New & custom boxes
Sometimes a lane genuinely needs a virgin box — export, food contact, regulated goods. We stock new stock sizes and run custom dies, with recycled content as high as the spec allows.
Quote new & custom boxes
Give us a size and a count and we will photograph the actual pallet before you commit.
- Recycled content
- Up to 100% on request
- Stock sizes
- 60+ held in St. Louis
- Custom lead time
- 10 – 15 business days
- 1 – 4 colour flexo
- Kraft and mottled white liners
- Die-cut inserts, pads and partitions
- ECT or Mullen certified to your carrier spec
- We will tell you when a used box would do the job
Work out the cube before you ask for a price.
Box Studio gives you the erected cube, the knocked-down cube, the pallet fit and the trailer count for any size — then attaches the spec to the form above.
We sell new boxes slightly reluctantly
It would be convenient to claim that reuse works everywhere. It does not. Some lanes genuinely need a virgin container: direct food contact, regulated goods, export with no return leg, or a retail unit where the box is the packaging and the print has to be perfect.
For those jobs we hold sixty-plus new stock sizes in St. Louis and run custom dies with a ten to fifteen working-day lead time. And when you brief us on a job where a grade-A used box would do exactly the same work for a third of the price, we will say so before we quote.
Recycled content
Most of our new board runs at 70 – 90% post-consumer recycled content as standard, because that is what US mills produce. On request we will specify up to 100% recycled test liner, with the caveat that very high recycled content slightly reduces burst strength for a given basis weight — so we may recommend stepping up a grade rather than losing performance.
One to four colour flexographic print on kraft or mottled white. For brand work requiring tight registration or photographic imagery, litho-lamination is available through our converting partner, though we will tell you honestly that it adds cost and reduces end-of-life recyclability.
- 60+ new stock sizes held in St. Louis
- Custom dies, 10 – 15 working days
- RSC, FOL, HSC, one-piece folder, die-cut mailer
- Inserts, pads and partitions
- ECT or Mullen certification to carrier spec
- Kraft and mottled white liners
A new 18-inch double-wall cube versus a grade-A used one: identical stacking performance in a rack for the first several trips, roughly a third of the price, and about 9 kg less CO₂e each. The only real difference is appearance.
Flute selection, which almost nobody asks about.
Flute height decides cushioning, crush resistance and print quality. Getting it right is usually cheaper than stepping up the wall.
| Flute | Approx. thickness | Density | Character |
|---|---|---|---|
| A | ≈ 3/16" | 33 flutes/ft | Highest cushioning and stacking strength; bulky, poor print. |
| B | ≈ 1/8" | 47 flutes/ft | Crush resistant, great for canned goods and printing. |
| C | ≈ 11/64" | 39 flutes/ft | The default compromise — most RSC shippers in the US. |
| E | ≈ 1/16" | 90 flutes/ft | Thin, crisp print surface; retail and subscription boxes. |
| F | ≈ 1/32" | 128 flutes/ft | Micro-flute for small, premium primary packaging. |
| N | ≈ 1/64" | 200+ flutes/ft | Nano-flute; folding-carton replacement, rarely seen in reuse. |
| BC | ≈ 5/16" | Double wall | B + C combined — the common double-wall build. |
| EB | ≈ 3/16" | Double wall | Thin, stiff, excellent print. Retail rather than logistics. |
| AC | ≈ 23/64" | Double wall | Maximum cushioning double wall; bulky and uncommon. |
| BCA | ≈ 1/2" | Triple wall | Gaylord territory. 1,100 lb test and crate replacement. |
Four questions we will ask you.
Does the box ever come back?
If there is any return leg at all — even an internal one between two of your own sites — a reusable container almost always wins on total cost. We would rather set up a small pool than sell you single-use board.
Is the print load-bearing on the brand?
If a customer sees the box and judges you by it, new board is often the right call. If the box is seen only by your own staff, it rarely is.
Is it ECT or Mullen on the carrier spec?
These are different tests measuring different things. Specifying the wrong one means either paying for strength you cannot use or failing a stack you needed. We will convert it with you.
What is the real stack height?
Not the designed one — the actual one, including the third pallet somebody puts on top at 4 PM on a Friday. We spec for that, which usually means one grade up.
Mullen and ECT, side by side.
