Every day our teams process many different types of board grades through our manufacturing processes to fulfil customers corrugated packaging requirements.

But what do the different types of board grades mean and why do they have such an impact on the packaging design and performance?

Here’s a quick overview of corrugated board and how we help our customers get the packaging they need.

Here’s a quick overview of the key parts of the process.

Paper types

All board grades are made using a combination of sheets of paper, referred to as liners, that are glued together with adhesive to a corrugated inner, referred to as fluting.

Two of the most common paper types, referred to in board grades are Kraft paper (chemically processed) which is typically is used for the outer liner of the board. This paper type is made from softwood and gives a smooth finish, ideal for printing. Test paper has a less smooth finish as it is made from hardwood or recycled paper which has shorter fibres. This is typically used for the inner liner or fluting.

Corrugators process either three or five reels of paper simultaneously to produce either single wall (two liners and one fluting) or double wall (three liners and two fluting).

The process

Firstly, reels of paper are loaded into the ‘wet end’ of the corrugator. Initially, the paper is treated with heat and steam to make it more flexible to allow for easier fluting before being fed into the single facer.  The single facer is the part of the corrugator that creates a series of arches (fluting) created by large rotating cylinders with a corrugated profile thereby creating the grooves. Different cylinders with different profiles create the different flute types.

At the next stage, adhesive is applied to the tips of the flute, and the first liner is pressed onto the fluting. A combination of steam, heat and pressure adheres the paper to the fluting to create a strong bond. This single face board, the first stage of any corrugated board production process continues its journey down the corrugated where a second liner is applied using the same methods. Less pressure is applied at this stage, so the flutes are not crushed.

To manufacture double wall board, both corrugator’s single facers will be running which delivers two single face webs to the bridge part of the corrugator to be joined together at the double glue unit. It is at this stage that the outside or double-faced liner will be joined to the single face web.

Finally, the board is cut to size both the width (deckle) and length (chop). The required sheet sizes are then palletised and ticketed for onward shipping to our sheet plant customers.

Strength and durability

Through the innovative use of different flutings, varying degrees of strength are achieved which gives corrugated its strength when used by sheet plants like us to manufacture corrugated boxes and packaging solutions.

Different board grades are achieved by putting different paper weights and grammage through the corrugation process.

How we help our customers

If our customers are new to corrugated board, or indeed just want some professional advice, our design and sales teams have very knowledgeable as to how the different types of corrugated board perform in a huge array of designs and scenarios.

This is why the consultation and design process is so important to us and our customers. By ascertaining all the key facts, understanding how the packaging is used, how it travels through the supply chain and how the product is packed and unpacked helps our team to design and manufacture corrugated packaging that truly adds value.

We have some superb vacancies available currently for Production Operators and a Multi-Skilled Engineer.

Check out the job descriptions below and if you’d like to apply, please email mthomas@thecardboardbox.co.uk

Full time Production Operator

Shift Pattern: Days and afternoons + permanent night shift

About the Role

We are looking for a reliable and motivated Machine Operator to join our production team. You will be responsible for running and maintaining a variety of machinery used in the packaging and print manufacturing process, including:

• Bobst machines
• High Quality Printing & finishing equipment
• Cardboard conversion machinery
• Casemakers
• Strapping & packaging equipment
• Compressors (basic operation and monitoring)

This is an excellent opportunity for someone who enjoys hands-on work, problem-solving, and being part of a fast-paced production environment.

Key Responsibilities

• Operate production machinery safely and efficiently.
• Set up machines for new jobs, ensuring correct materials, settings, and specifications.
• Monitor machine performance and quality throughout the production run.
• Make basic adjustments to maintain product quality and minimise downtime.
• Report faults or maintenance issues promptly to the engineering team.
• Carry out basic cleaning, lubrication, and routine checks as part of daily maintenance.
• Record production data accurately, including counts, waste, and job times.
• Work closely with team members to achieve production targets and deadlines.
• Maintain a clean, safe, and organised working environment.
• Follow company procedures, quality standards, and health & safety rules.

