Corrugated Box Packaging: Complete Guide to Manufacturers & Printing in India [2026]

India's corrugated packaging industry is valued at over ₹60,000 crore in 2026, driven by explosive e-commerce growth, FMCG demand, and the shift towards sustainable packaging. Whether you're shipping products across India or creating branded retail-ready packaging, understanding corrugated box packaging is essential for every business.

This guide covers everything procurement managers and brand owners need to know about corrugated box manufacturing — flute types, board grades, printing methods, quality standards, pricing, and how to select the best corrugated box manufacturer in Mumbai.

What Is a Corrugated Box?

A corrugated box is a packaging container made from corrugated fiberboard — a material consisting of a fluted (wave-shaped) paper layer sandwiched between flat liner papers. The fluting creates air cushions that provide exceptional strength-to-weight ratio, cushioning, and stackability.

Unlike plain cardboard (which is a single-layer material), corrugated board is engineered for structural performance. It's the most widely used packaging material globally for shipping, storage, and retail display.

Corrugated Board Structure

3-Ply (Single Wall)

One fluted medium between two liner papers. Total thickness: 2–4mm depending on flute type. Suitable for light products up to 10 kg — cosmetics, small electronics, garments, and food items.

5-Ply (Double Wall)

Two fluted mediums with three liner papers. Total thickness: 5–7mm. Suitable for medium-heavy products (10–25 kg) — appliances, automotive parts, industrial goods, and heavy FMCG packs.

7-Ply (Triple Wall)

Three fluted mediums with four liner papers. Total thickness: 8–10mm. Used for heavy industrial shipping (25+ kg) — machinery, chemicals, heavy equipment, and export packaging.

Flute Types & Their Applications

Flute	Height	Flutes/meter	Best For
A-Flute	4.8mm	108–118	Fragile products, cushioning, stacking strength
B-Flute	2.5mm	150–160	Die-cutting, retail packaging, litho lamination
C-Flute	3.6mm	128–138	General shipping, most common flute type
E-Flute	1.6mm	290–320	Retail-ready packaging, high-quality print surface
F-Flute	0.8mm	400+	Micro-flute, premium print, fast food packaging

Board Grades & Paper Quality

The strength of a corrugated box depends on the quality of liner and fluting papers used:

Liner Paper Types

• Kraft Liner (K): Virgin fibre — highest strength, tear resistance, and moisture resistance
• Test Liner (T): Recycled fibre — good strength for general packaging, most cost-effective
• White Top Liner: White-coated surface for premium printing and brand presentation
• Coated Kraft: Clay-coated surface for offset litho-laminated printing

Common Board Grades (BIS Standards)

• 120/100/120: Light-duty — small parcels, garments, lightweight items
• 150/120/150: Medium-duty — electronics, FMCG, general merchandise
• 180/150/180: Heavy-duty — appliances, industrial goods, export
• 200/150/200: Extra heavy-duty — automotive, machinery parts

Numbers represent GSM values: outer liner / fluting medium / inner liner.

Corrugated Box Printing Methods

1. Flexographic Printing (Direct Print)

Flexo printing is the most common method for corrugated boxes. Rubber or polymer plates transfer ink directly onto the corrugated board.

• Colours: 1–4 colours (typically Pantone spot colours)
• Best for: Shipping boxes, industrial packaging, basic branding
• Advantages: Cost-effective, fast, handles large volumes
• Limitations: Lower resolution than offset, visible flute marks on print

2. Litho-Lamination (Offset + Corrugated)

The premium printing solution for corrugated boxes. Full-colour artwork is offset-printed on a separate paper sheet, then laminated onto the corrugated board.

• Colours: Full CMYK + Pantone, photo-quality graphics
• Best for: Retail-ready packaging, e-commerce brands, premium products
• Advantages: High-resolution, brand-consistent colours, premium finishes possible
• Additional finishes: Lamination, spot UV, foil stamping, embossing

3. Digital Printing on Corrugated

Direct digital printing using inkjet technology is growing rapidly for short-run and personalised corrugated packaging.

• Best for: Short runs (100–2,000 pieces), prototyping, variable data
• Advantages: No plate costs, fast turnaround, personalisation
• Growing trend: HP PageWide, EFI Nozomi, and similar presses

Types of Corrugated Boxes by Application

E-Commerce Shipping Boxes

The explosive growth of Indian e-commerce (Flipkart, Amazon, Meesho, Myntra) has made e-commerce packaging a massive category. Requirements include:

• Right-sized boxes to minimise dimensional weight charges
• Tamper-evident closures (tear strips, security tape zones)
• Branded unboxing experience with inside printing
• Sustainable materials (recyclable, FSC-certified)
• Return-friendly design (dual adhesive strips)

Retail-Ready Packaging (RRP)

Shelf-ready packaging that serves as both transit and display packaging. Modern retailers like DMart, Reliance, and Big Bazaar prefer RRP as it reduces shelf-stocking time. Features perforated lids, display windows, and full-colour branding.

