Custom Corrugated Boxes in Any Flute, Style and Size

What is a corrugated box made of?

Corrugated board is a sandwich. Two flat paper liners hold a wavy middle layer, the flute, between them. Each arch of the flute works like a tiny column, so the board stands up to pressure from above and from the side.

Change the size of those arches and the board changes too. Small flutes give a thin, smooth board that prints well. Larger flutes give a thicker board that cushions knocks. Two flutes together make double wall board for heavy loads.

Every corrugated box we make is cut to order. Browse the full corrugated and shipping box range to see the styles side by side.

Which corrugated box styles can you make?

The slotted carton is the classic brown box with four flaps at each end, sealed with tape. It is quick to pack and suits deep or awkward items.

Roll end mailers fold from one piece into a tray with a hinged lid and locking tabs. They open like a gift and need no tape. Tuck end boxes close at one or both ends with a tuck flap, which suits long items like bottles. Handle boxes add a cut-out carry handle to the lid.

For the slotted carton in detail, see our page on regular slotted container boxes.

How do I size a corrugated box for my product?

Measure the product, or the product in its own inner pack, at the longest, widest and tallest points. Those are your inside measurements.

Add space for protection. A snug fit needs only 3 to 5 mm each way. Wrapped goods need 15 to 25 mm, depending on how much padding you use. Do not add the board thickness yourself. We allow for it when we set the outer size.

Smaller boxes save on postage, so trim the size to what the product really needs. Our guide to common box sizes in the UK is a good starting point if you are unsure.

How can corrugated boxes be printed?

We print in one colour, two colour or full CMYK, on the outside, the inside, or both. Plain kraft with a single colour logo keeps costs down and looks honest. White liners make full colour artwork brighter.

Mailers are often printed inside, so the customer sees a message or pattern as the lid opens. For finish, you can stay with bare uncoated kraft or add matte or gloss lamination. Spot UV, foil stamping and embossing pick out a logo.

Our designers help with layout at no charge and send a digital proof before anything is printed.

Kraft or white liner: which should I choose?

The liner is the paper on the outside and inside of the board. Brown kraft is the natural colour of the fibre. It hides scuffs and dirt, suits a plain or one colour print, and gives a practical, workshop look.

A white liner is bleached paper on the face. It costs a little more but makes printed colours brighter and truer, especially pale tones and skin colours in photos. Many brands choose white outside and kraft inside, or the reverse for a surprise when the lid opens.

If you plan full colour artwork, choose white. If the box will carry a single logo and a shipping label, kraft does the job and looks right for it.

How should I pack a corrugated box?

The box is only half the job. Packing decides whether the product arrives whole.

Load the heaviest pieces first, flat on the base, and keep lighter ones higher up. Fill every gap so nothing moves when you shake the box gently. Tape along the centre seam and across both edge seams on slotted cartons. On mailers, push every tab fully home. For delicate goods, a fitted insert does more than loose filler. See our corrugated inserts made to fit for the options.

Where do buyers go wrong with corrugated boxes?

Choosing the thickest board for everything is common, and it costs more and weighs more than needed. Most light parcels travel well in single wall.

The reverse also happens. A thin E flute mailer looks great, but it is not the right box for a heavy glass jar. Match the board to the weight and the risk, not to the look alone.

Last, people order one size for a whole range of products. A few well-chosen sizes usually cut both void fill and postage.

Before a large run, pack the real product in a similar box you already have and post it to yourself. How it arrives tells you more than any chart.

How long will my corrugated boxes take?

Approve your free digital proof and we start production, which takes 4 to 6 business days.

Tracked delivery comes next, in 2 to 3 business days, with no delivery charge to any UK address. Flat, banded bundles mean the order fits on a shelf until you need it.

How do I order corrugated boxes?

Corrugated boxes start from £0.25 per unit. The exact price depends on size, board, style and print, and we confirm it on a written quote.

Send your details through the trade quote request form or build the box in Design Your Box. Prefer to ask first? Write to info@ordercardboardboxes.co.uk or send a WhatsApp message. Boxes that arrive misprinted, damaged or faulty are reprinted or refunded if you report them with photos within 10 days.