Corrugated Plastic Fabrication & Conversion

Corrugated Plastic Fabrication with Rivet

Ortho Development Corrugated Plastic Fabrication

At Kiva Container, our corrugated plastic fabrication capabilities allow us to manufacture cost-effective custom packaging for various industries, such as aerospace, industrial, medical, and supply chain management. We begin with a flat sheet of corrugated plastic, die-cut it to the correct shape and dimensions, fold it into the desired shape, and weld the pieces in place.

We can manufacture reusable and clean alternatives to corrugated paper products, from corrugated plastic boxes and bins to pads, totes, mailers, and dividers. Our products come in various standard and custom sizes with add-ons like wire reinforcement and our proprietary method of flat welding or sonic welding to improve performance. Kiva Container has long-standing industry relationships with the main extruders of corrugated plastic sheets such as Coroplast, Inteplast, and Laminacorr.

List of Common Box Styles

Corrugated Plastic Fabrication Capabilities

At Kiva Container, we fabricate a wide range of light- to heavy-duty corrugated plastic packaging in various sizes, with add-ons for many applications. Our fabrication size capabilities include the following raw sheet extrusion sizes:

Minimum width: 4 inches
Minimum length: 4 inches
Maximum width: 104 inches

We have fabricated massive custom corrugated plastic boxes for specialty applications and can fabricate boxes with the following minimum dimensions as well:

Minimum width: 1 inch
Minimum length: 1 inch
Minimum depth: 1 inch

Corrugated plastic products are essential to various applications. The following depend on corrugated plastic:

Bins for agricultural picking and processing purposes
Chilled and frozen storage for medical and food applications
Containers for storing, shelving, and processing applications
Conveyor and packaging systems
Packaging and displays in retail stores
Shelf bins for organizing and storing pharmaceuticals
Shipping and distribution
Storage and shipping for part manufacturing and production

At Kiva Container, we manufacture custom corrugated plastic products with numerous add-ons and closures. Our add-ons include 4-color silk screening and full color in house digital printing for near-photo quality graphics, grommets that allow for the insertion of wire and cord into a slot without stress or wear, and durable rivets for joining two pieces of plastic. We also provide these additional add-ons and closures:

Aluminum and plastic railings
Buckles
Custom graphics (silk screening & digital flat bed printing)
Custom straps
Formed handles
Installed hinges
Labels
Placards
Velcro
Wireframes

Advantages of Corrugated Plastic

Corrugated plastics deliver a variety of benefits over other materials, including:

Cost-effectiveness. Corrugated plastic is inexpensive to manufacture, making it budget-friendly to purchase and replace.
Lack of toxicity. The non-toxic polypropylene that corrugated plastic is extruded from uses will not release chemicals in extreme temperatures and is safe for human and animal contact in consumer and medical applications.
Recyclability. Users can recycle, reuse, and up-cycle corrugated plastic to make other products.
Strength. Corrugated plastic can deliver long-lasting performance in harsh conditions without frequently requiring repair or maintenance. The industrial sector depends on durable corrugated plastic storage and transportation solutions, keeping products safe throughout the supply chain.
Versatility. Various commercial and consumer products rely on corrugated plastic construction given the many forms it can take. At Kiva Container, we offer electrostatic discharge (ESD) packaging that is specifically designed for safe use with electronics, and PMS match for color variation.
Weight. The material is easy to assemble, handle, and transport, making it ideal for aerospace applications.

Rely on Kiva Container for Corrugated Plastic Fabrication

At Kiva Container, our corrugated plastic fabrication capabilities allow us to manufacture pads, boxes, totes, and more in custom sizes and with utility-enhancing add-ons and closures. Corrugated plastic is an ideal alternative to corrugated paper products, providing improved durability, versatility, and reusability at an affordable price.

Kiva Container is a woman-owned business with over 35 years in the industry. We create solutions with optimal reusability in mind and easy returns for reprocessing. We are the only manufacturer that can convert both solid sheet forming and corrugated plastic in-house from our Anaheim, CA, facility, allowing us to deliver fast and local solutions to your needs.

