a lightweight, attractive, safe, and
affordable material. Therefore, choosing the appropriate
packaging is essential if one wants their goods to arrive at
their destination safely, cheaply, and damage-free. Luckily,
various plastic corrugated boxes are specifically designed to
handle different considerations.
Mode of Transportation
Before choosing the appropriate plastic corrugated box, one must
determine what means of transportation will transfer any items
housed within them. For instance, a corrugated plastic box
transported by land must be prepared for rough roads, while one
transported by air should be suited for atmospheric changes.
The Threat of Moisture
Packaging is vulnerable to moisture exposure from warehouse
storage, maritime shipping, or an unfortuitous encounter with
rain. Since paper absorbs water, packaging made from corrugated
cardboard or other materials may not be able to withstand
moisture and, once wet, will not protect the products inside
from this threat. Corrugated plastic would be a better choice in
this situation. However, the glue used to assemble the plastic
sheets into a box must be considered to prevent moisture damage.
As with any packaging material, the weight, size, and shape of
the product being housed within must be considered. It is
exactly because of these factors that plastic corrugated boxes
are manufactured in a variety of sizes and thicknesses.
Products are shipped to extremely diverse climates around the
world. Therefore, keeping such potential variances in mind while
looking into shipping options for goods is vital. For example,
plastic corrugated boxes can withstand an incredible variation
Containers house valuable things. Therefore, it is important to
consider the container used to secure the items within.
Corrugated plastic boxes contain three levels of material- an
interior liner, an arched form or fluting in the middle, and an
outer liner. Due to their design, plastic corrugated boxes can
support a wide range of product weights, provide excellent
dimensional stability, and are available in a wide range of
sizes to guarantee the material is secure. The product worth
should also be considered when choosing the strength of the
plastic used. When the product is of high worth, thick plastic
should be selected.
As opposed to more durable goods, crystals, mirrors, and
chinaware are fragile things requiring greater protection.
Therefore, the container housing these items must be considered
to prevent damage while storing or shipping fragile goods.
Plastic corrugated boxes protect their enclosed items from being
smashed or crushed. Double-walled boxes with partition inserts
are one option available. In addition, plastic corrugated boxes
may be constructed in special cases to handle specific handling
Nature of the Good
While the exterior of a packaging container is important,
consideration must also be given to its interior. For example,
one may reduce the danger of harm to the items held within by
using materials for cushioning empty spaces with the fills of
air pad, paper pad, foam, and loose fill. In addition to
cushioning, electronics packaging requires the prevention of
electrostatic discharge (ESD) and corrosion protection. Again,
plastic corrugated boxes come to our rescue.
Chapter Two: How Plastic Corrugated Boxes are Manufactured
As mentioned in chapter one, plastic corrugated boxes are
created to handle a variety of considerations. However, the
process is always the same. Three layers of a thin polypropylene
plastic substrate, essentially plastic cardboard, are used to
create corrugated plastic boards. Corrugator boxes are created
by machines through a process that are both detailed below.
A corrugator is a group of devices that continually create a
single, double, or triple wall board. The working principle of a
corrugator machine is quite simple. Two stages are used to make
plastic corrugated boxes: the containerboard combining process,
which involves adhering one or more fluted (wave-like patterns
created to provide strength and cushioning) plastic sheets to
one or more flat facings of plastic linerboard, and the box
manufacturing process, which involves putting the plastic
corrugated sheets together into boxes. Interchangeable
corrugating rolls with various flute sizes are available for
each corrugating machine. The width of the corrugated medium can
be altered by changing the flute size in the corrugator.
During the containerboard combining process, a roll of plastic
material is inserted into the corrugator. The corrugator's
enormous, electrically powered rollers take the material to be
corrugated and feed it through preheating rollers and
corrugating rolls before corrugating the material. On the
corrugating rolls, a layer of plastic sheet passes through
gear-like parts of the corrugator, which creates flutes in this
plastic. Next, another liner roll is fed into the corrugator to
align with the corrugated rolls. After a layer of fluted
material is completed, it is aligned with another solid layer of
plastic at another flat structure of the corrugator machine
called the bridge. At the bridge, a layer of corrugated plastic
is glued together with this solid layer of plastic to form a
A corrugated box can be described as being either a single-,
double-, or triple-wall board depending on the level(s) of
corrugated plastic. Once a wall is completed, the plastic’s
corrugated edges are meticulously coated in starch adhesive to
marry it to another wall at a glue station, Finally, the
completed sheets of layered material travel across plates heated
by steam as they continue through the corrugator, curing the
adhesive holding the walls together.
