Whether you are experienced packaging purchaser, or are entering the market for the first time, our teams at Coalville, Preston and Eurocentral are on hand to help you navigate all your corrugated board requirements.

With an array of board grades available it is important to understand why they are different and how they translate into corrugated packaging solutions ranging from boxes to high quality gift and display packaging.

Unlocking corrugated board

All our board grades are made using a combination of sheets of paper, referred to as liners, that are glued together with adhesive to a corrugated inner, referred to as fluting.

Two of the most common paper types, referred to in board grades are Kraft paper (chemically processed) which is typically is used for the outer liner of the board. This paper type is made from softwood and gives a smooth finish, ideal for printing. Test paper has a less smooth finish as it is made from hardwood or recycled paper which has shorter fibres. This is typically used for the inner liner or fluting.

Our five corrugators process either three or five reels of paper simultaneously to produce either single wall (two liners and one fluting) or double wall (three liners and two fluting).

Firstly, reels of paper are loaded into the ‘wet end’ of the corrugator. Initially, the paper is treated with heat and steam to make it more flexible to allow for easier fluting before being fed into the single facer.  The single facer is the part of the corrugator that creates a series of arches (fluting) created by large rotating cylinders with a corrugated profile thereby creating the grooves. Different cylinders with different profiles create the different flute types.

At the next stage, adhesive is applied to the tips of the flute, and the first liner is pressed onto the fluting. A combination of steam, heat and pressure adheres the paper to the fluting to create a strong bond. This single face board, the first stage of any corrugated board production process continues its journey down the corrugated where a second liner is applied using the same methods. Less pressure is applied at this stage, so the flutes are not crushed.

To manufacture double wall board, both corrugator’s single facers will be running which delivers two single face webs to the bridge part of the corrugator to be joined together at the double glue unit. It is at this stage that the outside or double-faced liner will be joined to the single face web.

Finally, the board is cut to size both the width (deckle) and length (chop). The required sheet sizes are then palletised and ticketed for onward shipping to our sheet plant customers.

Maximising your corrugated board choices

Through the innovative use of different flutings, varying degrees of strength are achieved which gives corrugated its strength when used by our sheet plant customers to manufacture corrugated boxes and packaging solutions.

Different board grades are achieved by putting different paper weights and grammage through the corrugation process.

Our corrugators are all capable of making a wide range of board grades, utilising differing paper types, and fluting to meet customer requirements.

By understanding each customer’s unique requirements, Board24 ensures a tailored approach—whether it’s optimising packaging performance, improving cost efficiency, or navigating new market trends.

Our comprehensive service includes technical advice, responsive communication, and proactive solutions to any challenges you may face during the procurement process.

Our range of board grades includes B, C, M, E, BC, MB, and EB flutes presents an array of options to ensure products are transported safely, displayed appropriately and brands and information is accurately conveyed.

Working with the team at Board24 will allow you to maximise the benefits of the corrugated board you choose.

We will help understand what your objectives are, how the board will be utilised in your production processes and how the products will ultimately be used.

Doing so will ensure you purchase the most appropriate board grade in the required quantities.

To speak with a member of our team call them on 01530 510022 or email contact@board24.co.uk