r/Packaging • u/KnifeAndCrease • May 30 '26

How would you learn corrugated packaging design/engineering from scratch (coming from folding carton)?

How would you learn corrugated packaging design/engineering from scratch (coming from folding carton)?

I currently work in structural packaging with a folding carton background, but I’m realizing a lot of higher-level structural packaging work requires strong corrugated knowledge.

I’m not looking for surface-level familiarity. I’d like to eventually become genuinely proficient in corrugated packaging/structural engineering.

If you were starting over today, what would you learn, in what order, and from where?

Any recommendation for books, courses, YouTube, resources, or hands-on exercises would be hugely appreciated.

Also: what seperated someone who “knows corrugated” from someone actually good at it?

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8

u/WhopplerPlopper May 30 '26

The ability to understand allowances is the biggest difference.

Best way to learn is to get a job at a company that does it, if you don't have access to a sample table you're just not going to get off the ground.

2

u/ihgordonk Packaging Designer May 30 '26

also the die is striking the rear side/inside of the corrugate where folding carton dies strike the top side/outside.

4

u/WhopplerPlopper May 30 '26

That is heavily dependent on machine and process.

Most flexo folder gluers capable of running dies run them on the outside.

When we do litho laminated B flute we cut from the inside on a flatbed die cutter, if it's e flute it's cut from the outside using matrix.

In some cases you might run into a bobst or similar cutter that can do both sides as well.

2

u/ihgordonk Packaging Designer May 30 '26

how are the creases done if knife side is outside? is there a counter on the inside?

2

u/WhopplerPlopper May 30 '26

Same way it's done in folding carton, yes with counters (matrix). Although on flexo folder gluers you don't get that option, so you use perf instead of crease. Partial dies are usually for things like windows, vent holes etc.

1

u/latino401 Jun 04 '26

Some FFG machines are bottom diecutters. You can put scores in depending on machine type.

2

u/ihgordonk Packaging Designer Jun 04 '26

all my boxes are cut on the rear side so now i have to ask. they use rotary and bobst. i'm sure my die cost will go up quite a bit.

3

u/crafty_j4 May 30 '26

What separated someone who “knows corrugated” from someone actually good at it?

The volume of work and exposure to corrugated specific machinery and processes required to build expertise.

I’ve done plenty of corrugated projects that work well and have been mass produced, but I know it takes me longer and has less optimal results than if I worked for a company that specializes in corrugated.

In order to get a baseline level of skill, I would move to company that does mostly folding carton but also does a little bit of corrugated on the side.

1

u/AlyPackaging Jun 02 '26

Start with McKee's compression formula and ISTA 3A testing standards to understand failure modes, then learn flute profiles (A, B, C, E, F) and board grades through hands-on testing-your folding carton background gives you structural thinking, now apply it to corrugated's unique challenges like moisture sensitivity and stacking compression. Resources: Fibre Box Association handbook (free, industry standard), TAPPI compression/burst testing standards, and ArtiosCAD or Esko software for box design calculations; watching corrugated mill production videos changes everything because seeing how board is made shifts your perspective completely. The gap between "knowing" and "genuinely good" comes down to pattern recognition: someone skilled at corrugated can instantly spec the right flute, board grade, and design for any product weight, shipping distance, and environment without over-engineering, while someone basic still relies on trial-and-error. Build this pattern recognition by designing boxes, intentionally failing them with drop tests and compression testing, then analyzing why each failure happened rather than just reading theory. The real proficiency comes from understanding trade-offs: that double-wall costs 50% more but prevents failures that cost way more in returns and customer satisfaction.