Forming the Blanks Into Boxes
The plastic board is trimmed and divided into sheets, known as
box blanks, by a slitter-scorer at the end of the corrugator.
Once the box blanks emerge from the slitter-scorer, they slip
into an automatic stacker, loaded onto a sizable, rolling
platform. Next, a folding machine bends the blanks into boxes
along pre-set score lines. After the boxes have been adequately
formed and trimmed, glue is applied to the portions that will be
put together to complete the box forming.
There is a wide variety of plastic corrugated boxes, each with
specific benefits for use in various contexts. These varieties
Plastic Profile Board - Plastic profile board offers a
lightweight, stiff material that may be made in various weights
Triple-Wall - As the name suggests, triple-wall corrugated
plastic boxes have three layers of flutes (grooves). To add
stability, each layer has flutes of various sizes. In addition,
the extra layers improve compression strength and cushioning.
Double-Wall - A box with a double-wall design has an extra layer
of fluting compared to a single-walled plastic corrugated box,
making it capable of holding heavier and larger objects.
Single-Wall - This is the basic corrugated wall design with a
single outer layer. It also has an inner layer fluting between
the two layers. It is also called a double-face corrugated
Honeycomb - Honeycomb corrugated boxes contain corrugation
featuring a honeycomb pattern. Honeycomb corrugated plastic is
pliable and can be used to create lightweight boxes that
transport simple material which is not fragile.
Types of Flutes
The following are the top five flute profiles for plastic
This is the original flute design incorporated into corrugated
plastics. A-flute profiles contain approximately thirty-three
flutes per linear foot and are a quarter inch thick.
With approximately 47 flutes per linear foot and a 1/8′′
thickness, B-flute corrugated plastic boxes are frequently used
to hold canned products.
Typical for shipping cartons, C-flute corrugated plastic has
5/32′′ of thickness and approximately 39 flutes per foot.
E-flute corrugated plastic contains about 90 flutes per linear
foot and is 1/16" thick.
F-flute corrugated plastic is used for small retail packaging;
it has about 125 flutes per foot and is 1/32′′ thick.
Many flute profiles can be mixed in a single composite board. As
an illustration, a triple wall board might have two layers of
C-flute medium and one layer of A-flute medium. By combining
flute profiles, designers can alter a plastic corrugated box's
total thickness, compression strength, and cushioning strength.
Divider/Partitioned Corrugated Plastic Boxes
This is a corrugated plastic box with partitions, so the
material packaged within may be held in different compartments.
The partitions are designed to suit the size of the individual
materials. In addition to providing better organization, these
boxes are thin, strong, and affordable, making them the perfect
packaging option for storing, protecting, or shipping delicate,
Plastic Corrugated Boxes With a Double Cover
A double-cover plastic corrugated box's body is made of square
or rectangular tubing with telescopic covers that can be swapped
out. They are kept flat in storage. When necessary, a tube is
opened, and the top and bottom slot-assembled pieces can be
removed or added to allow for better positioning of the items.
The interlocking form of a double-cover plastic corrugated box
is a safer and snugglier-fitting option for holding important
items. The covers and tubes in a double-cover plastic corrugated
box include interlocking flanges to strengthen their framework.
They are designed to enable the shipment of bulky objects like
appliances and large machinery.
Plastic-Handled Plastic Corrugated Boxes
These plastic corrugated boxes are designed for better handling
and easier carrying. A plastic handle is inserted in their
design. This box is usually implemented where the components to
be transported are fragile.
Corrugated Plastic Mailers
Corrugated plastic mailers, commonly referred to as corrugated
plastic shipping boxes, are designed to protect delivered goods.
These boxes are available in several colors to improve their
visual appeal and customer experience and can be personalized to
represent a business. Corrugated plastic mailers are frequently
used for subscription box packaging and e-commerce, and they can
convey one large item or numerous smaller products.
