High-Strength Industrial Corrugated Boxes – TSW Packaging
TSW Industrial Packaging Solutions Pvt. Ltd. is a trusted Corrugated Box Manufacturer in Pune, Maharashtra, specializing in high-performance industrial corrugated boxes for shipping, export, e-commerce and heavy-duty applications.
As a leading name in corrugated box manufacturing in Pune, we design and produce structurally engineered boxes that ensure maximum product protection, optimized logistics performance and cost efficiency.
Corrugated boxes are the backbone of modern supply chains and at TSW, we engineer them for strength, precision and reliability.
1. What is a Corrugated Box?
A corrugated box is manufactured from corrugated fiberboard consisting of:
- Linerboards (outer flat sheets)
- Fluting (medium) – the wave-shaped inner layer
This structure creates a high strength-to-weight ratio, making corrugated boxes ideal for:
- Industrial shipping
- Export packaging
- E-commerce fulfillment
- FMCG distribution
- Machinery & auto component packaging
2. Why Choose TSW for Corrugated Box Manufacturing in Pune?
We don’t just manufacture boxes – we engineer packaging performance.
a) Lightweight Yet High Strength
Optimized flute structure ensures superior compression strength without excess weight.
b) Cost-Optimized Design
Our engineering team balances paper grade, ply combination, and flute type to reduce material cost while maintaining performance.
c) Custom Corrugated Boxes
Every box is designed based on: Product weight, Fragility, Stacking height, Shipping distance, Moisture exposure
d) Heavy-Duty Industrial Packaging
Double wall and triple wall corrugated boxes for export and machinery packaging.
e) 100% Recyclable & Sustainable
Environment-friendly, renewable, and biodegradable packaging solutions.
f) Printable for Branding
Flexographic and digital printing options available for logo and handling instructions.
3. Structure of a Corrugated Box
a) Linerboard
Flat outer paper layers made from:
- Virgin kraft pulp (high strength)
- Recycled pulp (eco-friendly & economical)
Functions:
- Protects contents
- Supports stacking load
- Provides printing surface
b) Fluting (Medium)
The engineered wave structure between liners. Provides:
- Shock absorption
- Vertical load distribution
- Compression resistance
- Thermal insulation
The arch-like flute design distributes weight evenly, improving stacking strength during storage and transit.
4. Types of Corrugated Boards We Manufacture
| Type of Corrugated Board | Structure Composition | Common Uses / Applications |
|---|---|---|
Single Face Board |
1 liner + 1 flute |
Used for wrapping and cushioning |
Single Wall |
2 liners + 1 flute |
Most common shipping carton |
Double Wall |
3 liners + 2 flutes |
For heavy loads and export packaging |
Triple Wall |
4 liners + 3 flutes |
Industrial machinery & bulk packaging |
5. Flute Types Available
| Flute | Thickness | Best Use |
|---|---|---|
A Flute |
5 mm |
Fragile & cushioning |
B Flute |
3 mm |
Retail packaging |
C Flute |
4 mm |
Shipping cartons |
E Flute |
1.5 mm |
High-quality printing |
* C Flute is most widely used for shipping due to balanced stacking and cushioning performance. | ||
6. Corrugated Box Manufacturing Process
Our semi-automatic plant in Pune follows a controlled manufacturing process:
Step 1: Raw Material Selection
High-quality kraft paper and test liners.
Step 2: Corrugation
- Medium passed through heated rollers
- Flute formation
- Starch-based adhesive application
- Liner bonding
Step 3: Board Formation
Single facer and double backer operations.
Step 4: Cutting & Creasing
Precision die-cutting and rotary cutting.
Step 5: Printing
- Flexographic printing (bulk orders)
- Digital printing (short runs)
Step 6: Folding & Gluing
Final box formation and dispatch.
7. Corrugated Box Styles
Most designs follow global FEFCO codes.
Regular Slotted Container (RSC)
Most common shipping box with equal flaps.
Full Overlap Carton
Improved stacking strength.
Half Slotted Container (HSC)
Open top design for easy loading.
Die-Cut Corrugated Boxes
Custom shapes and internal partitions.
8. Strength & Performance Testing
We design corrugated boxes based on scientific strength calculations.
Edge Crush Test (ECT)
Measures edgewise compression strength — critical for stacking.
Box Compression Test (BCT)
Measures total load-bearing capacity before collapse.
We use engineering formulas such as the McKee Formula for BCT estimation to ensure accurate performance design.
9. Applications of Our Corrugated Boxes
Our corrugated box manufacturing in Pune supports:
- Industrial export packaging
- Auto component packaging
- E-commerce packaging
- FMCG distribution cartons
- Electronics packaging
- Pharmaceutical logistics
- Agricultural produce cartons
10. Key Factors That Influence Corrugated Box Cost
- Kraft paper pricing
- Flute type
- Ply combination (3 ply / 5 ply / 7 ply)
- Printing complexity
- Die tooling
- Order quantity
- Transportation distance
Our corrugated box manufacturing in Pune supports:
11. Sustainable Corrugated Packaging
Corrugated packaging is one of the most sustainable industrial packaging solutions.
- Renewable raw material
- 60–90% recycled content
- Fully recyclable
- Biodegradable
Globally recognized sustainability certifications include:
- Forest Stewardship Council (FSC)
- Programme for the Endorsement of Forest Certification (PEFC)
12. Looking for Corrugated Box Manufacturing in Pune?
If you are searching for:
- Corrugated Box Manufacturer in Pune
- Custom Corrugated Boxes in Maharashtra
- Heavy Duty Corrugated Boxes
- Export Corrugated Packaging
TSW Industrial Packaging Solutions Pvt. Ltd. is your trusted partner.
We combine engineering, quality control, and sustainable manufacturing to deliver packaging that protects your product and strengthens your supply chain.