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Demand for corrugated cardboard packaging is rising as companies prepare for the European packaging regulations, which will be phased in from August 2026. Corrugated cardboard has been a mainstay in the logistics sector for decades, but the new regulations are giving it a different role: from simply being a protective material to a conscious choice in making the supply chain more sustainable.
Corrugated cardboard consists of two smooth layers of paper with a corrugated layer, known as the fluting, sandwiched between them. This corrugation provides strength without making the material heavy. As a result, corrugated cardboard packaging is suitable for a wide range of applications, from e-commerce shipping boxes to pallet boxes for industrial goods. The cardboard is usually made from recycled paper and can be reprocessed after use. How many times this can be done depends on the quality of the fibre, but in practice, cardboard undergoes several recycling cycles before the fibre becomes too short to be turned into usable paper.
Regulations are putting corrugated cardboard packaging on the map
The Packaging and Packaging Waste Regulation, or PPWR for short, requires companies to reduce packaging waste and use more recyclable materials. For many shippers, this means that plastic void fill and non-recyclable packaging are being replaced by alternatives made from paper and cardboard. Corrugated cardboard is benefiting from this shift, as the material already meets the key requirements: it is recyclable, often FSC-certified and lightweight in relation to the protection it offers.
Earlier this year, PostNL demonstrated the benefits of well-designed packaging. At its fulfilment centre in Houten, the company processed one million parcels via an automated packaging line, thereby saving an average of 13 per cent in packaging volume – equivalent to the load capacity of around sixty lorries. Customised corrugated cardboard packaging makes such savings possible, as the box is folded around the product rather than the other way round. Less air in a parcel means more parcels per journey, fewer journeys per day and therefore less fuel and lower emissions per item dispatched. For companies that ship on a large scale, that difference really adds up over time.
From standard boxes to bespoke solutions
Not every product requires the same type of packaging. A manufacturer of fragile equipment has different requirements to an online shop that dispatches small items. Corrugated cardboard packaging is therefore available in various types: single-wall for light products, double-wall for heavier or fragile goods, and triple-wall for machinery and bulk transport. Which type is required depends on the weight of the product, the stacking height in the warehouse and the duration of storage or transport. The packaging industry uses FEFCO codes, an international system that specifies the folding or die-cut shape of a box. This makes it easier for buyers and logistics planners to compare quotations from different suppliers.
As well as custom-made boxes, some companies use corrugated cardboard on a roll or in fanfold form, whereby a continuous strip of cardboard is cut to length for each consignment. This is particularly practical for products with varying dimensions, where a fixed box size would quickly leave too much unused space. A roll of cardboard also takes up less storage space than a stock of ready-made boxes in all sorts of sizes, which is a significant consideration in a warehouse with limited floor space.
For those responsible for logistics, there is another factor to consider: compatibility with automated packaging lines. Machines that fold custom-sized boxes have specific requirements regarding the thickness and strength of the cardboard. Anyone wishing to use corrugated cardboard packaging in an automated process should discuss this with the supplier in advance, as not every type of cardboard is suitable for every line. Companies just starting to make the switch to customised packaging usually have this tested using a sample before converting an entire line.
Industry tip: Spee Golfkarton in Roermond has been manufacturing corrugated cardboard packaging for over thirty years, serving customers in industry, e-commerce and retail. The company works exclusively with FSC-certified cardboard and supplies both standard boxes and bespoke solutions, from design to printing. Companies looking for bespoke corrugated cardboard can turn to specialist manufacturers such as Spee Golfkarton, who, in addition to standard sizes, also advise on the correct corrugation thickness and printing for a specific product.
Paper or plastic
The debate surrounding packaging materials is not just about regulations. Companies are also considering costs and the experience of the customer opening a parcel. Corrugated cardboard packaging is generally cheaper than plastic alternatives and easier to recycle, but offers less protection against moisture. For dry general cargo, this is rarely a problem. For products stored or transported outdoors, an additional layer is often required, such as a film or a coated version of the cardboard.
The return flow also plays a part in this assessment. A box that fits the product perfectly is less likely to be damaged during transit, and a product that arrives undamaged is less likely to be returned. For online shops handling a high volume of small parcels, this is a reason to reassess the cost-effectiveness of their packaging, not only in terms of material costs but also in terms of the number of returns it helps to prevent.
With the packaging regulations drawing nearer, suppliers expect growing demand for corrugated cardboard packaging that both meets the new requirements and fits within existing logistics processes. For an increasing number of companies, these two questions – how to become more sustainable and how to package goods – are now part of the same discussion.
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