Production manufacture transport packaging made of paper and cardboard
Cardboard boxes are industrially prefabricated boxes , primarily used for packaging goods and materials and can also be recycled. Specialists in industry seldom use the term cardboard because it does not denote a specific material. The term cardboard may refer to a variety of heavy paper-like materials, including, card stock , corrugated fiberboard ,  or paperboard. A box or carton of cereal. Hard cigarette pack or paperboard box. In business and industry, material producers, container manufacturers,  packaging engineers ,  and standards organizations ,  try to use more specific terminology.VIDEO ON THE TOPIC: Corrugated Boxes: How It’s Made Step By Step Process - Georgia-Pacific
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The 20-year explosion in e-commerce has not increased US cardboard production
Packaging technologists love to talk about their products, but they are even happier to discuss the substrates that go into making boxes, tape, polythene and stretch film.
Cardboard boxes are of course one of the core products of the packaging industry. So, what is the process is for turning trees in to corrugated cardboard? Well the wait is over! Kite Packaging have grilled its technologists to tell us exactly what the process is for cleaning the raw materials and processing them to make the cardboard boxes you buy every day for your business. Because why not? You can add these facts to the general knowledge part of your brain, reserved for pub quizzes and showing off.
A cardboard box is basically made up of a flute made up of recycled paper , sandwiched between two liners. It is now very common for these liners to also be made up of a considerable proportion of recycled content, sourced from old cardboard or other sources of second hand paper.
However for top quality boxes virgin Kraft is still used. When manufacturing boxes we talk about two different types of liners, this is the material that lies on top and beneath the fluting and creates a corrugated board. Typically, cardboard boxes have a test paper inner liner, and a Kraft paper outer.
This is because Kraft is better quality than test, and has a smoother finish so that it can be easily printed on. Kraft also has the benefit of being more resistant to water penetration which is an added benefit of using it for the outer face. To get this smooth finish Kraft paper needs to be made from softwood trees that typically have long fibres, such as Pine, Spruce and Fir trees.
Long fibres are also better in tension which is why Kraft paper is often described as having a high tear and burst resistance. The look of Kraft paper can differ depending on the type of tree it has come from for example Kraft from Scandinavian Spruce, Pine and Silver Birch is dark brown in colour, however Russian variants of the same tree type appear a more varied brown with dark patches.
In Brazil, Eucalyptus and Spruce are used and the Kraft they produce is light brown, whereas Chinese trees have a yellowish hue due to the high straw content in their Kraft.
Test paper liners are typically made of hardwood trees that have short fibres, or recycled paper which is why it is cheaper and has a more abrasive quality. Kraft and Test paper is also used to create the fluted paper in between liners which finally create a strong board. To create the paper a long process is involved to ensure the wood chips that are pulped are clean and suitable for purpose. To start, the trees are cut and lumbered to create tonnes of logs which go through a machine to be debarked and chipped.
These chips are then put through one of two processes — mechanical pulping or chemical pulping. Mechanical pulping involves grinding, to reduce wood to individual cellulose fibres by forcing the debarked logs against a revolving stone to make a pulp. The stone is sprayed with water to remove fibres from the pulp stone however results in little removal of lignin a non-fibrous constituent of wood that binds fibres together and reduces paper quality, however mechanical pulping is low cost and generates a higher throughput.
There are two types of chemical cooking, sulphite and sulphate, and both results in better separation and reduction of lignin to produce better quality paper.
Out of both of these processes the Kraft is either used there and then and as mentioned before is dark brown in colour, or bleached during the pulping process to produce a white Kraft.
Nowadays however most of the paper products produced for boxes in particular are made from recycled waste. These come in various forms including:. Chip — Chip liners are manufactured from recycled fibre and are usually not sized and of a lower quality, they are restricted to centre liners in double wall board and inner liners.
Fluted cardboard is the wavy piece of board sandwiched between the liners and gives a box its strength and protection from knocks and impact damage. To create the fluted effect rolls of paper are fed into a corrugated roller machine, this process has been around since the 18th century and was originally used to add ruffles to shirts and hats!
Most recently R Flute was introduced; this is an alternative to B flute board, with the performance the same but the thickness reduced to reduce supply chain costs and save space for users. Now that we have established the key elements that go into creating a corrugated carton all that needs to be done is to stick them all together!
After the paper has gone through a corrugator, in which hot steam is sprayed on the paper to allow it to be pressed, another roller glues one side of the flute. The two liners are then adhered to the board by the machine; the cardboard is then cut each side with a circular saw to give the board straight sides. The corrugator machine then cuts the board as many as nine times, depending on the size of the box; this is determined by the FEFCO guide.
