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Novapor foam packaging everything about corrugated cardboard boxes guide

All About Corrugated Cardboard: A Comprehensive Introduction


In this in-depth blog post, you will learn all about corrugated cardboard and delve deep into the world of corrugated cardboard, from the basics like Kraftliner and Testliner to the different flute types and combinations (1-flute, 2-flute and 3-flute cardboard). For this article, Novapor sales representative Marc Niewidok explained the world of corrugated cardboard to us in more detail.

Corrugated cardboard – this versatile and widely used packaging material has a crucial impact on everyday life without us perhaps realizing it. At NOVAPOR, many square meters of corrugated cardboard are processed every day. Corrugated cardboard is a versatile material from which we produce  Cardboard boxes, Tote dividers and partitions, constructive packaging and inserts.  

What is the difference between Kraftliner and Testliner?

Corrugated cardboard is a multi-layer material consisting of two cover layers (outer cover and inner cover), the corrugations and intermediate covers. The combination of these layers gives corrugated cardboard its impressive properties, including stability, flexibility and lightness.

Kraftliner: The kraftliner is one of the outer layers of corrugated cardboard and is made of high-quality virgin fiber material. This layer gives the packaging strength and a smooth surface that is ideal for printing and provides better weather protection than the testliner.

Novapor foam packaging all about corrugated cardboard


The testliner is one of the outer layers and is made of recycled material, which means resources are used more efficiently. Although the testliner is less strong than the kraftliner, it is ideal for corrugated cardboard production and contributes a large part to the sustainability of corrugated cardboard packaging.

Novapor foam packaging all about corrugated cardboard

What types of corrugated cardboard are there?

  • Single wall cardboard:

    Consists of a flute between the cover layers and is suitable for products up to around 10kg. Particularly suitable for shipping and transporting light and less sensitive products.

  • Double wall cardboard:

    Consists of two flutes between the cover layers and separated by a false ceiling. The cardboard box is suitable for shipping and transporting medium-heavy products of around 10kg to 30kg.

  • Triple wall cardboard:

    Consists of three flutes between the cover layers and two intermediate layers. This cardboard box is particularly suitable for heavy products weighing over 30kg. This is extremely stable and is often used for large packaging and export packaging.

Novapor foam packaging all about corrugated cardboard

All about corrugated cardboard: the most commonly used types of corrugation

  • A-A-Flute (coarse flute):

    This is the oldest type of wave and has very good spring and cushioning properties.

    Flute pitch: 7.9 - 10.0 mm, Flute height: 4.0 - 5.0 mm

  • C-Flute (medium flute):

    Due to the need for higher production speeds and thinner corrugated cardboard qualities while maintaining product protection, the C-flute has largely replaced the A-flute since the early 1970s.

    Flute pitch: 6.5 - 7.9 mm, flute height: 3.1 - 4.0 mm

  • B-Flute (fine flute):

    The smaller flute pitch of the B-flute enables greater dimensional accuracy of the packaging, which is particularly advantageous in the area of vending machine packaging. Another advantage is the good printability.

    Flute pitch: 4.8 - 6.5 mm, flute height: 2.2 - 3.1 mm

  • E-flute (microflute):

    The E-Flute is excellent for printing due to its very small flute pitch and is mainly used in the area of product and sales packaging.

    Flute pitch: 2.6 - 3.5 mm, flute height: 1.0 - 1.9 mm


The most commonly used combinations of two-flute corrugation are the BC, EB/BE, EE and AC-flute.

In the three-flute range, the ACA and AAC flutes are the most common.


The variety of corrugated cardboard flutes makes it possible to customize packaging to specific requirements. Whether for light, medium or heavy products, selecting the right corrugation structure plays a crucial role in the safety and integrity of the packaged goods. We will be happy to support and advise you in choosing the right corrugated cardboard. 

Here you can see some examples of our individual packaging solutions made from different types of corrugated cardboard.

Where and how is corrugated cardboard used?

Corrugated cardboard is used for more than just shipping products. Their versatile properties make them an ideal material for various applications:

  • Packaging: The most obvious use of corrugated cardboard is packaging. From food to electronics to furniture, corrugated cardboard provides secure protection during transport.
  • Displays: The stability and adaptability of corrugated cardboard make it a popular material for advertising displays and retail shelves.

  • Architecture: Creative designers use corrugated cardboard for temporary architectural projects and exhibitions because of its lightness and flexibility.

Novapor foam packaging all about corrugated cardboard

How is corrugated cardboard made?

The manufacturing process includes several steps, starting with the selection of raw materials through to final processing.

  • Raw materials: The main components of corrugated cardboard are kraftliner, testliner and corrugated material. The mix of these materials influences the quality of the resulting corrugated cardboard.
  • Flute formation:

    The corrugated paper is shaped using moisture and heat in the corrugating unit. 

  • Bonding: The top layers, corrugations and intermediate layers are glued using vegetable glue. This step is crucial for the strength and stability of the final products.

  • Cutting and shaping: After gluing, the corrugated cardboard is cut into the desired formats and sizes. This step may vary depending on customers' requirements.

Is corrugated cardboard good for the environment?

At a time when sustainability plays a key role, it is important to consider the environmental impact of packaging materials. Corrugated cardboard has several advantages in this context:

  • Recyclability: Corrugated cardboard is easy to recycle and its recycling rate is very high at 90%. This helps reduce the need for fresh raw materials and minimize waste.
  • Lightweight: Compared to other packaging materials, corrugated cardboard is very light. This has a positive effect on transport as less energy is required to move the products.

  • Biodegradable: Corrugated cardboard is biodegradable, meaning it will naturally decompose over time. This reduces environmental impact compared to non-degradable materials.


  • Energy and water consumption:  Energy and water consumption are critical issues in cardboard production and recycling that need to be taken into account when selecting or comparing packaging materials. Life cycle assessments and carbon footprints can provide clarity in this respect. The limited cushioning and recovery behavior of very sensitive packaged goods also requires precise planning when selecting packaging materials. We support our customers in this phase by analyzing the final packaging product and carrying out packaging tests in accordance with various standards.
Novapor foam packaging all about corrugated cardboard

At Novapor, we know that finding the perfect packaging products for your unique goods can be challenging. That's why we are here to turn your packaging problems into successful packaging!


With our comprehensive portfolio of packaging products carefully crafted from high quality cardboard materials, we offer a wide range of solutions customized to your specific needs. Whether you want to ship sensitive electronics, sophisticated craft products, or rugged industrial equipment, we have the right solution for you. We offer a variety of customization options including size, shape, color and branding to ensure your packaging perfectly matches your products and highlights your brand identity.


We will work with you to find the right cardboard solutions for your needs, including corrugated cardboard inserts or a suitable foam insert for your product.

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