Rigid or set-up boxes have become one of the top choices for the brands to bring in a premium and top-notch experience. In fact, this packaging has become the top preference for brands, owing to its strong build, elegance, and ability to protect other items.
The beauty of the rigid boxes is that they are quite flexible, owing to the fact that you can use various materials to manufacture them. However, the right choice really depends on your needs and personal preferences. This blog will explain what types of materials are used in rigid box manufacturing. Let’s have a look:
Exterior
The exterior of the boxes is the area where you most definitely need to be considerate before starting. Since this area protects the items as well as handles the external pressure, it should be durable and sturdy. Here are the common materials to craft the exterior of rigid boxes:
The Most Common Material: Cardboard
One of the most common materials that brands prefer for packaging is cardboard. Its versatility, durability, and cost-effectiveness are what make this element the brand’s favorite. It exists in 3 types, as mentioned below:
Solid Bleached Board (SBB): This type presents a smooth and shiny surface, making it an ideal option for premium packaging.
Solid Unbleached Board (SUB): SUB offers comparatively a rough surface as it is not bleached to make a shiny exterior. This type is comparatively stronger and is preferred for heavy items.
Chipboard: Chipboard, or particleboard, is another type that is known for its durability and lightweight aspect. It has a low density of fiber, thus rendering it light in nature as well as required strength.
A Lightweight Alternative: Paperboard
If you want to chip away at the bulkiness of the cardboard, you should go with a paperboard. It is not only thinner but also less dense. Despite that, it is quite strong. The reason lies in its strong paper pulp fiber with more space.
Owing to this fact, this material is preferred when brands are looking to cut transit costs as well as want to streamline their assembly process. On top of that, this stock is also well-known for its good aesthetics because of its good build. Plus, paperboard also offers bespoke customization, making it a good first for premium products.
The following are different types of paperboard:
- Solid Bleached Sulfate (SBS): This is a premium-grade stock that is made from bleached paper wood. This is preferred for products that require both strength and beauty.
- Unbleached Paper: As the name implies, this type is made of rough wood, keeping the natural look intact. Brands incorporate this type when they are looking to go raw or maintain the natural beauty of the stock.
- Coated Recycled Paperboard: Made of recycled paper, this type is not only cost-friendly but also green in nature. On top of that, it's coated to produce a smooth surface to uplift the tactile engagement.
- Non-Bending Chipboard: This is also made of typical paperboard material; however, it is denser and has a little less gap between the fibers. Non-bending chipboards are used for book covers, mobile phone boxes, etc.
An All-round Option: Kraft
Suppose you need a stock with properties such as durability, sustainability, tailoring, and lightweight aspects - what is the preferred choice? If you are on the hike of the same material, Kraft should be a no-brainer for you. On the outside, it is a typical brown box with a rustic look.
However, the real magic is hidden in its build. Just like cardboard, it is made of paper pulp, but what makes the difference is its Kraft-making process. During the making process, wood is treated with sodium hydroxide (NaOH) and sodium sulphide (Na2S), breaking the stiff bond and rendering a soft outlook. The result is a stock that is as strong as cardboard but is more lightweight and green in nature.
Heavy-weight Lifter: Corrugated
Corrugated cardboard, or simply cardboard, is the stock that is utilized when you want to pack multiple items in one box or want to send the items over long transit routes. Corrugated is basically cardboard but with a more stiff build. However, it is more tightly packed than the corrugated ones. Further, it offers a combination of various layers, where various sheets are placed over each other. This construction gives it great strength and shock absorption, which makes it great for use when conveying sensitive and large loads.
PVC Sheets
PVC are the sheets that are known for their ultimate strength. An added benefit of this material is that it also offers resistance against the weather as well as a fight against chemicals. However, PVC struggles when it comes to customization, as you can’t add the final touch of your own choice. Further, it will also affect the sustainability touch of your brand as it is made of plastic.
Combination Option
So the real question is, ‘how is a rigid box made?’ The answer is the combination of the above stocks. Rigid packaging is made by combining either cardboard and paperboard or a blend of Kraft, cardboard, and paperboard. Some brands also love to add corrugated stock for added durability or when they want to send their items for delivery on long transits.
Owing to this merger, a rigid material possesses all the qualities of its parent stock. Further, the selection of individual stocks allows brands to be selective on the type of quality they are looking for. For instance, if they are looking for flexibility, a fusion of paperboard and Kraft would work. To ensure the safety of items during long transports, cardboard and corrugated items can be preferred.
Interior
The interior is the area that stays in touch with the products, ensuring good presentation as well as inner security. The following materials are used to design the interior:
Polystyrene Foam
Polystyrene foam is widely used for interior packaging because of its excellent cushioning abilities. It’s a lightweight material that offers better shock absorption, so that your fragile items are safely secured and unmoved en route. The benefit of polystyrene foam is that it is easy to form and cut to custom shapes for the product. These custom shaped inserts fit the product.
Foam Core
Foam core or foam board is basically a foam that is sandwiched between two layers of plastic. This stock is perfect for creating strong interiors fit to hold the items nicely. Owing to its unique build, this stock offers a combination of strength and rigidity. This material is quite versatile and enhances the protection feature in the packaging, such as magnetic lock boxes.
Covering
The covering material is used to wrap the outer surface of the boxes. Covering serves dual purposes. One, it enhances the durability aspect. Secondly, it gives a professional and pretty look. Here are some common options for covering the boxes:
Specialty Papers: These are unique types of very thin papers that are wrapped on the box surface to give a premium touch. There exist a wide variety of such papers. For example, texture paper is used when you want to get a tactical engagement. Similarly, metallic paper is used when you are interested in shining the design of your boxes.
Plastic Wrapping: Plastic wrapping or lamination is one of the most common options for custom packaging. The reason for its demand is that it not only gives durability to the packaging, it also makes them look transparent.
The TL;DR is that rigid boxes are made with a wide range of material options. Mostly a blend of common stocks is used. For example, you can mix cardboard and paperboard to create a basic rigid structure. Further, cardboard, paperboard, and Kraft can be added for a bespoke rigid packaging. Want to avoid the hassle of making these boxes? Contact CPP Boxes to get the packaging as per your needs.
Add Comment