Custom Corrugated Boxes

Custom corrugated boxes are built from a fluted board layer between flat liners. That wavy middle gives them the stacking strength and crush resistance products need. It handles shipping, palletizing, and storage.

Packaging Vista prints corrugated boxes with your logo in any style. Choose regular slotted carton (RSC), die-cut mailer, shipping box, full overlap, or telescoping two-piece. Flute profiles include E, B, C, and double-wall. Stock choices are eco-friendly kraft or bright white.

Print in full CMYK and Pantone. Add gloss or matte lamination. Order from just 100 boxes with no die, plate, or setup fees. Get free design, dieline, and 3D mockup. Your boxes ship in 8 to 10 business days with free US delivery.

What is a corrugated box?

A corrugated box is a shipping and product carton built from a fluted middle layer of paperboard glued between two flat liner sheets. The wave-shaped middle (the flute) is what gives corrugated its stacking strength, crush resistance, and cushioning — the three properties that let the box survive palletizing, carrier handling, and long-transit shipping. "Cardboard" is often used loosely to describe corrugated, but true cardboard is a single solid layer of paperboard used for retail folding cartons; corrugated is the multi-layer fluted board built for shipping.

Corrugated is the most widely used shipping-box format in US commerce. It comes in single-wall (one flute layer, most common) and double-wall (two flute layers stacked for heavy or fragile shipments), with flute profiles from thin E-flute for smooth retail print to thick C-flute for heavier shippers. Ship weight, stacking load, and transit distance decide which flute + ECT rating fits.

Corrugated box styles

The structure decides how the box folds, ships, and protects. These are the corrugated styles we make most often:

Regular slotted carton (RSC)

The RSC is the most common and cheapest corrugated box. It has four flaps on the top and bottom. The two outer flaps meet in the center when folded. It ships flat, folds up fast, and suits most product and shipping needs.

Die-cut mailer boxes

A one-piece die-cut mailer folds up with a self-locking front tab and wing flaps. No tape needed. The clean interior and printable exterior make it the go-to for e-commerce, subscription, and retail unboxing. See our dedicated mailer boxes for more.

Shipping boxes

Standard corrugated shipping boxes are sized to your product. They use a stronger flute or double-wall board. They hold up to carrier handling and stacking on a pallet. Don't need printing? Order them unbranded as plain corrugated shipping boxes for cheap bulk shipping and storage.

Full overlap (FOL)

On a full overlap box the top and bottom flaps overlap fully. That adds a double layer of board across the faces. The extra cushioning and stacking strength suit heavier products and rough transit.

Telescoping (two-piece) boxes

A separate lid telescopes over a matching base, like a tray and cover. Telescoping boxes add rigidity. They work well for flat, large, or delicate items. Think framed art, apparel, and printed goods.

Flute profiles and board strength

The flute is the wave-shaped middle layer, and its size sets the board's thickness, cushioning, and print quality:

• E-flute (about 1/16-inch) is thin with a smooth surface for crisp, high-resolution retail printing.
• B-flute (about 1/8-inch) is a versatile all-rounder with good crush resistance and a flat print face.
• C-flute (about 3/16-inch) adds more cushioning and stacking strength for shipping cartons.
• EB double-wall combines a fine E and a larger B flute for heavy-duty strength with a printable surface.

Board strength is rated by ECT (Edge Crush Test). It measures how much top-to-bottom stacking pressure the board can take before crushing. It is reported in pounds per linear inch, for example 32 ECT or 44 ECT. We match the flute and ECT rating to your product weight and stacking needs.

Custom corrugated boxes with your logo

We print corrugated to your exact artwork in full CMYK with Pantone-matched color. A smooth flute like E-flute gives crisp, high-resolution graphics. Add gloss or matte lamination for safety and shelf appeal.

Every job comes with a free custom dieline and 3D mockup. You approve the fit and finish before we print. No die, plate, or setup fees, from the first 100 boxes.

Corrugated boxes by use

Corrugated suits any product that needs protection in transit or on the shelf:

How much do custom corrugated boxes cost?

Custom corrugated pricing depends on size, flute, board grade, print coverage, and quantity. Typical ranges at a 500-unit run: a plain or single-color RSC shipper on B or C-flute runs $0.30 to $1.00 per box; a printed die-cut mailer on E-flute runs $0.40 to $1.50 per box; a double-wall (EB) corrugated shipper for heavy or fragile goods runs $0.80 to $2.50 per box.

