Corrugated vs. Cardboard vs. Kraft Packaging: Key Differences Explained
When it comes to product packaging, words like “corrugated,” “cardboard,” and “kraft” also would normally be interchanged with each other. But each one of these materials also carries its own unique characteristics, advantages, and applications that are of paramount importance to brands to keep in mind when selecting the most efficient packaging option. An improper packaging material will lead to spoiled goods, inferior consumer experience, and even dirtification of the environment.
This in-depth guide breaks the secrets of these three often misconceived forms of packaging by highlighting their composition, uses, cost considerations, sustainability considerations, and performance in markets. Whether it’s shipping a subscription box, selling handmade goods, or shipping retail merchandise, an understanding of these materials will help you better make informed and strategic choices when it comes to packaging.
Down to Basics: First Things First
1. What Is Corrugated Packaging?
Corrugated packaging is made of corrugated fiberboard, which is a three-layered material:
- An outside liner
- A wavy or fluted inside medium
- An inside liner
It is this structure that lends resiliency, cushioning, and rigidity to corrugated packaging. It’s typically used for shipping boxes, custom mailers, and packaging that needs extra protection to ship.
2. What Is Cardboard?
“Cardboard” is a catch-all name for thick paper products. Technically speaking, it refers to a wide range of packaging materials that include:
- Paperboard (found in cereal boxes, shoe boxes)
- Chipboard (used as the backing on notepads)
- Corrugated fiberboard (often informally referred to as cardboard)
But when packagers refer to “cardboard,” they usually are referring to single-layer paperboard.
3. What Is Kraft Packaging?
Kraft packaging is a material made up of kraft paper—a coarse, fibrous paper made by the kraft chemical process. It is characterized by its natural brown color, though sometimes bleached to white. Kraft packaging can come in the shape of paper bags, wrapping sheets, pouches, or even kraft corrugated boxes.
Structural Differences and Composition
Corrugated:
- Multi-layered: Outer liner, fluted middle, and inner liner
- Designed to be strength- and durability-engineered
- Thickness varies from single-wall to triple-wall
Cardboard (Paperboard):
- Single-ply heavy paper material
- Smooth surface, easily foldable
- Lighter and thinner than corrugated fiberboard
Kraft:
- Composed of virgin wood pulp
- Typically single-layered but can be used in conjunction (such as kraft liner on corrugated boxes)
- High tensile strength, rustic appearance
Strength and Durability Comparison
Corrugated Packaging:
- Excellent ability to resist crushing
- Superior load-carrying capacity
- Prefect for stacking and long-distance transport
- Can absorb shocks and vibrations
- Used for fragile or heavy products
Cardboard:
- Lightweight and flexible
- Appropriate for products with low weight
- Susceptible to water and damage if not laminated
- Thanks to its smooth surface, it is perfect for display but less than ideal for harsh handling
Kraft:
- High tensile strength
- Tear-resistant and puncture-resistant
- Not waterproof unless treated
- Works well for light-to-moderate protection
Common Uses
Corrugated:
- Shipping boxes
- Custom printed mailers
- Subscription packaging
- Retail display units
- Industrial packaging
- Bulk storage containers
Cardboard:
- Folding cartons (cereal boxes)
- gift boxes
- Lightweight retail packaging
- Inner cartons for added stability
- Point-of-purchase displays
Kraft:
- Kraft paper bags
- Protective wrapping for shipping
- Substitutes for tissue paper
- Eco-friendly retail packaging
- pouches and envelopes
- Product tags and labels
Appearance and Aesthetic
Corrugated:
- Can be lined with printed liners
- Generally utilitarian unless custom-branded
- Interior can be seen to contain fluted medium unless lined
- Comes in natural brown, white, or custom prints
Cardboard:
- Printable and smooth
- Possible high-end print finish
- Clean and sleek appearance ideal for shelf presence
- Possible to be laminated, varnished, or foil stamped
Kraft:
- Rustic, natural, and simple appearance
- Earthy color scheme
- Usually used to identify sustainability or handmade products
- Low in design vibrancy, but tells the story of authenticity
Printability and Customization
Corrugated:
- Supports flexographic and digital printing
- Can be laminated or coated for improved finishes
- High customization ability (die-cuts, inserts, etc.)
