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Objective of study
The objective behind the study of this topic was the hunger of
knowledge about a completely new industry viz Corrugated
Packaging.
There are studies been made on packaging industry but the
corrugation sector was not given so much importance, I wanted to
bring it to everyones notice that an industry known as corrugated
packaging not only exists but also yields great returns and has a
lot of scope for development.
Corrugated Packaging
Chapter I
Packaging Industry
Packaging overview
History of packaging
Factors
to
consider
packaging decision
when
making
Corrugated Packaging
Packaging an overview
Packaging is the science, art and technology of enclosing or protecting
products for distribution, storage, sale, and use. Packaging also refers to the
process of design, evaluation, and production of packages. Package
labelling (BrE) or labeling (AmE) is any written, electronic, or graphic
communications on the packaging or on a separate but associated label.
Packaging is heavily integrated into our daily lives, we see it all around us,
on everyday items such as chocolate bars and potato chip (crisp) packets- As
explained below, the main use for packaging is protection of the goods
inside, but packaging also provides us with a recognisable logo, or
packaging, we instantly know what the goods are inside
Corrugated Packaging
For each product's needs, there are good packaging solutions. Though
packages are often taken for granted, they are the result of many years of
innovation -- in some cases accidental. A brief review of the more popular
packaging developments are included in this fact sheet.
Paper and Paper Products
One way of placing packages into categories is to describe them as flexible,
semi-flexible, or rigid. Flexible packaging includes the paper sacks that dog
food comes in, the plastic bags that hold potato chips, and the paper or
plastic sacks in which we carry home our purchases. An example of semiflexible packaging is the paperboard boxes that cereal, many other food
products, small household items, and many toys are packaged in. For many
non-food items, the packaging is made more rigid by formed packing
materials that slip inside the box and hold the product and its accessories or
components in place. Forms of rigid packaging include crates, glass bottles,
and metal cans.
Cloth or paper may be the oldest forms of flexible packaging. Flexible
packaging is the most "source-reduced" form of packaging, that means that a
flexible package has the least amount of material compared to other forms of
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Corrugated Packaging
packages that would hold the product. This also means that flexible
packaging adds very little weight to the overall product, and there is very
little to discard when the package is empty.
The use of flexible packaging materials began with the Chinese, They used
sheets of treated mulberry bark to wrap foods as early as the first or second
century B.C. During the following centuries, the Chinese also developed and
refined the techniques of paper making. Knowledge of how to make paper
gradually moved west across Asia and into Europe. In 1310, paper making
was introduced to England. The technique arrived in America in
Germantown, Pennsylvania, in 1690.
Paper is basically a thin sheet of cellulose. Cellulose is a fibrous material
derived from plants. Early paper was made from cellulose fibers derived
from flax, the plant that also gives fibers for linen cloth. As demand for
paper grew, old linen rags were sought as a source of fiber.
In 1867, the process for deriving useful cellulose fiber from wood pulp was
developed. Because wood was so cheap and plentiful, this fiber source
rapidly replaced cloth fibers as the primary source of paper fiber. Today,
virtually all paper has wood pulp as the source of cellulose fiber.
An important step for the use of paper in packaging came with the
development of paper bags. Commercial paper bags were first manufactured
in Bristol, England, in 1844. Shortly thereafter, in 1852, Francis Wolle
invented the bag-making machine in the United States. Further
advancements during the 1870s included glued paper sacks and the gusset
Corrugated Packaging
design, producing the types of paper bags used today. In 1905, machinery
was invented to automatically produce in-line printed paper bags.
With the development of the glued paper sack, the more expensive cotton
flour sacks could be replaced. But a sturdier multiwalled paper sack for
larger quantities did not replace cloth until 1925, when a means of sewing
the ends was finally invented.
Another important use of paper in packaging came with the development of
paperboard -- the kind of paper that packages a box of cereal. The first
paperboard carton -- often called a cardboard box -- was produced in
England in 1817, more than two hundred years after the Chinese invented
cardboard or paperboard.
Another common form of "cardboard" based on corrugated paper appeared
in the 1850s. Basically, this form of cardboard is made from thin sheets of
paperboard that are molded into a wavy shape and then "faced" or
sandwiched between two flat sheets of paperboard. The strength, lightness,
and cheapness of this material make it very useful for shipping and storing.
