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Author Archives: AXIS Corrugated Container

  1. Everything You Need to Know About Corrugated Boxes

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    Many people use the terms “cardboard box” and “corrugated box” interchangeably. However, the two actually refer to different types of containers. The experts at Axis Corrugated Container—a premier supplier of corrugated product solutions—have put together the following guide to explain the differences between cardboard boxes and corrugated boxes to help readers understand which one is right for their packaging needs. 

    What Are Cardboard Boxes and Corrugated Boxes?

    The first step in explaining the difference between cardboard boxes and corrugated boxes is answering the following questions: 

    1. What is a cardboard box?
    2. What is a corrugated box?

    A cardboard box is a container made from thick paper stock or heavyweight paper-pulp. Common examples include cereal boxes, folding takeout containers, and toy packaging. A corrugated box is a container made from multiple layers of material (i.e., one or more fluted layers surrounded by flat liner layers). It is commonly used to package and ship products. 

    Key Differences Between Cardboard and Corrugated Boxes

    As indicated above, cardboard boxes and corrugated boxes are made from different materials. This difference in materials affects both the assembly process for and the sturdiness of the containers.

    Cardboard boxes are produced from one or more pieces of single-layer material. The pieces are cut to the proper shape and size and joined using glue, staples, tape, or other fastening methods. The result is a container that is suitable for packaging products. However, it is not strong enough to withstand the stresses of shipping, so additional packaging materials must be used if the packaged product needs to be shipped.

    Why Use Corrugated Boxes to Package Products

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    Corrugated boxes are produced from one or more pieces of multi-layer material. The material is created by gluing one or more pieces of fluting (i.e., wavy layers of materials) between flat liners. This sandwich construction results in a strong and sturdy material (i.e., corrugated board), which can be used to create pieces of the desired shape and size for the final container. The container pieces can be joined using a variety of methods, including glue, staples and other fasteners, or tape. The resulting container is capable of enduring the stresses experienced during shipping (e.g., bumping, crushing, and falling), so it can be used to product packaging and shipping operations.

    Why Choose Corrugated Boxes?

    There are many advantages to choosing corrugated boxes to package products, such as: 

    • Greater product protection. The multi-layer materials used for corrugated boxes provide greater strength and support than the single-layer materials used for cardboard boxes. As a result, corrugated boxes are better at protecting their contents from harsh conditions, such as those experienced during shipping operations, than cardboard boxes.
    • Broader customization options. Since corrugated boxes are made from multi-layer materials, there are more opportunities to customize the container design. The type of liner material used, the profile of the fluting, and the combination of liner-fluting layers can be tailored to achieve different functional and aesthetic characteristics. The corrugated board can be further customized with graphics and coatings to suit a specific product or brand image.
    • Better eco-friendliness. Corrugated board is highly recyclable. New corrugated boxes are generally made from a combination of virgin and recycled materials, which often makes them a greener product packaging option.

    Corrugated Boxes, Cartons, and More From Axis Corrugated Container

    Now that you know the differences between cardboard boxes and corrugated boxes, you can select the container solution that suits your product needs. If you’ve chosen corrugated boxes, Axis Corrugated Container is the ideal partner. Our extensive design and manufacturing capabilities, combined with our in-house graphic and printing capabilities, enables us to provide corrugated container solutions for a range of customer applications. We can support short-run or long-run production of standard or custom products. Whether you require a basic container or an out-of-the-box solution, we’ve got you covered. 

    To learn more about our corrugated product solutions or discuss your packaging requirements with one of our representatives, contact us today. 

  2. How Can a Packaging Assessment Save Me Money?

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    You stick your product in a brown box, stuff in some bubble wrap, tape it up, and you’re good to go, right? Not so fast. If this is your method for packaging your product, you could be costing yourself more than you realize.  

    A packaging assessment can reveal the opportunities where changes could save you money and create greater efficiencies. 

    Here is What’s Involved

    First, we need to get to know you, your processes, and your products. There is no one size fits all solutions. Some of the areas that we evaluate include packaging optimization, SKU management, and supply chain management.  Changes in any of these areas can bring long-term cost savings. 

