Cardboard vs corrugated cartons – what's the difference?

When it comes to packaging and shipping, choosing the right type of carton is crucial. You can choose from cardboard cartons and corrugated cartons, both of which are popular for being recyclable and lightweight. So what is the difference between these two cartons?

In this article, we explore the key characteristics of cardboard and corrugated cartons so you can decide which is the right option for your packaging application. 

What are cardboard cartons?

Cardboard cartons are made from thick paper stock, typically between 0.5mm and 3mm depending on the application. Common examples of this cardboard include cereal boxes, greeting cards, and tissue boxes. 

Cardboard cartons come in two types – single-wall and double-wall. Single-wall cardboard cartons have one layer of paper stock, while double-wall cardboard cartons have two layers of paper stock for extra protection. 

Cardboard cartons are an affordable option for packaging and shipping but they're not as strong as corrugated cartons. They're most suitable for storing, moving, and shipping lightweight items.

What are corrugated cartons?

Corrugated cardboard consists of three layers – an inside liner, an outside liner, and corrugated fluting in between. This fluting greatly increases the strength of the cardboard, making it ideal for cartons and packaging. 

Corrugated cardboard boxes, or shipper boxes, are both lightweight and strong, providing effective protection for the contents inside while still being easy to package and transport. 

At Primepac, we offer a range of corrugated boxes, including:

• Stock cartons (North Island or South Island)
• Heavy-duty cartons (North Island or South Island)
• Fishtail cartons (New Zealand-wide)
• Diecut boxes (New Zealand-wide)

The difference between cardboard cartons and corrugated cartons

Both cardboard cartons and corrugated cardboard cartons are used for packaging and shipping products. However, they differ in terms of strength, shipping distance, affordability, sustainability and most suitable applications.

1. Strength and durability

Due to the triple-layered construction of corrugated cardboard, it is much stronger than standard cardboard. The fluting between the paper stock creates rigid strength, making the cartons resistant to crushing, puncturing, and tearing. This means they are better suited to the stresses of transportation and handling, particularly in busy warehouses. 

On the other hand, standard cardboard is weak and easy to bend or tear. The single layer of paperboard offers minimal protection for the contents inside the carton, meaning they can only be used to transport lightweight or low-value products that don’t require extensive protection.

2. Different uses

With their high strength and durability, corrugated cartons are the most effective option for moving, e-commerce, and fulfilment. They are ideal for shipping items that are fragile, heavy, or high-value as they provide extra protection while still being easy to manoeuvre. Corrugated cartons are commonly used to pack and transport furniture, appliances, electronic devices, glassware, machinery, and other vulnerable or expensive items. 

On the other hand, cardboard cartons are better suited to packaging lighter, non-fragile items with less protection needed. For example, they are commonly used for packaging cereals, snacks, clothing, shoes, and stationery such as envelopes, notebooks, and folders.

3. Shipping distance

When shipping products over long distances, it is critical to ensure that they are well protected from potential hazards during transportation. Corrugated cartons are the better choice for long-distance shipping because the fluted inner layer adds strength and rigidity to the box, allowing it to withstand the strain of transportation, handling, and stacking.

During shipping, products are typically subjected to various bumps, jostles, temperature changes, moisture, and rough handling. For longer distances, corrugated cartons provide superior protection because the fluting acts as a shock absorber.

4. Sustainability

While both standard cardboard and corrugated cardboard can be recycled, corrugated cartons are the more sustainable option. This is because corrugated boxes are more durable and can withstand the pressures of warehouses, meaning fewer cartons need to be replaced. In many cases, corrugated boxes can be recycled and reused multiple times, saving both resources and money. 

5. Budget

At face value, corrugated cartons are generally more expensive than cardboard cartons due to their more complex construction. However, the additional protection corrugated boxes provide can save you money in the long run by reducing product damage. Additionally, you may also be able to reuse some corrugated boxes numerous times, reducing costs over time. 

Standard cardboard cartons are relatively inexpensive but more prone to damage, raising the additional costs associated with returns, replacements, and customer dissatisfaction. 

Cardboard boxes NZ

When deciding between corrugated cartons and cardboard cartons, several factors should be considered, including the nature of the product being shipped, the distance it will travel, and your budget. 

Cardboard cartons

Standard cardboard cartons are most suited to items that are: 

• Lightweight 
• Non-fragile
• And being transported short distances.

Corrugated cartons

Corrugated cartons are ideal for shipping most items, but especially those that are: 

• Heavy
• Fragile
• High-value
• Or being transported long distances.

At Primepac, our stock cartons are made with extremely strong, corrugated 20c board, and are available in a wide variety of sizes. These cover almost any packaging requirement, are 100% recyclable and are FSC certified. Order yours for the North Island or South Island here.

Heavy-duty cardboard boxes

At Primepac, we also have a heavy-duty carton available which is designed to protect items that are:

• Sensitive
• Fragile
• Or heavy. 

These heavy-duty boxes are made of 7mm corrugated cardboard with high crush strength and double cushion walls. These cartons come in a wide range of sizes and are 100% recyclable. Order yours for the North Island or South Island here. 

Our range of cartons and boxes are suitable for any application, from shipping and fulfilment to personalised product packaging. Whatever your packaging needs, contact us for expert advice, download our buyer's guide, or browse our wide range of products to find the most appropriate solution for your business.