Cardboard Boxes

Cardboard boxes – sturdy, versatile, sustainable

In 2021, Deutsche Post alone delivered more than 1.8 billion parcels. In total, the number of shipments transported annually by all courier, express and parcel services throughout Germany exceeds 3 billion. High-quality shipping boxes play a crucial role in this.

Cardboard boxes are logistically efficient and effective promotional packaging. When transporting goods, the choice of packaging material is therefore crucial. For example, corrugated cardboard is an excellent choice as a packaging material. Corrugated cardboard packaging is versatile, whether for transport, storage or product packaging – it is a stable, versatile and environmentally friendly material.

Sturdy cardboard boxes made of corrugated cardboard

Cardboard boxes made of corrugated cardboard provide optimum protection for your products during shipping. They are sturdy, yet light enough to enable economical shipping. This is mainly due to the material. Paper is particularly durable when it is corrugated or ‘ribbed’. The corrugated paper form is referred to as fluting in the packaging industry. When a smooth paper web and a corrugated paper web are glued together, this is referred to as single-faced corrugated cardboard. This is the simplest form of corrugated cardboard. Two smooth ‘outer layers’ with a corrugated paper web in between result in single-wall corrugated cardboard.

Versatile – corrugated cardboard packaging

Corrugated cardboard is very flexible and versatile. These packaging solutions are the largest category among all paper, cardboard and paperboard packaging. They are also the market leaders in the shipping and transport industry. What's more, the cardboard boxes can be adapted to your individual requirements in almost every respect. From size and material to finishing, with us you have complete freedom in designing your individual Cardboard Boxes!

For people and nature – sustainable packaging made from corrugated cardboard

Our corrugated cardboard shipping boxes are made from almost 100 per cent recycled paper, are durable in use and can be completely recycled after use. This means we offer a first-class and sustainable packaging product. In the United Kingdom, an average of 80 per cent of corrugated cardboard is made from recycled paper products. The remaining 20 per cent is fresh fibre. This consists of broken and thinned wood, which is produced during the maintenance of managed forests.

With cardboard boxes from packaging-warehouse, you get modern and environmentally efficient packaging that meets the highest standards. 

The advantages of packaging-warehouse at a glance:

What makes packaging-warehouse cardboard boxes so special?

To ensure that products can be transported cost-effectively and safely, shipping boxes should fit the product as well as possible. At packaging-warehouse, you can independently control complex processes, such as creating a shipping box. With the help of our intelligent configurator, you can easily coordinate everything in a clear manner – regardless of whether you are already a packaging professional or are new to the subject.

The intelligent configurator automatically makes some settings to make the entire process as clear and simple as possible for you. For example, it always selects the printing technology that is the most cost-effective solution for the desired order quantity. Of course, you can change these settings at any time. There are many other tools available to help you design your box perfectly, such as size selection, interior and exterior printing, and coating options. 

Another feature that sets our service apart is the cost-effective production of small print runs thanks to digital printing technology. The flexibility of digital printing even allows for individually printed small runs, for example with consecutive serial numbers. 

What's more, our express production service means your order can be produced in just 5 working days and tailored to your product thanks to the free formats.

Cardboard boxes for every industry

Due to their versatility, corrugated cardboard boxes are used in almost all industries, including the chemical industry, beverage manufacturers, consumer goods industry, cosmetics industry, food and luxury food industry, and the pharmaceutical industry. This is because the different requirements of trade and industry pose no problems for the number one transport packaging material. Whatever you want to pack and ship, it will be in good hands in a corrugated cardboard box! Our specialists at packaging warehouse will be happy to advise you on which shipping box is best suited to your product.

Different products require different packaging. It depends on whether the goods are solid, liquid or powdered. In addition, the question arises as to whether the packaging must be oxygen-, moisture- or aroma-tight and whether it must be protected against temperatures, pressure, scratches, spoilage and substance changes. Furthermore, different goods can also be combined in one shipping carton.  

