By the design team at The Display Boxes ·
Why does the board matter?
A display is judged on two things before anyone reads it: whether it stands up properly and whether the print looks crisp. Both come down to the board. Too light and the display bows, the front lip folds outwards and the header leans. Too heavy and you pay for strength you do not need, the folds look clumsy, and the display is harder to post.
The right board is the lightest one that will carry your product, in its placement, for as long as the display needs to last.
It also affects cost and delivery. Heavier board costs more, weighs more and takes more room in a carton, so an over specified display is more expensive twice: once to make and again to send.
What boards are used for displays?
Five boards cover almost every display we make.
| Board | What it is | Typical use |
|---|---|---|
| E flute corrugated | Thin fluted board with a smooth printed face | Counter displays, trays, pop ups, shelf ready cases |
| B flute corrugated | Thicker fluted board that resists crushing | Floor units, dump bins, displays for glass |
| White card | Smooth, solid folding card | Small displays, hanging cards, inserts |
| Kraft card | Unbleached brown folding card | Natural looking displays and headers |
| Rigid board | Thick board wrapped in printed paper | Gift displays and premium boxes |
When is E flute the right choice?
Most of the time. E flute is corrugated board with very fine flutes, which makes it light and stiff but still smooth enough to print sharp full colour. It folds cleanly, so tabs, lips and headers look neat. It is the standard for counter displays, slotted trays, pop up displays and most shelf ready cases.
E flute copes well with packs of bars, sachets, cosmetics and small bottles. It starts to struggle when the load is heavy for the size of the display, such as a tray full of glass jars.
For those heavier loads, E flute can still work if the base is doubled or a support is added under the tray. That keeps the light, sharp look of E flute where it shows while adding strength where the weight sits.
When do you need B flute?
When the display carries weight or takes knocks. B flute has larger flutes, so it is thicker and resists crushing. Floor display units, dump bins full of loose stock, and displays holding glass bottles or jars all need it. Floor units also take kicks from feet and trolleys, which E flute would not survive for long.
The trade off is print. B flute's surface is a little less smooth, so very fine detail does not look quite as sharp. Bold graphics look excellent on it.
- Anything standing on the floor
- Bins with loose stock pushing on the walls
- Trays and stands holding glass
- Displays that ship full and stack in transit
Many floor units combine boards: B flute for the frame, shelves and base, with a lighter E flute header that prints more sharply and carries no load.
When is card enough?
For small, light displays. White card gives the brightest colours and the finest detail, which makes it ideal for lip balm trays, small counter displays, hanging cards and inserts. Kraft card gives a natural, handmade look that suits farm shops, craft brands and simple one or two colour designs.
Card has limits. It bends under weight and does not like damp. If a card display holds anything heavy, we double the base or the top sheet, or move to E flute.
Kraft card also changes how colours look. Brown board darkens every ink printed on it, so pale colours can almost disappear. Brands that want kraft and bright colour often print a white layer under the colour areas, or choose white card with a kraft style print instead.
What about rigid board?
Rigid board is thick, solid board wrapped in printed paper, used for premium gift displays, candle boxes and presentation sets. It does not fold flat, so it ships made up and takes more space in transit. It feels substantial in the hand and lasts a long time, which suits displays that stay in place for months or are part of a gift.
Rigid board costs more than folding board and is not used for everyday counter displays. It earns its place where the box itself is part of what the customer is paying for.
How does placement change the choice?
The same product can need different boards in different places. A tray of jars on a counter might be fine in E flute with a doubled base; the same jars on a floor unit need B flute throughout. A display near a chiller or a door may pick up damp, which weakens any board, so lamination and a stronger build help there.
Also think about how long the display must last. A two week promotion can use a lighter build than a display a shop will keep for a season of sales.
Displays that ship full need to survive the journey as well as the shop. Stacked cartons in a van put pressure on the top edges, so a lidded display that travels full may need a slightly stronger board than the same display sent flat and filled in store.
How do you choose, step by step?
We always say which board we priced on your quote and why.
- Note the product weight and how many will sit on the display.
- Note where it will stand: counter, shelf, floor or peg.
- Note how long it needs to last and whether it ships full.
- Pick the lightest board in the table that copes with all three.
- If unsure, leave the board as not sure on the quote and we suggest one.
A quick way to judge strength is to imagine the display half empty after a week of handling. If you would expect it to lean or bow, go one step stronger.
What about inserts and dividers?
Inserts are usually made from card or E flute, chosen in the same way as the display itself. Light products such as lip balms sit happily in card cut outs; glass bottles need E flute so the holes hold their shape and the bottles do not touch. An insert can also add strength to a display by bracing the walls, which sometimes lets the outer box use a lighter board.
When you ask for a price, tell us whether the products need holding apart. We include the insert on the same quote and choose its board alongside the display.
How does board affect print and finish?
All five boards take full colour print. White card and E flute give the sharpest results; B flute suits bold graphics; kraft makes colours darker and earthier unless a white layer is printed first. Lamination, matt or gloss, protects the print and stiffens the surface slightly. Spot UV and foil work best on laminated E flute, card and rigid board.
For a deeper look at print and finishes, see boards and print for display boxes.
If your brand colours must match closely across displays and packaging, send colour references and, ideally, a printed pack. We match on the proof and note any board that will shift the colour.
