| By :
Mark Etinger
The box, such a simple item we take for granted every time we rip open a package or mail products to someone. You would think something so simple in design as a cardboard box would have been around forever, but these brown boxes weren't invented until the mid-19th century. Cardboard boxes and packaging were an ingenious idea that revolutionized the shipping industry. What we called "cardboard boxes" are technically corrugated boxes because they are made out of corrugated fiberboard. Fiberboard is made of paper and fluted. The fluted piece of paper lies between two flat liner boards, which results in a thick, durable material suited for packaging. However, when it was first patented in England in 1856, it was used as a liner for tall hats! Corrugated boxboard was not patented until 1871 and then it became a staple in packaging supplies, but had still not taken box form. An American, Albert Jones of New York City, originally used the cardboard for wrapping bottles and glass lanterns. (Bubble wrap was not invented until 1957.) Oliver Long improved upon Jones' design, but it was a few years later that we finally saw the development of the actual cardboard box. Robert Gair invented the cardboard box by accident in 1890. He was a paper bag maker and after a little mishap with one of the machines, he realized that by cutting and creasing the material in one operation, he could create a box. At first boxes and packaging were just used for glass and ceramics, but soon after, farmers used it for shipping produce. The box quickly replaced wooden crates for shipping due to its low costs. Corrugated board is manufactured on large machines called corrugators. They are able to produce 500 linear feet per minute. Just like any paper making process, the first step is pulping --the separation of wood into fibers. Next, the paper is softened with high-pressure steam and then dried. The fibers are bent into the appropriate thickness and put between paperboard sheets. Pressure is applied to increase its strength. Finally, the corrugated cardboard is sandwiched between two flat liner boards. Different flute sizes can be made depending on how thick you want the board to be. Now that you have corrugated board, you need to determine what type of box design. We all know the most common square design which is called the Regular Slotted Container. But what about the odd shaped box? Packaging engineers design the shape of corrugated boxes and try to do so with as little cost as possible. Engineers do more than just design, they have to test the box's strength, see if it can withstand high humidity, and determine if it has adequate crush resistance. Today, corrugated boxes are essential to packaging and shipping supplies. Think of all the boxes you have opened or shipped and how easy it has made your life. You may not be aware of its significance, but it is certainly one product that has left quite an impact.
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