In the following paragraphs, we would like to introduce you to some of the industries in which corrugated cardboard Cardboard Boxes can be used.

Logistics and transport

Shipping packaging is a very important tool in the logistics and transport industry. Goods must be transported and stored safely. To make this possible, packaging technology is needed to transport and store goods in an economical and environmentally friendly way. Our corrugated cardboard boxes are ideal for transport packaging. Corrugated cardboard is a lightweight yet sturdy material and can carry a load of up to 32 kg under certain conditions. In addition, the boxes can be stacked in a space-saving manner thanks to their rectangular shape. When the boxes are no longer needed, they can be folded up and stored for later reuse. Corrugated cardboard is also very durable and environmentally friendly due to its high recycling rate.

Product packaging

Product packaging directly encloses the product. Product packaging is also primary packaging and comes into direct contact with the product, for example, a yoghurt pot or toothpaste tube. Product packaging is designed to protect the product and make it transportable. Product packaging is also a good marketing tool. It allows sellers to present their product in an appealing design and place important information on the product packaging. For additional protection, product packaging can also be protected with outer packaging made of corrugated cardboard. Outer packaging is secondary packaging that does not come into direct contact with the product. At packaging warehouse, we have a wide selection of corrugated cardboard product packaging.

Food & luxury foods

The food industry is one of the largest consumers of corrugated cardboard transport packaging. Almost all foodstuffs can be shipped safely in such cardboard boxes. Around 50 per cent of packaging is used in the food industry. In this case, that means: 

Delicate fresh produce such as fruit and vegetables are optimally protected by the sturdy boxes at all times – the food remains undamaged during loading, temporary storage and transport.

Cardboard boxes from corrugated paper can be treated in such a way that they have no impact on the properties of the packaged food and prevent the migration of harmful substances. 

Baked goods, sweets, flour, sugar, pasta, rice, beverage bottles – with our cardboard boxes, you can safely and efficiently package a wide range of different food and luxury items.

Both food producers and packaging manufacturers are equally responsible for complying with the legal framework governing food safety. 

Chemical industry & agriculture

In addition to the food industry, other important customers for corrugated cardboard transport packaging are the chemical industry and agriculture. In these sectors, the main focus is on providing optimum protection for products both externally and internally.

The products of both industries must be protected from external influences such as moisture and dirt. Conversely, in many cases it must be ensured that the products do not escape through the barrier of the packaging (e.g. in the case of potentially hazardous substrates, fertilisers, etc.). Otherwise, depending on the chemical, there may be risks to humans and the environment.

As corrugated cardboard is a high-performance and durable material, it can also compete in these areas without any problems. With the right combination of corrugation and base type, our cardboard boxes can handle shipping weights of up to 32 kg.

Electrical industry and e-commerce

Electronic devices are particularly popular in online retail. Retail will continue to expand. This has become particularly apparent as a result of the lockdowns during the coronavirus pandemic in 2020/2021.

Electronic items vary greatly in size, shape and weight. This requires packaging that can be adapted to the respective product, protects sensitive items and is waterproof to prevent damage to the electronics. Cardboard boxes from corrugated cardboard can fulfil precisely these requirements. The hinged lid box from packaging warehouse, for example, is one of the top sellers in e-commerce. Another advantage of packaging warehouse is the intelligent configurator. This tool allows you to customise the format of your packaging, and there are also further design options for finishing. A protective coating or laminate provides additional protection for your cardboard boxes against moisture and is water-repellent.

The perfect flute for your cardboard boxes

Not all corrugated cardboard is the same. Although the principle behind the name is always the same, there are different types of corrugation. Depending on their structure, individual types of corrugation are better suited to certain applications. That's why our range offers you a choice of several types of corrugation, allowing you to put together the cardboard boxes that offer the best properties for your needs.

Types of shafts and what they are suitable for

Corrugated cardboard is generally available in single-wall or multi-wall (double-wall or triple-wall) versions. More flutes always mean more layers of paper and thus greater stability. The larger and heavier the shipping carton, the more flutes should be used. In addition to the flute layers, there are also different types of flutes. These have their own flute pitch (t) and flute height (h). This refers to how high the flute is and how far apart the adjacent flute peaks are.

