Few inventions have blended as seamlessly into our daily living routines as the humble cardboard box. We get excited to see piles of them near our front door. We stuff them with papers. Our cats love to claim them as their private living rooms. Yet we rarely stop to consider how much more convenient they are than a burlap sack. Who do we credit for this marvel of simple but indispensable ingenuity?
In the 1st and 2nd century BCE, the Han Dynasty of China was busy pioneering the use of paper. During the same era, sheets of bark from the Mulberry tree were used to wrap and protect food, one of the earliest examples of a sturdy, wood-based product being repurposed for packaging. But what we’d come to recognize as the earliest form of the cardboard box as we know it today didn’t appear until the early 19th century, with the 1817 German board game The Game of Besieging being the oldest example. Throughout the 19th century, companies began using the boxes as a means of storage and transport for cereals and even for moth eggs used by silk manufacturers.
But an additional twist—or pleat—was needed in order to turn these carriers into the cubical wonders we know today. In 1856, top hat peddlers Edward Allen and Edward Healey used a stiffer paper made with a fluted sheet in the middle of two layers to provide stability and warmth to the lining: It was a precursor to corrugated cardboard.
The real breakthrough, however, came in 1879. It was then that Robert Gair, owner of a Brooklyn paper factory, figured out that he could both score a single sheet of cardboard and then have his printing press cut it at the same time, eliminating laborious hand-cutting. When the flat pieces were folded together, the cardboard box as we know it was born.
Gair sold consumer product companies on this handy new form of storage, eventually scoring a 2-million-piece order from the cracker czars at Nabisco. Snack foods could now travel without the danger of being crushed, and, pretty soon, the cardboard box was migrating from kitchen cupboards to anywhere a cheap, effective form of packaging was needed. In the 1930s, the Finnish government even adopted the boxes as part of a take-home maternity package for new mothers who may not have been able to afford cribs. Babies took their first naps in the confines of the mattress-lined box—a practice that continues today.
Although it might seem a box is just a box, innovations in corrugated boxes have continued since Robert Gair’s initial brainwave almost 150 years ago. As Gair’s enterprise expanded, he, too, moved into different materials and began incorporating corrugated fiberboard into his box range in the 1900s.
Today, corrugated boxes come in a range of materials to incorporate different uses and functions. Hazardous substances and dangerous goods require specialized packing for hazmat shipping. Single- and double-walled corrugated boxes offer different degrees of strength. The current focus on environmentally friendly, sustainable, and recyclable packaging is leading to more creation and innovation for the years ahead.
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