How we manufacture corrugated cardboard

Corrugated cardboard derives from the process of fixing layers of paper together with at least one of the papers being coaxed into a corrugation wave shape. This paper is known as the Flute and makes up the centre layer.

 Single Wall cardboard is made up of just three layers of paper with one becoming a Flute giving the finished sheet of cardboard a single flute sandwiched between two layers of paper. The outer layers are known as Liners. This is what our No1 Cube, Small, Medium, Dvd Player, Cd/Dvd, Wine moving boxes & Storage Tray are made from.

Double Wall cardboard is made up of two flutes sandwiched between three liners. This adds strength to the box providing more protection for its contents. The No1box Large House Moving Boxes & Wardrobe boxes are made from this product.

The strength of the cardboard is dictated by various elements with the main contributing factors being:

·        Grade / GSM of paper used

·        Size / Pitch of Flute used

To keep in line with our environmental policy we use recycled and recyclable reels of paper for the different layers and our method of fixing these layers together is by the use of a maize based starch adhesive. All this provides a fully recyclable finished sheet of cardboard.

All of this process is conducted on a machine known as a Corrugator which can vary in size and capability. The above photo shows our automated corrugator which is over 75metres in length and produces thousands of linear metres of cardboard a day.

The Making of our House Moving Boxes

Now we have to convert the corrugated cardboard sheet into your house moving boxes (see FEFCO styles below)

The No1Box Cube, Small, Medium & Large house moving boxes are of a standard FEFCO (European Federation of Corrugated Board Manufacturers) Style 0201 design.

The No1Box Archive, CD/DVD, Storage Tray & Wardrobe boxes are Die-Cut designs. The Die-Cut process is often taken when the design is of a more intricate nature i.e. perforations, locking tabs, cut outs etc.

FEFCO Design

The 0201 Case. This is a basic case; it is relatively inexpensive to manufacture and requires no origination costs unless it is ordered with print on it. It is ideal for mass production, and is the most common of the removal boxes used.   The 0425 Tray. This is the Diecut design used for our Storage Tray. We have altered the design slightly to allow for hand holes for ease of carrying. Diecut designs incur origination costs i.e. cutting Forme       The 0422 Case. This is a Diecut case that makes for the perfect tray or base for a box that has a lid i.e. Cd/Dvd box.The lid is also of the same design but with a shallower depth.   There are many more designs in our portfolio to choose from or if requested we can bespoke a design, specific to a companies needs.