However, replacing wooden crates with the new paper alternative would
prove to be something of a battle. Nevertheless, about 1910, after much
litigation between manufacturers and the railroads, shipping cartons of faced
corrugated paperboard began to replace self-made wooden crates and boxes
used for trade. Today, cardboard boxes -- more accurately called "C-flute
corrugated paperboard cartons" -- are used almost universally for product
shipping.
Corrugated Packaging
Corrugated Packaging
Corrugated Packaging
until the late 1960s glass containers dominated the market for liquid
products. A typical modern bottle-making machine automatically produces
20,000 bottles per day.
While other packaging products, such as metals and plastics, were gaining
popularity in the 1970s, packaging in glass tended to be reserved for highvalue products. As a type of "rigid packaging," glass has many uses today.
High weight, fragility and cost have reduced the glass markets in favor of
metal and plastic containers. Still, for products that have a high quality
image and a desire for high flavor or aroma protection, glass is an effective
packaging material. The packaging glass used today is the only type of glass
accepted in US recycling programs.
Metals
Ancient boxes and cups, made from silver and gold, were much too valuable
for common use. Metal did not become a common packaging material until
other metals, stronger alloys, thinner gauges and coatings were eventually
developed.
One of the "new metals' that allowed metal to be used in packaging was tin.
Tin is a corrosion-resistant metal, and ounce-for-ounce, its value is
comparable to silver. However, tin can be "plated" in very thin layers over
cheaper metals, and this process made it economical for containers.
The process of tin plating was discovered in Bohemia in 1200 A.D., and
cans of iron coated with tin were known in Bavaria as early as the 14th
century. However, the plating process was a closely guarded secret until the
1600s. Thanks to the Duke of Saxony, who stole the technique, it progressed
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Corrugated Packaging
across Europe to France and the United Kingdom by the early 19th century.
After William Underwood transferred the process to the United States via
Boston, steel replaced iron, which improved both output and quality. The
term 'tin can' referred to a tin-plated iron or steel can and was considered a
cheap item. Tin foil also was made long before aluminum foil. Today many
still refer to metal cans as 'tin cans' and aluminum foil as 'tin foil', a
carryover from times well past.
In 1764, London tobacconists began selling snuff in metal canisters, another
type of today's "rigid packaging." But no one was willing to use metal for
food since it was considered poisonous.
The safe preservation of foods in metal containers was finally realized in
France in the early 1800s. In 1809, General Napoleon Bonaparte offered
12,000 francs to anyone who could preserve food for his army. Nicholas
Appert, a Parisian chef and confectioner, found that food sealed in tin
containers and sterilized by boiling could be preserved for long periods. A
year later (1810), Peter Durand of Britain received a patent for tinplate after
devising the sealed cylindrical can.
Since food was now safe within metal packaging, other products were made
available in metal boxes. In the 1830s, cookies and matches were sold in tins
and by 1866 the first printed metal boxes were made in the United States for
cakes of Dr. Lyon's tooth powder.
The first cans produced were lead-soldered by hand, leaving a 1 1/2-inch
hole in the top to force in the food. A patch was then soldered in place but a
small air hole remained during the cooking process. Another small drop of
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Corrugated Packaging
solder then closed the air hole. At this rate, only 60 cans per day could be
manufactured.
In 1868, interior enamels for cans were developed, but double seam closures
using a sealing compound were not available until 1888.
Aluminum particles were first extracted from bauxite ore in 1825 at the high
price of $545 per pound. When the development of better processes began in
1852, the prices steadily declined until 1942, when the price of a pound of
aluminum was $14. Although commercial foils entered the market in 1910,
the first aluminum foil containers were designed in the early 1950s while the
aluminum can appeared in 1959.
The invention of cans also required the invention of the can opener! Initially,
a hammer and chisel was the only method of opening cans. Then in 1866,
the keywind metal tear-strip was developed. Nine years later (1875), the can
opener was invented. Further developments modernized the mechanism and
added electricity, but the can opener has remained, for more than 100 years,
the most efficient method of retrieving the contents of a can. In the 1950s,
the pop top/tear tab can lid appeared and now tear tapes that open and reseal
are popular.
