Greyboard—also called chipboard or grey core board—is a multi-ply board made primarily from recycled fibers. Typically grey or grey-brown in color, it offers high rigidity, cost efficiency, and strong sustainability credentials, making it ideal for rigid boxes, book covers, and structural backings.
Key Properties
High stiffness & load bearing: Excellent structural support for rigid set-up boxes, book cases, and inner trays.
Excellent for lamination/wrapping: Commonly wrapped with coated papers, specialty papers, fabrics, or leathers to deliver premium looks.
Dimensional stability (with humidity control): Proper conditioning and wrapping minimize warp.
Sustainable: High recycled content with optional FSC Recycled; widely recyclable.
Cost-effective: Lower cost than SBS/FBB or white-backed boards for structural roles.
Grades & Typical Specs
Double grey (full grey): Grey on both sides; core color hidden after wrapping.
Single grey: One side lighter/smoother, the other grey—good where the inner face is not visible.
Caliper: approx. 0.8–3.0 mm (thicker via multi-layer lamination).
Density: typically 0.75–0.95 g/cm³ (brand/compaction dependent).
Tolerances: thickness tolerance commonly ±0.10–0.20 mm; confirm flatness and moisture content per order.
Converting & Process Notes
Cutting/Die-cutting: Straight cuts preferred; complex shapes via dies or digital cutting; laser possible (edges may show slight scorch).
Wrapping/Lamination: Single or double wrap; use water-based PVA/starch or low-odor adhesives; control glue laydown to prevent bubbles.
Corners & edging: Metal/board cornering; match turn-in allowance and corner radius (R) to board thickness.
Moisture & warp control: Store/work at 45–55% RH; balance inner/outer wraps and grain directions.
Surface finishing: Apply finishes (foil, emboss/deboss, spot UV, films) to the wrap material, not directly to the greyboard.
Odor/taint: Choose low-odor adhesives and liners; add barrier liners if needed for luxury packs.
Typical Applications
Rigid gift boxes: lid–base, drawer, book-style shells and structural trays.
Bookbinding: hardcovers, ring binders, folders, art boards.
Retail display: tent cards, display backers, poster frames.
Crafts & stationery: puzzle bases, sketch pads, protective boards.
Comparisons
Greyboard vs. SBS/FBB: Greyboard is thicker/stronger and cheaper for structure but not printable to a premium level without wrapping; SBS/FBB print directly with finer graphics.
Greyboard vs. White-backed board: White-backed can be printed directly but lacks the caliper/rigidity of greyboard.
Greyboard vs. Corrugated: Greyboard has a flatter, harder face for luxury wraps; corrugated offers lighter weight and better cushioning for shipping.
Quality & Acceptance Criteria
Caliper & tolerance: agree target (e.g., 2.0 mm) and tolerance (e.g., ±0.15 mm).
Flatness/warp: check diagonal lift/warp; pre-condition 24–48 h before wrapping.
Moisture: target 8–12%; too low → brittle, too high → warp.
Cleanliness & odor: specify low-dust, low-odor grades for premium boxes.
Edge integrity/cohesion: avoid ply separation and chipping.
Sourcing & Production Tips
Selection: choose thickness by box size and load; luxury rigid boxes commonly 1.5–2.5 mm.
Structure: add ribs/rails under large panels to prevent panel denting; consider E-flute/honeycomb inner parts to reduce weight/cost.
Sampling: build a white mockup to validate fit and turn-ins; then wrap with chosen cover stock to test foil/film/emboss.
Packing & shipping: heavy—reinforce outers; use corner protectors, anti-scuff films, and moisture protection.
Sustainability: prefer FSC Recycled, water-based coatings/adhesives, and recyclable films; minimize mixed-material layers.
Bottom line: Greyboard is the structural backbone of luxury rigid packaging and case binding—delivering strength, value, and sustainability. With the right caliper selection, humidity control, and wrapping process, you can achieve premium aesthetics with robust performance at an attractive cost.