The first cardboard box can be traced back to 1817, invented by Brooklyn printer Robert Gair. This regular cardboard box was uncorrugated, but the box folding technique would prove useful in the years to come for shipping boxes.

​In 1840, the French started using cardboard boxes to transport things. The rest, as they say, is history.

The method of corrugating material was developed in the 1850s. The first known use of corrugated material was actually as a liner for top hats to keep them standing up straight. 

It wasn’t until the 1890s that corrugation was used for boxes. And only by the 1970s were corrugated boxes widely used for shipping. 

Until today, corrugated boxes are one of the most common forms of shipping box. What makes corrugated cardboard boxes so popular for shipping? Let's take a look.

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Cardboard Box Build: What Makes Up a Cardboard Box

There are 8 elements combined to determine a box’s strength and crush resistance​. These elements are: 

1. CONSTRUCTION
Just like the walls of a house, the walls of a corrugated cardboard box have different constructions.

• Single Wall: Standard corrugated comprised of single fluting with two liners.
• Double Wall: Suitable for packaging heavier goods – this adds an additional layer of fluting an​d liners to single-wall construction.
• Triple Wall: To package extremely large and heavy items (like large machine parts), triple wall boxes add yet another fluting and liner.

2. FLUTE SIZE
We're not talking about the musical instrument your parents made you play when you were 9. Box flutes are the corrugated part of a cardboard shipping box.

• The thicker the flute size, the better padded your box will be.
• The most common flute sizes are labeled by letter, with A being the thickest and F being the thinnest.

3. BURST STRENGTH
A box's burst strength is measured using the Mullen test. The burst strength tells you how much pressure a box can withhold before it bursts.

• ​The common burst strength measure is 200#, meaning a box can hold 200 lbs of pressure before it bursts.

4. EDGE CRUSH STRENGTH
A box's edge crush strength is measured using the Edge Crush Test (ECT). The edge crush strength refers to a box's stacking strength.

• ​The most common edge crush strength is 32 ECT. Big players like Amazon use this ECT for all their boxes, so you know your products will ship well in a 32 ECT box.

5. FLAT CRUSH
The flat crush test tests the strength of the fluting (corrugated part).

• ​Perpendicular force is applied to the flute of a box to test and determine how much weight it can withstand before crushing.

6. BASIS WEIGHT
This measurement is used to tell how heavy cardboard sheets are per square inch or feet before they are turned into boxes.

7. PAPER WEIGHT
This weight refers to how thick the cardboard paper is. Think of regular printing paper. To show how thick the paper will be, the printing industry uses pounds. This is the same with cardboard.

• ​Some common cardboard paper weights:
  • 26lb (popular industry standard)
  • 31lb
  • 35lb
  • 42lb (popular industry standard)

8. SURFACE TREATMENTS AND COATINGS
As an added protective measure, the liners of corrugated boxes and boards can also have special coatings, finishes or properties.

​There are many styles of corrugated box structures out there. But don't worry. You'll most likely use the most common shipping box style.

The most popular styles for corrugated boxes are: 

1. Regular Slotted Container (RSC)

​This is the most popular and common style of cardboard box. You'll most likely use this style of box for shipping your products.

2. Full Overlap (FOL)
Like a regular cardboard box, except the two flaps that usually meet in the middle of the box fully overlap.

​These boxes are used for packing heavier items. The overlapping flaps add extra strength to the box.

3. Half Slotted Container (HSC)
These boxes are similar to regular cardboard boxes as well, except the top of the box is completely open.

4. Full or Partial Telescope Box
These boxes have separate tops and bottoms that fit over each other. These boxes typically don't have flaps and are used for paper, books or fragile products.

5. Corrugated Tray
Corrugated trays are exactly what they sound like. These cardboard trays can be added to the bottom of boxes as added support, or as a lid on top of half slotted containers.

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You've learned about what makes up a corrugated box. Now, we can get into shipping box quality and why it matters for your shipping purposes.

The most important thing about a corrugated box is that it gets your products to your customers safely. You want your box to withstand the shipping and transportation process. How can you ensure your boxes won’t wind up crushed when they arrive at their destinations? 

Two things we mentioned in the previous chapter—the ECT and Mullen test. 

We’ll walk you through why these tests are important and offer up some tips on what to avoid when shopping for shippers so you don’t end up with boxes that fall apart. 

In our earlier chapter, we mentioned a few different tests cardboard boxes go through. But the packaging industry has two major ways of measuring the strength and durability of a cardboard shipping box. Each test is designed to determine the same thing but in different ways. They tell you how much pressure your box can take before it breaks.