Two tests measuring two different failure modes. The equivalences below exist because carriers historically specified Mullen — treat them as conversational rather than contractual, and pick the test that matches how your boxes actually fail.
| Mullen (burst) | ECT (stacking) | Wall | Max size sum | Max gross weight | Typical use |
|---|---|---|---|---|---|
| 125 lb | 23 ECT | Single | 40" | 20 lb | Light retail, folding-carton replacement |
| 150 lb | 26 ECT | Single | 60" | 40 lb | Small parcel, light goods |
| 175 lb | 29 ECT | Single | 65" | 50 lb | General light shipper |
| 200 lb | 32 ECT | Single | 75" | 65 lb | The standard single-wall shipper |
| 250 lb | 40 ECT | Single | 85" | 80 lb | Heavier single wall |
| 275 lb | 44 ECT | Single | 95" | 95 lb | Top of the single-wall range |
| 275 lb | 48 ECT | Double | 100" | 120 lb | Entry double wall — the reuse workhorse |
| 350 lb | 51 ECT | Double | 110" | 180 lb | Heavy distribution |
| 400 lb | 55 ECT | Double | 120" | 225 lb | Industrial parts |
| 500 lb | 61 ECT | Double | 140" | 260 lb | Heavy double wall, bulk bins |
| 600 lb | 67 ECT | Triple | 160" | 300 lb | Entry triple wall |
| 700 lb | 71 ECT | Triple | 165" | 600 lb | Export crating replacement |
| 900 lb | 77 ECT | Triple | 170" | 1,200 lb | Heavy bulk bins |
| 1,100 lb | 82 ECT | Triple | 180" | 2,400 lb static | Gaylord standard |
“Max size sum” is length plus width plus depth. Exceeding it voids the certification even if the box is physically capable, which matters in a freight claim.
What a square foot of each build actually weighs.
The number you need to turn a die-line area into a shipping weight, a carbon figure or a freight class. Multiply blank area in square feet by the figure below.
| Construction | lb per ft² | lb per MSF | Caliper | Note |
|---|---|---|---|---|
| Single wall, 32 ECT (C flute) | 0.20 | 200 | 0.16" | Lightest practical shipper |
| Single wall, 44 ECT (C flute) | 0.24 | 240 | 0.17" | Heavier liner, same flute |
| Double wall, 48 ECT (BC) | 0.33 | 330 | 0.30" | The reuse workhorse |
| Double wall, 61 ECT (BC) | 0.40 | 400 | 0.32" | Heavy distribution |
| Triple wall, 71 ECT | 0.48 | 480 | 0.52" | Crate replacement |
| Triple wall, 1,100 lb test | 0.55 | 550 | 0.60" | Gaylord standard |
| Honeycomb panel, 1" | 0.35 – 0.60 | — | 1.00" | Dunnage and display substrate |
Fourteen references worth knowing by number.
Specifying packaging gets much easier once you can name the standard rather than describe the requirement. These are the ones that come up in our quotes and our customers' RFPs.
| Reference | Title | Why it matters here |
|---|---|---|
| ASTM D642 | Compressive resistance of shipping containers | The test behind box compression figures |
| ASTM D4727 | Corrugated and solid fibreboard sheet stock | Material specification for board itself |
| ASTM D5639 | Selecting corrugated box dimensions | How to specify L × W × H correctly |
| TAPPI T 811 | Edge crush test of corrugated board | The ECT number on a Box Maker's Certificate |
| TAPPI T 810 | Bursting strength of corrugated board | The Mullen number |
| TAPPI T 412 | Moisture in paper and paperboard | How moisture content is measured and deducted |
| ISTA 3A / 6 | Packaged-product performance testing | Transit simulation for parcel and distribution |
| ISO 12048 | Compression and stacking tests | International equivalent of ASTM D642 |
| FEFCO / ESBO code | International fibreboard case code | The four-digit style codes we quote against |
| ISPM 15 | Wood packaging phytosanitary measures | Why corrugated avoids an export compliance burden |
| ISRI Scrap Specifications | Recovered paper grade definitions | The #11 and #12 OCC specs we bale to |
| GRI 306 | Waste disclosure standard | The format our diversion statements fit |
| EPA WasteWise | Voluntary waste reduction reporting | Compatible reporting format on request |
| FDA 21 CFR 176 | Indirect food additives: paper and paperboard | Why used board cannot be direct food contact |
What holds the load together, and what it does to the box.