    Packaging Optimization

    It is so disappointing for someone to open a box and find that the product is damaged because it wasn’t packaged correctly. This can result in lost future sales and tarnish your brand. But damaged product isn’t the only reason to optimize your packaging. Some other considerations include:

    • Over Packaging – It is good that you don’t see goods damaged in shipping, but you need to find the right balance. Extreme packaging is costing you, too. Ensure the corrugated board type (single wall, double wall, etc.), flute size, and materials are appropriate for the product you are shipping. 
    • Wrong size boxes – Off-the-shelf boxes may require a lot of dunnage and packaging materials to keep your product from moving around. By optimizing the packaging for your product, you reduce the amount of corrugated board needed, reduce the internal packaging component, reduce your box’s footprint, and make it lighter. These changes can reduce material costs, reduce transportation costs, and are good for the environment.
    • Wrong type of box – Not all boxes are created equal. There are many types of corrugated boxes –regular slotted containers, telescoping boxes, wrap-around boxes, self-erecting die-cut boxes, and many more. Make sure your box is suitable for your product. Sometimes changing the box type can eliminate a step such as taping or gluing. 
    • Line inefficiencies – Is your box working efficiently with your packaging line. Sometimes changing the box can improve efficiency or reduce ergonomic hazards for employees.

    SKU Management

    A different box for every product may not be necessary. It may be possible to combine SKUs with minimal impact on the packaging of the product. One way this can be done is with multi-depth boxes. It has additional score lines in intervals down the side of the box, allowing you to change the size to fit the product. Consolidating SKUs may allow you to get volume pricing. 

    Supply Chain Management

    Optimizing your supply chain from corrugated inventory to palleted product can reduce costs. 

    Inventory Management

    If you are purchasing truckloads to save a few pennies per box, you could be losing money. Thinking you will eventually use them ties up warehouse space and can lead to waste through obsolescence or deterioration – box strength diminishes over time. Inventory management programs can ensure you get the boxes you need when you need them. 

    Pallet Yield

    Maximizing pallet yield impacts the supply chain from warehouse storage, trailer utilization, and distribution. However, you don’t just want to stack as many products on the pallet as possible. Choosing the appropriate stacking method, minimizing overhang or underhang, and being mindful of trailer capacity and specification can reduce transport costs.

    Why Axis Corrugated Container?

    We understand the factors that increase total costs and reduce those costs for our customers. In addition to providing packaging assessments to reduce costs, we also: 

    • Reduce lead times 
    • Have a streamlined job workflow, which minimizes production costs and speeds job processing 
    • Provide quick response to urgent orders and unusual packaging challenges 
    • Stock an enormous inventory of corrugated boards and materials, which enable us to fulfill short turnaround and specialty orders quickly 
    • Provide just-in-time delivery and next day turnarounds in many cases 
    • Ensure you always have the boxes that you need through inventory management
    • Improve logistics with our extensive fleet of trucks and dependable logistics partners

    Ready to see how a packaging assessment can save you money? Contact us to get started.

  3. Is Your Corrugated Supplier the Right Type For Your Needs?

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    The raw materials used to manufacture corrugated board come from cellulose fiber from wood. The corrugated is processed into boxes, which are used to hold and protect products. However, not all boxes are created equal, and the best value for you will and where you ultimately purchase your boxes depends on your needs.

    There are two categories of corrugated manufacturing companies:

    Integrated – The mammoths

    Integrated corrugated manufacturers can be giant corporations and tend to be publicly traded. This company is vertically integrated and does it all from forestry to finished box. They may own the forest, several paper mills, sheet feeders, corrugator plants, and sheet plants. Not only do they use the containerboard they make, but they also sell it. 

    Independent – Smaller but highly flexible

    Independent corrugated manufacturers are smaller and tend to be privately or family-owned businesses. They purchase raw materials to make finished products. The majority are sheet plants, but they may own a paper mill and operate a corrugator. 

    According to the Fibre Box Association, an independent buys “more than 50% of the raw materials from other companies and then produce their own finished products.”