 

Skills & Experience Required

Essential:

• Previous experience working in a fast-paced manufacturing, print, or packaging environment.
• Ability to operate or assist with industrial machinery.
• Good mechanical aptitude and willingness to learn new equipment.
• Strong attention to detail and commitment to quality.
• Ability to work both independently and as part of a team.
• Basic understanding of health & safety in a production setting.

Desirable:

• Experience operating Bobst, folder-gluers, die-cutters, printers, or casemakers.
• Background in corrugated or print manufacturing.
• Forklift licence (or willingness to train).
• Previous experience with machine setup/changeovers.

 

Personal Attributes

• Reliable, punctual, and hardworking.
• Positive attitude with a willingness to learn.
• Good communication skills.
• Ability to stay calm under pressure.
• Takes pride in producing high-quality work.

 

What We Offer

• Competitive salary and overtime opportunities.
• Company pension scheme – 5% employee and 3% employer.
• Death in service – 4 x salary.
• Health and Wellbeing app access We Care.
• Training and professional development opportunities (OEM training available).
• A supportive team environment.

 

Full time Multi-Skilled Engineer

Shift Pattern: Days and afternoons – 06:00 to 14:15, 14:10 to 22:30 + possible on call

About the Role

We are looking for a highly capable Multiskilled Engineer to join our dynamic engineering team. This is a hands-on role supporting a wide range of industrial equipment used in the packaging and print production environment. The successful candidate will be responsible for the maintenance, repair, and optimisation of machinery including:

• Bobst Machines (folder-gluers, die-cutters, etc.)
• Compressors
• High Quality Printing Machines
• Cardboard Conversion Machinery
• Casemakers
• Strapping and Packaging Equipment

If you thrive in a fast-paced production environment and enjoy working with varied, complex machinery, this role is for you.

Key Responsibilities

• Carry out planned preventative maintenance (PPM) and reactive maintenance across all equipment.
• Troubleshoot mechanical, electrical, pneumatic, and hydraulic issues.
• Reduce downtime by diagnosing faults quickly and implementing effective solutions.
• Support production teams during machine setups, changeovers, and performance improvements.
• Maintain documentation including maintenance logs, parts usage, and service reports.
• Ensure compliance with health & safety standards and company procedures.
• Contribute to continuous improvement projects to enhance machine reliability and efficiency.
• Liaise with suppliers, OEMs, and contractors when required.

Skills & Experience Required

Essential:

• Proven background as a Multiskilled Maintenance Engineer or Service Engineer in a manufacturing environment.
• Strong mechanical and electrical fault-finding capabilities.
• Experience with one or more of the following:
• Bobst or other folder-gluer/die-cut machinery
• Print machinery or finishing equipment
• Corrugated cardboard production or conversion
• Casemaking equipment
• Industrial compressors
• Strapping/banding machines
• Ability to read and work from engineering drawings (mechanical/electrical).
• Knowledge of pneumatics and hydraulics.
• Strong problem-solving mindset with a focus on continuous improvement.

Desirable:

• Experience within the packaging, print, or corrugated board industries.
• PLC understanding (inputs/outputs, basic fault finding).
• Relevant engineering qualifications (NVQ Level 3, HNC, or equivalent).
• 18th Edition wiring regulations

Personal Attributes:

• Proactive and self-motivated.
• Strong communication skills with the ability to work cross-functionally.
• Able to manage time effectively in a busy environment.

Kris Howson, who has been with the business for 15 years, has moved into a new role as Continuous Improvement Manager.

His design experience and knowledge of all the production capabilities of the business means he is well placed to develop and implement strategies to maximise output.

Initially, Kris will focus on the manufacturing element of the business focusing on improving machine performance, increasing running speeds, reducing waste, tightening up processes, and standardising best practice.

Commenting on his new role Kris said, “It’s very hands-on with the crews, reviewing layouts and workflows, and ensuring the correct systems are in place to ensure we are operationally efficient.

“A key part of the role is acting as a link between sales, manufacturing, health and safety, and operations, making sure communication is clear, projects are clearly defined and implemented, and the teams are aligned to deliver those projects efficiently and safely.”

