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how is cardboard packaging made

how is cardboard packaging made

how is cardboard packaging made插图

From the paper mill,rolls of kraft paper are transported to acorrugating,or converting,plant. At the plant,layers of kraft paper are crimped and glued to form corrugated cardboard,which is then cut,printed,folded,and glued to make boxes.

How are cardboard boxes made?

A brief guide to cardboard boxes by Kite Packaging. 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.

What substrates are used to make cardboard boxes?

It is well known that our packaging technologists love to talk about our 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 our business, and is a product typically associated with the packaging industry.

What is the process of making custom boxes?

An older process for this which is still used for smaller runs is by using a die-cutter where the design is laid out on a large ‘stamp’ and cut out of the board. 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.

What kind of wood is used to make cardboard boxes?

Hardwood includes Oak, Sycamore, Birch and Chestnut and again is sourced predominantly from sustainable SCA forests. Kraft and Test paper is also used to create the fluted paper in between liners which finally create a strong board. A brief guide to cardboard boxes by Kite Packaging.

What is Cardboard?

And even if you haven’t, you will have definitely used a product that was at some stage transported using this material.

What is a pulp mill?

A Pulp Mill is an industrial facility usually large in size which converts timber, woodchips and other wood products into pulp using the Kraft or other processes.

What is the purpose of pulping?

Pulp Processes. The aim of the pulping process is to break down the structure of the fibre source into the fibres ready to be made into market pulp. To achieve this the fibres are put through either of the two processes that are used to develop the pulp.

How is cardboard made?

Cardboard, as you are likely to be aware of, is manufactured using fibres from trees / plants. Pulp is not only produced from timber but can also be created in an environmentally friendly way by recycling woodchips and shavings leftover from lumber mill waste.

What is the chemical process of wood shavings?

The chemical process, as you may have previously read involves cooking the wood shavings in a sulphate solution to digest the wood. Both sulphate and sulphite can be used to separate the fibres from the lignin which, is a natural glue like substance that bonds the fibres.

How many sheets of paper are in a corrugated board?

Simply put, a set of machines in a row, which is designed to adhere three (a standard board), five or seven sheets of paper that shape single, double or triple walled corrugated boards. The corrugator is a continuous system which produces in bulk.

How is pulp made into paper?

Before the pulp can be made into the finished paper product however, it must go through a process called “beating”. In effect, the pulp is squeezed and pounded by machine beaters in a large tub.

The Structure of Cardboard

In our business there are two types of cardboard sheets: solid board and corrugated board, which are the subject of this article. The structure of corrugated cardboard is made up of the corrugated inner layer called the ‘fluting’ or ‘wall’, and this is lined with liners either side. This creates a cushioning effect.

The TreEs Used

All our cardboard is made from sustainably sourced recycled cardboard and paper, and the outside Kraft liner is made from pure pulp which is also sourced from sustainable forests. These are managed by our suppliers who are all FSC accredited.

Making the Corrugated Sheets

To produce corrugated cardboard sheets, the first step is to make the fluting. Cardboard reels go through a series of rollers to form the fluting. There are several sizes, and they are alphabetically categorised, e.g. ‘A’, ‘B’, ‘C’ and so on. The most effective thickness of flute for our cardboard packaging is ‘E’ flute.

Bespoke Printing

We design boxes from scratch based our customers’ briefs. We print a high quality, full colour litho image from artwork supplied by our customers onto a sheet of paper. Once printed, we mount the printed paper sheets on to the corrugated sheets. We then finish the process by die-cutting and creasing the final product.

Order Cardboard Packaging UK Today

If you’re an artisan wine, beer, cider, beverage or preserve supplier in the UK or in Europe, we can help you create impactful and high-quality food and drink packaging for your brand. To find out more, please get in touch. Alternatively, have a look at some of the projects we’ve previously worked on.

What is the difference between a cardboard box and a Kraft box?

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.

How many times does a corrugator cut cardboard?

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.

What is a cardboard box made of?

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.

