What Is Fluting and What’s the Best Option For My Brand?

Kate Wright
Kate Wright | 5 min read

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Depending on the weight of your product, the fluting size might play a key role in your decision.

Corrugated cardboard boxes - exactly the ones we offer at Packhelp - are made of recycled pulp. This recycled pulp is mostly made of used paper. It is firstly composted, dried and then used as the material for further production process, which causes it to be an ecological solution.

The machine that later creates kraft paper out of the recycled pulp is known as Fourdrinier machine. It’s gigantic - the square structures of the machine, used to form the paper, are more than 182 meters long!

Corrugated cardboard cuts are made on machinery called corrugators.

The process of forming the corrugated cardboard begins with pressing the raw materials with high-pressure steam. Then, the paper is exposed to heat. As it dries out, the machinery forms it into the desired type of fluted cardboard. It happens due to the pressure applied from the top. Only then the prepared cardboard can be cut by a die into patterns of boxes (this happens in a different facility though).

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Recycled cardboard is s solution that doesn't require cutting down the trees. Instead, it uses already used materials for recycling.

What are flute height and grammage?

Flute is the space between cardboard layers. There are different variants of fluting. Each choice influences the box in a way that the packaging can be more durable, more resistant towards stacking or recommended for a certain kind of product. The main role of those arched layers of cardboard is to provide cushioning for the items inside.

On our website, you can find that every flute has two main features: flute height and flute grammage.

  • Flute height is basically the height of the cardboard. In terms of packaging, it describes how thick are the walls of a certain box.
  • Grammage is an indicator of the paper density in the cardboard. Note, that the higher the density, the heavier the box is.

One feature that is not directly addressed is the printing surface. All of the flutes that we use are recommended for printing.

What does Flute E, B and EB mean?

Once we understand the process of cardboard production and its main features, it is much easier to understand the meaning of exact flute types.

  • Flute E is the most common choice in our shop. It is recommended for all types of e-commerce packaging - cosmetics, clothing, even glass and ceramics (but fillers should be included). This type of flute is not advised for heavy products though.
  • Flute B is a variant for heavier products. The grammage for mailer boxes is 450g/m2. The walls are thicker, which is good for securing more fragile products too.
  • Flute EB is the thickest variant available in the standard offer of Packhelp. It is available solely in shipping boxes. The grammage is 660 g/m2, whilst the five layers of the cardboard are a very thick wall. However, this type of flute is possible only for big boxes, as such thick walls would not fold in small sizes.

Note: In case you have any further questions, don’t hesitate to write to us. We also encourage you to join our Facebook design & packaging group.

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