Kraft vs SBS vs Corrugated: Packaging Material Guide for Custom Boxes

Choosing Your Packaging Material

Every custom box starts with one decision: what is it made of? The three most common packaging materials — kraft board, SBS (Solid Bleached Sulfate), and corrugated board — each have distinct strengths. This guide breaks down the real differences with specific numbers.

Kraft Board: The Natural Choice

Kraft board is made from virgin or recycled wood pulp using the kraft process (German for "strength"). The natural brown color comes from unbleached fibers, which also makes it the strongest paperboard per gram.

Technical Specs

• Weight range: 250-450gsm (single-ply)
• Thickness: 0.3-0.6mm
• Burst strength: 2.5-4.0 kg/cm² (higher than equivalent SBS)
• Surface: Natural brown, rough texture
• Printability: Good with dark inks; white ink needed for light colors
• Cost: 15-25% cheaper than SBS

Best Applications

• Artisan and organic brands — kraft communicates authenticity and eco-consciousness
• Soap packaging — kraft with die-cut windows is the artisan soap standard. See custom soap boxes
• Bakery boxes — kraft with grease-resistant coating for pastries. See custom bakery boxes
• Subscription boxes — natural aesthetic for monthly curated boxes
• Budget-conscious brands — lower material cost with premium perception

Limitations

Kraft board has a brown base color, so achieving bright whites or pastels requires white ink underprinting (adding $0.05-0.10/unit). Full-color photographic printing is possible but muted compared to SBS.

SBS (Solid Bleached Sulfate): The Print-Perfect Choice

SBS is the premium paperboard made from bleached virgin wood pulp. The bright white surface delivers the best print quality of any paperboard — colors pop, gradients are smooth, and metallic finishes look stunning.

Technical Specs

• Weight range: 250-400gsm (C1S or C2S)
• Thickness: 0.3-0.55mm
• Burst strength: 2.0-3.5 kg/cm²
• Surface: Bright white, coated one side (C1S) or both sides (C2S)
• Printability: Excellent — the industry standard for high-quality printing
• Cost: Premium (15-25% more than kraft)

Best Applications

• Cosmetics and beauty — SBS with soft-touch lamination is the beauty packaging standard. See custom cosmetic boxes
• Pharmaceutical — FDA-compliant with excellent text legibility
• Candle boxes — bright white base for vibrant brand artwork. See custom candle boxes
• Chocolate and confectionery — food-grade SBS with grease barrier. See custom chocolate boxes
• Any product requiring photographic-quality printing

Limitations

SBS costs more per gram than kraft and has lower tear strength. It is not suitable for shipping without additional corrugated protection.

Corrugated Board: The Protection Choice

Corrugated board is a sandwich: two flat liners with a wavy fluted medium between them. This structure creates the best strength-to-weight ratio of any packaging material.

Technical Specs

• Flute types: E-flute (1.5mm), B-flute (3mm), C-flute (4mm), BC double-wall (7mm)
• ECT ratings: 23-51 lbs/inch (determines stacking strength)
• Burst strength: 125-400 lbs/sq inch
• Surface: Kraft brown or white top liner
• Printability: Moderate (flexo direct) to excellent (litho-laminated)
• Cost: Varies widely by flute type and wall construction

Best Applications

• Shipping and e-commerce — corrugated is the shipping standard worldwide. See custom shipping boxes
• Mailer boxes — E-flute corrugated for DTC brands. See custom mailer boxes
• Heavy products — double and triple-wall for industrial loads. See custom corrugated boxes
• Food service — pizza boxes, produce boxes, catering trays
• Retail displays — corrugated POP displays and counter units

Limitations

Corrugated is bulkier than paperboard, takes up more storage space, and the fluted surface creates a less smooth printing surface (unless litho-laminated, which adds cost).

Material Comparison Table

How to Choose

Choose kraft when your brand values authenticity, sustainability, or rustic aesthetics. Kraft saves 15-25% on material cost and resonates with eco-conscious consumers.

Choose SBS when print quality is paramount. Beauty brands, pharmaceuticals, and any product with photographic artwork on the box should use SBS.

Choose corrugated when your product needs protection during shipping, weighs more than 3 lbs, or requires stacking strength for warehouse storage.

The combo approach: Many products use SBS or kraft for the retail box (the one customers see) inside a corrugated shipping box (the one logistics handles). This gives you the best of both worlds.

Frequently Asked Questions

Is kraft packaging really more eco-friendly?

Yes, for two reasons: kraft uses unbleached fibers (eliminating chlorine bleaching chemicals) and is typically lighter per square meter than SBS. Both kraft and SBS are recyclable and biodegradable. For maximum sustainability, choose FSC-certified kraft with soy-based inks.

Can I print white on kraft board?

Yes, using opaque white ink as a base layer under your artwork. This adds one printing pass ($0.05-0.10/unit) but allows full-color artwork on kraft. The slight kraft show-through actually creates a trendy vintage aesthetic many brands prefer.

What is the minimum order for each material?

At Cubit, all three materials start at MOQ 100 units. Kraft and SBS folding cartons start at $0.50/unit. Corrugated mailers start at $0.75/unit. Get an instant quote.