At packaging-warehouse, we use E, B and EB flutes for our cardboard boxes. This guarantees a wide range of possible uses.

E-flute: The wave height of the so-called ‘microwave’ is a ‘slim’ 1–1.9 mm. This is sufficient to withstand a maximum surface load of up to 7 kg. E-flute is primarily used for smaller cardboard boxes with light packaging goods. The biggest advantage over thicker flute types is that its low flute height makes it ideal for printing, offering plenty of creative scope for individual design. 

B flute: It is twice as high as the E flute, but is still considered a ‘fine flute’. It is often a component of multi-flute corrugated cardboard, but can also be used on its own with excellent results. Smaller items with a maximum surface load of around 14 kg are very well suited to B-flute cartons. Like the smaller E-flute, the B-flute is particularly suitable for product packaging where appearance plays an important role. 

EB-flute: The combination of E and B fluting ensures even greater robustness. With a flute height of 3.2 to 5 mm, corrugated cardboard with EB fluting is comparatively thin. Because it can withstand a surface load of up to 32 kg, you can easily use it for packaging large and heavy products – especially when combined with a solid folding base, you get reliable transport packaging. 

The right shipping box for your products

Various base types and closure options for boxes

Bei packaging warehouse findest du eine große Auswahl an Faltschachteln aus Wellpappe:

American cardboard boxes: This classic shipping packaging is characterised by its simple design and easy handling. It is no surprise that the FEFCO 0201 shipping box made of sturdy corrugated cardboard is one of the most popular types of packaging in e-commerce and mail order worldwide. 

Insert tab:

American cardboard boxes - FEFCO 0201 are also very easy to fill automatically and are available in the following versions:

The tuck-in flap (FEFCO 0211) is a simple and practical solution for sealing corrugated cardboard packaging. The tuck-in flap prevents the base and lid from opening by themselves – without the need for additional sealing material. 

Plug-in base:

The boxes with plug-in bases (FEFCO 0215) can be assembled in just a few simple steps, without the need for accessories such as parcel tape. Thanks to the special design, all four flaps of the base can be easily plugged together and hold each other in place. This type of base is particularly suitable for transport by roller conveyor, as it cannot get caught. The particular advantage of this base construction is that the weight of the packaged goods provides additional reinforcement for the base area.

Automatic floor:

Compared to tuck-in flaps and tuck-in bases, folding carton with crash lock base is suitable for packaging heavier products. The carton can be assembled in just a few simple steps. The base automatically locks into place with the four side walls and snaps into position immediately. This is possible because the folded base is already glued. Glass bottles or jars are therefore ideally stored in a shipping carton with an automatic base. This type of carton saves time and material when assembling and filling.

Folding base:

The folding base (also known as American cardboard box - FEFCO 0201) allows you to assemble the box quickly. Adhesive tape or other aids are required for fastening. Together with our EB corrugated cardboard, the folding base is ideal for shipping large and heavier products.

Folding lid with adhesive strip:

Our FEFCO 0885 cardboard box is ideal for an even more pleasant unboxing experience and for the safe return of goods. It is easy to open and reseal and is one of the most convenient and popular types of packaging for customers. The front flap has a tear-off and adhesive strip.

Customised cardboard inserts with cut-outs

To secure products or present them appropriately, packaging warehouse offers a wide range of inlays and slipcases that can be perfectly combined with all boxes and cartons:

Reinforcement inlay: Our reinforcement inlay made of corrugated cardboard is particularly suitable for fragile goods. It is an insert that increases safety and ensures that the product is better secured within the packaging.

Slipcases:

This is a practical protective cover made of corrugated cardboard that slides over the packaging and can also be customised thanks to its full-surface printing. The slipcases (0503) are a special type of folding box that is open on one or two opposite sides. The slipcases provide protection for books or serve as packaging sleeves for special products. They are therefore intended as an extension of the packaging.  