Kris is also overseeing the implementation of larger projects, onboarding of new key accounts coming into the factory and reviewing new machinery and upgrades to support the additional growth and maximise capacity.

Longer term, the role will extend beyond manufacturing into other areas of the business including sales and transport, so the business is as efficient as it possibly can be.

 

Daniel Johnston, Managing Director, The Cardboard Box Company said “We have some exciting plans for 2026 and beyond and it was necessary to have a single person who could co-ordinate performance improvement across the whole business, not just on the shop floor.

 

“We have a very good business and team here that is operationally strong. Now it’s about making those small incremental changes that will maximise our performance and efficiencies, delivering small gains that will make big differences.”

Casemakers are an integral part of many sheet plant operations and are suited to manufacturing larger volumes of standard FEFCO boxes.

Our two BOBST  – a BOBST924 and a BOBST618 – are both four colour rotary die cutters which operate at high speeds bringing great efficiency to our operations.

What is a casemaker?

A corrugated casemaker is specifically designed for the efficient production of corrugated boxes, often combining several processes such as printing, cutting, creasing, and folding in a single machine.

This integration of multiple functions within one machine allows for greater throughput and consistency, making casemakers particularly valuable in sheet plant operations focused on FEFCO box styles.

The BOBST four colour casemakers, such as the BOBST924 and BOBST618 which we have, excel in producing high-quality corrugated boxes by integrating printing, cutting, creasing, and folding processes. Their four-colour rotary die cutting capability allows for vibrant, detailed graphics and branding to be applied directly onto the boxes, while maintaining precision and consistency across large production runs. These machines operate at impressive speeds, significantly boosting efficiency and output.

Why is a casemaker a good piece of equipment to have.

A casemaker is an essential piece of equipment for several reasons.

• It has the ability to process large sheets and print up to four colours allowing for superb versatility in packaging design. This ensures that we can meet the diverse requirements of our customers, no matter how complex.
• The high-speed operation of the casemaker allows our highly skilled casemaker operators to produce large volumes of boxes efficiently and cost-effectively, which is especially important for businesses that require bulk packaging solutions.
• The precision and consistency offered by the casemaker ensures each box is manufactured to the highest standards, providing robust and reliable packaging that protects products during transportation and storage.

Supporting our high-volume packaging customers

For customers who require high volume packaging, our casemaker offers several key benefits. The ability to process large sheets and print in multiple colours allows for the creation of customised packaging that meets specific brand and product requirements.

The precision and consistency of our casemakers also guarantee that every box produced is of the highest standard, which is essential for protecting products during transit and storage. Yet the versatility of the casemaker allows for the production of a wide range of FEFCO box styles and sizes, catering to various packaging needs.

This flexibility means businesses can easily adapt their packaging solutions to different products and market demands. Overall, our casemakers are an indispensable tool in our machinery portfolio for customers requiring high volume packaging, offering speed, cost-efficiency, customisation, and high-quality output.

How we support our customers to benefit from our casemaker

We offer comprehensive support to ensure our customers can fully benefit from our casemaker’s capabilities. This begins with a thorough consultation to understand their specific packaging needs and requirements. Our team of experts works closely with customers to design and develop innovative and individual packaging solutions that align with their brand and product specification. We also advise on most efficient run volumes to ensure our customers packing and despatch lines keep flowing efficiently.

Depending upon volume and call-off requirements we also offer a stock-and-serve option to customers which may help to support their business operations.

Recognising that whilst there is a simplicity to products manufactured on our casemaker we also recognise the individuality it offers to our customers.

Simply, we work together to determine your requirements and find the best solution for you.

By partnering with our customers and providing the support they need, we help them leverage the full potential of our casemakers to achieve their packaging goals and drive business success.

We are very pleased to share we have retained the highest BRC accreditation at our most recent audit.

Visitors from the accreditation body for BRCGS called to do a full inspection and were delighted with the standards and procedures kept by the Cardboard Box team awarding them AA status for the third year in a row.

