Corrugated Cardboard: History, Production, and Sustainability

The Invention of Corrugated Cardboard

The history of corrugated cardboard begins in the mid-19th century. In 1856, the Englishmen Edward Allen and Edward Healey patented corrugated paper, which was initially used as cushioning material for hats. In 1871, the American Albert Jones recognized the potential of corrugated paper as a packaging material and patented it for this purpose.

Just a few years later, in 1874, Oliver Long developed the first "true" corrugated cardboard by gluing a smooth sheet of paper to a corrugated one. This was the birth of single-faced corrugated board. In 1882, Robert Thompson invented double-faced corrugated board.

In the following decades, the industrial production of corrugated cardboard, driven by companies like Thompson & Norris, spread throughout the USA and Europe. At the beginning of the 20th century, the triumph of corrugated cardboard boxes as transport packaging began.

Production and Structure of Corrugated Cardboard

Corrugated cardboard is produced on so-called corrugators. Several layers of paper are glued together:

• The corrugated middle layer (fluting) made of corrugating medium
• The smooth outer layers (liners) made of kraftliner, testliner, or recycled liner
• In between, starch-based adhesive

Depending on the number of layers, we speak of single-wall, double-wall, or triple-wall corrugated board. The height and spacing of the flutes also vary. The most common flute profiles are B-flute (fine), C-flute (medium), and E-flute (micro).Modern corrugators achieve production speeds of up to 400 meters per minute.

Sustainability and Recycling

As a packaging material, corrugated cardboard has many ecological advantages. It consists mainly of renewable raw materials and is very recyclable.

Corrugated cardboard produced in Germany contains an average of 80% recycled fibers from waste paper. The rest are virgin fibers from sustainably managed forests. The adhesive used is made from potato, wheat, or corn starch.

Used corrugated packaging is collected mainly in retail and industrial companies, processed into waste paper, and fed back to the paper industry as a raw material. This creates an almost completely closed recycling loop. In Germany, the return rate for corrugated and cardboard packaging is over 90%.

Various labels such as the RESY symbol or the eco-label of the German Corrugated Board Industry Association (VDW) inform consumers about the recyclability and environmental compatibility of corrugated cardboard.

Conclusion: Corrugated Cardboard - An Excellent Choice for Transport and Sales Packaging

Corrugated cardboard is a versatile and sustainable packaging material with a history of over 150 years. The layered structure of paper combines low weight with high stability. In modern high-performance production, corrugated cardboard can be manufactured very efficiently and flexibly for a wide variety of packaging requirements.

With a recycling rate of 80% and more, corrugated cardboard is also a prime example of the circular economy. Used packaging does not become waste but a valuable raw material for new products. This makes corrugated cardboard an excellent choice for transport and sales packaging from both an economic and ecological point of view.