Packaging Guide · 10 min read
Corrugated Packaging Guide — Flute Selection & Design
Everything you need to know about corrugated board, flute types, and designing for shipping protection.
Flute types explained
E-flute (1.0–1.5mm) for retail mailers and litho-lamination — smooth print surface. B-flute (2.5–3.0mm) for standard shipping — good crush resistance. BC-flute (5.0–6.0mm) for heavy-duty freight — double-wall construction.
Board grades
32 ECT is the standard for ecommerce. 40 ECT for heavier stacking. 200# burst for rough handling. Choose based on product weight and shipping route.
Designing for shipping
Include die-cut inserts to prevent movement. Add tear-strips for easy opening. Use crash-lock bottoms for auto-erect at the packing station. Avoid sharp corners that can puncture in transit.
Printing on corrugated
Flexo for high-volume shipping cartons — lowest cost. Litho-lamination for premium retail mailers — full-color CMYK or Pantone. Digital for small runs — no plate setup.
Frequently asked
Yes — it is the most-recycled packaging material.
Corrugated board is curbside-recyclable in standard paper streams. Avoid foil lamination if recyclability is a priority.
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