When it comes to packaging, one of the most important yet often overlooked factors is cardboard thickness. Whether you are a business owner shipping products worldwide, a designer working on branded packaging, or simply someone curious about how boxes are made, understanding cardboard thickness is essential.
The thickness of cardboard not only affects how strong and protective a box is but also influences printing quality, shipping costs, and environmental impact. Choosing the wrong thickness can lead to damaged goods, unnecessary expenses, or packaging that doesn’t align with sustainability goals.
In this guide, we will explore what cardboard thickness means, standard thickness measurements in millimeters and inches, and how different wall types (single, double, triple) compare. By the end, you’ll know exactly which type of cardboard works best for your packaging needs.
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What Is Paperboard? Difference Between Paperboard vs Cardboard
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Paper Weight (GSM) Chart: Choose the Best Paper for Printing, Packaging
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Corrugated Fiberboard vs. Cardboard: Differences, Benefits & Future Trends in Packaging
What is Cardboard Thickness?
Cardboard thickness refers to the measurement of how thick a sheet of cardboard is, usually determined by its fluting (the wave-shaped middle layer) and linerboards (the flat outer sheets). The thickness impacts strength, durability, print quality, and cost-effectiveness.
It’s important to note the difference between folding carton (paperboard) and corrugated cardboard:
- Folding carton (paperboard) is thinner (around 0.3–1 mm) and used for retail packaging like cereal boxes, cosmetics, or small product sleeves.
- Corrugated cardboard is thicker (1.5 mm up to 15 mm) and designed for shipping boxes, storage, and heavy-duty packaging.
Understanding thickness helps businesses choose the right type of carton for shipping, branding, or eco-friendly packaging solutions.
Standard Cardboard Thickness (in mm & inches)
Cardboard thickness is most often measured in millimeters (mm) or inches. Each flute type has its own standard thickness. Below is a quick breakdown of the most commonly used flute profiles:
- A-Flute → approx. 5 mm (¼″): Excellent cushioning and stacking strength.
- B-Flute → approx. 3 mm (⅛″): Rigid, space-saving, often used for retail packaging.
- C-Flute → approx. 4 mm (11/64″): Most common shipping box flute; balance of strength and printability.
- E-Flute → approx. 1.5 mm (1/16″): Thin, lightweight, great for high-quality printing and retail displays.
- F-Flute → approx. 0.6–0.8 mm (1/32″): Very fine fluting for luxury packaging and detailed graphics.
Among these, B-flute and C-flute are the most widely used across industries because they provide a balance between durability and cost.
Cardboard Thickness Chart: Single, Double, and Triple Wall
Corrugated cardboard can be classified by the number of walls (layers of fluting). More layers mean more thickness and greater strength.
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Single Wall (2 liners + 1 flute)
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Thickness: ~2 mm to 7 mm
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Most common for shipping small to medium products.
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Double Wall (3 liners + 2 flutes)
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Thickness: ~5 mm to 12 mm
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Used for heavier or fragile goods needing extra protection.
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Triple Wall (4 liners + 3 flutes)
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Thickness: ~10 mm to 15 mm+
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Extremely durable; often called “the alternative to wooden crates.”
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This classification helps manufacturers and businesses pick the right board grade depending on the weight of the product, shipping distance, and storage conditions.
How to Choose the Right Cardboard Thickness
Selecting the right cardboard thickness depends on the type of product, the shipping method, and the customer experience you want to create. Here are some guidelines:
- Lightweight products: A single wall B-flute or C-flute box is usually sufficient. It keeps packaging costs low while still offering protection.
- Fragile or heavier products: A double wall box provides better cushioning and resistance against crushing.
- Very heavy or industrial goods: A triple wall carton can withstand extreme pressure and is often used as a replacement for wooden crates.
- Premium or retail packaging: Thin flutes such as E-flute or F-flute are ideal for sharp printing, smooth surfaces, and a professional unboxing experience.
When deciding, businesses should balance product safety, shipping efficiency, and sustainability goals.
Cardboard GSM Explained (What is the GSM of Corrugated Cardboard?)
Apart from thickness, another important factor is GSM (grams per square meter), which measures the weight and density of the paper used in corrugated cardboard. Higher GSM means stronger and more durable paper.
Common GSM ranges for corrugated cardboard include:
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90 GSM WBF (fluting grade) – lightweight, economical.
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105 GSM WBF – widely used as a standard option.
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112–150 GSM – stronger fluting and liner boards for heavy-duty use.
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175–300 GSM – premium board grades for high strength and durability.
For reference: office printing paper is usually 80 GSM, while thick retail packaging often uses 300 GSM or higher.
Comparison Table: Flutes and Wall Types
| Type | Thickness (mm) | Strength Level | Best For |
|---|---|---|---|
| A-Flute | ~5 mm | High cushioning | Fragile items |
| B-Flute | ~3 mm | Good stacking | Retail packaging |
| C-Flute | ~4 mm | Balanced | Standard shipping boxes |
| E-Flute | ~1.5 mm | Lightweight | Custom printing & displays |
| Single Wall | 2–7 mm | Standard | Everyday shipping |
| Double Wall | 5–12 mm | Strong | Heavy or fragile goods |
| Triple Wall | 10–15 mm+ | Extra strong | Industrial shipping |
This chart shows how flute type and wall structure work together to determine the final thickness and performance of corrugated cardboard.
Eco-Friendly Choices in Cardboard Thickness
Today, businesses are also considering the environmental impact of their packaging. Choosing the right thickness is not only about strength but also about reducing waste and carbon footprint.
- Recycled paper (Test paper) and Kraft paper are sustainable linerboard options.
- Using the right thickness prevents over-packaging, reduces shipping weight, and saves costs.
- Many eco-friendly packaging companies now focus on recyclability, biodegradability, and reduced material usage without compromising on durability.
By balancing product safety with sustainability, businesses can deliver a greener packaging solution that customers appreciate.
Frequently Asked Questions (FAQ)
How thick is standard corrugated cardboard?
Most single wall corrugated cardboard ranges between 3 mm and 5 mm, but heavy-duty options can be as thick as 15 mm.
Does higher GSM mean thicker cardboard?
Not always. GSM refers to the paper weight, while thickness depends on the flute profile. A high GSM liner with a thin flute may still be thinner than a low GSM liner with a thick flute.
Which cardboard is best for printing?
E-flute is widely used for retail packaging and custom-printed boxes because of its fine surface and print quality.
Conclusion
Cardboard thickness is one of the most critical factors in packaging. From thin, lightweight flutes for retail boxes to heavy-duty triple wall cartons for industrial shipping, the right thickness ensures safety, cost efficiency, and customer satisfaction.
As packaging continues to evolve, businesses must also consider the environmental impact of their choices. By choosing the right balance of strength, printability, and sustainability, companies can protect their products and their brand image while reducing waste.
If you are looking for eco-friendly cardboard packaging solutions, selecting the right thickness is the first step toward smarter, greener packaging.
