Custom Corrugated Folding Boxes

Board Strength and Flute Choice

Corrugated board comes in several flutes. E flute is thin and smooth, good for print and small mailers. B flute is thicker and stronger, suitable for heavier products. Double wall board combines two layers for heavy or fragile items and for boxes that will be stacked high.

Choose the board based on the heaviest product the box will carry and how it will travel. A courier network with sorting belts treats boxes more roughly than a local delivery van, so stronger board pays off for national shipping.

Brown kraft is the standard outer colour. White outer liners give brighter print and a cleaner look for retail-facing brands.

Moisture is something to watch in a warehouse without heating. Corrugated board softens slightly in damp air, so if boxes are stored in a cold unit for long periods, a heavier grade keeps them stiffer. Keep bundles off the floor and away from external walls. Flute profiles and liners are explained in the guide to corrugated and card types.

Sizing Your Range

Most businesses need only three or four box sizes to cover their range. Measure your most common products and group them. A box that fits each group snugly, with a little space for padding, reduces void fill and protects items better than a large box with lots of loose packaging.

Courier pricing often depends on dimensions as well as weight, so keeping boxes compact can lower shipping costs. We can suggest sizes that sit within common courier bands.

If you sell items that vary a lot in size, ask about adjustable height boxes with scored lines at several heights. The box is folded at the right score for each order, reducing empty space.

Test the fit before ordering in large numbers. Pack each main product into a sample box and shake it. If the item moves freely, a smaller box or an insert will reduce damage and save on void fill. The guide to measuring your product shows how to work out internal sizes before you order.

Printing Folding Boxes

A plain kraft box with a one colour logo on the lid is simple, cost-effective and recognisable. Full colour printing on the outside or inside suits brands that want a stronger unboxing moment.

Printing inside the lid adds a message customers see as soon as they open the box, such as a thank-you or care instructions. Handling marks and return instructions can be printed on the side.

Keep space for a shipping label on the top or side, so couriers do not cover your logo.

Even a single colour logo on plain kraft can make a box look professional. If your budget is tight, print one design across all sizes so you only set up artwork once, then add a sticker for special editions or promotions.

Who Uses Folding Corrugated Boxes

Online shops and small e-commerce brands, small warehouses and fulfilment rooms, market traders who ship orders, businesses moving stock between sites, removal and storage companies, and subscription boxes all use folding corrugated boxes. Any business that needs boxes ready quickly but does not have room to store them assembled will benefit.

Event companies and exhibitors use folding boxes to transport display materials, leaflets and samples to trade shows, then fold them flat for the journey home. Schools and offices use them for archive storage, where a lock-tab lid keeps files dust-free and the boxes stack neatly on shelves.

Craft sellers who post orders from home appreciate them most of all, since flat boxes slide under a bed or into a cupboard until an order comes in. Sellers posting small items often pair them with our small mailing boxes for single orders.

How to Order

Tell us the sizes, the style, the board and the quantity. A custom quote comes back by email within one working day, with minimums set per job.

A free design proof shows each box flat with print positions. Production runs 4 to 7 working days from approval, and boxes travel flat on free tracked delivery to UK mainland addresses in 2 to 3 working days. Report any damaged or misprinted boxes within 10 days for a reprint or refund.

We keep dielines and artwork on file, so repeat orders for the same sizes are quick to quote and simple to produce.