Custom Shipping Boxes: E-Flute, Single Wall and Double Wall Corrugated Guide

The shipping box is often the first physical touchpoint between an e-commerce brand and its customer — it arrives on a doorstep and is photographed, unboxed and sometimes shared on social media. Yet the shipping box also needs to survive a distribution journey that includes automated sorting belts, fork-lift handling, stacking in a container, and the last-mile drop. Getting the specification right means balancing protection, cost and brand experience.

Corrugated Flute Types

Board Grades

Corrugated board is specified by the liner and medium grades. Common specifications:

• Kraft liner (KL): Brown natural kraft; highest strength-to-weight ratio; standard for shipping boxes
• White top liner: White-coated outer face; better print quality for branded boxes without litho lamination
• Test liner (TL): Recycled content; lower cost, lower strength; used for inner liners and non-critical outer boxes
• Mottled white liner: Smooth white surface for high-quality printing; used for e-commerce branded mailer boxes

Printing on Corrugated

For short runs and e-commerce mailer boxes, there are two options:

1. Direct flexo print: Inks printed directly onto the corrugated board. Cost-effective for 1–3 colours; surface texture limits fine detail. Minimum quantity typically 500 boxes.
2. Litho lamination: A lithographically printed paper sheet is laminated onto the corrugated board. Allows full CMYK photo-quality print with gloss, matte or spot UV finish. Higher cost but premium appearance; minimum quantity typically 300–500 boxes.

Box Styles

• RSC (Regular Slotted Container): Standard shipping box; all four top/bottom flaps the same length; most economical
• Mailer box (full overlap): Lid tucks into the base; resealable option available; premium unboxing experience for DTC brands
• Tray with lid: Separate tray and lid; used for subscription boxes and gift sets where the lid is retained by the customer
• Die-cut with auto-bottom: Unique shape; auto-lock bottom folds and locks without tape; used for retail display and e-commerce

Testing Standards

For Amazon FBA, corrugated boxes must pass Amazon's ISTA 6A test (SIOC — ships in own container) or be packaged to pass fragmentation test with a certified over-box. Key parameters: Edge Crush Test (ECT) minimum 32 ECT for single-wall, Burst Test (Mullen) or BCT (Box Compression Test) matched to stacking weight. Ask your supplier to confirm the BCT value for your packed box weight and stacking configuration.

RFQ Details

• Internal dimensions L × W × H in mm
• Maximum gross weight of packed product
• Flute type and board grade
• Box style (RSC, mailer, tray)
• Printing: direct flexo colour count, or litho lamination
• Finish (gloss/matte laminate, spot UV)
• Quantity and annual volume