How Corrugated Boxes are Manufactured: A Step-by-Step Guide

Corrugated boxes are the backbone of modern packaging—strong, sustainable, and reliable. But have you ever wondered how these essential boxes are made?

At Delight Engineers, we’ve been perfecting the art of corrugated box manufacturing since 2001. With decades of expertise, state-of-the-art machinery, and a passion for quality, we deliver packaging solutions that stand the test of time and transit.

In this blog, we take you behind the scenes to explore how corrugated boxes are manufactured—step by step.

Step 1: Raw Material Selection

It all begins with kraft paper, the main raw material made from wood pulp or recycled paper. At Delight Engineers, we source high-quality kraft paper to ensure our boxes are durable, eco-friendly, and cost-effective.

Key Materials Used:

• Linerboard (outer and inner layers)

• Fluting medium (wavy inner layer)

• Adhesives (usually starch-based, biodegradable glue)

  
  

Step 2: Corrugation Process

Next, the kraft paper enters the corrugator machine, where it’s transformed into fluted or wavy paper. This fluted sheet is the heart of a corrugated box—it provides strength and cushioning.

The Corrugation Process:

• Paper is heated and passed through corrugating rolls

• Flutes are glued between two flat sheets (liners)

• Result: Single-wall, double-wall, or triple-wall corrugated board

  
  

Step 3: Board Cutting and Trimming

Once the corrugated board is formed, it’s trimmed into specific sizes. Our advanced cutting machines ensure precision and minimal waste, tailored to each client's requirements.

Did you know? Custom sizes reduce shipping costs and environmental impact—an important consideration in today’s green-conscious world.

Step 4: Printing and Branding

At this stage, we print logos, product details, barcodes, and designs using flexographic or digital printing methods. Branded packaging not only protects products—it promotes your business!

Options Available:

• Single-color to multi-color printing

• Water-based eco-friendly inks

• Customizable for bulk orders

  
  

Step 5: Die-Cutting and Slotting

Using die-cutting machines, we shape the boxes into specific designs like regular slotted containers (RSC), die-cut boxes, or custom inserts. Slotting machines add creases and scores for easy folding.

This step ensures the final box matches your product dimensions and functionality needs.

Step 6: Folding and Gluing

The box panels are folded and glued together using automated folder-gluer machines. Our strong adhesives ensure long-lasting bonding, even under heavy loads.

Quality Tip: Each batch is manually checked for glue strength and box symmetry.

Step 7: Quality Inspection and Testing

Every corrugated box at Delight Engineers goes through rigorous quality checks, including:

• Bursting strength test

• Edge crush test (ECT)

• Compression test

We make sure the boxes meet both Indian and international packaging standards.

Step 8: Packing and Dispatch

Finally, the finished boxes are bundled, stacked, and shipped to clients. We take care to optimize storage and reduce damage during transport, ensuring that your packaging reaches you in perfect condition.

Why Choose Delight Engineers for Corrugated Packaging?

• ✅ 20+ years of manufacturing excellence

• ✅ Custom packaging solutions across industries

• ✅ Eco-friendly and recyclable materials

• ✅ On-time delivery with zero compromise on quality

  
  

Conclusion

From raw paper to ready-to-ship boxes, corrugated packaging involves a precise, sustainable, and quality-driven process. At Delight Engineers, we combine cutting-edge technology with human expertise to manufacture boxes that protect your products and enhance your brand.

📦 Need customized corrugated boxes for your business?

📞 Get in touch with Delight Engineers today! Let’s pack your product the right way.