Strapping applied directly to corrugated is the fourth largest cause of container death in our retirement coding — and the only one eliminated completely by an accessory costing pennies.
| Type | Break strength | Tension retention | Recyclable | Use | Note |
|---|---|---|---|---|---|
| Polypropylene | 200 – 600 lb | Poor | Yes, with film | Light bundling, carton closing | Loses tension quickly; fine for short trips |
| Polyester (PET) | 600 – 2,000 lb | Excellent | Yes | Palletised loads, bulk containers | Holds tension on corrugated far better than steel |
| Woven cord | 500 – 2,400 lb | Good | Limited | Irregular or settling loads | Absorbs load movement without snapping |
| Steel | 1,200 – 9,000 lb | Poor on board | Yes, separately | Metal, lumber, rigid loads | Cuts into corrugated; avoid without corner boards |
| Paper-based | 150 – 400 lb | Moderate | Yes, same OCC stream | Light bundling in a closed loop | Goes into the bale with the box; no separation step |
| Type | Recyclable | Tamper evidence | Use | Note |
|---|---|---|---|---|
| Water-activated paper (gummed) | Yes, same stream | High | E-commerce, reusable cartons | Bonds into the fibre; strongest closure for reuse |
| Reinforced water-activated | Mostly | Very high | Heavy cartons, export | Fibreglass reinforcement; separates at the mill |
| Acrylic BOPP | Tolerated | Low | General carton sealing | Cheapest; leaves residue that downgrades grade A |
| Hot-melt BOPP | Tolerated | Low | High-speed lines | Better initial tack, worse residue |
| Filament | No | High | Bundling, heavy closure | A prohibitive in an OCC bale; strip before baling |
| Paper masking | Yes | Low | Labelling, temporary marking | Our re-face station's preferred option |
The four questions we will ask before quoting
- Does the box ever come back? Any return leg at all — even an internal one between two of your own sites — usually makes a reusable container cheaper on total cost than single-use procurement.
- Is the print load-bearing on the brand? If a customer sees the box and judges you by it, new board is often right. If only your own staff see it, it rarely is.
- Is the carrier spec ECT or Mullen? Different tests, different failure modes. Specifying the wrong one means paying for strength you cannot use while failing on the one you needed.
- What is the real stack height — including the pallet somebody adds at four o'clock on a Friday? We spec for that, which usually means one grade up.
Recycled content, honestly
Most US-made containerboard already runs at 70 to 90 per cent post-consumer recycled content, because that is what domestic mills produce. Specifying 100 per cent recycled test liner is possible on request, with one caveat worth stating: very high recycled content slightly reduces burst strength for a given basis weight, because repeated pulping shortens fibres.
So we may recommend stepping up a grade rather than losing performance — which costs a little more board but avoids the outcome where a sustainability specification quietly causes product damage.
Print, and its end-of-life cost
One to four colour flexographic print on kraft or mottled white covers the large majority of what customers need. For tight registration or photographic imagery, litho-lamination is available through our converting partner, and we will tell you plainly that it adds cost and reduces end-of-life recyclability because you have laminated a plastic-coated sheet onto corrugated.
Where new genuinely wins
Export with no return leg and an unknown destination recycling infrastructure. Regulated goods with a documentation chain. Direct food contact. Cleanroom environments. Retail units where the box is the packaging. We stock sixty-plus new sizes in St. Louis for exactly these cases, and we run custom dies on a ten to fifteen working day lead time.
What we will not do is sell you new board for internal movement without telling you that a grade-A used container would do identical work for a third of the money.
The liners and mediums underneath every box.
Board specification starts one level below the box: which liner, which medium, at what basis weight. Basis weight is stated in pounds per thousand square feet.
