Corrugated Plastic Shipping Boxes manufacturer

How to Custom Corrugated Plastic Shipping Boxes?

Those who are engaged in the packaging industry realize that although standard corrugated plastic shipping boxes are relatively cheap, they might be “a little bit off”: the size doesn’t match, the strength isn’t enough, or the client simply considers them unattractive. So custom corrugated plastic shipping boxes are necessary. Today, I will describe the whole process step by step.

Step 1: Clarify what you need

Just ask yourself several questions:

What goods are being loaded? The size, weight, fear of moisture or static electricity? All the factors will affect the choice of the thickness and structure of the corrugated plastic box directly.

Where are the boxes used? Are they used in internal warehouse turnover or transportation over a large distance? Will the goods be stored in a cold storage area or outdoors? Different environments will have different requirements in moisture resistance and weather resistance

How many times are they going to be used? One-time shipment or repeated reuse? Then the thickness and structural strength of the board will have to be increased.

The more details you know, the better and more effective the communication with the factory will be, as well as the lower risk of deception.

Step 2: Selection of materials and thickness

PP Hollow Board (also known as corrugated plastic board) is the raw material. Common thickness is 2mm to 6 mm. If you require high load-bearing capacity, you will have to choose a greater thickness, and the smaller one is cheaper, but it tends to be easily deformed.

2-3mm – Suitable for lightweight products, for example, files and small components;

4mm – universal thickness, most turnover boxes and packaging boxes use it;

5-6mm: for occasions with high load-bearing requirements, such as mechanical parts and heavy object packaging

There are two kinds of materials available: new materials and recycled materials. The new material has good toughness, long service life, and good color. Recycled materials are economical but tend to become brittle and turn grayish. If the corrugated plastic boxes are required to be reused, we strongly recommend using brand new materials.

Besides, some special functions should be informed in advance, such as anti-static, fire-retardant, UV resistance (UV stable), food grade (FDA/SGS certified).

Step 3: Produce drawings and make samples

Drawing confirmation: you inform the length, width, and height of the corrugated plastic shipping box to the factory.

The professional manufacturer will help you optimize the design, such as adding reinforcing bars to improve the load-bearing capacity, and designing folding structures to save return space.

Sample production: we recommend making samples first.

Many customers want to save costs or avoid some trouble; therefore, they ignore making samples and go for placing orders directly. However, when the box arrives, they find that the size and structure are unreasonable, causing huge losses.

Step 4: Making sure about the processing and printing

There are many different methods to process the corrugated plastic shipping boxes:

Screen printing: full color, economic, suitable for large area simple patterns

Offset printing/film coating: can produce complicated patterns and gradient color, but needs film coating, slightly expensive

Ultrasonic welding: stronger than nail or rivet, with a smooth edge, harmless to hands

Step 5: In bulk production and acceptance

After the sample is confirmed, the factory enters the mass production stage. The good manufacturer should have its quality inspection process, such as size check, color confirmation, structural stability test, etc.

The End

Before choosing a manufacturer of custom corrugated plastic shipping boxes, we recommend you find a factory with experience, production capacity, and the ability to make samples. Purepack, as a factory with 13 years of experience, can meet all the requirements above. Don’t hesitate to contact us freely!