Per-box cost drops sharply as quantity rises — corrugated is one of the most volume-sensitive formats we make because press setup amortizes fast on flexo runs. There are no die, plate, or setup fees on any run.

What drives corrugated price:

1. Quantity — the biggest lever. Per-box cost drops sharply from 100 to 500 to 1,000+ as flexo setup amortizes.
2. Flute + wall — E-flute and single-wall are the cheapest; double-wall (EB, BC) adds board cost for heavy shipments.
3. Size — larger boxes use more board and take more press sheet.
4. Print method — flexo is cheapest for simple artwork on large runs; litho-lam (offset bonded to fluted board) costs more but gives photo-quality graphics; digital wins on short runs.
5. Print coverage — a single-color logo on kraft is cheaper than full-color inside and out.
6. Finishes — matte or gloss lamination adds a small step; most corrugated shippers skip finish entirely.

Send your product weight, dimensions, and quantity on the quote form for exact per-box pricing.

How long do custom corrugated boxes take to make?

Standard production is 8 to 10 business days after proof approval. Rush production runs in 4 to 6 business days on most orders at no additional charge, including double-wall builds. Litho-laminated corrugated (offset print bonded to fluted board) adds 1 to 2 days for the lamination step.

Ground freight from Cheshire, Connecticut adds 2 to 5 days to reach the West Coast — expect a full quote-to-dock timeline of about 2 to 3 weeks for a first order.

Corrugated vs cardboard vs mailer boxes: which should you choose?

The three formats solve different jobs. A corrugated box is the fluted-board shipping carton built for stacking, crush resistance, and long transit. A cardboard box (folding carton) is a single-layer paperboard box built for retail shelf and light retail packaging. A mailer box is a printed corrugated wrap-around that combines shipping strength with a branded DTC unboxing.

Choose corrugated when the box has to protect a heavy, fragile, or palletized shipment. Choose cardboard when the box is a retail-shelf presenter and unit cost matters most. Choose a mailer when the same box has to protect AND present in a DTC shipment.

A common pattern: cardboard folding carton for the retail SKU inside a corrugated master shipper for bulk transit; or a printed mailer as the single-package DTC alternative.

Pricing, minimums, and turnaround

Corrugated box cost depends on size, flute and board grade, print coverage, finishes, and quantity. Double-wall costs more than single-wall. For a deeper dive see our corrugated and shipping boxes guide. The per-box cost drops as volume rises.

There are no die, plate, or setup fees. The minimum is 100 boxes. Standard runs take 8 to 10 business days after proof approval, with rush on hand. Every order comes with a free dieline, 3D mockup, and free US shipping. Shipping high volume? See why brands choose a US corrugated box manufacturer. Request a free quote with your size and quantity for exact pricing.

Are custom corrugated boxes worth it for a small business?

Yes, for any small business that ships product and cares about protecting inventory in transit. Sized-to-fit corrugated cuts void fill and dim weight, and printed corrugated turns a plain shipper into a branded touchpoint. At a 100-box minimum with no plate or setup fees, custom corrugated is affordable at the smallest scale — many first-time customers order 100 or 250 shippers for a launch SKU and reorder as sell-through builds.

The cheaper alternative is a plain corrugated shipper cut to your size (custom fit, no print), which saves the print cost but skips the branded exterior. For DTC brands where the box IS the unboxing, see printed mailer boxes.

Are corrugated boxes recyclable?

Yes. Corrugated is the most-recycled packaging material in the US — the American Forest & Paper Association reports old corrugated container (OCC) recovery rates consistently above 90%, one of the highest recovery rates of any packaging category.

Kraft and white-lined corrugated are both curbside-recyclable in nearly every US municipal program. Soy-based and water-based flexo inks keep the box recyclable; aqueous coatings stay in most streams. Heavy laminates (gloss or matte film) and wax coatings are mixed materials that reduce recyclability — some programs require them pulled or reject them entirely.

For a fully recyclable corrugated shipper, request kraft or FSC-certified board, soy or water-based inks, and skip laminate coatings unless the product needs moisture protection. See our eco-friendly boxes and kraft boxes ranges.

Frequently Asked Questions

Which flute grade should I choose for my corrugated boxes?

It depends on the job. E-flute (about 1/16-inch) and B-flute (about 1/8-inch) are best for retail and product boxes that need a smooth print surface. C-flute and double-wall builds add stacking and shipping strength for heavier items. Tell us your product weight and use. We'll recommend the right flute.

