November 5, 2025
Winter’s almost here, and while we’re bundling up in parkas and fuzzy socks, corrugated packaging isn’t so lucky. Cold weather can make sturdy boxes go from strong to brittle faster than you can say “subzero.” Whether you’re shipping holiday gifts or storing supplies in a frosty warehouse, the chill can do a number on corrugated material. But don’t worry—there are plenty of ways to keep your corrugated ready to weather the cold.
In chilly weather, corrugated packaging confronts a triple threat of temperature, humidity, and adhesive-weakening, which can all undermine box integrity during distribution and storage. The material becomes stiffer and more brittle, and adhesives can lose effectiveness, raising risk of delamination or failure under load.
High relative humidity (RH)—common in winter warehousing or cold chain transport—causes the fibers in corrugated to absorb moisture and soften. This significantly reduces stacking strength—often to about 50% of its potential when RH climbs above 85%. Moreover, prolonged storage under load in humid conditions accelerates strength loss; for instance, boxes may lose nearly 45% of their compression strength after 90 days, with humidity amplifying that degradation. Temperature fluctuations, such as moving from heated to unheated zones, can also cause internal condensation or moisture migration, further weakening the board.
Cold weather doesn’t have to crush your corrugated game. Keeping packaging strong in winter starts with climate control: Store and convert corrugated materials in heated areas (above 55 degrees Fahrenheit) to prevent brittleness and adhesive failure. Avoid unconditioned storage spaces, especially near loading docks or drafty zones, where boxes can absorb excess moisture or become frozen. Applying moisture-resistant coatings, using wet-strength liners, and adding desiccants can also guard against high humidity, which drastically reduces stacking strength. For extra protection, boxes can be engineered with stronger flute profiles or double-walled designs to boost performance in cold-chain logistics.
Corrugated manufacturers play a crucial role in fortifying packaging against winter’s harsh effects. By carefully selecting raw materials and enhancing the board’s construction, they boost moisture resistance and cold tolerance. For example, companies like Smurfit WestRock and International Paper use wet-strength resins and higher-quality fibers to help maintain structural integrity in damp or freezing conditions. Many producers offer specially engineered liners and flute profiles designed to improve stacking strength and durability during cold-chain transport. Additionally, surface coatings and barrier treatments reduce moisture absorption, while tailored adhesive formulas ensure strong bonds even at low temperatures. Through these innovations, corrugated companies help ensure that packaging thrives in the cold.
To ensure that your board is up to the challenge, it’s important to run the right tests. Start with conditioning per ASTM D4332, then follow with edge crush tests, box compression tests, and burst strength tests to evaluate structural integrity. If your packaging faces extreme cold or fluctuating temperatures, use environmental chambers to simulate freeze-thaw cycles and cold storage conditions, watching how the material reacts over time. For specialized testing support, Clemson University’s Package Dynamics Lab offers advanced facilities and expertise to help you thoroughly evaluate your corrugated materials under real-world environmental conditions.
Winter weather may challenge your corrugated packaging, but with the right strategies and testing in place, you can keep your shipments safe and sound no matter how low the temperature drops. From controlling storage environments to leveraging moisture-resistant materials and thorough testing, you have all the tools you need to beat the cold.
Don’t wait for winter to wreak havoc on your packaging. Take action now: Evaluate your current processes, invest in proper testing, and ensure that your corrugated materials are ready to stand strong through every frost and freeze. Your products—and your customers—will thank you.
Julie Rice Suggs, Ph.D., is academic director at the Packaging School. She can be reached at 330-774-8542 or julie@packagingschool.com.
Alli Keigley, is production coordinator at the Packaging School. She can be reached at alli@packagingschool.com.
