10 Custom Box Material Comparisons: Cardboard, Kraft, Corrugated & More | UPrinting
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10 Custom Box Material Comparisons: Cardboard, Kraft, Corrugated & More

Written by UPrinting - Updated on June 18, 2025

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Choosing the best custom box for your packaging goes beyond the size and design. It’s also about what it’s made of. Most people would often choose the material that boosts the packaging’s durability. However, different industries rely on various materials for their shipping and packaging boxes, and understanding those differences can help you make the best pick for your business. In this article, we’ll break down 10 of the most used box materials, highlighting what makes each one reliable and when it makes the most sense to use them.

10 Popular Custom Box Materials and Their Benefits

From sturdy corrugated boards to sleek folding cartons, each box material offers different strengths, appearances, and benefits. Below, we’ve broken down 10 commonly used custom box materials to help guide your decision-making.

 

1. Single-wall corrugated (E-Flute)

  • This lightweight material still provides enough durability to ship most standard products safely. It is a versatile option used by various industries.
  • Its smooth surface is perfect for high-quality custom printing, allowing your packaging to double as a powerful branding tool.
  • Due to its balance of strength, weight, and printability, it’s commonly used for e-commerce orders, retail displays, and subscription boxes.

    • 2. Folding Carton (Paperboard/Cardstock)

  • Folding cartons are ideal for lightweight products like cosmetics, health supplements, or packaged snacks that need a clean and stylish presentation.
  • The box is easy to store, fold, and assemble, making it a cost-effective option for high-volume packaging.
  • Its smooth finish makes it the perfect box for vibrant full-color printing, special coatings, and unique designs that help products stand out.

    • 3. Kraft Corrugated (Brown)

  • This material’s rustic, natural look appeals to eco-conscious consumers and brands aiming for a sustainable or organic image.
  • It is typically made from natural materials combined with recycled paper. It is also biodegradable, making it a strong choice for sustainable packaging efforts.
  • Despite its earthy appearance, it still delivers excellent durability and is well suited for product shipments and minimalist retail packaging.

    • 4. Double-Wall Corrugated

  • This box has two layers of fluting, offering superior protection against crushing, heavy handling, and punctures during transit.
  • It’s an ideal material for shipping heavy or fragile items that require sturdier and more structural support than standard single-wall boxes can provide.
  • This type is often used for industrial packaging, bulk deliveries, and long-term storage and shipping. The box is also optimal for equipment requiring extra durability during storage and transport.

    • 5. Micro-Flute Corrugated (E-Flute)

  • Micro-flute corrugated boxes are thinner than standard corrugation, offering a more compact profile while providing reliable structural integrity.
  • It’s excellent for packaging that needs high-resolution graphics, such as branded mailers or point-of-sale displays.
  • This material perfectly balances strength and print quality, making it a top choice for products that ship and sell directly.

    • 6. Triple-Wall Corrugated

  • This material offers more strength with three layers of corrugation, making it one of the most durable box types for shipping.
  • It serves as a strong and cost-effective alternative to wooden crates, especially for businesses needing heavy-duty packaging without the added weight.
  • Frequently used for large appliances, export shipments, or high-value electronics, it ensures products are well-protected during extended transport or rough handling.

    • 7. Rigid Setup Boxes

  • Known for their luxurious, high-end appearance, rigid boxes are often used for premium items like electronics, jewelry, watches, or holiday gift sets.
  • Unlike foldable boxes, they are pre-assembled and highly durable, giving products a solid and sophisticated packaging structure.
  • Their sturdy build and smooth finish offer a more premium unboxing experience, enhancing people’s ideas about the product’s value.

    • 8. Molded Pulp (Fiber)

  • Molded pulp is made from recycled paper fibers and offers a fully compostable and biodegradable option for protective packaging.
  • The box is also perfect for cushioning delicate items, either as an insert or a standalone container, while keeping sustainability in mind.
  • It combines protection with eco-conscious appeal and is often used for electronics, health products, and egg packaging.

    • 9. Corrugated Plastic (Coroplast®)

  • This material is waterproof, chemical-resistant, and reusable, making it ideal for environments that demand durability and moisture control.
  • The box is lightweight yet rugged enough for long-term use. It’s often found in reusable shipping crates, moving boxes, and office storage boxes.
  • Its long lifespan and protective features make it an efficient solution for businesses looking to reduce single-use packaging.

    • 10. Chipboard (Recycled Paperboard)

  • Chipboard is a thin, economical material made entirely from recycled paper, offering an affordable packaging solution.
  • It’s best suited for lightweight products and is commonly used in retail boxes. Chipboard materials are also used as inserts and inner dividers for cosmetics or dry foods.
  • Though not ideal for shipping heavy items, it’s a go-to option for cost-effective, everyday packaging needs.

    • Key Factors to Consider When Choosing a Box Material

    Given the top box materials available, you may want to determine which fits your needs best. Smart packaging starts with knowing what really matters when choosing your custom boxes.

     

    1. Durability Needs

    Choose the box material most suitable for your product’s weight, shape, and fragility.

  • Delicate items like electronics or glassware require sturdy protection from thicker materials.
  • Thinner and lighter boxes are suitable for lightweight goods such as clothing, dry snacks, or paper products.
  • You should also prepare sturdy and weather-resistant boxes for longer shipping distances to ensure your products arrive safely.

    • 2. Environmental Impact

    Check for boxes that adopt environmentally friendly packaging if you want to align with sustainable practices.

  • Materials like corrugated kraft, molded pulp, and chipboard are biodegradable or recyclable, making them excellent choices for promoting green packaging.
  • If you need to use plastic boxes, go for durable and reusable options for multiple shipments to contribute to eco-friendly initiatives.

    • 3. Print Quality and Branding

    Many brands choose standout packaging that elevates their branding. This is where box materials that support high-quality printing come in.

  • Folding cartons and micro-flute corrugated boxes offer smooth surfaces for vibrant, detailed designs.
  • Kraft boxes can add a rustic touch that not only makes it natural but also traditional.
  • You can also choose elegant rigid setup boxes that enhance people’s unboxing experience.

    • 4. Shipping Constraints

    Shipping carriers often price packages based on size and weight. Try to balance your box options to optimize both safety and savings in your brand.

  • Lighter materials like chipboards, folding cartons, or single wall corrugated cardboard can help reduce delivery costs, while fitting most shipping guidelines.
  • Heavier-duty boxes such as rigid setups or triple-wall corrugated ones offer better protection. Go with these for a more reliable packaging option, even with the increased shipping weight.

    • 5. Overall Savings

    Speaking of saving. A clever mix of materials can help control costs while meeting your packaging goals.

  • Go for cost-effective materials for quick, mass-produced packaging. You can then use sturdier options for premium products.
  • Chipboard and kraft corrugated work well for large orders without breaking the bank.
  • Rigid boxes, Coroplast, and corrugated boxes cost more but add value for high-end products.

    • Custom shipping boxes are often the first thing your customer touches, sees, and opens. They build curiosity, add ceremony, and set the tone for what’s inside. This is one of the reasons why choosing the proper materials is essential. From subtle elegance to bold personality, your packaging can speak volumes before customers unbox and get to the items they ordered.

    If you’re ready to turn that first impression into a lasting connection, UPrinting can help design and print the custom boxes that carry your brand.

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