Cardboard insert/inlay:

This is a clever option that allows you to expand your shipping or product box on the inside. They are popular in many different industries and are mainly used for large gift boxes. On the one hand, they can be designed to perfectly hold individual items (e.g. flacons, bottles, cosmetics or ampoules) or several products (such as chocolates). On the other hand, our inlay/cardboard insert can also be printed over the entire surface. For example, this is used in the pharmaceutical industry to mark tablet boxes with the respective days on which they should be taken.

Customised printed cardboard boxes made to measure

Advantages of a customised box

Our cardboard boxes at packaging warehouse can be customised according to your ideas and wishes. You can easily and conveniently design your own shipping box with our intelligent configurator!

More freedom: All shipping and product packaging from packaging-warehouse is available in your desired format. Under ‘Size’, you can adjust the length, width and height of the boxes and cartons to suit your product. 

More creativity: The cardboard boxes can be printed over their entire surface. This allows you to incorporate your designs and create packaging with a unique look and real recognition value. Feel free to send your print data to packaging warehouse. We will advise you on how to achieve the best possible result. 

More protection: Your customised cardboard boxes will make an even bigger impression if you apply a protective coating or laminate – available in either a glossy or matte finish. Both protect your box design from scratches and dirt during transport and also contribute to a particularly high-quality look. 

By the way: if you only order small quantities of cardboard boxes, packaging warehouse guarantees fast production times. This saves you long waiting times for shipping and product packaging. Top quality in a short time – we at packaging warehouse make it possible for you!

Standard-size cardboard boxes for sending letters

The maxi letter is considered the largest letter format offered by Deutsche Post. It is also available as a maxi letter box made of corrugated cardboard and solid cardboard. A maxi letter box offers more options for sending items. For example, clothing or other light goods can be sent in such a letter box. This means that the ‘maxi letter’ format is not limited to standard documents. Maxi letters can be between 10 and 35.3 cm long, between 7 and 25 cm wide and up to 5 cm high. The maxi letter has a maximum weight of 1000 g. If you are unsure about the dimensions, it is best to consult packaging warehouse. We will find the right solution for you.

Unlike maxi letters, large letter boxes may only have a maximum height of 2 cm and a maximum weight of 500 g. However, large letters can be used in virtually any industry. We only use high-quality corrugated cardboard for our large letter boxes in accordance with FEFCO 0427. Corrugated cardboard gives the box greater stability and thus provides particularly good protection for your packaged goods. Large letter boxes are particularly useful for sending documents, records and printed matter. They can also be used for textiles, books or smaller products.

Our finishes – protection and visual enhancement in one

Protective coating

To protect your cardboard and the print image even better from scratches, you can choose between two coating options in our configurator:

A thin layer of varnish on your shipping box ensures that the print image is not damaged by scratches, dirt or even liquids. There is also another advantage: the gloss makes the print stand out even better and protects it from fading due to sunlight. The print image itself appears more detailed and high-quality thanks to the varnish. Our protective varnish is available in both matt and glossy finishes.

Protective laminate

Here, the cardboard is not coated with a varnish, but covered with a thin film. This makes the outside even more resistant to external influences and also protects the print image from scratches and UV radiation. Our laminate is also available in matt or glossy. It offers the highest level of protection and, just like the protective varnish, enhances the print image.

Both finishing options are available in our intelligent configurator and give your shipping carton an elegant and protective finish. 

Sustainability at packaging-warehouse

Sustainability at packaging-warehouse

For us, sustainability is a central tenet of our company philosophy. That is why all our materials are sustainable in nature:

In addition, our corrugated cardboard is characterised by resource-saving and energy-efficient production. Almost no trees are felled in corrugated cardboard production. The primary raw material for paper production is obtained from broken and thinned wood during the maintenance of managed forests.

