What Are Corrugated Boxes & Why They Matter for Food Businesses UK

October 20, 2025

Corrugated boxes are everywhere — from your favorite takeaway pizza to online food deliveries. But they’re not just about looks; they’re the backbone of packaging solutions — strong, cost-effective, and eco-friendly. At Custom Supplies UK, we use corrugated boxes because they’re ideal for food packaging — protective, sustainable, and versatile.

In this guide, you’ll learn:

What corrugated boxes are
Their internal structure and different types
Their key benefits (especially for the food industry)
How to choose the right corrugated box (thickness, strength, flute type)
Custom corrugated box options and use cases

What Exactly Is a Corrugated Box?

A corrugated box (or corrugated cardboard box) is a packaging container made from corrugated cardboard, which consists of three or more layers:

Outer liner: A flat layer of paper/cardboard on the outside.
Fluted (wavy) medium: One or more arched layers that provide cushioning and strength.
Inner liner: The flat layer on the inside.

The fluted layer is what gives the box its cushioning and shock-absorbing properties. These layers are bonded together using glue or starch-based adhesive.

Types of Corrugated Boxes & Wall Structures

Corrugated boxes come in different types depending on the level of protection and the type of product being packed. Here are the most common types:

Type	Description	Best For
Single Wall	One fluted layer + two liners (outer & inner). The most common and lightweight type.	Light food items, delivery packaging, standard takeaway boxes.
Double Wall	Two fluted layers + three liners. Provides more strength and protection.	Heavier food items, stacking, long-distance delivery.
Triple Wall	Three fluted layers + four liners. Designed for maximum load and protection.	Heavy-duty transport, bulk supplies, industrial food packaging.
Custom Corrugated Boxes	Fully customizable — size, shape, flute type, wall thickness, and printing.	Unique food items, fragile goods, strong branding, and bulk orders.

Flutes & Strength: Choosing the Right Wall / Flute Type

The flute type plays a key role in determining cushioning, rigidity, print quality, and even cost.

Common flute profiles include:

A-Flute: Thick, large waves — excellent cushioning.
B-Flute: Thinner than A, more rigid walls, and better for printing.
C-Flute: Medium thickness — a balance between cushioning and printability.
E-Flute / F-Flute: Very thin flutes, used for premium display packaging with smooth surfaces for high-quality graphics.

Benefits of Corrugated Boxes for Food Businesses

Using corrugated boxes in food packaging offers several key advantages:

Protection During Transit: Fluted layers absorb shocks and protect fragile items such as pastries, sauces, and desserts.
Stackability & Strength: Double or triple-wall boxes allow easy stacking — ideal for transport and storage.
Lightweight but Strong: The material is lightweight, reducing shipping costs, especially for local deliveries.
Customisable & Printable: Perfect for adding brand logos, graphics, messages, and eco-labels.
Sustainability: Corrugated board is recyclable and often made from recycled materials — with sustainable paper sourcing.
Cost-Effective: Low cost per unit (especially in bulk), reduced damage, and less waste lead to better profit margins.

How to Choose the Right Corrugated Box for Your Product

When selecting Customised food packaging, consider the following:

1. Product Type & Fragility
If your items are delicate (like cakes, glass jars, or desserts), opt for double or triple-wall boxes with thicker flutes or internal inserts.

2. Transport & Handling
For long-distance deliveries or frequent handling, choose sturdier boxes. For local deliveries, single-wall boxes are usually sufficient.

3. Size & Flute Thickness
The box should allow proper internal clearance. Thicker flutes require more internal depth, so select accordingly.

4. Printing & Branding Needs
If you need detailed graphics, choose thinner flutes like E-Flute for smoother surfaces and sharper printing.

5. Sustainability & Regulations
Ensure the corrugated material is recyclable or compostable and meets UK food safety and environmental standards.

Common Use Cases of Corrugated Boxes in the Food Industry

Pizza boxes (single wall or coated corrugated)
Takeaway cartons for curry, noodles, etc.
Display trays or shelf-ready packaging for baked goods
Bulk transport packaging for fruits and vegetables
Catering boxes with dividers for multiple dishes

Custom Supplies UK: Your Corrugated Packaging Partner

At Custom Supplies UK, we provide:

Custom corrugated boxes tailored for size, wall strength, flute type, and printing.
Eco-friendly options — recycled materials, FSC-certified boards, and food-safe coatings.
Samples & mockups for testing fit, stacking, and closure.
Brand printing & finishes — from cost-saving brown kraft to premium white liners.
Competitive pricing and UK-wide delivery for both small and large orders.

Final Thoughts

Corrugated boxes aren’t just “shipping containers” — they play a vital role in product protection, cost efficiency, branding, and sustainability.

For any food business in the UK that wants to deliver products safely, attractively, and responsibly, corrugated packaging is the perfect choice.

👉 Ready to upgrade your packaging?
Contact Custom Supplies UK today — let’s design corrugated boxes that protect your food, showcase your brand, and support the environment.