custom corrugated boxes

custom corrugated boxes are cartons and mailers made to your exact size, board grade and print specification rather than taken from a stock shelf. Corrugated board combines a wavy fluted layer with flat liners, which gives it high strength for its weight and useful cushioning in transit. Custom Postal Boxes manufactures custom corrugated boxes in house in Wolverhampton for UK businesses, with low minimum order quantities and free design support.

How custom corrugated boxes are built

Every corrugated sheet has three working parts to consider: the flute profile, the liner papers and the number of walls. Flute letters describe the height and spacing of the waves. Fine flutes such as E flute, around 1.5 mm thick, give a smooth surface that prints sharply and suits mailer boxes and retail packaging. B flute, around 3 mm, balances cushioning and strength for everyday shipping. C flute, around 4 mm, adds more cushioning and stacking strength for larger shipping cartons.

Single wall board has one fluted layer between two liners. Double wall board has two fluted layers and three liners, which raises crush and stacking performance for heavy or fragile loads. Liner choice changes the look and print result. Natural kraft liners give an earthy finish and hide scuffs well, while white liners give cleaner colour reproduction for printed designs. Explore the base formats on our corrugated shipping boxes and single wall corrugated boxes pages.

Matching flute to product and journey

Light, well boxed retail products in a mailer usually suit a fine flute, where print quality and a slim profile matter. Loose, heavy or fragile goods on multi drop courier routes suit thicker flutes or double wall board. Tell your supplier the product weight, how it will travel and whether boxes will be stacked, because those facts drive the specification more than appearance does.

Inserts and internal fit

Corrugated inserts, dividers and fitments made from the same family of board can hold bottles, jars or components apart inside the box. A fitted insert often protects better than loose fill, because it stops items striking each other, which is where many breakages start.

Print options for custom corrugated boxes

Corrugated board can carry anything from a simple one colour logo to full colour artwork inside and out. Simple bold designs print most reliably on kraft board, while detailed artwork and photography usually need a white liner or a smoother fine flute surface. Keep fine text large enough to stay legible on a fluted surface, and keep critical artwork away from creases and glue flaps. Our custom shipping boxes show how print and structure combine for despatch, and for postal formats the Royal Mail Tracked parcel sizes page helps you size boxes inside the parcel band you want.

Ordering custom corrugated boxes well

Start with internal dimensions, packed weight and the route to the customer. Then choose wall and flute, liner colour, print coverage and any inserts. Because the boxes are made to order, you can size them tightly to the product, which cuts void fill, reduces movement damage and keeps parcels in lower postal bands. Pricing depends on size, material and quantity, so request a tailored quote through our contact page for a quote and include a photo or sample of the product if fit is critical.

FAQs

What flute should I choose for custom corrugated boxes?

Choose a fine flute such as E flute for slim mailers and sharp print, B flute for a balance of strength and cushioning in everyday shipping, and thicker flute or double wall board for heavy, fragile or stacked loads.

What is the difference between single wall and double wall board?

Single wall board has one fluted layer between two liners and suits light to medium loads. Double wall board has two fluted layers and three liners, giving greater crush resistance and stacking strength for demanding journeys.

Can custom corrugated boxes be printed inside and outside?

Yes. Corrugated boxes can be printed on the outside for branding and on the inside for messages revealed on opening. Detailed artwork usually reproduces best on a white liner or a fine flute board with a smooth surface.

Why make boxes to a custom size instead of buying stock sizes?

A custom size fits the product closely, so you use less void fill, reduce movement damage, store boxes more neatly and can often keep parcels within a cheaper postal size band. Stock sizes rarely fit every product well.

What do you need from me to quote custom corrugated boxes?

Send the internal size you need, product weight, how the goods will travel, your print requirements and the quantity. Pricing depends on size, material and quantity, and quotes are prepared individually.