Corrugated boxes: choosing the right ply, size and supplier

A box that is too weak costs you damaged goods and returns. A box that is too strong costs you money on every single shipment. Getting the specification right is the most useful thing you can do before asking manufacturers for prices.

Measure the inside, not the outside

Box makers work to inner dimensions: length × width × height, in that order. Measure your product (or its inner pack) and add a little room for padding if you use it. Sending outer dimensions is the most common reason a first batch does not fit.

Ply: how many layers you actually need

Corrugated board is made of alternating flat and fluted layers.

• 3-ply — light products, short distances, little stacking
• 5-ply — most shipped goods, moderate weight, courier and truck transport
• 7-ply — heavy items, long-distance transport, high stacking in godowns

Weight and stacking matter more than the product's value. Tell the supplier what goes inside, how much it weighs, how it travels and how high the boxes are stacked — a good manufacturer will recommend the board and paper grade, not only the ply.

Printing and finish

Plain brown boxes are the most economical. One- or two-colour printing of your logo and handling marks adds cost per box and usually a minimum run. If boxes go to retail shelves or are part of an unboxing experience, ask about better printing options — but price them separately so you can see the difference.

Questions to ask before a bulk order

1. What board and paper grade will you use for this ply?
2. What is the minimum order, and the price at two or three quantities?
3. Can you send a sample for approval?
4. What is the lead time for the first order, and for repeat orders?
5. Is delivery included to my location?

Plan for repeat orders

If you ship every week, a manufacturer who can hold a small buffer stock or deliver on a fixed schedule is worth more than the lowest one-time price. Mention your monthly quantity in the enquiry.

Compare corrugated box manufacturers or post your box requirement with inner size, ply, quantity and city.