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Double-layer cardboard boxes have become one of the most interesting input materials for businesses. The reason for this is the value of safety, which is so appreciated in today's culture of usage. As society becomes more aware of the damage caused by waste, sustainable packaging that does not compromise on quality becomes imperative.
These boxes come in many types depending on the items they carry. Moreover, each type of double-layer cardboard box has a distinct purpose in terms of the goods that are packed in it.
Some of the most basic and common types include:
Boxes
These are the most common packaging products that have a large variety of shapes and sizes. Strong, double-sided boxes are ideal for products such as electronic equipment, bottles, glass, furniture, etc.
Cases
These boxes are designed for tougher tasks. The edges of case boxes are usually reinforced, and the projects are built to hold very heavy and bulky objects. They feature a double wall structure that improves their stacking strength.
Slotted containers
It is a very common design that features a slot in its folding parts. All its four edges overlap, making it extra stable. Since the flaps form a sturdy base, slotted containers are the best for many businesses and help them carry their general-purpose items.
Banana boxes
Because of their distinctive name, people know very little about the shape and function of these boxes. The similarity in the name is brought about by their resemblance to the boxes used in transporting bananas. It is therefore a corrugated box that has been designed with ventilation holes integrated into its sides. Because of this, these boxes are very ideal for storing and transporting items that require airflow to avoid spoilage, such as fruits or vegetables. In addition, it is excellent for all kinds of foods.
RSC boxes
It is common to have an RSC box, with the long flap of each end folding and tucking in between the short flaps. The boxes are simple to assemble, making them the most popular choice for retail and shipping applications. They are suited for lighter products that do not need much protection.
Die-cut boxes
Double wall cardboard boxes-These are customized boxes that allow a company to present and sell its brand to its consumers. Because of this, its structure is modified to suit certain items intended for sale. These boxes can include cutouts for handles, viewing windows, or inserts for additional protection. Die-cut boxes are perfect for items that need to be visually marketed, like gifts and premium products.
The design of a double-layer cardboard box depends on the type of products it will be holding and certain core principles that need to be addressed.
The following are some features taken into consideration during the designing of these boxes:
Material selection
To make a double-layer cardboard box, a manufacturer uses a combination of linerboards and medium paper, giving it two layers of corrugation. This puts extra protection in place to handle the perforated surfaces and fend off crushing when needed.
Box dimensions
The thickness of the cardboard and the size of the box are commonly interrelated and determined by the weight and size of the item that is to be placed inside. Furthermore, the dimensions should always be accurate to prevent items from moving inside the box and, in so doing, damaging them. A large box leads to the item moving about, and a tight-fitted box can cause pressure on the items, injuring them as well.
Weight
The design of packing boxes has a common target: to keep the items safely packed from the day the items start their journey until the day the items reach their owner. In addition, they must avoid using unnecessary materials, from shipping to storage. When it comes to shipping, lightboxes cause low transport costs and less fuel consumption.
Eco-friendly features
It is an expedite cardboard box that is designed to achieve environmental harmony through recyclability and the use of water-based adhesives in its construction.
Graphic and structural design
These boxes can be lithographed and printed with logos, vibrant graphics, and interesting color schemes. This is to aid the brand and provide a better ability to protect the product.
These double-layer boxes are applicable everywhere, meaning they have a significant role in this world.
Some scenarios include:
Retail packaging
Still in retail business, corrugated boxes are the packaging of consumer products on the store shelves. These boxes are made strong enough to sustain handling, transportation, and even some environmental conditions. So, their beautiful designs aid advertisement and their sturdiness; they protect the item on sale.
Shipping and logistics
Shipping companies use double-layer cardboard boxes to pack a variety of products for transport by sea, land, or even air. Because of their lighter weight and strength, they minimize transport costs and product damages. They are important for intermodal transport systems, which move products by more than one mode of transportation.
Industrial packaging
In the industrial areas, these boxes are used to package machine components, tools, and raw materials in this industry. Packaging such products ensures that they are protected against dangers that may hinder their proper functioning.
Moving and storage
Double-layer cardboard boxes are the most preferred boxes when people are relocating or putting some items in storage. They offer very nice protection for fragile items during transportation. These boxes store clothes and seasonal decorations and thus give storage facilities a chance to maximize space.
