When launching a product, the packaging you choose for your product can be just as important as the product itself. For many startup companies, selecting the right card stock or cardboard for packaging can seem complex, especially with considerations like strength, protective needs, budget constraints, and even the option to use the packaging as a display case. Here, we’ll cover everything you need to know to make an informed decision.
Why Selecting the Right Card Stock Matters for Your Packaging
The thickness, durability, and finish of your packaging say a lot about your brand. The right choice of card stock can help protect your products during shipping, create an attractive display, and ensure a positive unboxing experience for your customers. In this guide, we’ll explore how to choose the right packaging card stock and why it matters for your startup.
1. Determine the Strength and Durability Required
For startups, choosing a packaging material that offers the right strength is essential. Corrugated card stock or corrugated cardboard is ideal if your product requires extra durability. Corrugated materials are typically made with fluted paper layers which are the wave-shaped ridges between layers, creating air pockets that absorb impact and keep your products safe during transportation. This is especially important if you’re shipping fragile or heavy items.
We've listed the different types of corrugated flute thicknesses below.
A-Flute
Thickness: Approximately 5mm
Properties: A-Flute is the thickest flute type, providing excellent cushioning and compression strength. It’s ideal for heavy or fragile items that need more protection.
Uses: Often used for shipping boxes, protective packaging, and cases that require high stacking strength.
B-Flute
Thickness: Approximately 3mm
Properties: B-Flute is thinner than A-Flute but offers good puncture resistance and compression strength. It’s suitable for smaller, more compact packages.
Uses: Commonly used for retail packaging and boxes that require higher crush resistance without as much thickness.
C-Flute
Thickness: Approximately 4mm
Properties: C-Flute provides a good balance between thickness and durability, making it one of the most widely used flute types. It has moderate strength and cushioning, suitable for a range of products.
Uses: General-purpose packaging, including shipping boxes and display-ready packaging.
E-Flute
Thickness: Approximately 1.5mm
Properties: E-Flute is very thin and offers a more refined look, making it ideal for high-quality printed designs. It provides a lower level of cushioning but is still sturdy.
Uses: Preferred for retail packaging, point-of-purchase displays, and products that benefit from detailed print.
F-Flute
Thickness: Approximately 1mm
Properties: F-Flute is one of the thinnest options, designed for intricate and detailed printing while maintaining a rigid feel. Its slim profile is ideal for small, delicate items.
Uses: Premium packaging, cosmetics, and small, lightweight retail items.
BC-Flute (Double Wall)
Thickness: Approximately 6-7mm
Properties: This is a double-wall option that combines B-Flute and C-Flute layers, offering exceptional strength and cushioning. It’s ideal for heavy-duty packaging.
Uses: Suitable for large, heavy products, or items that require added protection during transport.
EB-Flute (Double Wall)
Thickness: Approximately 4mm
Properties: EB-Flute combines E-Flute and B-Flute layers, offering a blend of printability and durability. It’s strong and compact, making it useful for smaller, heavier items needing protection and a high-quality appearance.
Uses: Often used in premium packaging where both structural integrity and aesthetics are essential.
(Image from AO Pack Machine)
For products that don’t require as much protection, such as lightweight items, you might opt for standard card stock. Standard card stock is more affordable, yet it still offers sufficient protection for lighter products. For instance, products like cosmetics, stationery, or accessories can often use lighter card stock without compromising on safety.
Card stock thickness is typically measured in points (pt) or GSM (grams per square meter), with higher numbers indicating thicker and more durable card stock. Here’s a breakdown of common card stock thicknesses and their applications.
10pt Card Stock (230gsm)
Properties: Thin and lightweight, offering basic protection but limited structural support.
Uses: Good for flyers, brochures, or very lightweight product packaging.
12pt Card Stock (250gsm)
Properties: Slightly thicker, providing a balance of flexibility and light protection. It’s still relatively lightweight but has more durability.
Uses: Often used for business cards, postcards, and packaging for lightweight items.
16pt Card Stock (350gsm)
Properties: Medium thickness, offering sturdiness and a higher-quality feel. It’s strong enough to provide moderate protection.
Uses: Ideal for retail packaging, premium business cards, and promotional packaging.
18pt Card Stock (400gsm)
Properties: Thick and durable, with good structural integrity. It offers a solid feel and can withstand more handling.
Uses: Often used for more protective packaging, heavier items, or items that need a premium look.
24pt Card Stock (450gsm)
Properties: Very thick, offering high durability and rigidity. It’s suitable for heavier products or packaging that requires additional support.
Uses: Used for premium packaging, rigid boxes, and products needing extra durability.
2. Consider Whether the Packaging Needs to Be Protective
Protective packaging is critical, particularly if your product is breakable or needs to be shipped across long distances. In addition to the card stock’s thickness, protective packaging considerations may involve selecting materials that are resistant to moisture or temperature fluctuations.
Double-wall or triple-wall corrugated cardboard can provide the added strength needed to protect more delicate items. If your product requires a softer interior, consider adding inserts or dividers made from the same card stock to prevent damage.
3. Factor in Budget Constraints
Startups often have limited budgets, and packaging can become a costly line item if not managed carefully. Selecting the right card stock allows you to find a balance between cost-effectiveness and durability.
Lightweight card stock is often less expensive than thicker, multi-layered cardboard options. However, going too thin on card stock may compromise product safety, leading to additional costs in customer returns or replacements. Make sure to choose a stock that’s affordable but also meets your durability requirements.
4. Choosing Between Corrugated Card and Standard Card Stock
Understanding the difference between corrugated card stock and regular card stock is essential. Corrugated options are typically more durable due to the extra layers, making them better suited for items that require more protection. On the other hand, regular card stock is usually a single layer, suitable for items that are lighter and don’t need as much protection.
Your choice will also depend on how your products will be displayed or stored. Corrugated card stock is more versatile, offering durability while allowing for structural integrity if the package needs to be converted into a display case.
5. Consider if the Packaging Will Double as a Display Case
Some products benefit from display-ready packaging, especially if you plan to place them directly on shelves. If your startup aims to make the packaging functional and visually appealing, selecting a sturdy material is crucial. Corrugated cardboard can often be shaped into point-of-purchase displays that are durable enough to support various products while also attracting customers’ attention.
For this purpose, a combination of strength, design, and structural integrity is key. Laminated or printed corrugated card stock can offer a professional look while standing up to the weight and frequent handling.
6. Selecting the Right Thickness of Card Stock for Branding and Perception
Packaging often represents the first physical interaction customers have with your brand. Choosing the right card stock thickness can convey a sense of quality and durability, enhancing your brand’s image. If you’re using thinner, lightweight stock, it may be cost-effective but could give an impression of lower quality. Conversely, choosing thicker card stock can suggest a premium feel.
Key Takeaways for Startups Choosing Packaging Materials
For startups, selecting the right packaging card stock can be the difference between a positive or negative customer experience. By considering factors like durability, protection, budget, and presentation, you can choose materials that reflect your brand’s values while protecting your products.
Choosing the right card stock is more than just a protective measure—it’s a strategic decision that impacts your brand’s success. Whether you’re a startup looking to make a strong first impression or seeking a cost-effective way to package your products, selecting the right materials is key to building customer trust and product loyalty.
Thanks for reading.
Jack Pounce
Owner of Drop-Ship Packaging
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