At first glance, a circular box sounds logical. But from a manufacturing perspective, it creates far more problems than it solves. Square pizza boxes are made from a single sheet of corrugated cardboard that is cut, folded and locked into shape using relatively simple machinery. The design produces very little waste, is quick to assemble and keeps production costs low.
A round cardboard box, on the other hand, requires more complex cutting patterns, specialised machinery and often additional materials to maintain its structure. That makes it significantly more expensive to produce on a large scale. When millions of pizza boxes are manufactured every year, even saving a few cents per box translates into enormous savings for restaurants and packaging companies.
