Resource Efficient Innovations Database (REID)

Diagonal fluting reduces corrugated box converting process waste and improves properties

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Diagonal fluting reduces corrugated box converting process waste and improves properties
Turning the orientation of the cuts reduces process waste by significantly improving the layout, whilst also delivering a stronger box.
In Use – Commercially available.

Packaging Reduction, Resource efficiency (e.g. filling line efficiency)

Product Categories
Drinks, Food, Home Improvement, Household & Personal Care

Relevant Materials

Relevant Packaging Formats
Corrugated box/case

Supply Chain Phase


A corrugated packaging manufacturer’s design team has gone against convention and rotated the direction of the corrugations on an E-corrugated board box.
The shipper is used for premium hair care products and the objective of the project was to optimize the existing transport packaging without changing any part of the existing construction.
The team identified that twisting the arrangement of the cuts on the punching sheet resulted in a considerable improvement in the layout. This led to material savings of 20 per cent in the packaging converting process.
In addition, the improved technical characteristics meant that the diagonal corrugation achieved a roughly 13 per cent higher Box Compression Test value (a measure of stacking compressing resistance). This also meant that the machine operation could be improved - with the improved flatness and uniform bending resistance of the grooves, the blanks are cut more smoothly and thus processed faster.
The content in this entry has been obtained from publicly available information sources only (e.g. press releases, website and trade press articles) and is subject to completion of a validation process with the technology supplier.

Potential Benefits

This simple reconfiguration has identified potential savings of 20% for the box maker, whilst higher compression strength may allow some light-weighting of the box to be achieved. This innovation will deliver both cost and environmental benefits.

Intellectual Property

This innovation has been developed by the design department of Smurfit Kappa in Herzberg, Germany.

Consultant View

This neat solution to a well-known issue shows that there is plenty of scope to challenge standard practices and deliver significant cost and environmental benefits. Although the initial project has focused on secondary packaging for personal care products, the concept shown here could be applied for many different product categories.

There are many entries in the REID database which feature innovations and technologies addressing light-weighting of corrugated board and other secondary packaging. To identify other examples, try using combinations of search terms such as “Light-weight” and “Corrugated”.

Contacts and Further Information

Smurfit Kappa
Andreasberger Straße 1, 37412 Herzberg am Harz
Tel: +49 5521 820
Email:  email contact can be made via the company contact page 

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