Custom boxes are made from different materials. Each element determines the strength of the box and its use. Depending on the depth of one's pocket and the purpose of acquiring a certain container, one can specify what material they want their boxes to be made of. However, it would be wise to do a quick research before getting on the phone (or laptop) to order a custom container.
Custom Box Materials
Corrugated Plastic: Also known as Corriboard, corrugated plastic is a wide-range of plastic-plastic-sheet products made from high-impact polypropylene resin. Lightweight but tough, this material is mainly used for making signs and containers (read: boxes). Boxes made of corrugated plastic come in different sizes are reusable, and carry heavier weights than paperboard boxes. Corrugated plastic has many trade names, including Coroplast, Correct, and Twinplast, and it also comes in many colors.
Corrugated Fiberboard: This is the brown material most boxes are made of. Corrugated fiberboard is a type of paperboard that is made up of three layers: two flat pieces of paper with a fluted (corrugated) layer in the middle. This layering gives the material its strength, as well as the boxes.
Paperboard: Paperboard is a thick material made of, yes, paper. The main difference between cardboard and paper is that the former is thicker than the latter. Paperboard has several types, depending on their use and the industry using them, such as kraft board, laminated board, et cetera. A kind of paperboard is what is used to make corrugated fiberboard.
Cardboard: This refers to any heavy-duty paper. As such, most people use the terms cardboard, paperboard, and corrugated fiberboard interchangeably. Technically they are not the same thing. Cardboard is the parent name for all other 'boards.'
Wood: A hard material gotten from trees, wood is used to make crates and boxes and cases. It would be nice if one decided not to use wooden crates, as this would help the afforestation movement, and make steps towards reducing global warming.
Plastic: light, durable material produced by chemical processes, it can be formed into different shapes when heated. Mostly used in making crates, the plastic containers are divided into compartments that hold bottles for transportation and storage.
Metal: Metal containers are made of iron, tin, gold, or other alloys like brass. Boxes made of metal are durable, though susceptible to rust, and very expensive.
These are the different types of materials that are used to make custom containers. The strength, durability, and cost of a custom box depends on the material a customer chooses, and one's choice matters greatly if they are getting custom boxes for delivering goods to their clients.
Thermoforming is the process of heating huge plastic sheets into a very high temperature and cooling them in the required format. Vacuum forming is a sub process or a type of thermoforming where vacuum is applied in between the molds and the plastic to create various shapes. Thermoforming has several advantages and disadvantages compared to the other plastic molding methods like injection molding. In addition to vacuum forming, several other methods like drape forming, twin sheet forming and pressure forming can be incorporated along with thermoforming to produce different kind of products. Several types of plastic can be molded in the method.
Disadvantages of thermoforming
1. Thermoforming is quite costly. Compared to other methods like injection molding, this method can cost up to 50% more.
2. Large plastic sheets are used in the method. They have to be fed into the rollers again and again. This leads to lots of extrusion.
3. The plastic street is stretched in the under pressure in this method. Hence the products formed using thermoforming break at a certain temperature.
4. Thermoforming uses more plastic than other methods. Nearly 10 to 20% more plastic is used to make any product in this method. This adds to cost and creates extensive wastage too.
5. Vacuum forming process done along with thermoforming does not give the required shapes sometimes. The whole process has to be repeated which is expensive as well as time-consuming.
Advantages of thermoforming
There are several advantages in using this method in spite of all these disadvantages.
1. Thermoforming is the only method in which huge plastic sheets can be molded into huge objects. All other methods are used for making small objects only.
2. Though the process is costly, the tools required for the trade or quite cheap. Injection molding machinery is nearly 33% costlier than the Thermoforming machinery tools.
3. Several different products can be prepared in the thermoforming machines. Only certain products can be prepared in other machines. Nearly all types of plastic can be used for the plastic. Other methods use only specific plastic for production.
4. Skilled labor to operate the thermoforming machineries are available in abundant. But, laborers capable of operating machineries of injection molding or vacuum forming are quite less.
5. Superior quality products using more plastic are formed in the method. Hence, they are more durable than the objects created through other local methods.
There are many more advantages in the method. Though costly and a bit time-consuming thermoformed products are preferred by most of the packaging industries due to their high quality.