Custom Corrugated Boxes

B flute (approximately 3 mm total thickness) and C flute (approximately 4 mm) are the two most common single-wall corrugated configurations used in Australian product packaging. B flute has a higher flute density — more corrugations per linear metre — which produces a smoother outer surface that accepts higher quality print. C flute has fewer, taller flutes per linear metre, which produces higher compressive strength and better flat crush resistance at the same board grade. B flute is typically specified where print quality matters; C flute where load-bearing strength is the priority.

BCT (Box Compression Test) measures the maximum vertical load a corrugated box can sustain before it deforms or fails. It determines whether your boxes can be stacked safely in a warehouse, on a pallet, or in a truck without the lower boxes crushing under the weight of those above. BCT is determined by flute configuration, board grade, and box dimensions — a larger box of the same specification has a lower BCT than a smaller one. If your logistics involve pallet stacking, share the stack height and load per pallet with our team and we will specify the board grade required to meet the BCT you need.

Flexographic (flexo) printing applies inks directly to the corrugated liner surface using flexible rubber plates. It is cost-effective for high volumes and produces clear, legible brand graphics and solid colours accurately. It does not achieve photographic print quality or fine colour gradients. Litho laminate printing involves printing full-colour on smooth art paper using offset printing (the same process as premium retail cartons) and then laminating that printed sheet to the corrugated board. It achieves near-retail-carton print quality on a structurally corrugated box. Litho laminate is specified when the exterior of the corrugated box needs to perform as a brand communication surface at retail or direct-to-consumer unboxing level.

Yes. Interior printing on corrugated boxes is available — printing on the interior panels, the inside of the base, or a printed interior liner sheet. This is used by premium e-commerce brands for whom the unboxing experience is a deliberate customer relationship moment. Branded interior messages, care instructions, promotional codes, and pattern or colour fills are all achievable on corrugated box interiors using flexo or litho laminate.

Self-locking corrugated mailer boxes — where the lid and base lock together using pre-scored tabs without tape — in single-wall B or E flute are the most efficient format for most e-commerce applications. E flute (approximately 1.5 mm) is the preferred format for e-commerce mailer boxes where a sleeker, less bulky format is preferred and the product does not require the compressive protection of B or C flute. Self-locking tabs reduce assembly time per unit and eliminate the tape gun requirement in the packing operation.

For food products shipped in corrugated outer cartons (where the food is inside a primary food-safe package within the corrugated shipper), standard corrugated board specification applies. For food products in direct contact with corrugated board — fresh produce trays, food service boxes, bakery corrugated crates — food-safe kraft liner and food-safe adhesive are required. Advise our team of the food contact configuration at the quoting stage.