| Grade | Basis weight | Fibre | Typical use | Note |
|---|---|---|---|---|
| Kraft liner 26# | 26 lb/MSF | Virgin kraft | Light single wall | Lowest practical outer liner |
| Kraft liner 33# | 33 lb/MSF | Virgin kraft | Standard 32 ECT outer | The commonest liner in North America |
| Kraft liner 42# | 42 lb/MSF | Virgin kraft | 44 ECT and double wall | Noticeably stiffer, better print |
| Kraft liner 69# | 69 lb/MSF | Virgin kraft | Triple wall outer | Gaylord-grade facing |
| Test liner 2 | 27 – 50 lb/MSF | ≥ 80% recycled | General shipper | Most recycled-content board |
| Test liner 3 | 27 – 50 lb/MSF | 100% recycled | Internal and bulk | Lower burst for the same weight |
| Mottled white | 35 – 42 lb/MSF | Mixed | Retail-facing print | White outer, kraft back |
| Semi-chem medium 26# | 26 lb/MSF | Semi-chemical | Standard flute medium | Highest stiffness per weight |
| Recycled medium 23# | 23 lb/MSF | 100% recycled | Economy flute medium | Common in test-liner board |
| Type | Where it is used | Water resistance | Recycling | Note |
|---|---|---|---|---|
| Starch (corrugating) | Liner to medium | Low resistance | Ideal | The standard bond in all corrugated board |
| Hot melt EVA | Manufacturer's joint, cases | Moderate | Tolerated | Fast set; brittle when cold |
| Cold-set PVA | Case sealing | Low | Ideal | Slow set, strong fibre tear |
| Water-resistant starch | Produce board | High | Good | Alternative to wax for damp environments |
| Pressure-sensitive | Tape, labels | Varies | Tolerated in small amounts | Residue downgrades grade A board |
| Stitching (staples) | Manufacturer's joint | Unaffected | Removed in the junk trap | Outlasts glue through reuse cycles |
Seven ways to put a mark on a box.
Ranked roughly by setup cost. The last two are what we use on recovered board — removing somebody else's brand is a different job from applying your own.
| Method | Setup cost | Quality | Recyclability | Use | Lead time |
|---|---|---|---|---|---|
| Flexographic, 1 colour | Low | Basic | Fully | Identification, logistics marks | 3 – 7 days |
| Flexographic, 2 – 4 colour | Medium | Good | Fully | Brand on shipper | 10 – 15 days |
| High-graphic flexo | High | Very good | Fully | Retail-ready packaging | 15 – 20 days |
| Litho-lamination | Very high | Photographic | Reduced | Premium retail display | 20 – 30 days |
| Digital inkjet | None | Good | Fully | Short runs, versioning | 3 – 10 days |
| Blank-out over-print | None | Functional | Fully | Removing a previous owner's brand | Same day |
| Stencil | None | Industrial | Fully | Pool container marking | Same day |
How long each thing actually takes.
Measured from a confirmed order, not from the first email. Artwork approval and procurement onboarding sit outside these figures and are usually the real critical path.
| Item | Lead time | Note |
|---|---|---|
| Graded used shippers, stock size | Same week | Often 48 hours on Midwest lanes |
| Graded gaylords, stock size | Same week | Knocked down and banded |
| Reconditioned gaylords | 7 – 10 days | Bench time plus re-grading |
| Lids, liners and accessories | Same week | Ships on the same pallet |
| Recovered pallets, repaired | 3 – 7 days | Depends on repair queue |
| New stock-size boxes | 2 – 5 days | 60+ sizes held in St. Louis |
| New custom die | 10 – 15 working days | Includes die making and first article |
| Printed new board, 1 – 4 colour | 10 – 15 working days | Plate making included |
| Honeycomb panel, stock | 5 days | Pressed from recovered board |
| Die-cut dunnage to profile | 7 – 10 days | Tooling for non-standard profiles adds time |
| Printed retail display | 10 – 12 days | Artwork approval is usually the critical path |
| Baler placement | 2 – 4 weeks | Site survey, delivery and commissioning |
Eight claims, and how strong each one actually is.
Two of these we make and document. One we refuse to make. One we consider close to meaningless.
| Claim | Evidence needed | Strength | Caveat |
|---|---|---|---|
| Recycled content, post-consumer | Mill certificate of analysis | Strong | Percentage varies by mill and by run |
| FSC Recycled | Chain-of-custody certificate | Strong | Requires certified converters at every step |
| SFI Certified Sourcing | Chain-of-custody documentation | Strong | Covers sourcing practice, not recycled content |
| Recyclable | Material composition | Moderate | Depends on local infrastructure; wax and laminate break it |
| Repulpable | Supplier test data | Moderate | Verify with your actual recycler, not the datasheet |
| Reusable | Trips-per-container data | Strong if measured | Meaningless without a trip count behind it |
| Carbon neutral | Offset purchase | Weak | We do not make this claim and are sceptical of those who do |
| 100% diversion | Usually none | Very weak | Ask what they do with wax-coated produce board |