Why is pulp stone sprayed with water?

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.

What is Kraft paper made of?

The majority of European paper is made using trees from sustainable forests owned by SCA (Svenska Cellulosa Aktiebolaget -English: Swedish Cellulose Company) who plant two trees for every one cut down. Long fibres are also better in tension which is why Kraft paper is often described as having a high tear and burst resistance.

What is fluted cardboard?

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!

What is the color of Kraft paper?

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.

What is the difference between a cardboard box and a Kraft box?

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.

How to tell if a board is fluting?

Fluting comes in various forms to create different thicknesses and strengths of corrugated board. You can use the diagram below to see how fluting is made up, and the varying measurements used to identify the type of fluting. The way that we typically identify the type of fluting in a board is by how many ‘tips’ appear in a 100mm length of the board. Traditional flutes are A Flute (12 tips), B Flute (16 tips), C Flute (14 tips), E Flute (30 tips) and N Flute (45 tips), notice how C Flute is in between A and B – that’s because C came after A and B…just to confuse things! The number of tips in 100mm also affects the thickness of the board, less tips mean a bigger wave which also means a thicker board so A is the thickest board (around 4.5mm) and N the thinness, making it ideal for direct litho printing and decorative packaging.

How many times does a corrugator cut cardboard?

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.

What is cardboard box?

Cardboard boxes are of course one of the core products of our business, and is a product typically associated with the packaging industry. Of course, it’s easy to forget that the cardboard boxes you use on a regular basis were once humble trees, and we often get asked what the process is for turning trees in to corrugated cardboard.

What is fluted cardboard?

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 18 th century and was originally used to add ruffles to shirts and hats!

How many tips does a flute have?

Traditional flutes are A Flute (12 tips), B Flute (16 tips), C Flute (14 tips), E Flute (30 tips) and N Flute (45 tips), notice how C Flute is in between A and B – that’s because C came after A and B…just to confuse things! The number of tips in 100mm also affects the thickness of the board, less tips mean a bigger wave which also means …

How is wood pulp made?

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.

What do they add to cardboard boxes to make them brown?

When the pulp is available, it’s now ready to enter paper production. To have the familiar color of cardboard boxes, they add clay and chalk for the brown opacity. They also add items like starch, rosin, and gums for the sizing effect.

What is pulping in pulping?

Pulping is the process of breaking down the raw material structure. Once broken, you’ll get with fibers. These are ready for processing into market pulp.

How is paper made?

Papermaking starts with vendors collecting tree saps. The quality of the paper depends on the specific species of trees chosen. Wood chipping and excess tree materials from manufacturers is another way of making paper.

What is boxboard made of?

The board used to make a boxboard or paperboard carton is called (surprisingly!) boxboard or paperboard. Most boxboard mills in Canada use 100% recycled pulp, as much as 60% of it being old corrugated boxes or containers (OCC). The other components are old newspapers, used printing and writing paper, and old boxboard (OBB) itself.

What is the process of blending linerboard and medium?

The linerboard and the medium are shipped from the mill to a corrugated converter who uses a piece of machinery called a corrugator to blend the medium and the linerboard together. Once blended, the combined sheet can be printed, slotted, creased and folded as noted above, then sent on to the customer or his packer to be filled with product.

What is corrugated box?

The corrugated box is primarily used for the shipping of heavier products to factories and supermarkets but it is also widely used to deliver consumer goods such as appliances and electronics, and food and beverages. For further information on corrugated boxes see www.corrugatedboxescanada.org.

What are Kraft paper bags?

Kraft paper bags essentially come in two types: stronger industrial sacks containing things like flour and cement, and lighter grocery bags used at retail. For more information on kraft paper bags see www.paperpackagingcanada.org.

What is the process of milling paper?

Non-paper materials such as plastic, glass and metals are removed through a series of cleaning and screening processes. The paper fibres are then pumped onto a fast-moving screen to form paper or board. The rest of the process involves removing the moisture out of the paper or board so that it can be wound onto big rolls or cut into sheets.