Collapsible, soft metal tubes, today known as "flexible packaging," were
first used for artists paints in 1841. Toothpaste was invented in the 1890s and
started to appear in collapsible metal tubes. But food products really did not
make use of this packaging form until the 1960s. Later, aluminum was
changed to plastic for such food items as sandwich pastes, cake icings and
pudding toppings.
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Corrugated Packaging
Plastics
Plastic is the newest packaging material in comparison with metal, glass,
and paper. Although discovered in the 19th century, most plastics were
reserved for military and wartime use. Plastics have become very important
materials and a wide variety of plastics have been developed over the past
170 years.
Several plastics were discovered in the nineteenth century: styrene in 1831,
vinyl chloride in 1835, and celluloid in the late 1860s. However, none of
these materials became practical for packaging until the twentieth century.
Styrene was first distilled from a balsam tree in 1831, but the early products
were brittle and shattered easily. Germany refined the process in 1933 and
by the 1950s styrofoam was available worldwide. Insulation and cushioning
materials as well as foam boxes, cups and meat trays for the food industry
became popular.
Vinyl chloride, discovered in 1835, provided for the further development of
rubber chemistry. For packaging, molded deodorant squeeze bottles were
introduced in 1947 and in 1958, heat shrinkable films were developed from
blending styrene with synthetic rubber. Today some water and vegetable oil
containers are made from vinyl chloride.
Celluloid was invented during the American Civil War. Due to a shortage of
ivory, a United States manufacturer of billiard balls offered a $10,000
reward for an ivory substitute. A New York engineer, John Wesley Hyatt,
with his brother Isaiah Smith Hyatt, experimented several years before
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Corrugated Packaging
13
Corrugated Packaging
In the 1660s, imports into England often cheated the public and the phrase
"let the buyer beware" became popular. Inferior quality and impure products
were disguised and sold to uninformed customers. Honest merchants,
unhappy with this deception, began to mark their wares with their
identification to alert potential buyers.
Official trademarks were pioneered in 1866 by Smith Brothers for their
cough drops marketed in large glass jars. This was a new idea - using the
package to "brand" a product for the benefit of the consumer.
In 1870, the first registered U.S. trademark was awarded to the Eagle-Arwill
Chemical Paint Company. Today, there are nearly three-quarters of a million
(750,000) registered trademarks in the United States alone. Labels now
contain a great deal of information intended to protect and instruct the
public.
A Review
From containers provided by nature to the use of complex materials and
processes, packaging has certainly changed. Various factors contributed to
this growth: the needs and concerns of people, competition in the
marketplace, unusual events (such as wars), shifting lifestyles, as well as
discoveries and inventions. Just as no single cause influenced past
development, a variety of forces will be required to create the packages of
the future, but a very important factor will always be consumer choice.
Ultimately, only the packaging that our society demands is produced. We
choose by the products we purchase.
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Corrugated Packaging
product.
structures that make the product easier to use while stylistic designs
can make the product more attractive to display in the customers
home.
Distributor
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Corrugated Packaging
most often with the intention of having the design on the market for an
extended period of time. In fact, changing a products packaging too
frequently can have negative effects since customers become
conditioned to locate the product based on its package and may be
confused if the design is altered.
Environmental
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Corrugated Packaging
Chapter II
Corrugated Packaging Industry
Corrugated Packaging overview
Industry Info
17
Corrugated Packaging
18
Corrugated Packaging
high precision boxes with attractive graphics and large integrated production
capacities.
Corrugation Industry .
Corrugated boxes industry is a packaging industry. Corrugated boxes are
manufactured from paper. Initially the paper used for manufacturing was
obtained from wood pulp which is known as virgin paper. Now a days, in
order to reduce the wastage and make optimum utilization of resources,
recycled quality paper is also used which is known as non- virgin paper.
Boxes were also made from bagasse (by product of sugar cane), but it was
not environment friendly. Thus, due to the above reasons recycled paper is
being largely used by the industries today to manufacture corrugated boxes.
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Corrugated Packaging
Chapter III
History of Corrugated Packaging
Industry
20
Corrugated Packaging
History of Corrugated
950 BC
The ancient Egyptians produced the first writing material by pasting together
thin layers of plant stems..
