Rigid Versus Corrugated Packaging Boxes: What Is the Difference and Which Should You Use?

It is no surprise that packaging boxes are a necessity for the majority of brands, and with a highly competitive market, you do not want to just pick any box. Corrugated and rigid boxes have their own unique strengths and play distinct roles. Learn their differences and benefits so that you can choose the right…

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Rigid Versus Corrugated Packaging Boxes: What Is the Difference and Which Should You Use?

Learn their differences and benefits so that you can choose the right one for your goals.

What Is a Corrugated Box?

While many people may think that corrugated boxes are the same as cardboard boxes, this is not the case. Corrugated boxes are made from corrugated fiberboard, whereas cardboard boxes are made with heavy paper pulp.

Corrugated boxes are constructed with three different layers of materials – an inside liner, an outside liner, and “fluting.” The term “corrugated” refers to the ridges and grooves of the fluted material, which is a piece of thick, rippled paperboard sandwiched between the liners that give these boxes their strength. The liners are glued to both sides of the fluting with professional-grade adhesive to reinforce it. Because of this, corrugated boxes are much stronger than cardboard boxes.

These boxes are lightweight, yet highly durable, making them the best option for shipping. Their multi-layer design creates a sturdy solution that can give you peace of mind when you ship your products.

In addition to their durability, corrugated boxes are a popular choice for shipping because they are highly customizable. Choose from different sizes, thicknesses, adhesives (like eco-friendly options), shapes, and more. Boost brand awareness with printed designs or text on your shipping boxes’ exterior, or customize its interior like the brand did in the image above.

You can also customize your corrugated boxes’ form and function. In the image below, you can see that this brand created a high-end, unique unboxing experience using drawers and dividers on their eCommerce shipping box. They also customized the lid’s interior, printed a memorable phrase, and used their brand colors to catch their consumer’s eye.

What Is a Rigid Box?

Also known as set-up boxes, rigid boxes are manufactured from strong paperboard (kraft) that’s usually 36- to 120-point thickness, wrapped in any material you want. While printed paper is a common choice, you can also choose fabric or embellished paper that has glitter, 3D designs, foil, or a mix of textures. Since these customizations are more fragile, rigid boxes are a great option to give consumers with purchases in your store.

Like corrugated boxes, rigid boxes are highly customizable. You can choose structures like an economy tuck top, two-piece box, folding boxes, and sleeve boxes. Rigid boxes can also have pull drawers and magnetic closures. They can be made in different sizes and shapes to complement the products they are meant to hold.

These boxes do not fold flat, as their rigid structure is designed to keep its shape. Because of their durability, versatility, and luxurious look and feel, these boxes are the ideal choice for brands that want to create a unique experience. Plus, many people keep rigid boxes and repurpose them as home décor or gift boxes, so they give you a chance to reap the continued benefits of package marketing.

Which Retail Packaging Box Should You Choose?

Depending on your business model, goals, product, and other factors, you may want to choose a rigid over a corrugated box, and vice versa.

Corrugated Boxes are:	Rigid Boxes are:
A great choice for subscription boxes	Best used as a gift box
Ideal for eCommerce order shipments, heavy items, and store displays	A popular choice to give consumers at the point of purchase, in-store
Lower cost	Higher cost
Commonly used as a secondary component for food and grocery brands	Commonly used for luxury retail, jewelry, apparel, beauty and cosmetics, men’s grooming, and other similar retailers
Usually made with a bleached or mottled board, and natural kraft	Made with kraft wrapped in paper

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What Interior Packaging Components Are the Right Fit?

The box you choose for your custom packaging solution is only part of the equation. You also want to choose the right interior packaging components. This helps protect your products during shipping and can make for a five-star unboxing experience.

For rigid boxes, customized printed tissue paper and seals can add the finishing touch you need for gift-ready packaging. You can also use foam and carton inserts to keep small products in place. If the purchase is a gift for someone else, add a flat or folded card for your consumers to fill out before they give it to their loved ones.

For corrugated boxes, you may want to add more cushion to your products while they are in transit. You can customize things like printed void fill, air pillows, bubble wrap, packing peanuts, foam pouches, or kraft paper to do the job. Corrugated inserts are another great option to keep your products in place while simultaneously creating a stunning product display.

Create the Best eCommerce Boxes for Your Brand

Now that you know the differences between corrugated and rigid boxes, their benefits, and which one is the right fit for your goals, you can move on to the next step in the process: making them. Before you start actually creating your boxes, you need to find the right manufacturer. To make this process run smoothly, and get the most out of your packaging, you need to find a one-stop-shop packaging service provider. This is where we can help.

Edge2Edge is a full-service packaging provider. We help our clients from the beginning stages of design concepts, all the way to packaging manufacturing and distribution. Our team has an in-depth understanding of how the retail packaging industry works – including how to keep an optimal supply chain and give your consumers what they want.