The ECT

The ECT, which stands for Edge Crush Test, was designed to test and measure the durability of a corrugated cardboard box. It works by applying pressure to either the top or bottom of the box​ and seeing how much it can withstand when vertical before collapsing.

It tests the strength of a shipping box from top to bottom. This is important for when boxes are stacked on top of each other during the shipping process.

Invented in the 1990s, the ECT is the most common test used​ and 32 ECT is the most common corrugated box sold. We mentioned earlier that Amazon's boxes are 32 ECT. This is largely because it costs less and partly because stacking strength​ is a better indicator of how a corrugated box will hold up while shipping.

The Mullen Test

The Mullen Test, or burst test, tests the bursting strength of a corrugated cardboard box​​. It determines how much weight per square inch your box can hold before it is punctured or before it bursts. 

While the standard result of the ECT is 32, the standard result of the Mullen test is 200# — measured in pounds. The higher the number, the stronger the box. While the ECT focuses on how a box will hold up while stacked, the Mullen test focuses on how a box will hold up when being handled individually​, including when it’s handled roughly.

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Boxes that aren’t measured with the ECT or Mullen Test

When you’re shopping for boxes online, you’ll see most likely the product specifications in the details of each product description. Most corrugated boxes have that standard 32 ECT or 200# specification. This measurement is like having the packaging industry’s stamp of approval. Without that spec, you run the risk of ending up with boxes that aren’t sturdy or durable.

Boxes that can only hold less than 40 pounds

A standard corrugated box should have 32 ECT or 200# meaning it can hold up to 40 pounds worth of product. Most boxes that have the 32 ECT stamp can hold a range of weight from 30 pounds up to 65 pounds. However, if you opt to use a box that cannot hold more than 30 pounds, you may have crushed shipping boxes and angry customers to deal with later.

Boxes that have been used previously

Don’t sacrifice box quality just to save a few dollars. Used boxes may have more dents and bruises than a new one. It’s best to avoid the stress of wondering whether or not the product you worked so hard on will make it to its destination in one piece.

If you’re concerned with waste, there’s an easier solution than you think. Recycled shipping boxes are the best option for strength, durability and sustainability. Just because something is recycled doesn’t mean it’s low quality.

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There’s a lot of nuance in finding the perfect shipping box. It’s about protecting your small business’s products and stewarding the brand of your company, but it’s also about keeping costs down along the way. After all, companies spent $1.5 trillion on shipping costs in 2017​ — a record-breaking sum that includes transportation, warehousing costs and boxes.   

In addition to ensuring your items are appropriately packaged, a lot goes into finding the right box for what your small business is shipping. But don’t worry, you don’t need to be an expert in box measurements to get started. 

We’ve gathered everything you need to know here so you can be confident and more budget-savvy about your next box purchase.

Here are four questions to ask yourself to help you determine the perfect box measurements for your business and your budget.

The standard box measures 17 x 12 ⅜ x 12 ⅜. It’s also commonly referred to as “the book box” because it was designed to accommodate heavier items like books, albums, records, CDs, hand tools and more. It’s the most common size offered at shipping centers, and it’s typically the most cost-efficient in terms of size, weight and price.

However, just because it’s the standard size box doesn’t mean it’s standard for you. When you ship products in a box that’s too large or too small, you risk your package arriving damaged, or not being shipped at all. You can also avoid higher shipping costs by ensuring your box is a snug fit for your items, which is another reason the book box might not be the right box for you.

Why does this matter? Because the majority of business packaging comes down to just a few sizes — even Target ships 70% of their inventory using only three different sizes​ — so you want to make sure that the ones you are using ensure your packages not only arrive safely but ship efficiently. So the logical next step is discovering what the standard for your small business should be. This could be a standard size​, a custom option​​ or a mix of both.

So how do you find the right fit? That leads us to question two...

To find the right fit, you first need to find out what measurements are best for your desired package. You need to know how box sizes are measured.

The first thing to note: the dimensions you see on boxes are always measured from the inside of the box, and they’re consistently formatted by length x width x height. Here’s what you need to know about each.

Length: The first quantity to measure is also the easiest to find. It’s the longest side of the box with a flap and is measured horizontally.

Width: This measurement is typically the second in terms of the longest side. You can distinguish it from the height measurement because it also has a flap and is also measured horizontally.

Height: Height is measured vertically from the bottom of the box to the top. This is the only measurement not to include the flaps.

Now that you know how a box is measured, you can move onto the size of your products. Matching your product size to the right box size will ensure a snug and safe journey. Stay away from leaving too much breathing room around your products. The shipping process can jostle your package around a lot.

Another critical thing to note is how fragile your product is. If you need packing material as cushioning for your product, consider adding 1-2 inches on each side of your box measurements. This will help guarantee the box has enough room for packing material.