What is ECT and how do I know my box is strong enough?

ECT (Edge Crush Test) measures how much top-to-bottom stacking pressure the board can take. That is the key spec for shipping and pallet strength. We'll match the ECT rating to your product weight and stacking needs. Your boxes hold up through transit and warehouse storage.

What is the difference between an RSC and a die-cut mailer box?

An RSC (regular slotted carton) is the standard four-flap shipping box. It ships flat and is taped closed. That makes it the cheapest choice. A die-cut mailer is a one-piece box with self-locking flaps. It folds up without tape and gives a cleaner unboxing for e-commerce and retail. We make both styles to your size.

How should I provide dimensions so my corrugated box fits correctly?

Give us the inside sizes in length x width x depth. Corrugated boxes are measured by inside space to fit the product, not the outer wall. If you're unsure, send a sample or the product specs. Our team will size the box and give you a custom dieline.

Can corrugated boxes be printed in full color with our branding?

Yes. We print corrugated in full CMYK and can match Pantone colors. A smooth flute like E-flute gives crisp, high-resolution graphics. Finishes like gloss or matte lamination are also on hand. The 100-box minimum and no setup fees still apply.

How much do custom corrugated boxes cost?

Cost depends on box size, flute and board grade, print coverage, finishes, and order quantity. It drops as volume rises. Every job is custom, so we quote per project rather than list a flat price. There are never die, plate, or setup fees. The minimum is just 100 boxes. Send your sizes and quantity for an exact, no-obligation quote.

What is the lead time and minimum order on corrugated boxes?

The minimum is 100 boxes with no die, plate, or setup fees. It stays affordable to order custom. Plan for the standard 8-10 business-day turnaround after proof approval. Rush production is on hand if your launch date is tight. US shipping is free.

What is a corrugated box?

A corrugated box is a shipping and product carton built from a fluted middle layer of paperboard glued between two flat liner sheets. The wave-shaped flute gives corrugated its stacking strength, crush resistance, and cushioning. It comes in single-wall (one flute layer, most common) and double-wall (two flute layers for heavy or fragile shipments), with flute profiles from E-flute (thin, smooth retail print) to C-flute (thicker, heavier shippers).

How are custom corrugated boxes made, step by step?

Six steps: (1) share product weight, dimensions, box style, and stacking needs, (2) our engineering team recommends flute + ECT rating and builds a free dieline + 3D mockup, (3) you approve the digital proof (physical sample optional), (4) we print on flexo (large runs, simple artwork), litho-lam (photo-quality graphics), or digital (short runs), (5) we die-cut, crease, and glue, then stack-test to the ECT rating, (6) boxes ship flat-packed and free across the US.

Are custom corrugated boxes worth it for a small business?

Usually yes for any small business that ships product. Sized-to-fit corrugated cuts void fill and dim weight, and printed corrugated turns a plain shipper into a branded touchpoint. At a 100-box MOQ with no plate or setup fees, custom corrugated is affordable at the smallest scale. Cheaper alternatives: plain corrugated shippers cut to your size (no print) or stock shipping boxes.

Are corrugated boxes recyclable?

Yes — corrugated is the most-recycled packaging material in the US. Old corrugated container (OCC) recovery rates are consistently above 90% (American Forest & Paper Association), one of the highest of any packaging category. Kraft and white-lined corrugated are curbside-recyclable in nearly every US municipal program; soy inks and aqueous coatings stay recyclable; heavy laminates and wax coatings are mixed materials that reduce recyclability.

Corrugated vs cardboard: what's the difference?

Corrugated is fluted board built for shipping strength — a wave-shaped middle layer glued between two flat liners. Cardboard (folding carton) is a single solid layer of paperboard built for retail shelf presentation. Corrugated protects in transit; cardboard shows the product on shelf.

They are often used together — a folding carton for the retail SKU nested inside a corrugated master shipper for bulk transit.

What is litho-laminated corrugated and when do I need it?

Litho-laminated corrugated is offset-printed paper bonded to a fluted corrugated sheet. It gives photo-quality full-color print on the shipping-strength substrate you get from corrugated. Use it when a large corrugated shipping carton needs sharp graphics (retail display shippers, hero-brand DTC master cartons, retail-ready packaging).

For most utility shippers, direct-to-flexo print is cheaper and sufficient.