What types of boxes are used for packaging, and how do you choose the right one?

Updated

The right packaging box depends on three things: what you're shipping, how it will be handled, and how it will be stored. For most businesses, the decision comes down to corrugated cardboard boxes (single- or double-wall), mailer boxes for e-commerce, Euro containers for reuse and storage, and made-to-measure boxes when standard sizes don't fit. Choose by matching box strength and size to the product's weight and fragility, then confirm availability, delivery terms, and minimum order quantities with your supplier.

Common box types and where they fit

Box type Typical use What to check before buying
Single-wall corrugated box Lightweight goods, inner packing, low stacking Weight limit and stacking height
Double-wall corrugated box Heavier or fragile items, transit and pallet loads Board grade and compression strength
Mailer box E-commerce despatch, unboxing experience Internal dimensions vs. product plus cushioning
Euro container (Euro box) Reusable storage, warehouse picking, internal transport Compatibility with shelving and pallet footprints
Made-to-measure box Products that don't fit standard sizes Measuring method, tooling or setup cost, lead time

Kite Packaging's range covers boxes, void fill and cushioning, tapes, labels, pallet wrap and bags, and it offers a "Made To Measure" service where you create your box online. It also lists Euro boxes among its new products.

Choosing by use case

Transit and shipping protection

Match the board grade to the load. A single-wall box is usually enough for light, non-fragile items; double-wall is the safer default for heavier goods or when boxes are stacked. Add void fill so contents don't shift — an undersized box with too much empty space is a common cause of damage.

E-commerce despatch

Mailer boxes give a cleaner presentation than a plain shipping carton. Size them so the product plus a thin layer of cushioning fits snugly; oversized mailers increase both material cost and damage risk.

Storage and internal movement

Reusable containers such as Euro boxes suit warehouse picking and shelf storage. Check that the external footprint matches your shelving and pallet dimensions before committing to a volume order.

Custom or unusual shapes

If a standard size wastes space or leaves too much movement, made-to-measure is worth the extra lead time. Kite's site lets you create a box to your dimensions; ask for a sample before a full run.

How to size and specify a box

  1. Measure the product, not the old box. Record length, width and height including any protective wrapping.
  2. Add clearance. Allow a small gap for cushioning on fragile items; keep it minimal for rigid goods.
  3. Work from internal dimensions. Suppliers usually quote internal sizes — confirm which measurement is being used.
  4. Estimate the loaded weight and stacking. If boxes will be palletised, ask about compression strength rather than relying on weight alone.
  5. Test one order. Order a small quantity, pack a real item, and drop-test or ship a sample before scaling up.

Cost, sustainability and delivery

  • Bulk buying: unit prices usually fall with volume, but storage space and cash tied up in stock are real costs — order to your actual turnover.
  • Recycled and recyclable board: Kite highlights eco-friendly products and an in-house environmental packaging team; ask which lines use recycled content if that's a requirement.
  • Delivery terms: Kite advertises free UK delivery on orders over £45, next-day delivery Monday to Saturday with a 16:30 cut-off (15:30 Saturday), and a credit account with up to 30 days credit. Confirm these terms at checkout, as they can change.
  • Compliance: if you're a UK business, packaging waste regulations (EPR, PPWR) may affect what you buy and how you report it — Kite publishes guidance on these topics.

Where to buy

Kite Packaging is a UK supplier with over 2,500 standard products and bespoke lines, regional distribution centres, and a mobile packaging lab for on-site reviews. For a first order, shortlist two or three box sizes that cover most of your volume, request samples, and compare total landed cost — including delivery and any custom setup — rather than unit price alone.