From packaging deliveries, containing our food or storing products, cardboard is seen everywhere today. The brown boxes have become pretty much the basic building blocks of the e-commerce industry. According to data analysts Statista, the global output of cardboard in 2020 was estimated to be 66 million tonnes. And since the COVID-19 pandemic, that witnessed a massive surge in e-Commerce, the global output of cardboard in 2022 rose to 72 million tonnes. Now, that’s quite a lot!

These mailer boxes often use self-locking structures and corrugated material for durability. Mailer boxes are designed with interlocking flaps and wings, allowing for easy assembly and closure without the need for adhesive tape.

In the retail sector, mailer boxes can be used as gift boxes. They are not just easy to assemble but also extremely effective to keep ecommerce orders safe and secure.

History and emergence of cardboard boxes

But do you know when exactly was cardboard invented and how have they become so popular today?

Before we dive into its history and emergence, we need to know that Cardboards are classified in two categories, mainly. They are:

Paperboard. This is a thick paper most commonly used for things such as cereal boxes, playing cards, juice boxes, book covers and greeting cards. It is heavier than ordinary paper.

Corrugated cardboard. This type of cardboard is most commonly used in boxes. It is composed of a fluted (wavy) layer of waxy paper sandwiched between two flat layers of thick, paper. The fluted layer gives corrugated cardboard boxes much of their strength.  

Talking about its history, the first ever cardboard dates back to 15th century when it was first invented in China. Taking inspiration, an English company called M.Treverton & Son in the UK then invented the first ever paperboard box in 1817. Years later, Scottish born Robert Gair invented the pre-cut cardboard box in 1879. His product was perfect for shipment and general use as it could be stored and easily folded.

Boxes made from paperboard were first used in the transportation industry in France during the 1840s, when silk manufacturers began using them to carry Bombyx mori moths and their eggs. Corrugated paper was patented in England in 1856 and was originally used as a liner to thicken the tall hats that were in fashion at the time.

The arrival of lightweight flaked cereals further accelerated the use of cardboard boxes. The first to use cardboard boxes as cereal cartons was the Kellogg Company.

The first machine for producing large quantities of corrugated board was built in 1874 by G. Smyth. Oliver Long made further improvements and invented corrugated board the same year with liner sheets on both sides. This is the corrugated cardboard that is commonly used today.

The first corrugated cardboard box manufactured in the US was in 1895. By the early 1900s, wooden crates and boxes were replaced by corrugated paper shipping cartons.

Cardboard output has increased to around over 72 million tons by 2022. This would be an increase of more than 25 percent compared with cardboard production in 2015. Today, cardboard is used across the world for a huge variety of uses, including creating cereal boxes, paper towels, shipping packaging and cartons.

Kraft paper, derived from the German word "kraft" meaning strength, is a durable, brown-colored material widely used in packaging. The Kraft cardboards are popular due to its strength and eco-friendly properties, as the raw material is made from wood pulp through a specific pulping process.

Today there are a number of online portals from where companies can buy good quality sustainable corrugated cardboard boxes.

Cardboard boxes revolutionizing e commerce

Cardboard boxes play a key part in e-commerce revolution due to their versatility, cost-effectiveness, and ease of use for shipping and protecting products. Let’s talk about this in detail:

Cost-Effectiveness: Cardboard is comparatively inexpensive material to produce, which leads to lower shipping costs for businesses.

Lightweight and Durable: It’s light in weight and is also durable enough to protect products during shipping, especially when using corrugated cardboard (with its layers of cardboard placed on top of each other to provide cushioning).

Easy to Assemble and Disassemble: Cardboard boxes save time, energy and resources as they are simple to put together and can be easily disassembled.  

Protection of Products: Corrugated cardboard provides cushioning for fragile items, minimizing damage during transit.

Recyclable and Sustainable: Cardboard is a recyclable material, making it an environmentally friendly option compared to some alternatives like plastic.

Here are some of the categories of shipping boxes widely used:

  1. Tuck top boxes: Tuck top boxes are a type of folding carton or paperboard box that have top flaps that fold inward, tucking into the sides. The inward-tucking flaps of a tuck top box provide a secure closure without the need for sealing tape or glue.
  2. Mailing tubes: These are cylindrical, cardboard shipping containers used to securely mail items that are rolled or long, like blueprints, posters, or artwork. They prevent damage during transit to a large extent.
  3. Regular Slotted Container (RSC): It is the most common box style. It is highly efficient design for many applications as all flaps are the same length.
  4. Die-cut box: A die-cut box is a type of cardboard box created using a specialized cutting process (die-cutting) where a die, is used to precisely cut and shape the cardboard to achieve a particular design. If a customer wants a custom box for his growing e-commerce business, he is looking for a mailer die-cut box.
  5. Mailer Boxes: These are made with Premium Imported Papers. They come in a wide range of sizes and need no die or graphics charges.
  6. T-fold boxes: Also known as one-piece folder (OPF) or regular slotted box (RSB), these are perfect for shipping flat, shallow items like books or albums. They feature a flat bottom, end flaps, and side flaps that fold to form the top.
  7. Bubble Padded Kraft Envelopes: These padded envelopes are used for shipping jewelry, cosmetics, essential oils, vitamins and nutraceuticals, skincare, books, accessories, and other products that need extra protection.
  8. Holiday Mailer Boxes:they serve the purpose for gift and shipping box. They pack the gifts without the usage of wrapping paper, making the gifting process more economical and eco-friendly.  

How to ship a box?

To make sure that your package is delivered to your friends, family or customer, here are few tips and things to keep in mind for a seamless process:

  1. Choosing the right box:choose the right box that fits in your item perfectly at the same time snugging it aptly so that it doesn’t move too much. You can opt from single- or double-corrugated walls, depending on the weight of the package and how far it has to travel.
  2. Measure the good:Precise measurements of your package will help you decide the right box and send it with ease.
  3. Packing:Make sure you use lightweight cushioning products like bubble wrap, shipping paper, and peanut fills that keep the items safe and stable.
  4. Labeling:Labeling your product is important to ensure it doesn’t get lost. Make sure the label is easy to see, and is placed away from seams and corners.

How to choose the right box?

Consider the size, weight, and fragility of the items while choosing the right box, consider you're packing. You also need to look into your budget and any specific needs like stacking or branding, while choosing the right box.

In case you want to send fragile item, choose a larger to allow for padding like bubble wrap or packing paper.

Cube boxes are best for storage, while rectangular boxes are more commonly used for shipping.

If the item is heavy, boxes with double or triple walls are needed.

Corrugated cardboard is a common choice for shipping as it offers good protection while rigid boxes are durable and suitable for luxury items or electronics.

If you want to go for specific size, shape, or print, consider custom boxes as it can save money.

How cardboard boxes machine works?

Ever wondered how cardboard boxes machines work?

Cardboard box machines, specifically corrugator machines, use rollers and heat to create the fluted or ridged corrugated medium between two flat liners, forming corrugated board, which is then cut and processed into finished boxes.

In the start, the machine is fed with a large sheet of raw cardboard. It then passes through a series of rollers. Once the corrugated cardboard is finished, it is cut to size and glued together to form cardboard.