“Grading is achieved through a rigorous certification process and achieving the grade of AA BRCGS is a fantastic accomplishment by the entire team,” said Daniel Johnston, Managing Director, Cardboard Box Company. “Having the highest accreditation gives assurance to our customers that we operate at the highest standards, always.”

BRCGS is a globally recognised accreditation body that evaluates company practices and procedures to ensure they are operating at the required standards across all elements of the business including health and safety and legal requirements.

Customers also benefit from knowing that products are manufactured consistently to the highest standards of quality and safety. Furthermore, the team constantly strive to be the best in its field bringing confidence to the supply chain and beyond.

Daniel concluded; “This audit saw us have just one minor non-conformance. To achieve this status for the third year in a row highlights the commitment our team has to maintaining high standards.

“My thanks go to the Janine Bodill our Quality Systems Coordinator who managed the process on her own after the loss of a colleague in August, with support from the team and to the team for their professionalism towards the process throughout all that we do.”

BRCGS certification is used in over 130 countries across the globe and sets the benchmark for good manufacturing processes.

We are pleased to announce that Marc Stobbs has been appointed as our Head of Design.

Marc had been our Design Manager for the construction side for many years and joined the business in October 20024.

Now, Marc will also resume responsibility for the graphics side of the design, after the retirement of our Graphics Manager, Tom Penman, at the end of last year.

Marc commented’ “The constructional and graphic elements of design are closely intertwined for many of our customers so a cohesive approach between the two will allow the team to continue delivering success in this area of the business.

“I’m looking forward to the new challenge and working with the team to continue pushing the boundaries of packaging design and print.”

Marc is supported by Repro Designers Mark Greenwood, Nathan Czuczko and Sam Kearns along with CAD and Digital Print operator Lee Ullah and Junior Corrugated Packaging Designers Kelsey Ritson and Darcey Hudson.

Daniel Johnston, Managing Director, The Cardboard Box Company added; “Marc has a wealth of experience across all our design functions, and his calm leadership will ensure we continue to deliver the highest of standards with both our constructional designs and our print, both of which we are renowned for.”

To discuss construction and print design the team can be contacted on 01254 232223 or on info@thecardboardbox.co.uk

As 2025 draws to a close, so will the career of Tom Penman, our Graphics Manager.

Tom has been in the print and packaging industry for decades and has been award winning for his achievement.

We asked Tom to take us on a quick trip down memory lane, about where it all began, what happened in the middle and what retirement holds for him.

In Tom’s words –

My career in the print and packaging industry has been shaped by innovation, problem-solving, and a commitment to raising print quality standards.

Over the years, I have had the privilege of working with outstanding teams, major clients, and forward-thinking businesses across the UK.

I began my career at Outline Engraving in 1976 as a stereo hand engraver, crafting rubber stereos for corrugated printing. I could engrave so quickly that I earned the nickname “The Flashing Blade.” I later became Label Department Supervisor, overseeing artwork creation using traditional drawing boards, exposure frames, and step-and-repeat processes.

For the next decade, I managed the Repro Department, helping guide the shift from traditional methods to digital work. With the introduction of Apple Macs in the late 1980s I supported the move from analogue platemaking to the first CDI digital “computer-to-plate” technology.

As Business & Print Development Manager, I worked with clients across the UK to improve print quality, leading fingerprint trials and turning results into reliable artwork and plate specifications. During this time, we secured several premium accounts and set up on-site studios at locations such as Smurfit Tannochside, Smurfit Chelmsford, and Assi Cumbernauld.

After Pamarco acquired Outline Engraving, I continued supporting national clients, combining technical print development with sales in platemaking and anilox technology.

In 2001, I took on a major new challenge with my colleague John Brown at Excel Formes and Stereos (North), building a full manufacturing unit from the ground up. Over nine years, we developed in-house studios, advanced platemaking facilities, and—with John Tait on board—secured exclusive supply partnerships with TRM, Saica Wigan, Saica Ellesmere Port, and Saica Hartlepool.