Now that you’ve considered the size of your package, it’s time to understand how weight will affect your shipment. 

This can literally make or break your product shipment process — pun intended! 

Figuring out your shipping weight can get slightly complicated. But don't worry, we've laid it all out in our post: How To Calculate & Use Dimensional Weight For Shipping.

To explain it here as well, shipping carriers don't always charge based on how heavy your product is. They use a factor called dimensional weight, which measures the volume of a box. This factor helps them ship more efficiently. 

When figuring out the weight of your product to ship, you'll need to measure the volume of your box. If your dimensional weight is more than your product, you'll be charged for that weight instead of the actual product weight.

With the actual product and box weight aside, let's tackle the box durability.

Think about the last package you received from Amazon. You were most likely delivered a 32 ECT box. As we mentioned in our previous chapters, this is the most widely chosen stacking strength for safe shipping.

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Question 5: Can I Create My Own Custom Shipping Box?

Yes, you can!

You're now a pro at measuring the size of your shipping box and figuring out what type you need. With that out of the way, it’s time to get to the fun stuff: customization and eco-friendly options.

These details may seem small, but they can have a significant, positive impact on your business in the minds of consumers​ and your bottom line. Here’s how you can have fun with the details:

Create your own packaging with custom branding.

Ever wanted to see your name in lights? Customizing your shipping boxes with a logo, picture, or even an ad feels just as good. And, it’s definitely better for your business. Not only does box branding make your products more memorable with your customers, but it also shows your business values quality as well.

Consider environmentally-friendly options.  

If your business is eco-friendly or you just want to have a positive impact on the planet with your processes, you can choose recycled boxes to help decrease your carbon footprint.

There are multiple options out there for people who don’t want to increase their bottom line to be environmentally friendly. You don’t need to spend more to make a greener decision. The best part? Sustainable boxes can also be customized, so you’re not giving up any of your creative freedom either — it’s a win-win.

If you’ve ever ordered anything from Amazon, you’ll likely recognize that bright blue tape and wide A-Z smile on the box while you’re still steps away. It’s a powerful experience for the consumer to know exactly what brand their package is from. What ecommerce business wouldn’t want that experience for their customer?

If you’re an ecommerce business owner, custom printed shipping boxes may seem out of reach. You may think your audience is too small, your price point isn’t high enough or maybe it’s just not in your marketing budget. 

But here’s why you should think about custom boxes a little differently. 

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Traditional or digital advertising is often extremely expensive to any startup or ecommerce small business. Sometimes, it’s not an option at all. But that’s where you have to get creative. Custom printed shipping boxes are the creative alternative to a low marketing budget and the most underused marketing tool in ecommerce.

Adding your logo to your boxes automatically helps increase your brand awareness. More eyes on your brand means more curiosity, which could lead to more business. In fact, 61% of consumers get more excited about receiving a package from that brand based on packaging, according to a study from DotCom Distribution​. The study also found that when customers are happy with a brand, they’re more likely to recommend it to their peers.  

You don’t have to take money away from your marketing budget to get custom boxes. You can skip the full customization and opt for eco-friendly kraft brown boxes with just your logo on it for free. 

Yes, for free​. 

Custom printed shipping boxes may be the hidden marketing tool you never knew your business needed. 

You’ve put a lot of time and effort into creating your products. The hours of hard work on your products won’t go unnoticed by your customers, but your boxes might. You shouldn’t have to put your creativity on pause when it comes to your shipping box. Create your own custom shipping boxes to give your products the packaging they deserve.

It’s easier than you think. Brandable Box makes it easy and affordable for you to get branded boxes. 

In less than five clicks, you can have perfectly procured custom printed boxes for your perfectly procured products. But what’s the true benefit for your business? According to the study from DotCom Distribution​, premium packaging is more likely to influence shoppers to make repeat purchases. 

Premium packaging can be as simple as a logo on the box, a few promotional materials on the inside or even full customization​. Any of those will increase your chances of shoppers making repeat purchases.

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Here’s a short exercise: ​Put yourself in the mindset of a consumer. Would you rather open a plain brown box or a custom printed box? Let's assume you said custom printed box. According to a study​, product packaging has the potential to trigger impulsive buying even for consumers with no intention to make a purchase. So does the unboxing experience really matter? The answer is yes.

As an ecommerce store owner, you have very few touchpoints with your customer​. The amount of opportunities you have to wow your customers the same way physical retailers do are much smaller. Because of this, your customers are buying an experience with your entire brand when they shop online. Taking the touchpoints you do have, like boxes, and turning them into memorable moments can go a lot farther than you could probably imagine.

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