We fabricate custom products to meet a myriad of container applications. Kiva Container offers light- and heavy-gauge thermoformed packaging for consumer products or industrial/commercial applications, respectively. Our ESD packaging for UHDI flex circuits, hermetic packaging, and custom LEDs is useful for transport and storage. Kiva Container has fully customizable integrated packaging solutions, such as sleeves, heavy-gauge dunnage, and formed trays with dividers. We also offer clean and hygienic plastic pallets for applications where wood pallets are unsuitable

We’re here to help. Contact us or request a quote for more information about the corrugated plastic solution for your needs.

Specifications

Capabilities
- Die cutting
- Sonic welding
- Flat welding
- Aluminum railing
- Wire frames (wire reinforced)
- Custom formed handles
- Complete manufacturing to assembly
- Cleaning and bagging
- 4 color silk screen printing
- Full CMYK + White digital flatbed printing
- Riveting
- Grommet Installation
- Deep Grommet (up to 15 inches deep)
- Stacking corners
- Secondary routing and trimming processes
- ESD coating processes
- Custom wire handles
Materials
- Material thicknesses from 2mm – 10mm
- Stock colors of blue, black, white
- Special colors occasionally stocked, usually custom ordered
- Any color available (PMS match available)
- ESD conductive material in stock
- ESD anti-static coated blue in stock

Frequently Asked Questions

What is corrugated plastic fabrication?

Corrugated plastic fabrication is the process of cutting, folding, scoring, and welding extruded polypropylene twin-wall sheet into custom containers, trays, boxes, and packaging systems. The material, also called Coroplast or corrugated polypropylene is lightweight, durable, and reusable. Kiva Container has been fabricating corrugated plastic since 1986.

Can Kiva Container make corrugated plastic packaging in custom colors?

Yes. We stock white, black, and blue corrugated plastic, as well as other non standard colors. Custom colors and PMS matching are available through special order. We can also print custom graphics directly on any corrugated plastic surface using digital flatbed printing or 4-color silk screening.

What is the difference between corrugated plastic and corrugated cardboard?

Corrugated plastic (polypropylene) is waterproof, reusable, and far more durable than cardboard. It does not degrade from moisture, handling, or repeated use. Corrugated plastic is typically used for returnable packaging applications where cardboard would be replaced many times over.

Who makes corrugated plastic packaging in Southern California?

Kiva Container, based in Anaheim, CA, manufactures custom corrugated plastic packaging. We have been fabricating corrugated polypropylene totes, boxes, trays, and dividers since 1986 and serve customers throughout Southern California and nationally.

Can corrugated plastic be used for aerospace packaging?

Yes. Kiva Container is AS9100D / ISO 9001:2015 certified and produces corrugated plastic packaging for aerospace customers, including trays, bin liners, and dividers with Class A laminated surfaces (Tyvek, Spunguard). Our quality system supports the traceability and documentation requirements of aerospace programs.

What is the lead time for custom corrugated plastic fabrication?

Lead times depend on complexity, tooling, and volume. For designs using existing dies, we can often produce and ship in 1-2 weeks. New die tooling adds time, typically 1-2 weeks for die fabrication. CNC-routed parts without new tooling can turn quickly. Call 714-630-3850 for a specific estimate.

Can Kiva Container fabricate ESD-safe corrugated plastic?

Yes. We fabricate ESD-safe corrugated plastic packaging in both conductive and anti-static materials. Conductive material is available in 3mm and 4mm and is used for applications requiring a low-resistance static dissipation path. We have been producing ESD corrugated plastic packaging since the early 1990s.

Does Kiva Container offer printing on corrugated plastic?

Yes. We offer both digital flatbed printing and 4-color silk screen printing in house on corrugated plastic. Digital flatbed printing supports short runs and full-color graphics. Silk screening is more cost-effective for high-volume production runs. Both processes are managed in house from prepress artwork approvals to final production printing.

How large can Kiva Container cut corrugated plastic parts?

For most standard box styles and trays, die cutting is used. We have multiple die cutters that can handle 150″ x 65 For oversized blanks, complex geometry, or thicker material, we use CNC routing. Our CNC router table measures 120″ × 75″, allowing us to cut corrugated plastic parts that exceed the capabilities of standard die-cutting presses.

What thicknesses of corrugated plastic does Kiva Container work with?

We work with corrugated polypropylene in thicknesses from 2mm to 10mm. Common thicknesses are 3mm, 4mm, 6mm, and 8mm. Thicker material is used for heavier loads and more demanding applications.