Industrial & Export Packaging

Heavy-duty 5-ply and 7-ply boxes for automotive parts, machinery, chemicals, and export shipments. Must comply with ISTA testing standards and international shipping regulations.

Food & Beverage Packaging

Pizza boxes, cake boxes, fresh produce trays, and beverage carriers. Require food-grade inks, grease-resistant coatings, and FSSAI compliance.

Point-of-Sale Displays

Counter-top displays, floor-standing units, and dump bins made from printed corrugated board. Branded displays that drive impulse purchases at retail locations.

Quality Testing for Corrugated Boxes

Quality testing ensures boxes perform under real-world conditions. Key tests include:

Burst Strength Test (Mullen Test)

Measures the force required to puncture the board. Minimum values as per BIS standards: 3-ply (7 kg/cm²), 5-ply (10 kg/cm²). Critical for stacking and handling resistance.

Edge Crush Test (ECT)

Measures the compressive strength of the board edge. Directly relates to box stacking performance. Industry standard: 3-ply (11 kN/m), 5-ply (15+ kN/m).

Box Compression Test (BCT)

Tests the maximum load a finished box can withstand before collapsing. Essential for warehouse stacking calculations.

Additional Tests

• GSM Test: Verifies paper weight meets specifications
• Cobb Test: Measures water absorption — critical for humid climates
• Puncture Resistance: Tests resistance to pointed objects during transit
• Drop Test: Simulates shipping drops from various heights and angles

Corrugated Box Pricing in India (2026 Guide)

Box Type	Specification	Price Range
Small e-comm box (3-ply)	200×150×100mm, brown	₹8–15/pc
Medium shipping box (3-ply)	400×300×200mm, printed	₹18–30/pc
Branded e-comm box (litho)	300×250×150mm, full colour	₹30–55/pc
Heavy-duty box (5-ply)	500×400×300mm, kraft	₹35–60/pc
Export box (5-ply, printed)	600×400×400mm	₹50–80/pc

How to Choose a Corrugated Box Manufacturer

1. Manufacturing Capacity

Check if the manufacturer has corrugation plants (for making board) and conversion facilities (for printing, die-cutting, and box-making). In-house corrugation ensures quality control over board specifications.

2. Printing Capabilities

For branded packaging, ensure the manufacturer offers litho-lamination with offset printing capabilities. A facility with both corrugation and offset printing (like Hira Print Solutions) provides better quality control and faster turnaround.

3. Testing Infrastructure

A quality-conscious manufacturer will have in-house testing equipment for burst strength, ECT, BCT, Cobb, and GSM verification.

4. Certifications

• ISO 9001:2015 — Quality management system
• FSC Certification — Sustainable raw material sourcing
• BIS Compliance — Indian standards for corrugated boxes
• ISTA Certification — International transit testing standards

5. Design & Structural Engineering

Good manufacturers offer structural design support — optimising box dimensions, selecting the right flute-liner combination, and creating custom inserts. This reduces material waste and shipping costs.

Sustainability in Corrugated Packaging

Corrugated board is one of the most sustainable packaging materials available:

• Recyclability: 80%+ recycling rate — the highest of any packaging material
• Renewable: Made from wood pulp — a renewable resource
• FSC Certified: Sourced from responsibly managed forests
• Biodegradable: Breaks down naturally, unlike plastic packaging
• Lightweight: Reduces fuel consumption in transportation

Why Hira Print Solutions for Corrugated Packaging?

Hira Print Solutions Pvt. Ltd. combines world-class offset printing with corrugated packaging expertise:

• Litho-laminated corrugated boxes: Full-colour offset printing (Manroland 700) laminated onto corrugated board
• Premium finishes on corrugated: Lamination, spot UV, foil stamping, embossing
• Certified production: ISO 9001:2015, FSC-C224680 certified
• End-to-end service: Design → pre-press → printing → lamination → box-making → delivery
• Serving 500+ B2B clients since 1996 from our 50,000 sq.ft. facility in Navi Mumbai

Frequently Asked Questions

What is the difference between 3-ply and 5-ply corrugated boxes?

3-ply corrugated boxes have one fluted layer sandwiched between two liner papers, suitable for light-weight products (up to 10 kg). 5-ply boxes have two fluted layers with three liner papers, providing extra strength for heavier products (10–25 kg) and longer transit distances.

How much do corrugated boxes cost in India?

Corrugated box prices in India range from ₹8–80 per piece depending on size, ply, board grade, and printing. Basic brown 3-ply boxes start at ₹8–15 per piece, while printed 5-ply boxes with full-colour graphics cost ₹30–80 per piece for 1000+ quantities.

Can corrugated boxes be printed with full-colour graphics?

Yes. Corrugated boxes can be printed directly using flexographic printing (1–3 colours) or digitally. For full-colour CMYK graphics, a litho-laminated approach is used where the artwork is offset-printed on paper and then laminated onto the corrugated board.