Board Packaging

The Evolution of Board Packaging


Board packaging has seen tremendous evolution over the past few decades to meet the dynamic needs of industries and consumers. From simple corrugated boxes to sophisticated designs with added features, board packaging has greatly advanced. Let’s dive into how board packaging has evolved.

Early Days of Corrugated Boxes

Corrugated boxes were among the earliest forms of board packaging used widely for product shipping and storage starting in the late 19th century. Made from thick brown kraft paper sheets glued together in alternating ridges and grooves for strength, corrugated boxes served basic protective and containment needs. While effective at the time, these early boxes lacked stylish designs or added functionality. Their main purpose was to get products from point A to point B intact. Through the 20th century, slow improvements were made to corrugated board formulations and designs.

Advancements in Materials and Production Technologies

Major breakthroughs began occurring from the 1970s onwards driven by new materials and production technologies. The introduction of lightweight bleached linerboards and new adhesives allowed for thinner yet stronger boards. Automated cutting and assembly lines ramped up production speeds. Computer-aided design software facilitated complex designs. Combined, these innovations enabled multi-panel, customized box forms that were not possible before. Boards could now be made with specific performance properties like moisture resistance or crush strength tailored for product demands.

Emergence of Value-Added Features

With enhanced design flexibility and production efficiency, board packaging evolved from simple containers to value drivers. Features integrating convenience, safety, sustainability and more started emerging widely. Some examples include windows or cut-outs for product visualization, peal-off labels, tamper-evident or re-sealable opening styles, printed imagery and messaging, special coating and lamination treatments. Interactive and augmented reality features also entered the fray recently leveraging digital technologies. These value-added functions boosted brand engagement while ensuring ideal product protection.

Sustainable Design Advancements

Sustainability became an influential factor as both regulations and consumer preferences elevated green considerations. Board producers responded with numerous eco-friendly innovations. Lighter-weight designs using minimum material, optimized stacking strength, recycled content boards, mixed material composites, bio-based polymers, starch-based or plastic-free coatings – the options continue expanding. Packaging can now have sustainability attributes like recyclability, composability, reduced fossil fuel usage embedded throughout while meeting performance needs. Another area seeing focus is optimizing the circular economy potential of board packaging through design for recycling principles.

Customized Solutions through 3D Printing

A cutting-edge evolution is the advent of 3D printing technologies which enabled highly customized one-off or short-run production without line tooling costs or design constraints of traditional manufacturing. 3D printed board packaging offers limitless designs, on-demand production according to shipping/retail needs and shapes conforming perfectly to any product dimensions down to last millimeter. They make for ideal prototypes or specialized small batches. While 3D printing scale-up and cost hurdles must still be overcome, it presents tremendous future potential especially to small businesses needing bespoke designs.

Current and emerging industry and consumer trends continue shaping Board Packaging development. Factors like e-commerce growth requiring robust but lightweight boxes for shipping small orders, medical/pharma sector needs for tamper-evident solutions, food industry demands for moisture/gas barriers, single-use mindset influencing compostable designs – all exert influence. Advancing virtual technologies too will blur digital and physical worlds with concepts like interactive print media, augmented usage instructions, integrated sensors and more finding roles. As evolve day by day with challenges and opportunities, board packaging answers the call through continuous innovation in materials, production processes as well as applied design thinking.

1.  Source: Coherent Market Insights, Public sources, Desk research
2. We have leveraged AI tools to mine information and compile it