Another advantage of corrugated cardboard is its recyclability. Once adhesives, impregnations and other chemicals have been removed from corrugated cardboard, it can be almost completely recycled. Approximately 80 percent of the annual production volume therefore consists of recycled material. Cardboard fibres can theoretically be recycled up to 25 times. However, the fibres become shorter with each new cycle. Therefore, fresh fibres must always be added during corrugated cardboard production to prevent a loss of quality in the end material. In the United Kingdom, however, only 20 per cent of fresh fibres are used for corrugated base paper.  

Energy consumption in corrugated cardboard production is also significantly lower than in glass recycling. In addition, there is less chemical waste than in plastics recycling. 

Our printing processes: offset and digital printing

The digital printing process

In digital printing (xerography), data is transferred directly from the digital database (e.g. via data transfer from the cloud or via a USB stick) to the packaging. The advantage here is that, as the process is not as complex as offset printing, even smaller print runs can be produced cost-effectively. The printing inks are liquid or powder-based.

Thanks to digital data transfer, it is easy to make individual adjustments within a series, such as printing a consecutive serial number. With offset printing, this would involve very high costs and a considerable amount of time. A new printing plate would have to be produced each time. Digital printing is therefore the ideal solution for printing cardboard boxes in smaller runs of 1 to 500 pieces.

Flexographic printing process

A third printing process that we also offer is known as ‘flexographic printing’ – another direct printing process that is particularly suitable for large print runs of 25,000 boxes or more.

When putting together your desired product, our intelligent configurator automatically selects the most cost-effective process depending on your order quantity. However, you can of course change this at any time and adapt it to your individual requirements.

The ordering process at packaging-warehouse

Would you like to configure a special shipping box without a lot of effort? At packaging-warehouse, we have made it our mission to make this process as simple as possible, yet flexible and with maximum control. We achieve this with our intelligent configurator. This makes it possible to quickly achieve a professional result without extensive prior knowledge in the field of packaging configuration.

First, select your carton shape, for example a hinged lid box FEFCO 0427. In the intelligent configurator, first enter the desired quantity of cartons you would like to order. If you make changes in this (or any other) field, the quote total will adjust automatically. This allows you to keep an eye on the costs at all times.

You can then determine the size. Either choose one of the standard formats or specify the size of your box yourself within the available minimum and maximum values.

The next step is to decide on the material. Here you can choose between different types of fluting (E-flute, B-flute or EB-flute) in various colour combinations. Then you can choose whether and how the cardboard should be printed. There are separate fields for printing on the inside and outside.

For the exterior printing, you can choose between 4/0-colour Euroscale and 4/0-colour Euroscale + white. For the interior printing, you can choose between single-colour black or 4/0-colour Euroscale. 

This is followed by two selection fields for the coating of your boxes. First, choose whether you would like a protective coating (matt or glossy) for your shipping box. Second, you can select a protective laminate if required. Here, you also have the choice between matt or glossy, but soft-touch laminate is also available. 

The final steps in our intelligent configurator are the additional options and delivery time. As already mentioned, a basic data check is carried out for every print job. As standard, our experts check the data format, font and font size, and colour space formatting. With the additional ‘professional data check’ option, we also check the bleed, safety margins, special colours, resolution and line thickness.

The most frequently asked questions about our cardboard boxes

Question 1: What is the minimum number of boxes I must order?

Answer 1: We want to be the perfect partner for companies of all sizes – from large corporations to newly founded start-ups. For small businesses in particular, which may still be in the market entry phase with their product, large orders are not economical or often not feasible at all. That's why there are no minimum order quantities at packaging-warehouse. We can provide the perfect packaging solution for your business, starting from just one item. 

Question 2: What sizes are cardboard boxes available in?

Answer 2: At packaging-warehouse, you can choose the format of your shipping box. We offer the following dimensions: length 60–700 mm, width 60–700 mm and height 15–250 mm. This makes it possible to configure a wide range of formats – from particularly small to particularly large cardboard boxes. 

Do you have any further questions? No problem, our customer service team will be happy to help. All our employees are experts in the field of packaging and are on hand to offer you advice and assistance.