- Foil stamping and embossing are possible with rigid forms
Cardboard:
- Great for high-resolution prints
- Tends to be used for intricate visual designs
- Well-suited for embossing, UV coating, and lamination
- Custom shapes and structural designs are easily facilitated
Kraft:
- Poor color accuracy with brown base
- Suitable for single-color or minimalist aesthetics
- Fit for brands that prefer a raw, eco-friendly look
- My be augmented with custom stamps, stickers, or labels for branding
Environmental Impact
Corrugated:
- Often made from recycled materials
- Fully recyclable and biodegradable
- Easy to dispose of responsibly
- Can be reused for storage or repurposing
Cardboard:
- Recyclable depending on coatings/laminates
- Can be reused, especially in lighter applications
- Higher carbon footprint if using virgin materials
- Waste is minimized with efficient design
Kraft:
- Highly biodegradable
- Often unbleached, reducing chemical use
- Recyclable and compostable
- Made from sustainably managed forests (if certified)
Cost Considerations
Corrugated:
- Mid to high cost depending on customization and wall thickness
- Economical in bulk
- Increased shipping costs by size and weight
- Long-term cost savings through lowered damage rates
Cardboard:
- Typically cost-effective
- Low material costs
- Perfect for low-risk, high-volume packaging
- Easy to store and ship
Kraft:
- Medium cost
- Usually less expensive than coated options
- Saves on printing and finishing costs with minimalist design
- Flexible for startups and green-friendly businesses
Industries and Use Cases
Industry | Corrugated | Cardboard | Kraft |
E-commerce | Mailer boxes, shipping cartons | Product sleeves, inserts | Tissue wrap, inner liners |
Food & Beverage | Takeout boxes, produce trays | Cereal boxes, chocolate bars | Bread bags, dry goods pouches |
Retail | POP displays, bulk shipments | Folding cartons for display | Paper bags, rustic packaging |
Subscription Boxes | Full structural packaging | Lightweight boxes | Wrapping, filler, tissue |
Cosmetics | Outer protective packaging | Product boxes, gift sets | Minimalist branding wraps |
Electronics | Anti-static mailers | Inner compartments | Dust covers, wrap paper |
Pros and Cons at a Glance
Corrugated:
Pros:
- Strong and protective
- Recyclable and sustainable
- Customizable for inserts, shapes, etc.
- Good for long-distance shipping
Cons:
- Bulky for small products
- Can be plain unless customized
- More expensive than paperboard
- Requires more storage space
Cardboard:
Pros:
- Lightweight and printable
- Cost-effective
- Easy to fold and store
- Sleek and retail-ready appearance
Cons:
- Not as protective
- Susceptible to moisture damage
- Less long-lasting for shipping
- Limited reusability in logistics
Kraft:
Pros:
- Biodegradable and green
- Tear-resistant and strong
- Best suited for natural/organic branding
- Conveys sustainability
Cons:
- Limited in visual appeal
- Non-waterproof
- Less structural integrity
- May not visually awe premium shoppers
Customization Tips Based on Material
- For delicate products, use corrugated boxes with foam inserts or die-cut partitions to reduce movement during shipping.
- For high-end retail, use cardboard packaging with laminated surfaces, magnetic clasps, and spot UV finishes.
- Kraft paper or kraft-laminated corrugated boxes offer an organic brand a rustic, responsible look.
Add distinctive unboxing elements such as:
- Embossed logos
- Printed inside walls
- QR codes that link to tutorials or brand stories
- Personal thank-you cards or coupons
Packaging Material Innovation
New technologies have enabled hybrid and upgraded materials:
- Kraft-corrugated: Balances strength with eco-appeal
- Water-resistant kraft: Special coatings enhance durability
- Digital printed cardboard: Small-run, full-color print packaging
- Recycled corrugated: High post-consumer waste content options
- Bioplastics and compostable liners: For hybrid functionality
Startups and eco-conscious brands often explore these options to balance performance and environmental impact.
Choosing the Right Material: Strategic Questions to Ask
- What is the weight and fragility of your product?
- Will the package be shipped or displayed in-store?
- Is visual presentation a high priority?
- How important is sustainability to your brand and audience?
- What is your budget per unit?
- Do you require the packaging to be used as storage or reusable following unboxing?
- How will the packaging affect the customer experience or unboxing appeal?
Your responses will refine the best packaging solution.
Conclusion
Though “corrugated,” “cardboard,” and “kraft” are commonly grouped together, each has unique characteristics that are best utilized in particular business applications. Corrugated box packaging provides unmatched protection and versatility, cardboard is ideal for displays and retail applications, and kraft is the leader in natural beauty and sustainability.
Knowing the differences isn’t only about semantics—it’s about using the proper tool to symbolize your brand, safeguard your product, and build customer experience.
At PackifyMe, we assist companies in choosing and tailoring the most suitable packaging material for their products. If you are in search of robust corrugated shipping boxes, classy cardboard product packaging, or sustainable kraft solutions, our specialists are ready to assist you step by step.
Lost for words on the right packaging material for your company? Call PackifyMe today and get a free consultation.