    Within those two categories are three types of plants.  Sheet feeders only make corrugated sheets that they sell to sheet plants to make boxes or other corrugated products. Corrugated plants make corrugated board, like the sheet feeders, but it also makes boxes and other corrugated products. It may also sell sheets to other box plants. And the third is a sheet plant, which purchases corrugated board and makes boxes or other corrugated products. 

    So, what does this mean?

    When it comes time for you to evaluate your corrugated box supplier, how do you know which is best for you? The primary decision is whether to go with an integrated or independent company. The level of customization and personalization differs between them. 

    First, you need to prioritize what is most important to you? Are you concerned about lead times, or is unit pricing the only thing you consider? Do you need to ensure your products aren’t damaged in shipping, or are your products lower value where off-the-shelf boxes will do?

    Integrated companies are huge and tend to have less flexibility, but they may give large volume discounts. 

    Best For:

    • Very high volumes with little customization 

    Not So Good For:

    • Smaller volumes – Integrated companies tend to give preference to higher volume customers leaving smaller volumes with extended lead times. 

    Independents have much more flexibility and often offer additional services and a personal touch. Shorter lead, times, packaging optimization, and other benefits can reduce a company’s total costs. 

    Best For:

    • Small to medium volumes
    • Optimized packaging
    • Companies that evaluate total landed costs

    Not so good for:

    • Companies that evaluate cost solely on unit price

    Consider Axis Corrugated

    As a privately held independent corrugator, we strive to deliver cost savings through shorter lead times and optimized packaging that best fits your needs. If you have had it with long lead times, low quality, and slow response time, give us a call and let’s get started on unfolding endless possibilities. 

    You will receive greater value, though:

    • Reduced lead times
    • Optimized boxes and DIM factors, which reduce packaging waste and improve logistics costs
    • Our streamlined job workflow, which minimizes production costs and speeds job processing
    • Quick response to urgent orders and unusual packaging challenges
    • Our enormous inventory of corrugated boards and materials, which enable us to fulfill short turnaround and specialty orders quickly
    • Just-in-time delivery and next day turnarounds in many cases
    • Inventory management, ensuring you always have the boxes that you need
    • Improved logistics with our extensive fleet of trucks and dependable logistics partners
  4. Many Companies Miss This Key Method For Saving Money On Packaging

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    Product packaging is the often underappreciated hero of the product life cycle. Without proper packaging, most products would never make it safely through transit to the end user. But when it comes to sourcing packaging, some companies look for the lowest unit price. We support not wanting to overpay for packaging, but many fail to realize that the lowest unit price may carry the highest total costs. 

    Analyzing your packaging options before making a decision is prudent. When you evaluate total cost, don’t forget to include the avoidable cost in the analysis. An avoidable cost is an expense that will not be incurred when a product or activity is continued. Deciding to discontinue a product or activity, such as changing your packaging vendor, will eliminate or reduce these costs.

    When comparing packaging, you should look at all activities that are increasing your total costs or that may potentially decrease your total costs. Here are some things to consider that may be increasing your total costs.

    Packaging Design

    If your packaging vendor offers design services, there are several opportunities to reduce your total costs. Optimized packaging design can reduce product damage and returns, excess inventory, material waste, packaging line inefficiencies, and shipping and handling costs. 

    Optimizing your packaging design isn’t just ensuring your product arrives without damage. It takes it a step further by reducing material, footprint, and weight while maintaining protective properties. Internal packaging (dunnage, partitions, etc.) may be changed or reconfigured. It may be done for one product in one box, or you may decide that it makes more sense to package multiple products together for better efficiency and cost savings. 

    The design also impacts how your boxes flow through your packaging line. If your packaging is creating bottlenecks or inefficiencies on your line or ergonomic issues for your employees, you may have opportunities for cost savings through packaging optimization. 

    Your packaging designer may also help you to combine SKUs for similar products. This can help with inventory management costs and prevent waste (costs) in the case of product obsolescence. Optimizing your packaging can also maximize pallet configuration and DIM factors, which all lead to lower shipping costs. 

    Minimum Quantities 

    Consider the minimum quantities you are required to purchase to get the lower unit price. The most obvious reason to buy only the quantities of packaging you need is to optimize cash flow. But there are even more compelling reasons.

