Frequently Asked Questions

Corrugated cardboard is made by sandwiching a fluted layer of material between two flat sheets, called liners. This creates a sturdy, crush-resistant structure that’s perfect for packaging. The fluted middle layer adds strength, making it ideal for protecting goods during shipping.

• Single Wall: Consists of one fluted layer between two liners. It’s suitable for lighter items and can generally handle weights up to 10kg.
• Double Wall: Two fluted layers provide extra strength, making it capable of holding up to 30kg. Ideal for heavier goods that need more protection.
• Triple Wall: Three layers of fluting for maximum strength, capable of handling large, heavy items. Great for palletising and shipping items up to 50kg, ensuring safe transport even under pressure.

1. Kraft Paper: Made from virgin wood pulp, kraft paper is the strongest and most durable option. It is commonly used for the outer liners of corrugated cardboard, providing excellent protection and structural integrity.
2. Test Paper: This is a recycled option often used for the inner liner of corrugated cardboard. While not as strong as kraft, it’s eco-friendly and cost-effective, making it a suitable choice for lightweight packaging applications.
3. Fluting: The fluted layer, positioned between the liners, adds strength and cushioning to the corrugated cardboard. It is typically made from recycled paper, providing a balance between strength and weight. The fluting structure is essential for enhancing the compressive strength and shock absorption of the cardboard, making it ideal for protecting goods during transit.
4. Other Paper Types: Depending on specific packaging needs, corrugated cardboard may also incorporate recycled or semi-chemical paper variants to optimise cost and performance.

Corrugated cardboard weight is measured in grams per square meter (gsm). This refers to the weight of one square meter of the material. Higher gsm numbers generally indicate a stronger material.

Double or triple wall boxes offer the best protection against crushing. These multi-layered boxes are designed to withstand stacking and rough handling during transit, making them the best choice for safeguarding your products. You can also combine these boxes with polystyrene endcaps or polystyrene packaging for enhanced protection, especially when shipping fragile or valuable items.

For fragile or delicate items, we recommend double or triple wall boxes for added protection. To further safeguard your products, use polystyrene packaging or polystyrene endcaps to cushion your items inside the box. These materials help absorb impacts and protect against shocks that the box alone may not handle.

Yes, we offer a range of standard box sizes suitable for most common packaging needs. However, if your products require custom sizes or shapes, we can also provide bespoke packaging solutions tailored to your specifications.

Our press platen size is 1500x1050mm, and our flatbed digital cutting area is 1680x3050mm. This allows us to create large, custom boxes to meet your packaging needs, especially for oversized or uniquely shaped items.

Corrugated cardboard is sometimes referred to as corrugated fibreboard, combined board, or corrugated board. It’s important to note that “cardboard” by itself doesn’t always mean corrugated—it could refer to thinner, less durable materials like paperboard.

While the natural brown finish is the most common, corrugated cardboard is available in other colours such as white. However, please note that we are unable to offer custom printing on our packaging at this time.

Yes, polystyrene is recyclable, although there is a widespread myth that it cannot be recycled. The key to recycling polystyrene is to have access to proper facilities, as it is not always accepted in standard curbside recycling programmes. However, with specialised recycling systems, polystyrene can be compacted and processed into materials that can be used for creating new products, such as insulation, plastic items, and even new packaging materials. The recycling process significantly reduces the environmental impact of polystyrene, diverting it from landfills and reintroducing it into the supply chain. Due to its lightweight and versatile properties, polystyrene recycling consumes less energy compared to other plastics, making it a more sustainable option when handled correctly. It’s vital that businesses and consumers help to support the development and utilisation of recycling infrastructure to ensure that polystyrene can be effectively reused rather than discarded.

Polystyrene comes in a range of densities, suited to different applications. Expanded Polystyrene (EPS) is the most common and comes in densities ranging from light packaging foam to higher-density types used in construction. Depending on the application, choosing the correct density is crucial for balancing weight, strength, and insulation properties.

Polystyrene is safe to use in normal conditions and does not emit harmful fumes during typical use. However, when polystyrene is burned or exposed to very high temperatures, it can release harmful chemicals, including styrene gas and other compounds. This is why it is crucial to avoid subjecting polystyrene to open flames or high heat. Under proper use conditions, polystyrene poses no danger to air quality or health.

Polystyrene has its environmental challenges, but it is far more sustainable than many realise. While it is not biodegradable and can persist in landfills for a long time, the fact that it is recyclable mitigates much of its environmental impact. When recycled properly, polystyrene can be repurposed into new products, which helps reduce the need for virgin materials. Additionally, polystyrene’s lightweight nature means it requires less fuel for transportation, reducing carbon emissions during transit. Its insulating properties, particularly in construction, also contribute to energy savings by reducing the need for heating and cooling in buildings. With proper recycling practices in place, polystyrene can play a part in sustainable development, especially when compared to non-recyclable or less energy-efficient alternatives.

No, you do not have to pay the plastic tax when purchasing our polystyrene products. We use a composition of 70% recycled and 30% virgin materials in our polystyrene, which qualifies us for exemption from the plastic tax. The plastic tax was introduced to incentivise the reduction of plastic waste and promote the use of recycled materials. By utilising a significant portion of recycled content in our products, we not only align with sustainable practices but also avoid the additional costs associated with the tax. This commitment to recycling helps lower our environmental footprint while providing cost-effective solutions for our customers.

Our standard lead time for most polystyrene orders is 5-7 working days. However, we understand that urgent needs may arise. For short notice or priority orders, we are flexible and can often expedite production to meet tighter deadlines. If you have an urgent request, we encourage you to contact us, and we will do our best to accommodate your timeframe.

No, we do not have a minimum order quantity (MOQ). Whether you require a small, one-off batch or a large production run, we can fulfil your needs. This flexibility is ideal for businesses of all sizes and allows you to order exactly what you need without unnecessary commitments to large volumes.

Polystyrene can be painted using water-based paints, such as acrylics or latex, without damaging the material. However, solvent-based paints and varnishes should be avoided as they can dissolve or degrade the polystyrene surface. If you need to decorate or colour polystyrene, we recommend sticking to water-based coatings for the best results.

While we do not specialise in food packaging, polystyrene is widely used for certain food containers and packaging applications. It is considered safe for food contact when produced under the right standards. However, it’s always important to verify the specific product’s compliance with food safety regulations.

Yes, polystyrene contributes significantly to energy efficiency. Its insulating properties help maintain consistent indoor temperatures, which can lower the need for heating and cooling in buildings. By reducing energy consumption, polystyrene can lower energy costs and decrease the carbon footprint of buildings where it is