100 BC
The Chinese created the first authentic paper from bamboo and mulberry
fibers.
1400s AD
Paper mills appeared in Spain, Italy, Germany and France
1690
The first sheet paper mill in North America was built near Philadelphia.
1767
England wanted to regain their loss of colonial paper exports. They imposed
the Stamp Act, which included a tax on all paper made in the colonies. Many
consider this fuel for the American Revolution.
1803
The first continuous papermaking machine was patented.
1854
In England, the first pulp from wood was manufactured
1856
The first known corrugated material was patented for sweatband lining in
tall hats of Victorian Englishmen.
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Corrugated Packaging
1871
Unlined corrugated first appeared as a packaging material for glass and
kerosene lamp chimneys
1874
A liner was added to one side of the corrugated material to prevent the flutes
from stretching.
1894
Corrugated was slotted and cut to make the first boxes. Wells Fargo began
using corrugated boxes for small freight shipments.
1903
Corrugated was first approved as a valid shipping material and was used to
ship cereals.
1909
Rubber printing plates were developed which allowed for greater design
creativity.
1914
Tariffs imposed on corrugated shipping containers were ruled
discriminatory.
1957
Flexographic printing virtually replaced letterpress and oil-based ink.
1960s
The flexo folder-gluer was invented.
Early 1980s
Preprinted linerboard emerged.
Late 1980s
New developments in the anilox roll, plate and press design drove the
industry into short-run, high-graphic products.
1991
The edge crush test was added to Item 222 and Rule41 as an alternative to
burst strength and basis weight, allowing the manufacture of lighter weight
liners.
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Corrugated Packaging
Chapter IV
Corrugated Packaging
What is Corrugated packaging
Why Corrugated Packaging
23
Corrugated Packaging
Corrugation
An introduction
Corrugated board is essentially a paper sandwich consisting of corrugated
medium layered between inside and outside linerboard. On the production
side, corrugated is a sub-category of the paperboard industry, which is a subcategory of the paper industry, which is a sub-category of the forest products
industry. Traditionally, corrugated is best known for its structural strength
that offers protection to packaged products throughout the transportation
cycle. However, it has evolved over the course of time and today it is a much
more versatile product. It can be easily cut to any shape and creased to fold
in any direction. Thus, corrugated boards can be further converted to
produce cartons, boxes, cases, containers, inherent fitments/ accessories such
as interlockers, partitions, dividers, pads, plates, supporters, fillers etc. which
provide internal cushioning and restrict movements. The various shapes and
forms described above are referred to as corrugated boxes for sake of
brevity.
Packaging done by corrugation helps in the movement of goods from the
manufacturer to the seller to the buyer without any hassles of breakages,
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Corrugated Packaging
Why Corrugated?
Corrugated. It's not just a brown box.
Corrugated is a complete, high-performance material design, manufacturing
and delivery system. Corrugated is the preferred packaging material because
it is:
Versatile
Lightweight
Sustainable
Environmentally Responsible
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Corrugated Packaging
Customizable
Graphically Appealing
Cost-Effective
Chapter V
Features Of Corrugated Packaging
& Raw Materials Used
26
Corrugated Packaging
ratios,
printability,
moisture
barriers
and
recyclability.
Corrugated components, designs and end products are manufactured
on sophisticated, automatic equipment that reduces costs and ensures
consistent performance.
The vast majority of corrugated products are designed and prototyped
with advanced, computer-aided design and manufacturing systems,
providing customers with the best and most cost-effective solutions to
their packaging challenges.
Infinitely Customizable.
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Corrugated Packaging
Tenaciously Protective.
Corrugated combines structural rigidity with superior cushioning qualities.
Containers, packages and pallets nest products in an optimally protective
environment, so even heavy or fragile contents arrive undamaged.
Corrugated offers excellent tear, tensile and burst strength to withstand
shipping pressures. It resists impact, drop and vibration damage while
offering uniform stacking and weight distribution so the load stays put,
regardless of the form of transportation.
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Corrugated Packaging
reusable and
recyclable.
Graphically Appealing.
Corrugated containers and packaging are mobile billboards that create
product image wherever they travel. Corrugated displays are eye-catching
modular units that can be set up quickly and recycled at the end of a
promotion.
