Cardboard boxes have been a fundamental part of the food and beverage industry since the 1800s. And what was earlier assumed to be a simple and cheaper means of packaging, has now become an imperative tool for maintaining the integrity and freshness of our food and beverages during transportation and storage.
In fact, according to recent findings of IMS, the global market for cardboard boxes was $1.10 billion in 2020 and is expected to rise to $2.50 billion by 2025 driven by the growing awareness about their environmental benefits.
A total of 40% of the world’s food and beverages are secured in cardboard boxes as they are not only cost-effective but biodegradable and highly eco-friendly. In this blog, we’ll delve into the different types of cardboard, how to select the right one for your needs, and why making informed choices about packaging can benefit both your brand and the environment. Understanding these aspects will help you ensure that your packaging is both effective and responsible.
- The Basics of Cardboard Packaging
Types of Cardboard Used in Food Packaging
Cardboard boxes for food and beverage packaging typically comprise a corrugated layer sandwiched between two flat liners. This layered structure is bonded at temperatures higher than 100°C, making it moisture-resistant and a hygienic choice for food and beverage packaging. Additionally, it provides necessary strength and cushioning, crucial for safeguarding products in transportation and storage. The three types of cardboard used in food packaging are:
1. Single-Wall Cardboard
Single-wall cardboard features a single layer of fluted paper positioned between two liners. It is the most frequently used type of cardboard, suitable for a wide range of packaging applications. This option is generally cost-effective and works well for lighter products.
Considerations:
- Limited for Heavier Items: It might not offer adequate protection for heavier or more fragile products.
- Lower Durability: More susceptible to damage during transit and handling compared to thicker alternatives.
2. Double-Wall Cardboard
Double-wall cardboard comprises two layers of fluting and three liners. This design enhances the strength and durability of the packaging, making it more suitable for heavier or delicate items due to its improved cushioning and resistance to impacts.
Considerations:
- Increased Cost: It is more expensive than single-wall cardboard due to its additional layers of protection.
- Additional Weight: The added strength may result in higher shipping costs.
3. Triple-Wall Cardboard
Triple-wall cardboard includes three layers of fluting and four liners, providing the highest level of strength among corrugated options. It is ideal for very heavy or fragile products, as well as for items that require extended storage periods.
Considerations:
- High Expense: This type is the most costly of the three options due to its superior strength.
- Increased Shipping Weight: The added weight can significantly impact shipping costs.
2. Food-Grade Safety Standards & Cardboard Boxes
When using cardboard boxes for food packaging, it’s essential that the cardboard meets food-grade safety standards. This means it should be free from harmful chemicals and contaminants. Look for certifications such as:
- FDA Compliance: Ensures that the cardboard is safe for direct contact with food.
- EU Food Contact Regulations: For packaging used in Europe, ensuring compliance with EU regulations is crucial.
Preventing Contamination
Proper handling and storage of cardboard are vital to prevent contamination. The cardboard should be kept dry and away from direct contact with food products until use. Regular inspections for any signs of damage or contamination can help maintain safety.
Barrier Coatings
Some cardboard boxes come with barrier coatings that help prevent moisture and grease from seeping through. This is particularly important for packaging greasy or liquid items. Ensure that any coatings used are also food-safe and approved for use.
3. An Environmentally Responsible Choice of Packaging
Cardboard is often used for its eco-friendly qualities. Made from wood fibers, a renewable resource, they are recyclable with the flexibility to be processed into new products. They also decompose naturally, helping minimize landfill contributions. Recent advancements in packaging technology are making cardboard even more sustainable by using water-based inks for printing to reduce the environmental impact. Some new coatings offered in modern printing practices are compostable, allowing the entire package to break down in composting facilities.
However, when it comes to food and beverages, there are some critical safety aspects you should take into consideration:
Recycled Content Selection:
- Source of Recycled Materials: Ensure the recycled cardboard comes from reputable sources and does not contain harmful contaminants. Cardboard that has been recycled from non-food sources might have been exposed to chemicals or substances unsuitable for food contact.
- Quality Standards: Work with suppliers who follow strict quality control measures and adhere to relevant safety certifications, such as those from the FDA (Food and Drug Administration) or equivalent regulatory bodies.
- De-Inking & Purification: The recycling process should include purification steps to remove any remaining contaminants or impurities that could affect food safety.
4. Practical Tips for Choosing the Right Cardboard Packaging for Your Product
When selecting cardboard boxes, take care of the following:
- Product Size and Weight: Choose the appropriate type of cardboard (single, double, or triple-wall) based on your product’s requirements. Measures how much force the cardboard can withstand before bursting. Higher bursting strength means better protection. Many suppliers conduct the Edge Crush Test, which indicates the compressive strength of cardboard. A higher value of ECT means greater strength and ability to withstand stacking.
- Fit & Protection: The packaging should fit the product precisely. Overly large packaging can lead to excessive movement, which increases the risk of damage. For example, packaging that is too large for a small item might result in shifting and potential breakage. Properly sized packaging reduces the need for additional padding materials, which can be cost-effective and environmentally friendly.
- Shipping and Handling: Ensure the cardboard can withstand the rigors of transportation and handling. Well-sized packaging can help maximize warehouse storage efficiency and reduce shipping costs by allowing more products to fit in a single shipment.
5. Aesthetic Qualities of Cardboard Packaging for Branding and Marketing
Cardboard packaging has evolved beyond its functional role to become a powerful medium for branding and marketing. Its aesthetic versatility enables brands to create visually striking and memorable packaging that resonates with consumers.
- Custom Shapes and Structures:
- Innovative Die-Cutting: Cardboard can be custom die-cut into shapes that highlight the product’s uniqueness. For instance, a gourmet chocolate brand might use a die-cut box with intricate patterns that reveal the product through a window, enhancing visual appeal and creating a sense of luxury.
- Structural Innovations: Beyond traditional boxes, structural designs such as trays, sleeves, and fold-out panels can enhance functionality and presentation. A premium wine might come in a rigid cardboard tube with a hinged lid, adding a touch of sophistication and making it a perfect gift items
- Advanced Printing Techniques:
- Offset Lithography: Ideal for high-quality, consistent prints, offset lithography is perfect for large-scale production. This technique can produce vibrant, intricate designs for products like craft beers or gourmet sauces, ensuring color consistency and detailed imagery.
- Digital Printing: Suitable for short runs and quick turnarounds, digital printing allows for customization and personalization. For example, a seasonal beverage might have different designs for limited-edition releases or personalized labels for special promotions.
- Flexography: This method is effective for printing continuous patterns and large quantities. It’s commonly used for products like snack foods and beverages that require consistent, high-speed production.
Similarly, you have the freedom to apply any type of coatings or finishes to maximize the aesthetic appeal of your product packaging. Cardboard may seem like a simple and cheap material, but it in reality it is versatile and flexible. If you have come reading this far and are finally convinced about cardboard packaging for your product, you now need an expert supplier. The MailerBox packaging has a versatile portfolio of cardboard packaging that is not only highly durable, but aesthetically pleasing and memorable. Get in touch with our team today and get a free design sample based on your requir
