Carton & Corrugated - PowerPoint Presentation

1. Carton & Corrugated Fibre BoardBy Dr. Abhishek Thakur(Assistant Professor)College of Fisheries, KishanganjBASU, PatnaSubject: Fish Packaging TechnologyDate of Lecture: 13.05.2020

2. Boards for food packagingSolid white board produced from bleached chemical wood pulp.

3. Boards for food packagingFolding Box board (Duplex or Triplex).Duplex: The liner is produced from the bleached chemical wood pulp and the remainder of the board from unbleached mechanical wood pulp (ground wood).

4. Boards for food packagingOther board grades used for food packagingTriplex: Outer liners are from bleached chemical wood pulp and the middle layer is from ground wood pulp.Chip board: All plies of chipboard are made from recycled waste paper and has natural grey colour. Not suitable for direct contact with food stuffs. It has poor printing surface.

5. Boards for food packagingWhite lined chipboard: White lined chipboard has inner plies of recycled waste paper; the outer liner is bleached chemical pulp. Not suitable for direct exposure to food products which are susceptible to odour and taint. Used for food packaging if the product is pre-wrapped (for dry products such as corn flakes). The liner gives a good white printing surface, e.g. Kraft lined chip board: Virgin kraft liner on chip board gives enhanced strength and appearance and suitable as an outer carton for distribution of confectionery and ice cream products.

6. Carton board and carton makingThere are 4 basic types of carton boards.Solid white boardFolding box board (Duplex or Triplex)Chip board.White lined chipboard

7. What is a carton?Carton is defined as any holding receptacle made of carton board from about 250 microns (0.01”) to 1000 microns (0.04”) caliper or thickness. It can be of any shape and can involve any method of construction from glueing, folding, tucking stitching etc. This is not to be confused with a container which is constructed from solid fibre board having thickness of over 1000 microns (0.04”) caliper which is generally used as on outer case for transportation purposes from manufacturer to retail outlet.

8. Carton makingThere are 3 stages in carton making and distribution.Carton board is printed mostly in sheet form. The most popular printing technique being offset lithography.

9. Carton makingThe next step is cutting and creasing. Here the carton blanks are cut out and the folding lines are made. The outer trim is then stripped off.The individual carton which is still flat is then passed through a folding and gluing machine at very high speeds, when a skillet is obtained.Then the folding cartons (in the form of either blank or skillet) is supplied to the carton user in a lay flat condition.

10. Carton making

11. The carton must be stiff enough to hold the contents without bulging. The bulged cartons are difficult to stack, will have poor appearance and the contents may leak out. The creasing operation is one of the important factors in determining the quality of a carton. The function of a crease is to weaken the structure of the board. Bowed sides are formed by creases that are too stiff compared to stiffness of the board.

12. Carton making

13. Creasing conditionsThe quality of the crease is affected by moisture content, relative humidity of the atmosphere, the thickness of the board as well as creasing conditions.Creasing conditions include rule thickness, grove width and the pressure exerted during the operation.

14. Types of cartonsA variety of shapes of folding cartons are available and used by trade.Two major classesTray typeTube type

15. Tray type constructionIn these, the side and end wall panels are hinged to an unbroken bottom panel. The closing of the carton is done by a variety of means, such as glue flaps, hook engaging slits etc.Trays have larger area for initial filling. Hence these are useful in all such cases where it is difficult place the contents through the ends.

16. Tube styleIn general these will have a seam or a flap which is glued at the manufacturers plant. The carton is formed or erected at the user end by applying pressure along the crease lines at the opposite creased edges of the flat carton forms.Image.The tube types are further subdivided into other categories depending upon the features of end closure.Glue end cartons.Tuck end cartons.Lock end cartons.In addition to the above there are some special types of construction which may incorporate features of both the types or additional features as in the case of cigarette packs with flip type opening. However, most of the carton manufacturers design cartons in such a way that they use minimum board to hold maximum volume of goods to be packed.

