Packaging Glossary

This glossary covers the essential terms used in corrugated packaging, box manufacturing, print finishing, and packaging design. Definitions are written from a manufacturing perspective — the way we actually use these terms on our factory floor — rather than textbook abstractions. Use this as a reference when reviewing quotes, discussing specifications with our team, or evaluating packaging options for your products.

Corrugated Board & Flute Types

Corrugated board is the backbone of packaging manufacturing. Understanding flute profiles and board construction is essential for choosing the right material for your product.

• Corrugated Board — A composite structure with one or more fluted (wavy) inner layers (medium) glued between flat outer layers (linerboards). The flutes create air columns that provide cushioning, insulation, and stacking strength.
• Flute — The wavy, arched corrugation in the middle layer of corrugated board. Flute profile determines the board thickness, cushioning, crush resistance, and print surface quality.
• A-Flute — 4.8 mm profile. The original flute size. Maximum cushioning and vertical stacking strength. Used for fragile items and heavy products. Rarely used for retail packaging due to thick profile.
• B-Flute — 3.2 mm profile. Excellent crush resistance and good print surface. The most commonly used flute for retail packaging, shipping boxes, and die-cut boxes. Good balance of strength and print quality.
• C-Flute — 4.0 mm profile. Good stacking strength and cushioning. Common for shipping cartons and export packaging. Between A and B flute in both thickness and performance.
• E-Flute — 1.5 mm profile. Very thin with a smooth, flat surface ideal for high-quality offset printing. Used for retail boxes, cosmetics packaging, and point-of-purchase displays. Replaces carton board in many applications.
• F-Flute — 0.75 mm profile. Micro-flute with exceptional print quality. Used for premium retail packaging where print resolution is critical. Thinner than E-flute but still provides some cushioning.
• Single-Face — One linerboard glued to one fluted medium. Used as wrapping material, padding, or as a starting material for further conversion.
• Single-Wall — Two linerboards with one fluted medium between them. The standard construction for most shipping and retail boxes.
• Double-Wall — Three linerboards with two fluted media (e.g., B+C flute). Used for heavy items, industrial packaging, and products requiring maximum protection.
• Triple-Wall — Four linerboards with three fluted media. Used for heavy industrial items, bulk bins, and export crates that need to replace wooden crates.
• Linerboard — The flat outer layers of corrugated board. Kraft liner (brown, strong) and test liner (recycled, lighter) are the two main types.
• Medium — The fluted inner layer of corrugated board. Made from semi-chemical pulp or recycled fibre.

Board Grades & Materials

Beyond corrugated, packaging uses a range of paper and board substrates. Each has specific properties for weight, print quality, rigidity, and cost.

• Kraft Paper — Strong, unbleached paper made from chemical pulp. Used for wrapping, paper bags, and as the brown outer liner in corrugated board. High tensile strength and tear resistance.
• Duplex Board — Two-ply board with a white coated top surface and a grey recycled bottom surface. Used for inner cartons, pharmaceutical packaging, and light retail boxes. Cost-effective for short-run printing.
• SBS (Solid Bleached Sulphate) — Premium white board made from bleached chemical pulp. Used for luxury packaging, cosmetics, chocolate boxes, and any application requiring bright white print on both sides.
• Grey Board (Chipboard) — Dense, rigid board made from recycled paper. Used as the structural core of rigid (setup) boxes. Covered with printed art paper or specialty paper for the visible surface.
• Art Paper — High-quality coated paper (gloss or matte) used for litho lamination onto corrugated or as the wrap material for rigid boxes. Available in 128-300 GSM.
• GSM (Grams per Square Metre) — The standard measure of paper and board weight. Common packaging weights: 120 GSM (lightweight liner), 170 GSM (standard kraft liner), 250 GSM (retail box board), 300+ GSM (rigid box wrap, heavy carton).
• Caliper — The thickness of paper or board, measured in microns (µm) or points (pt). 1 pt = 0.0254 mm. Caliper affects rigidity, foldability, and machine compatibility.
• Bursting Strength (Mullen) — The pressure required to rupture the board, measured in kPa or psi. Indicates the board ability to resist puncture and containment failure.
• Edge Crush Test (ECT) — Measures the stacking strength of corrugated board by compressing a sample on its edge. Higher ECT = more boxes can be stacked safely.

Box Structures & FEFCO Codes

The FEFCO (European Federation of Corrugated Board Manufacturers) code system standardises box structure designs worldwide. Our factory manufactures all standard FEFCO codes plus custom structures.

