A Step-By-Step Guide To Manufacturing Cardboard Boxes

Custom boxes are one of the best packaging solutions available in the market. They have several features that make them unique from others. The material used in manufacturing cardboard boxes is high-quality and environmentally friendly.

They are the most preferred cases by many successful brands due to their durability and catchy look. You can consider them as your packaging if you are a new business. If you choose these packages, then the other thing to understand is how they are made. The following steps could assist you in making cardboard boxes;

Selecting The Perfect Paper For Packages

Cardboard boxes are made of two layers; the inner line is test paper and the outer liner is kraft paper. Kraft paper is made from some specific type of softwood trees with long fibres. These trees provide a smooth and catchy finish to kraft papers. Kraft paper is used as the outer layer because it is easy to print any design on it due to its smooth finishing. There are several types of kraft paper available in the market.

Preferable paper is those made from trees with long fibre as they have more water resistance. They will provide more strength to your boxes and make them durable. The Colour and appearance of kraft paper also depend on the usage of wood. Kraft paper made from trees such as spine and fir is the best choice for you. You can use it in your cardboard boxes to make them reliable as well as eye-catchy with smooth finishing.

Recycled Paper Can Be Used

cardboard packaging boxes

In manufacturing cardboard cases, you can select test paper that is an inner liner made from raw material or recycled paper. Because of this, they are cost-effective with more premium quality. The recycling process also helps in reducing the cutting of trees. In this way, you can make your packages in an affordable way. Another benefit of using this paper in cardboard boxes is their eco-friendliness. The durability of this paper also provides more strength to your packages and makes them durable for storing your fragile products.


Another thing is to choose the method of pulping that is best for producing the paper for boxes. A long process is involved in creating a paper to get a smooth finish. In this method, long blocks of wood are pulped that are more suitable for the paper. First, trees are cut and turned into small logs for further processing. These logs then go through one of two processing techniques of pulping; mechanical or chemical pulping.

Mechanical Pulping

Using a rotating stone to grind debarked logs, mechanical pulping reduces wood to individual cellulose fibres. This method is cost-effective and also gives higher results.

Chemical Pulping

In this process, cooking wood logs into individual fibres takes place. There are two ways of chemical pulping; one is sulphite and the other is sulphate. Both these methods provide higher throughput and quality paper.


Now that you have selected key elements for your cardboard cases, this is the time for manufacturing them. You can use flute cardboard in between two liners to give more strength to the boxes. Paper passed through the corrugator to spray hot steam allowing it to be pressed. These dried rolls of paper will then go through the corrugated roller. This fluted process depends on the quality of the box.

custom product box

You can enhance fluting for more high-quality cases. This will require a large amount of material. For cost-friendly fluting, you can utilise a less fluting process which will require a small amount of material. The corrugated machine uses hot steam to make cardboard soft and convert it to a specific shape. At the same time glue is also used to stick the edges of the box.

Cutting Into Pieces

The bending machine then folds the cardboard into its shape. Converting it to the desired shape and size, it then sends it to the trimmer machine. It will then trim all the extra material from the kraft box packaging and make it perfect. This process will give your box a custom shape and size that best suits your items.

Final Process

Converting it to the perfect shape, stitching or glue is used to stick the sides to make it a complete box. You can add any other features to these boxes as per your products’ requirements. After the process is finished, the extra material is recycled to continue in the chain of boxes.


These steps will help you in selecting the best material and key elements for your cardboard boxes. This will also allow you to customise your cases as per your desire and items’ specifications. You can shift to high-quality and affordable packaging with the use of customised cardboard packages.

Additionally, many producers now manufacture boxes using as many eco-friendly materials as possible so that their processes are carbon-neutral. In this way, you can manufacture your own boxes very easily.