Posted on January 27, 2023 by Michael Boik

Corrugated Board Fluting Options and Applications

It is probably a topic we should cover with more regularity, as fluting is often the unnoticed or forgotten component of mailer boxes. Attention is typically paid to every other aspect of the mailer box. The board color inside and outside. The printing and graphics inside and outside. The size of the mailer, as well as the style. But fluting can be just as important as these other points of focus, especially for that all important balance we often talk about: the balance between product protection and presentation during shipment.

Many first-time packaging buyers may not realize there are different board flutes, or fully understand the options or benefits/drawbacks of each. As always, there is no one size fits all solution when it comes to fluting. The product being shipped will play as big of a role as any other factor when determining the best solution.

C Flute

Of our vast collection of cutting dies, only about 2% are comprised of C Flute cutting dies. This is truly a rare fluting to be seen in a die cut mailer, and most items that are being shipped in a mailer are not heavy enough to warrant the need for C flute. Having a C Flute box will certainly make your box heavy, strong, durable and for lack of a better word, bulky, in appearance, but it could be ideal for large mailers or RSCs shipping heavy products.

B Flute

Our most common fluting, comprising over 50% of our cutting dies. B flute is versatile, in that it can be used on some very large mailers, as well as smaller mailers, and all sizes in between. As a rough guideline, B Flute can accommodate products ranging up to about 30 lbs. Books, many glass products, jars, clothing and food products are all commonly shipped in B Flute die cut mailers.

E Flute

Almost as common as B Flute, and certainly the one that has become most popular in recent years is E Flute (read more about the trend in the first link under related posts below). Many cosmetic and beauty brands have made the transition from B to E in favor of a sleeker, slim, more attractive mailer where the fluting is less noticeable to their customers/end users. Of course, with a thinner fluting, there is some protection lost between B to E, but E flute boxes can still be very safe and effective, given the right ship-testing and structural design attention. This often involves creating an insert to hold the product, especially if it’s a glass or breakable product, to ensure it remains secure and safe during shipment.

Microflutes (N and F)

We do have the ability to create a die cut mailer in a microflute such as N or F Flute. These would not be recommended for any heavier products or fragile items, but could be ideal for retail applications such as CDUs and other boxes that either may not be mailed, or could be placed within an outer box or bag/envelope before shipping.

Double Wall

In certain RSC applications where the product is heavy, a double wall box may be appropriate. This is essentially two layers of flutes (commonly B and C) together for added protection, strength and stability.

Triple White Board

This is strictly on the presentation side of the scale, as triple white board does not factor in terms of a protection standpoint. Triple white just means that the fluting is white to match the board liner, thus creating a box where the fluting truly can go unnoticed. You can read more about triple white board here.

Want to know more about corrugated board fluting options? Contact us below and we can give you a no cost, no obligation consultation. We have over 230 cutting dies in a variety of flutes, as well as the ability to customize fully, meaning a new size with the fluting of your choice, with the purchase of a new cutting die.


Please Contact Us Today

As always, if you have any questions, one of our branded packaging advisors is standing by to assist, with decades of experience behind them. Want to know more about custom packaging options? Please call us at 630-551-1700 or contact us via email at


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