Straight consistent body scores on plastic corrugated boxes and a process for making same

A plastic corrugated box comprising:

• a sheet of plastic corrugated material having a first outer layer, a second outer layer and a plurality of flutes extending between the first outer layer and the second outer layer;
• the sheet having a plurality of panels defining side walls of the box and a plurality of fold lines between adjacent panels of the plurality of panels defining side walls wherein the sheet includes a first plurality of welded portions each having a width wherein the first outer layer, second outer layer, and plurality of flutes extending between the first outer layer and second outer layer are welded together proximate a top edge of the plurality of panels and a second plurality of welded portions each having a width wherein the first outer layer, second outer layer, and plurality of flutes extending between the first outer layer and second outer layer are welded together proximate a bottom edge of the plurality of panels defining side walls and wherein each of the plurality of fold lines between adjacent panels of the plurality of panels defining side walls includes a first portion in one of the first plurality of welded portions proximate the top edge and each having a width less than the width of each of the first plurality of welded portions and a second portion in one of the second plurality of welded portions proximate the bottom edge and each having a width less than the width of each of the second plurality of welded portions and wherein each of the plurality of fold lines includes a third, middle portion extending between the first portion of the fold line and the second portion of the fold line in an un-welded area of the sheet.