17. Tube styleGlue end cartons

18. Tube styleTuck end cartons

19. Tube styleLock end cartons

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21. Corrugated Fibre Board BoxesThe packaging code of British standard institution defines corrugated board as one or more corrugated sheets of paper faced on both sides with flat paper. The paper that is corrugated (or fluted) is referred as corrugating medium or fluting medium.Paper that is used as facing (That is the paper glued to corrugated sheet on each side) is referred to as a liner. The operation of gluing the liner to the corrugated sheet is called facing. The fluted sheet faced only on one side is called single faced paper which is used as a cushioning material for packaged goods to prevent internal damage with the carton or a box.

22. Corrugated Fibre Board Boxes

23. Corrugated Fibre Board Boxes

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26. Wall boardsCorrugated board is made from a corrugated sheet faced on each side of the fluted sheet is called single wall board.Double wall board has 3 facings and two fluted sheets with the following sequence. Liner, fluted sheet, centre liner, fluted sheet, liner.Triple wall board has seven layers of paper three fluted and four liners alternatively.

27. Type of papers used as linersKraftTest tin paper (also called as jute sheet)Chip liner made from straw or chip board pulpKraft is the strongest test (made from combination of low grade pulp and craft pulp). The quality of the liner is expressed in terms of basis weight or weight in grams per square meter. Kraft liner for corrugated board should not be less than 130 gsm and 0.23 mm thick. If other papers are used as liners, then the grammage of such papers may be more say 150 gsm.

28. Types of flutesThere are four types of flute in general use designated as A B C and E. They are distinguished on the basis of flute height and number of corrugations per unit length.

29. Flute formNumber of Corrugation/meter (mm)Corrugation heightA105-1254.5-4.7B150-1852.1-2.9C120-1453.5-3.7E290-3201.1-1.2

30. Stiffness and rigidity are the function of number of corrugations per unit length. They increase with number; cushioning ability is a function of height of the corrugations. Different flute forms combine these properties in different proportions.

31. Principle operations in board and box makingCorrugate one layer of paper called the fluting or corrugating medium and then using an adhesive, bond it to another layer of paper called liner. This results in a single faced paper.Using an adhesive, paste a third layer of paper (the second liner) to the corrugated side of single faced paper producing a single wall board.Trim the sheets at the edges, cut into blanks (Blank is nothing but rectangular pieces of required size to make a box).Apply indentions or score lines by pressing on the blanks that are perpendicular to the flutes and these score lines later serve as hinges for the box flaps. The type of board decides the width, depth and shape of score line.Print the blanks for identification and sales appeal.Make slots for the flaps. Small width of the material at the end of the score limes is removed to enable easy folding of the overlapping faces or flaps.Apply indentations that are parallel to the flutes that will become edges of the box. These indentations are called creases.Fold the blanks on its crease and seal it by stitching/glueing/gum taping or by stapling. The box is ready for the user.

32. Strength of the corrugated fibreboard boxAbility to withstand rough handling resistant to impact, resistance to puncture and bending which depends on puncture resistance and bending stiffness of the board respectively.Ability to withstand compressive load in stalking.Depends on the perimeters (perimeter) 1/3Increases with flute height.Increases directly with strength (ring stiffness) of the paper.Depends on the busting strength of the board.Depends on the relative humidity of the atmosphere.Depends on the fabrication defects of the board and the box.

33. Selection criteria of corrugated fibre board containersNature of the contentsWeight of the contentsVolume of contentsMode of transportStack height in warehouse and also in transport vehicles.Duration of stackingEnvironmental conditions during storage and transport.Handling conditions during distributionSpecial requirement (inspection, ventilation and hand holes)Pallet or container size.Cost and availability.

34. Advantages of corrugated fibre board containersLighter and hence reduced freight chargesStored and transported in lay flat form (saves space)Can be printed and decorated.Free from infestationAvailable in various shapes.Provides good sun shining.Can be made pilfer proof or tamper evident.Can be reused.Environmentally friendly.

35. DisadvantagesNot water resistance (Can be made water resistant to some extent, by using coated papers)Not highly puncture resistant.No resale value. 

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