    If you are required to purchase more than you can use, you increase your risk for product damage and returns. After only 90 days, 40 percent of a box’s stacking strength is lost. If your warehouse doesn’t have environmental controls (i.e., temperature and humidity), that percentage is much higher. The higher your product costs, the higher these costs associated with damage and returns will be.

    The third way minimum quantities cost you is through managing excess inventory. You have to store it, which means space can’t be used for something else – like a saleable product. If your product becomes obsolete, you are stuck with the packaging you have paid for that becomes waste.


    It goes without saying that delays cost you in many ways. You may have to pass those delays off to your customers, who may go elsewhere. You may have to pay expedited shipping costs to make up for the delay to keep your customers happy. Unexpected things happen, and if a project shifts or unexpected orders happen, can the packaging vendor meet your needs on time?

    If you plan well and all your orders are reoccurring, but your packaging vendor’s lead time is inconsistent, you may find you need to have excess inventory on hand to ensure you don’t run out before the next delivery. You are faced with the same challenges, such as the risk of obsolescence, reduced stacking strength, and the cost of warehouse space.

    Calculating Total Costs Paints the Full Picture

    In addition to the unit price, by taking into account costs associated with packaging design, minimum quantities, and late deliveries or long lead times, you will have a better idea of what your packaging is costing you. You may even want to go a step further and see if poor communication and customer service add to your total costs.

    Axis Corrugated Container Can Reduce Your Packaging Total Cost

    As a valued supplier of custom and standard die-cut, flexo, and specialty corrugated box and display products, we understand the factors that increase total costs and reduce those costs for our customers. Some of the ways we do this are through: 

    • Reduced lead times
    • Optimized design and DIM factors
    • Our streamlined job workflow, which minimizes production costs and speeds job processing
    • Quick response to urgent orders and unusual packaging challenges
    • Our enormous inventory of corrugated boards and materials, which enable us to fulfill short turnaround and specialty orders quickly
    • Just-in-time delivery and next day turnarounds in many cases
    • Inventory management, ensuring you always have the boxes that you need
    • Improved logistics with our extensive fleet of trucks and dependable logistics partners

    We would love to help you reduce your total packaging costs. Contact us to get started.

  5. Axis Corrugated Container Named Manufacturer/Distributor for Lifdek Containerboard Pallets

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    Lifdek Containerboard Pallets

    BUTNER, North Carolina — Axis Corrugated Container, a leading manufacturer of custom and specialty corrugated packaging, is pleased to announce a manufacturing and distributing agreement with Lifdek Corporation, an innovator in pallet technology. As a licensed manufacturer and distributor, Axis can produce and ship Lifdek’s revolutionary site-assembled Lifdek containerboard pallets to customers in the Southeast at a fraction of the cost of timber pallets.

    “We are excited to become part of this unique network of eco-friendly pallet manufacturers and distributors,” said Scott Russell, president of Axis. “Lifdek has engineered a unique, low-cost, high-performance pallet. Axis is dedicated to providing customers with flexible corrugated solutions that meet their needs for performance, sustainability and cost-efficiency. At the same time, ventures of this sort reflect the company’s expansion beyond the ‘box-buying’ market we currently serve.”

    Lifdek pallets perform like wood pallets, yet they are cleaner, safer and more sustainable than wood systems,” added Russell. “Our existing and new customers can save time and money by taking advantage of Lifdek’s durable, lightweight pallets and Axis’ production capacity, fast turnarounds and short shipping distances. Plus the environmental advantages of these pallets fulfill our commitment to sustainable business practices.”

    Lifdek Manufacturer

    Based in Melbourne, Florida, Lifdek offers on-demand containerboard pallets designed to be assembled by hand or by machine at the point of use. Lifdek pallets are capable of handling fast-moving, high-volume static load configurations up to and exceeding 2000 pounds.

    The pallets consist of die-cut top and bottom pallet blanks that Axis produces at its Butner plant. The tops and bottoms are shipped knocked-down flat ready to assemble, making them easier to transport, handle and store until needed. A typical cargo-carrying semitrailer holds 2,520 Lifdek pallets, more than four times as many as manufacturers of wood pallets can ship by the same method.