Agricultural packaging
These boxes are commonly used in the agricultural field to market produce like fruits and vegetables. The reason vented banana boxes came about was to help airflow and keep crops fresh until they reached their market destination. They also handle the rigors involved in transporting perishable goods.
Electronic product packaging
Because of the delicate nature of electronic gadgets, shipping and manufacturing industries prefer double-layered boxes for their devices. These boxes prevent damage to the devices during transportation or even when they are on display at retail outlets.
When purchasing these boxes, one has to be mindful of their specifications. Conventional specifications mean that the thickness of the corrugated and liner paper plays an important role in the box's endurance. To put it more explicitly, the flute size and paper grades determine the weight of the box and the kind of product it is meant to be used for. Boxes meant for heavy bundles use thicker paper and bigger flutes, while those meant for light duty use of small flutes.
Just as important are the maintenance and reuse of these boxes, which need to be emphasized as well. Shipping boxes can be used more than once, which is an economical and environmental way of packing goods on pallets.
Box maintenance tips
Some of the important ways to keep a box in good condition are not to put any extra weight on it, not to put any items that could spill inside, and not to expose it to bad weather.
Recycling
Recycling is equally important, as it increases the life cycle of the packaging material: the box can be made over and over again, reducing the demand for virgin paper products and sending less material to landfills.
Before disposal
This is where all the parts of the box should be clean and dry. The best option is to collapse the box. Here it is flattened to save space, and its various components are held together for easy transportation to a recycling center.
Many of these boxes are used in various industries, so their quality needs to be consistent. They need to be reliable in delivery performance without sacrificing safety.
Quality control means managing all the measures taken to maintain the desired level of quality in a product. To ensure this quality, several parameters deserve careful consideration when constructing double-layer cardboard boxes, including the following:
Material integrity
These apply to the double-layer corrugated boxes that are produced from sturdy and fine-quality raw materials such as liner and medium paper. To guarantee quality, the Corrugated Medium should be free from defects like punctures, tears, or soft spots, which compromise structural integrity.
Flute size
Flute size determines the stiffness and flexibility of corrugated cardboard. This can be done through flexural tests, where one measures how much bending a sample undergoes when a load is applied and reports that dose as the effect.
Box construction
Only this ensures boxes are properly glued, stapled, and attached. Glue lines should be even and free from excess or deficiency since these two could lead to structural weaknesses.
Load testing
This tests the boxes by putting distributions on top of them and measuring the load they can carry before bending, buckling, or breaking.
Environmental testing
Since double layer boxes are expected to deliver performance in adverse weather, they undergo tests in which their package is subjected to conditions such as high humidity and extreme temperatures and is then assessed for endurance.
Cycle testing
The more cartons travel and are used, the more products they protect. In quality control, cycle tests are carried out to simulate repeated use and recycling to determine their longevity.
Visual inspections
These involve a good examination to observe flaws that aren't easily detectable, like small tears in the paper or uneven glue application.
Standard compliance
International safety and health standards specify minimum requirements for a packaging box. Quality control involves ensuring the package conforms to those standards, including ISO and EDGE. For example, the ECT minimum indicates that the box meets the strength criteria to qualify for EE, ECT, or other tests.
A1. A double-layer cardboard box is stronger than a single-layer cardboard box because it has one more layer of corrugated paper. Therefore, it provides more support and protection to the items it carries.
A2. Yes, double-layer cardboard boxes are recyclable. A variegated cardboard box is constructed from renewable resources. Hence, when it is recycled, it reduces the overall wastage in the environment and contributes to the production of new packaging materials.
A3. Retail, agriculture, electronics, moving and storage, and shipping and logistics use double-layer cardboard boxes. Any industry that transports or stores products that require extra protection still uses them.
A4. Double-layer cardboard boxes can be customized for unique sizes and prints. Companies can print unique designs or logos to promote their brands.
A5. When making double-layer corrugated boxes, strong and high-quality base materials like corrugated medium and liner paper are used. Testing and quality checks are done based on industry standards to keep their quality up to par.