When Excel North was acquired by Contact Originators in 2010, I continued as Business Development Manager, supporting key accounts and on-press development before moving to Chemence in 2011.

In 2012, I joined The Cardboard Box Company as Graphics Manager, overseeing artwork production and working closely with the print team to elevate print quality with the introduction of new presses.

Together with our talented teams and suppliers, we are pushing the boundaries of flexo printing and achieved award-winning results on the Bobst 618 and Bobst 1624 presses.

It has been my pleasure to serve the company for over 13 years. I’ve been incredibly fortunate to have the support of senior management, Peter Street, Ken Shackleton, and Dan Johnston, and to work alongside colleagues who have become not just teammates, but genuine friends.

I will always look back fondly on my years at CBC and remain deeply grateful for the opportunities, support, and friendships I’ve gained along the way. I have every confidence that the future holds even greater achievements for both the team and the business.

And as for me, after Christmas, my itinerary will be golf, travel, and “Homes Under the Hammer.” ?

Daniel Johnston, Managing Director, The Cardboard Box Company concluded; “We really miss Tom, not just for his exceptional skills and knowledge but also for his gentlemanly manner and calm, friendly personality.

“He’s been a trusted member of our team and we wish him a long and very happy retirement! With our best wishes to you Tom – thank you from us all.”

Inclusive Packaging is something of a new concept to elements of the packaging sector, however it’s something the team at Cardboard Box Company has been working on for some time to offer the best advice to our customers.

Essentially, designed to be more easily opened by everyone, accessible and inclusive packaging is becoming a much more popular request amongst our customer base. However, there are other elements that add value to customers who may face other challenges, not just dexterity ones.

Kristian Howson, Design Manager, Cardboard Box Company explains the steps we take to help customers achieve their accessible and inclusive packaging goals, and why many of our solutions already support this.

Empowering customers

Providing packaging that is accessible and inclusive is all about empowering the customer, allowing them to independently access products.

This is not just about how easy it is to open a box or pack; it can also be about improving how visible product information is by choosing clear fonts and appropriate font sizes, colour contrasting print to make it clearer, or including some tactile elements to help those who are visually impaired.

Many corrugated ecommerce solutions already support accessible and inclusive targets by way of ripper strips, easy peel open packs with self-seal strips and designs where every unnecessary complexity has been removed.

With over 16m people registered as disabled in the UK, it’s important that we make packaging as accessible as possible to help those with challenges such as decreased fine motor skills challenges or impaired vision as just two examples. And, with an aging population, it is likely in the next decade or so, these challenges could become more commonplace.

Something else to consider, which is becoming less common place in today’s digital world is to consider how you can make returning an unwanted product easier. Very few businesses now help consumers to return products with instructions or labels in the pack. Perhaps consider providing these, printed onto packaging to avoid unnecessary wasting of paper. It may just make the difference to customers who find it hard to access the digital world and be a differentiating factor when faced with a decision as to which product, brand or supplier to choose.

Maybe the wider packaging industry, and businesses who currently use other packaging materials that prove challenging to open and hard-to-recycle, could be adding value to their products by sourcing and choosing packaging which is accessible and inclusive.

Features to elevate the unboxing experience

There are several things’ businesses can choose to incorporate into corrugated packaging solutions to ensure they are inclusive and promote a positive unboxing experience rather than consumers fighting with packaging simply to access their goods!

As designers we always take many elements into consideration to create a design fit for purpose however, when specifically designed with accessibility and inclusivity in mind, we especially consider the following:

Flexibility – This means the design should support a range of different abilities and demands from the packaging depending upon the product size, shape, weight and fragility contained within the pack. Could tactile markings be incorporated into the design, so it appeals to an even wider audience?

Intuitive simplicity – This means the design should be easy to open in one or more simple steps and that this must be easily understand by all consumers, irrelevant of level of dexterity or other challenges they may be facing

Accessible print – Not only does the print on packaging need to convey the brand and make customers want to buy the product, but it should also consider colour accessibility and contrast especially where text is required. The typeface chosen should be as large and as clear as practical, whilst still ensuring the pack remains on brand.