    Lifdek pallets fold together quickly on Lifdek assembly tables or Lifdek assembly machines at the user site without the application of adhesives or staples. Two assemblers can put together one pallet a minute on the Lifdek assembly table. The Lifdek machine can assemble a pallet in just under 60 seconds with a single operator.

    “Lifdek set out to develop the best possible containerboard pallets featuring the necessary load capacity, lowest amount of board and easiest onsite assembly,” said Joseph Danko, the company’s president. “We believe that our cost-effective business model of utilizing the infrastructure of corrugators that produce boxes to produce our die-cut top and bottom pallet blanks will encourage widespread adoption of corrugated pallets. The Lifdek system is a logistics cost-savings solution.”

    About Lifdek Corporation

    Lifdek is a developer of corrugated pallet technology that enables companies to reduce their logistics costs and pallet-related liabilities. Lifdek pallets can be uniquely and completely assembled onsite prior to use. The patent-pending pallets are available worldwide.

  6. Fast Action Overcomes Bottleneck, Puts Company Back in Snacks

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    The last thing a consumer products company wants is an idle production line. But sometimes employee productivity is too good for its own good. This rare occurrence recently happened to a popular snack food maker, when the workers got out ahead of their equipment.

    As a result, the demand for box dividers exceeded the supply by 400 dividers. The throughput choke threatened to shut down the line.

    Axis received the distress call at 4:30 in the afternoon and immediately sprung into action. A simple, hands-on solution presented itself. An Axis team member carefully hand packed his SUV with the 400 dividers that the customer needed. He then hopped into the driver’s seat and piloted the vehicle to the production site.

    By 8:30 p.m., the line workers were fully outfitted again. This is a good example of how Axis drives customer loyalty.

  7. TonyP

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    Being one of fastest growing manufacturing and distribution centers in the Triad area, we could not have accomplished what we have without the great production and management support and prompt deliveries from Axis. Their quality and pricing are outstanding for this region. Employees — from the office to the production floor to the delivery personnel — are always kind and courteous. We throw unplanned challenges their way, and they respond every time with success. Axis is very good at meeting and most of the time beating the committed delivery dates. Each time we have a one-off project, they meet our requirements and timeline so we can deliver to the end customer on time. Axis is a great partner. We plan to grow together and continue to present even more challenges to them in the coming years.

    Tony P.
    Supply Chain

  8. Same-Day Delivery Brings Super Smile to Supermarket Chain

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    BUTNER, N.C. — Axis Corrugated Container is a nimble company, which makes it a fast-turnaround expert. A major supermarket chain came to Axis looking for a way to meet its packaging obligations without interruption. The chain needed 10,000 more regular slotted cartons than its regular supplier could deliver, and needed them right away.

    To get the customer enough boxes to keep its packing line operating through the night, the Axis team pulled stock corrugated sheets from inventory and cut them down to the necessary specifications. An ample supply of sheets of various flute profiles is always on hand at the Axis facility in Butner, N.C., to accommodate emergency short runs like this one. With the clock ticking, a load of RSCs, 800 in all, was in the customer’s hands in plenty of time to greet the evening shift.

    The job wouldn’t be done, however, until the remaining 9,200 shipping cartons arrived at their final destination. Axis placed a rush order for board from its supplier and got to work making more boxes for the supermarket chain. The delighted customer had the completed shipment bright and early the very next day.

  9. MarkS

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    We want you to know how pleased we are with the level of service Axis provides. Rarely has a supplier given us such complete attention and cooperation. We have always been able to rely on your flexibility and outstanding service. Your staff consistently meets and exceeds our expectations. We appreciate your efforts and look forward to continuing our business relationship.

    Mark S.
    Merchandise Manager

  10. MikeM

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    Just wanted to take a moment to express my complete satisfaction with the excellent customer service Axis has provided to us. The nature of our ever-changing demands is much more than just a challenging task. On an almost daily basis, we are asking for rush items delivered to one or both of our facilities. I appreciate the efforts put forth by your team. Axis consistently exceeds the normal expectations placed on a supplier. Thanks again!

    Mike M.
    Inventory Planner

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