Slotted Plastic Corrugated Boxes
Corrugated plastic that has been scored and slotted is used to
create slotted boxes. The slotted form is the most popular and
commonly used type of corrugated plastic box. Corrugated slotted
boxes can ship or store various goods, chemicals, and parts.
There are many common slotted box designs. The regular slotted
box has the following characteristics; when folded, its four
flaps meet in the middle of the box and are all the same length,
with the two outside flaps being half as wide as the container.
The half-slotted corrugated box is identical to the full
version, except that the top lacks one set of flaps. There is
also the overlap slotted box where the outer flaps overlap and
are the same length as the inner flaps. The overlapping flaps
are stapled together to form the shape. The length of this
design is bigger than the width. For the full overlap box, the
top and bottom flaps overlap and are the same length to provide
more support for larger goods. For a corrugated box containing a
center slot, the inner and outer flaps are different lengths and
fold together in the middle.
Telescopic Plastic Corrugated Boxes
The lid of a telescoping plastic corrugated box is larger than
its bottom portion due to its two-piece construction. The lid
adds stacking strength and ease of opening when the tray is
closed by extending partially or completely over the sides of
the tray. In many industries, telescoping plastic corrugated
boxes are frequently used for everything from displaying
products to careful packaging and moving and shipping items.
Heavier and bulkier things are typically packaged and shipped in
stronger telescoping boxes that still provide easy removal of
the contents inside.
Rigid Plastic Corrugated Boxes
A rigid plastic corrugated box features two end parts and one
middle piece. A single piece of scored corrugated plastic that
can fold into a slotted or telescope-shaped container makes up
the self-erecting variation of a rigid corrugated box.
Folding Corrugated Plastic Reusable Box
The bottom of a folder-style box is solid, and the overlapping
flaps are notched so they can be folded or wrapped around a
product. This kind of box is frequently used to carry smaller
items, books, and other printed goods. Their one-piece design
features a flat bottom, and the expansions of the side flaps
form flaps for the sides, end, and top. There are versions with
either five-or four-panel trays. The five-panel variation has a
top, but the four-panel variant does not. The second and fourth
panels of the five-panel form are located at the top and bottom,
and the fifth panel is a side in the one-direction folding
Auto Bottom Tuck-Top Boxes
The tuck-top plastic corrugated box is designed to be quick,
effective, and simple to close. The tuck flap of these boxes
tucks into the body of the box, and the top flaps close over the
top when extended. As a result, the bottom of the box flattens,
and the sides split apart when opened, making it easier to load
objects. The tuck-top snap-lock bottom plastic corrugated box is
a variation on the tuck-top auto bottom plastic corrugated box
in which the bottom is made up of four interlocking flaps rather
than being pre-glued.
Chapter Four: Applications, Advantages, and Disadvantages of
Plastic Corrugated Boxes
Applications of Plastic Corrugated Boxes
Office supplies and stationery are packaged in plastic
It is recommended that consumers utilize plastic corrugated
boxes to move their goods if they are relocating and considering
hiring a moving company to assist them. Plastic corrugated boxes
are sturdy enough to safeguard delicate items that could
otherwise sustain harm if transported in cardboard boxes. The
nicest thing about plastic corrugated boxes is that they do not
shatter under enormous weight, guaranteeing that one's
possessions remain unharmed and simplifying the moving
Supply Chain and Logistics
Plastic corrugated packaging is one of the best things to have
happened to the supply chain. Plastic corrugated boxes are
readily accessible on the market, simple to pack and unpack, and
able to deliver various products safely. They can be used to
transport most industrial goods with ease.
Plastic corrugated boxes come in different sizes and styles and
are perfect for carrying a wide range of textiles.
Auto components come in various sizes and forms. Therefore,
storing and shipping them takes careful planning. In addition,
it is essential to use a durable, weight-bearing, cushioned
packing material to prevent parts from being damaged. Plastic
corrugated boxes meet these various requirements.
Medications often must get to their destinations securely and
within an established temperature range. Plastic corrugated
boxes are an excellent solution. Plastic corrugated containers
naturally maintain temperatures and can transport numerous items
simultaneously through dividers or partitions without causing
damage to the items within. Plastic corrugated boxes may be the
best choice for moving several small items from one location to
Electronic devices are typically fairly delicate items;
therefore, they must be packaged to protect them from damage
during transport. These packages also need to shield electronic
components from potential static electricity. Luckily,
electronic devices can be packed in plastic corrugated boxes
since they don’t conduct electricity.
