Corrugated board is one of the most useful materials in takeaway packaging. It is light, stiff, holds heat reasonably well and goes straight into the paper recycling stream once it is clean. This guide explains what corrugated packaging is, where it works best for food businesses, where it does not, and how to choose the right boxes for your menu.
What is corrugated packaging?
Corrugated board is made from two or more flat sheets of paper (the liners) glued to a wavy middle layer (the fluting). The arches in the fluting act like tiny beams, which is why a corrugated box is far stiffer than a single sheet of card of the same weight. The Confederation of Paper Industries describes it as a lightweight, strong material made largely from recycled fibre.
The air trapped in the flutes also gives a little insulation, which helps hot food stay warm on the way to the customer.
Flute sizes in plain English
- E-flute and F-flute (fine): thin, smooth and easy to print on. This is what most burger boxes and many pizza boxes use.
- B-flute (medium): a balance of strength and thickness, common for larger takeaway boxes and outer cartons.
- C-flute (thick): more cushioning and stacking strength, mainly used for transit cartons rather than food that goes straight to the customer.
For food served direct to customers, finer flutes are usually the right choice: they fold neatly, look good and are strong enough for a single meal.
Where corrugated works best in food service
- Burgers and wraps. A corrugated burger box keeps its shape when stacked in a delivery bag and does not crush the bun. We stock paper corrugated burger boxes in small, medium and large.
- Pizza. Pizza boxes need to be rigid and stackable, which is why corrugated board is the standard material. See our pizza boxes in white, brown and printed, from 7″ to 16″.
- Multi-item orders. Corrugated boxes stack well in delivery bags and on counters, so larger orders arrive in better condition.
- Branding. The smooth outer liner of fine-flute board takes printing well, which makes it a good canvas for your logo.
Where corrugated is not the right choice
Corrugated is paper, so it has limits. Be honest about them when you plan your packaging:
- Wet or saucy food. Plain corrugated absorbs liquid and softens. Curries, soups and saucy dishes are better in foil containers, kraft soup containers or sealed plastic containers.
- Very greasy food. Oil can soak into uncoated board. For fried food, look for grease-resistant boxes or add a greaseproof bag or liner.
- Long journeys. Corrugated holds heat for a short trip, but it is not an insulated container. For long delivery times, pair it with an insulated delivery bag.
- Steam. Closed boxes trap steam, which softens crispy food. Vented designs or a slightly open lid help.
Corrugated and sustainability
Paper and card packaging is one of the most widely recycled packaging materials in the UK. The Confederation of Paper Industries reports a recycling rate of almost 70% for paper and card packaging, and most UK-made paper uses recovered fibre.
There is one catch: heavily food-soiled card is often rejected by recyclers. Encourage customers to put clean boxes in recycling and to compost or bin greasy ones, and choose box sizes that fit your portions so there is less waste.
If you want a plant-based alternative for wet or greasy food, bagasse packaging made from sugarcane fibre handles moisture and grease better than plain card.
UK rules worth knowing
- Food contact. Any packaging that touches food must be suitable for food contact and must not transfer harmful substances into it. The Food Standards Agency explains what businesses need to check.
- Extended Producer Responsibility (EPR). Under the UK packaging EPR scheme, businesses with a turnover of £1 million or more that handle more than 25 tonnes of packaging a year have reporting duties, and larger producers pay fees. Most small takeaways fall below these thresholds, but it is worth checking the government guidance.
- Plastic Packaging Tax. This tax applies to plastic packaging with less than 30% recycled plastic, not to paper and card. See GOV.UK for details.
How to choose corrugated boxes for your menu
- Start with the food. Dry, firm items (burgers, pizza, baked goods) suit corrugated well. Wet or saucy dishes need a different container.
- Match the size to the portion. A box that is too big lets food slide around and loses heat faster.
- Think about the journey. Collection and short deliveries are fine in plain corrugated. For longer trips, use insulated bags and consider vented boxes for crispy food.
- Test before you switch. Pack your best-selling items, leave them for the length of a typical delivery, then check heat, grease and shape.
- Buy by the case. Wholesale cases lower the cost per box and mean you are less likely to run out at a busy time.
Frequently asked questions
Is corrugated cardboard safe for hot food?
Yes, as long as the box is made for food contact. Corrugated handles hot, dry food well. For very greasy or saucy food, use a grease-resistant box or add a liner.
Can corrugated food boxes be recycled?
Clean corrugated boxes can go in paper and card recycling. Boxes heavily soaked in grease or food are often rejected, so check your local council’s guidance.
What is the difference between corrugated and paperboard?
Paperboard (folding carton) is a single thick layer of board, used for things like noodle boxes and chip boxes. Corrugated has a fluted middle layer, which makes it stiffer and better for stacking. Read more in our guide to paperboard.
Which corrugated boxes do you stock?
We stock corrugated burger boxes in three sizes and a full range of pizza boxes, all sold by the case with fast UK delivery. Browse everything in our shop.