The FEFCO European Federation of Corrugated Board Manufacturers guide is the bible of corrugated cartons, and outlines every style you could imagine — with several categories including 01 categories for commercial rolls and sheets, 02 for slotted-type boxes using one piece of glued board, 03 for telescope style boxes consisting of more than one piece usually a bottom and lid design , 04 for folder type boxes similar to book wrap mailers and 05, 06, 07, 08 and 09 which consist of more complicated styles.
The FEFCO guide is pretty much every box style you could possibly wish for; all that needs to be bespoke to you is the measurements and if extra flaps need adding — of course at Kite our packaging technologists are fully familiar with the guide and can pick out a few styles that they think will work effectively for you. Once the boards have been cut the corrugator separates the boards in to layers and stacks them in to pack quantities ready to be fed in to the trimmer.
A bending machine then folds the boxes along the scored lines, and glue or stitches are applied to the places which will come together to form the box. Glue is the most common adhesive to use for boxes, and is much more hygienic which is important for industries such as food, stitching can also be used as can staples but these are more costly options and mostly only used for heavy duty boxes that need a tougher adhesive.
Once the adhesion has been applied another machine then folds the sections to secure them together and the flat boxes are piled up to be sent out to customers and distributors like us! Finally, the offcuts of paper is recycled and used to produce more boxes and other paper products, many corrugators now produce boxes in the most eco-friendly way possible to ensure that their processes are carbon-neutral.
A simple product, a complex process. How a cardboard box is made Posted on 18 Sep by Tim Brown.
Top 20 Packaging Companies Leading the Global Packaging Industry 2019
For example, a manufacturer may opt not to use full wrap-around corrugated cases and instead substitute corrugated trays shrink-wrapped in plastic. In some cases, this has gone further, eliminating the cardboard altogether. We see this in the shipping of carbonated drinks or bottled spring water where they are shrink-wrapped in plastic film only and then shipped on pallets. The use of less corrugated material in shipping, due to the use of lighter materials or simply alternative and cheaper ideas on how to ship products, would help to explain why the amount of cardboard out in the world seems to remain consistent despite the overall increase in shipping.
Industries in all parts of the world are now thinking of replacing traditional transport packaging solutions made of wood and plywood with almost equal products made of substantially lighter and easily recyclable paper board. The spearhead developer and manufacturer of pallets and transport boxes as well as other transport packaging solutions based on paper board, is the Finnish Eltete Group. The company has its own factories in 15 countries and a sales network reaching in excess over 60 countries. Dimensions and other specifications are easily adaptable according to the customers' demands. Eltete has been on the market for almost 40 years.
An award-winning team of journalists, designers, and videographers who tell brand stories through Fast Company's distinctive lens. Leaders who are shaping the future of business in creative ways. New workplaces, new food sources, new medicine--even an entirely new economic system. Packaging is an ancient practice. Humans have been improvising containers for holding and transporting things for millennia, from baked clay vases to tanned leather satchels to sawed and nailed wooden crates. Lightweight and disposable, they were first used in France in the s to transport the delicate Bombyx mori moth to silk manufacturers—likely because it kept moths alive better than less breathable boxes. Around this time, several entrepreneurs began pushing the boundaries of paper. By we had the corrugated cardboard box as we know it.
Ideal Packaging Material: Corrugated Cardboard
The success story of corrugated cardboard started in , and it is now the transport packaging material of choice. Interactive hall plan. Products Product categories. Download Exhibitor list as txt file Exhibitor list as html file Exhibitor list as csv file Hall plan. MyOrganizer International Representatives.
Carton board challenges wood as the base for transport packaging
The packaging market is dominated by modern, innovative solutions - for the packaging as well as for the manufacturing process. Given the increasing requirements with regard to quality, flexibility and productivity, it is essential to have innovative partners providing support for all processes - from manufacturing, to packaging and transport. As the importance of packaging increases, so does the variety. Manufacturers change the packaging more frequently; lifecycles are reduced significantly. At the same time, the material surface becomes more and more challenging due to superior finishing. While the visual aspect is important, the packaging also has to be functional and serve a purpose.
Jump to navigation. How to recycle paper? Where does it come from? What tools are used to collect paper and transport it to the sorting and recycling facilities? Here they are, step by step:. But before collecting those last bits of paper, Paprec also collects the different packaging used for the spools, the paper reams, cardboard mandrels, and the paper that these are wrapped in.
Cardboard boxes are usually heavy-duty or thick-sheets of paper known for their durability and hardness. Examples of cardboard include packaging boxes, egg cartoons, shoe boxes, and cereal boxes. The steps below provide an explanation of the cardboard recycling system. Collection is the first step of recycling cardboard.
Most items at your favorite supermarket, discount store, or shopping mall were safely delivered in boxes made of corrugated cardboard, and many are displayed in the same boxes, which were manufactured so they could be opened and used for this purpose. Other items may arrive in their own corrugated or uncorrugated paperboard boxes. Because corrugated cardboard is such a versatile packaging material, millions of tons are used each year to protect and display products.
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