In the world of e-commerce, presentation is crucial. One can
personalize the plastic corrugated boxes used in the e-commerce
sector with a distinctive design, aesthetics, and brand
quirkiness to help increase marketing and branding through
packaging. Plastic corrugated boxes can be branded to promote
Plastic corrugated boxes are constructed from materials that
adhere to FDA food storage guidelines and are designed to endure
various temperatures. This can ensure the freshness of food when
it is being transported or temporarily stored.
Advantages and Disadvantages of Plastic Corrugated Boxes
Storage, transportation, and distribution are crucial operations
for most industries. The packing of items must be done in a way
that satisfies the requirements of both the customer and the
business. Convenience, portability, and the safety of the goods
are among the main factors to consider. Typically, cardboard
boxes are used in the packing process. However, plastic
corrugated boxes perform better than cardboard packing for
various reasons, as we will discuss in greater detail.
Plastic corrugated boxes are an intelligent substitute for
cardboard boxes and hardwood containers. They fold several
times, making transportation simpler. Their manufacturing
process is also cheaper and requires less energy.
Corrugated plastic boxes are typically reusable. Compared to
cardboard or paper-based boxes, they are more durable, have a
longer shelf life, and can be recycled when the time finally
comes after their extremely long period of service.
Typically, plastic corrugated boxes don’t need to be disposed
of, even after several uses, and, instead, can be returned to
the shipper for reuse.
Because of their material and folding capabilities, plastic
corrugated boxes may be easily folded and opened.
Contrary to other, more-rigid plastic containers, plastic
corrugated boxes are lightweight and thin.
Since they can be partitioned into specific internal
boundaries, multiple goods can be packaged in plastic
Plastic corrugated boxes maintain their structure and surface
integrity and are waterproof. These features of plastic
corrugated boxes help guarantee the safety of workers and the
Based on customer requirements, plastic corrugated boxes can
be created for a specific order. The packing requirements
provided by the customer can influence the dimensions and
design of any box. Designs for plastic corrugated boxes with
high-density capabilities are also feasible.
Plastic corrugated boxes are made using ecologically-friendly
and environmentally-sustainable production techniques.
Glass, lighting, mirrors, and chrome-plated items need special
handling during shipment because they are scratch sensitive.
Due to this reason, several kinds of plastic corrugated boxes
have been specially created for this specific function.
They last a long time. Corrugated plastic containers survive
30 to 50 times longer on the job than corrugated cardboard
Corrugated plastic is very inexpensive to make and buy. Even
in the unlikely event, a plastic corrugated box is damaged,
replacing it won’t cost much money. In addition, they are a
more cost-effective packaging choice due to their durability
compared to the alternatives.
Containers made of corrugated plastic provide an excellent
strength-to-weight ratio. They also withstand impact,
dampness, corrosion, dirt, dust, and most chemicals better
than other packing choices. Additionally, these containers
keep their shape even when fully loaded.
Plastic corrugated boxes come in a wide variety of designs.
They are made in any size to fit any material-handling
application an individual may have, including pick and pack,
warehousing, and automated storage and retrieval systems.
Space can be saved by using plastic corrugated containers.
When not in use, many designs allow them to nest inside one
another to conserve space.
Plastic corrugated boxes are strong enough to lay flat
independently, so one can easily set items inside. In
addition, one can cut, bend, staple, and even punch holes in
Although corrugated plastic is a rather durable material, it
isn't designed to endure forever and will eventually show
signs of wear and tear. A person might notice some fading,
bending, or even ripping in the corners rather quickly,
depending on the materials enclosed inside and the
environmental factors which the container may be exposed to.
Plastic corrugated boxes are designed to last and not to
decompose. Although some curbside pickup services will accept
them, it is more common that one might have to transport these
items to a recycling facility.
It's critical to remember that corrugated plastics produce
substantial carbon waste during their manufacturing process.
Corrugated plastic is not advisable for a company's primary,
permanent branding on its boxes. Printing on this material can
fade after just a few months when exposed to harsh
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chloride used especially for making pipes, films and
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