A corrugated Roll is a 2-ply paper board packaging material that is used to make corrugated or carton boxes or to protect the product during transit.
How is corrugated roll manufactured?
It has a certain process that involves several steps to be manufactured.
- Wood chips are transformed into pulp which is the raw material or base material for making kraft paper.
- Now pulp is transformed or processed into heavy types of paper called kraft paper, which is strong, durable and has certain gram and BF.
- Now one sheet of kraft paper is passed through the heated corrugating rolls of the corrugation-making machine which gives it a wavy, fluted shape now this sheet is glued with another plane kraft paper sheet for making a liner board.
- There are so many sizes of ruler in the machine for making these fluted shape sheets. The flute shape of the sheet can be increased or decreased as per the client’s need or as per the strength of that particular box that is to be manufactured.
- After the corrugating process, the continuous corrugated sheet can be rolled into large rolls, now these rolls are ready to manufacture boxes or to wrap any material to prevent damage during shipping.
There are some flute types in which height is measured from the bottom of the liner to the tip (the highest point on the flute curve) of the flute. These flutes vary in thickness ranging from 0.4mm to 6mm, where the name of the flute suggests a size order, their name is based on the order in which they were invented.
| Flute Type | Flute Height | Flutes per 30cms | Flute per mtr | Nominal take-up factor |
| K | 5.5-6.0 mm | 28-32 | 93-107 | 1.6 |
| A | 4.2-4.6 mm | 32-38 | 107-127 | 1.5 |
| C | 3.4-3.8 mm | 38-44 | 127-147 | 1.45 |
| B | 2.4-2.8 mm | 50-56 | 167-187 | 1.4 |
| E | 1.2-1.6 mm | 90-96 | 300-320 | 1.3 |
| F | 0.7-1.1 mm | 110-126 | 365-420 | 1.25 |
| N | 0.4-0.6 mm | 150-167 | 500-560 | 1.22 |
Use cases of corrugated rolls.
- If the sheet of these rolls is pasted with a single sheet of paper it is called 3 ply in which mostly e-commerce corrugated boxes are made.
- When two or three corrugated sheets or liner boards are pasted with paper it is called 5 Ply and 7 Ply in which most of the heavy carton boxes are manufactured.
- Nowadays many e-commerce and D2C brands have started using it to wrap their fragile items as a substitute for bubble wrap.
- The external surfaces of corrugated rolls can be printed to make them useful for retail displays and promotional packaging.