Its functional properties give designers freedom to create innovative structures. A simple folding carton is an excellent packaging design solution because it has large flat surfaces that are ideal for branding and communicating the product’s benefits.

The calliper of the paperboard is specific to a carton’s size and function and the product’s containment needs. Both the size and weight of the product determine the structure and strength of its container. The form of packaging follows its function.

The structural design is dependent on the marketing objectives for how to feature the brand and the product. For example, the packaging might need to accommodate and protect a primary package inside, such as a can or bottle, or included an inner structure, such as a plastic tray or corrugated sleeve.

Paperboard is manufactured by laminating several layers of paper together.
There are two basic types of paperboard and each is produced differently.

Fourdrinier paperboard is made of one to four plies, or layers, of mostly virgin fibre. 

Cylinder paperboard is made of seven to nine plies or layers, from mostly recycled grades of paper fibre.

There are a variety of weights and finishes of both.

The following are the most common paperboards:

• SBS (solid bleached sulphate)

is made with the highest percentage of bleached virgin fibre. High-end paperboard is coated with clay for a premium solid-white printing surface.
It is commonly used for packaging food, dairy, cosmetics, and medicinal and pharmaceutical products.

• SUS (solid unbleached sulphate)

is made with the highest percentage of unbleached virgin fibre.
This natural kraft paperboard (the kraft process is chemical pulping that results in a stronger paperboard) is available with either a coated or uncoated surface.
Its strength makes it a common choice for beverage carriers, hardware products, and office supplies.

Recycled paperboard is a multi-ply material made from different percentages of recovered

or recycled papers and paperboard from pre-consumer or post-consumer waste. 

• Pre-consumer waste comes from mill conversion waste or paper that hasn’t gone to market.
• Post-consumer waste is from paper products that have been used and discarded. 
• Recycled paper and paperboard are available in both uncoated and coated sheets. 
• Manufacturing techniques have given 100% recycled board a better surface for printing. 
• The uncoated board can be used for composite cans (paperboard spiral-wound cylinders), canisters, and fibre drums. 
• Coated board can be used for dry food packaging, such as cookie and cake mixes, as well as for household goods and powdered detergents.

Plain chipboard (also called shirt board) is made from wastepaper and is usually grey or tan. 

• It may be used for set-up boxes (rigid structures covered in decorative papers or other materials commonly used for gift items such as perfumes and glassware), folding cartons, backing boards for blister packaging, low-end packaging, and for the inner structures not visible on the shelf. 

• Plain chipboard is usually unsuitable for direct printing.

The use of 100% recycled paper and paperboard has expanded proportionately to Consumer product companies’ commitment to sustainable packaging. 

Using 100% recycled materials saves energy, water, and trees and reduces greenhouse gas emissions.