• FEFCO 0201 (Regular Slotted Container / RSC) — The most common box style. All four flaps are the same length; outer flaps meet in the centre. Efficient material usage, suitable for most products.
• FEFCO 0203 (Full Overlap Slotted Container) — Outer flaps fully overlap, providing double-thick top and bottom. Extra stacking strength for heavy products.
• FEFCO 0310 (Serving Tray) — Open-top tray with reinforced corners. Used for fresh produce, bakery items, and food service display packaging.
• FEFCO 0320 (Telescope Box / Shoe Box Style) — Separate lid and base that telescope over each other. Classic shoe box structure. Also used for garments and gift packaging.
• FEFCO 0426 (Mailer Box / Tuck-End) — Hinged lid that tucks into the front panel. The standard e-commerce and subscription box structure. Self-locking, no tape required on the front.
• FEFCO 0427 (Die-Cut Box) — A broad category for custom die-cut structures including roll-end tuck-top, crash-lock bottom, and retail display boxes.
• Die-Cut — Any box shape created using a custom steel rule die, rather than standard slotting. Enables windows, curves, fold-out panels, and non-rectangular shapes.
• Crash-Lock Bottom — A die-cut box base that locks into place when the side walls are folded, without glue or tape. Fast assembly for high-volume packing lines.
• Self-Locking Lid — A tuck flap with friction-fit tabs that hold the lid closed without tape or glue. Common on mailer boxes and retail packaging.

Print Finishes & Converting

Print finishing transforms a printed sheet into a premium, durable, shelf-ready surface. The finish you choose affects cost, lead time, and visual impact.

• Flexographic Printing (Flexo) — Relief printing using flexible photopolymer plates. Best for 1-4 spot colours on corrugated board. Cost-effective for large runs. Limited gradient and photo reproduction.
• Offset Lithographic Printing (Litho) — Flat-bed or web printing using CMYK process colours. High-resolution, photo-quality reproduction. Printed on paper or board, then laminated to corrugated (litho lamination) or used directly on carton board.
• Digital Printing — Toner or inkjet printing without plates. Suitable for short runs, variable data, and prototyping. Higher per-unit cost but zero plate charges.
• Lamination — Applying a thin plastic film (gloss, matte, or soft-touch) over printed surfaces. Protects against moisture, scratching, and UV fading. Adds rigidity to the board.
• UV Spot Varnish — A clear, high-gloss coating applied to specific areas (logos, images) using a screen or flexo unit. Creates contrast against matte lamination and adds tactile interest.
• Embossing — Pressing a raised pattern into the board using matched male and female dies. Adds tactile texture and visual depth. Used for logos, borders, and decorative elements.
• Debossing — The opposite of embossing — pressing a recessed pattern into the board. Creates subtle, elegant impressions on premium packaging.
• Foil Stamping (Hot Stamping) — Transferring metallic or pigmented foil onto the board using a heated die. Gold, silver, copper, holographic, and coloured foils. Used for luxury packaging and special editions.
• Die-Cutting — Using a custom steel rule die mounted on a platen or rotary press to cut specific shapes, windows, perforations, and fold lines into the board.
• Creasing / Scoring — Pressing a groove into the board along fold lines to prevent cracking when the box is folded. Essential for heavy-weight boards and reverse-tuck structures.

Industry Standards & Testing

Packaging performance is verified through standardised tests. These terms appear on specifications, quality certificates, and regulatory documents.

• FEFCO — European Federation of Corrugated Board Manufacturers. Sets international standards for box structure codes and corrugated board specifications.
• BSTI — Bangladesh Standards and Testing Institution. National body that sets quality and safety standards for products sold in Bangladesh, including food-contact packaging materials.
• ISO 9001 — International quality management system standard. Ensures consistent manufacturing processes, documentation, and continuous improvement.
• ISO 14001 — International environmental management system standard. Covers waste reduction, energy efficiency, and environmental compliance in manufacturing.
• FSC (Forest Stewardship Council) — Certification system for sustainably sourced wood and paper products. Chain-of-Custody (CoC) certification tracks certified material from forest to finished product.
• Food-Grade — Materials and inks that are safe for direct or indirect contact with food. Must comply with relevant food safety regulations (BSTI, FDA, EU Framework Regulation).
• Drop Test — A standard test where a packed box is dropped from a specified height onto different faces, edges, and corners to simulate shipping handling. ISTA and ASTM standards apply.
• Compression Test — Measures the maximum load a box can bear before collapsing. Determines safe stacking height for warehouse storage and palletisation.
• MOQ (Minimum Order Quantity) — The smallest production run a manufacturer will accept. Driven by setup costs for dies, plates, and machine calibration. Our standard MOQ: 100 pieces for most box types.

Still Have Questions?

If a term in this glossary needs more explanation, or if you want to discuss how a specific material, structure, or finish applies to your packaging project, our team is ready to help. We can also send you physical material samples so you can see and feel the differences between flute types, board grades, and print finishes before making a decision.