 

In conclusion, businesses should consider how easy their packaging is to open, how easy it is to recycle and can the print be read with ease (especially important if vital instructions or safety warnings are conveyed on the packaging)

By embracing these points businesses will be supporting people with a disability to enhance the overall experience when receiving a home delivery or choosing a product in a retail environment.

Why not let our design team work with you to create and develop your own range of inclusive and accessible packaging?

We can be contacted on 01254 232223 or info@thecardboardbox.co.uk

It’s time to meet our Night shift supervisor, Paul Watson-Scholes.

Paul joined The Cardboard Box Company in Jun 2015 and became a skilled multi-point gluer operator, a key part of our service offering to customers.

Initially he worked on the Pacific and then moved over to the market leading BOBST Expertfold when that was installed. A move back to the Pacific in late 2020, when the night shift was established saw him then promoted to lead operator in 2021, and then supervisor in February 2023.

Paul’s supervisory role is key to ensuring the night shift achieves maximum productivity and that all work is completed ready for delivery to the customer. As the only nighttime supervisor in both factory and warehouse, Paul’s shift tasks are multi-faceted and include liaising with shift leaders either side for hand overs, targets for the shift and any challenges that be present.

Paul commented; “I deal with many queries overnight and with me being the most senior person on site, I have learnt to go with my gut instinct and to trust myself with the decisions I make.”

Alongside the day-to-day production Paul also schedules one to one meeting with his team every three months to provide feedback from both sides to ensure the team continues to perform at the highest level.

Paul added; “I love working at CBC. There’s a good work life balance and you feel like your work is valued. The atmosphere is positive, and no two days are ever the same. The leadership team is very understanding and supportive and I work with a great bunch of people.

“It’s been great to see some younger people begin their careers with us recently and I would encourage people to consider joining our industry which is so much more than a brown box. There’s such a wide range of jobs for them to do and if you work hard, great promotions can be had.”

 

Just for fun:

*If you didn’t work in corrugated, what would you do?

I’ve always fancied being a green keeper or groundsman.

*A fact that people may not know about you

I’ve run 2 marathons (London & Chester)

*What do you like to do outside work?

I’ve got in to running over the last 12 months. The furthest I’d ever ran was 5 miles, but I’ve now completed 2 marathons this year.

Me and my wife also love to travel and enjoy holidays. We aim to try and get away at least twice a year, sometimes a few more!

We are very pleased to welcome Kelsey Ritson and Darcey Hudson, both 18 years old, to their first full time jobs as Junior Corrugated Packaging Designers.

Design is a huge part of the service the business offers to its customers and as we enter the next phase of our growth plans it was important we added extra resilience to the design department and begin to educate our employees of the future.

Kelsey previously studied engineering at Burnley College and worked at Iceland supermarket before joining CBC.

Kelsey commented; “When I was studying at Burnley College, I gained a little bit of design experience when creating engineering projects and using similar design software such as Auto CAD.

“I joined CBC because I had enjoyed the design aspect of my college course the most and this was the perfect opportunity for me to join a local business in a trainee design role that would allow me to be in the industry while learning and progressing in design.”

Darcey Hudson completed A Levels in Product Design and Graphics, a CAD Course and had previous work experience at an engineering firm and a graphics company before joining the CBC team.

Darcey commented; “I wanted to join The Cardboard Box Company to get genuine industry experience in packaging design as that is what I found my passion for during my time in education. Furthermore, when I came to visit the company, I loved how versatile the company seemed, especially after mentioning how many interesting projects they had been part of.

“I’ve already experienced this when visiting customers and have enjoyed seeing first hand how we can meet their packaging needs by solving their challenges through design and innovative solutions.”

Marc Stobbs, Packaging Design Manager, The Cardboard Box Company added; “Both Kelsey and Darcey have great career aspirations, to grow as designers, gain experience in the industry and learn about other aspects of the company.

“They have both had a great start, shown great team spirit and an appetite for learning and I am sure they will continue to do well with CBC and in our industry.”