Corrugated is a very flexible medium that accommodates a wide range of
printing options to support the end-use requirement:
Preeminently Cost-Effective.
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Corrugated Packaging
One of the least expensive containers ever developed, the overall cost of
corrugated shipping containers is usually between one percent and four
percent of the value of the goods they carry.
The cost of labor and tools required to produce, fill, and move the container
is low. The cost of shipping is low, due to lower weights and higher fill
densities than alternative packaging. The trend toward lightweighting will
continue to drive down shipping costs. Low raw material costs and mass
production of corrugated containers makes them particularly cost-efficient.
The ultimate contribution to cost reduction is when corrugated is used as an
all-in-one shipping, storage, advertising and display medium - a growing
trend both in warehouse and other retail stores.
Environmentally Responsible.
Corrugated, made from a natural renewable resource, has a great
environmental record. Corrugated is frequently manufactured using high
percentages of secondary fiber (including old corrugated containers, kraft,
old newspapers and even straw), thereby diverting these materials from the
municipal solid waste stream.
In 2005, 24.7 million tons of corrugated were recovered and recycled in the
U.S. -- that's 76.6 percent of all containerboard produced in the same year.
Corrugated has the best recycling rate of any packaging material used today.
And that's what happens after the corrugated box has been used and reused
time and time again to store and move items around the home, store and
office.
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Corrugated Packaging
RAW MATERIALS
1 Craft paper: Craft paper used is recycled paper. The quality of the craft
paper depends upon the burst factor( BF). This burst factor is of A, B and
semi A grade. A grade is the best quality paper made of wood pulp. It is
also called virgin quality paper. But since it is not environment friendly, it
is not used. B grade is indigenous recycled paper of 12 BF while semi A
grade is imported recycled paper between 16- 25 BF. These two types are
called non virgin quality papers. Customers order craft papers from these
two grades and the BF entirely depends upon the customers and so, no
specific quality craft paper is recommended. Also the papers are ordered
according to the cut size or the deckal as we know it in the corrugation
industry. It varies according to customers requirements. He can order
accordingly. Also gram per sq.m. (GSM) also varies in craft paper. GSM
varies from 80-200. what the customer wants depends entirely on his
choice.
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Corrugated Packaging
2 Gum: Gum is basically used for corrugating and pasting machine. There
are two different gum used for these machines. One is corrugation gum
for corrugating machine and another one is pasting gum for pasting
machine. Both are starch based. Silicate based gum is also available, but
it is hazardous to workers hands as it contains pieces of glass.
Corrugating gum used in corrugation machine is half cooked. The reason
for this is when it goes through the heater, it gets completely cooked and
fully effective. Pasting gum is completely cooked and contains 18- 20%
starch.
3 Pins:
for pinning machine, pins are required. There are two types of
pins- aluminium and rust proof pins. Basically, rust proof pins are
recommended as it is cost effective and also because it does not rust.
Aluminium pins cost Rs. 50/ kg. while rust proof pins cost Rs. 38/ kg.
and 1 kg. contains around 2000 pins. Also the wires used for these pins is
MS Galvanised. The thickness of the pin is around 16 guage.
4 Binding cloth and fevicol are other raw materials used. These are not the
main raw materials but value adding materials. Binding cloth required in
a day is 20 m.
These are some of the basic raw materials used for the manufacture of
the corrugated packaging.
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Corrugated Packaging
Chapter VI
Corrugated Box Structure
33
Corrugated Packaging
The design of the box varies depending on the purpose of its use. A
manufacturer might choose to design corrugated boxes to be sized
and/or shaped to best suit the purpose it will be used for.
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Corrugated Packaging
Linerboard
Medium
These two components are made of a unique type of heavy paper, referred to
as container board.
What is Linerboard? Linerboard is the flat cardboard surface that adheres
to the medium and acts as liners.
What is Medium? The medium is the grooved corrugated paper channels in
between the liners.
Double Wall:
35
Corrugated Packaging
36
Corrugated Packaging
Please note, to the right, the diagrams indications of the various flute sizes
currently manufactured on the market:
F is the smallest flute size shown.
E is the second to smallest flute size.
C is considered the medium flute size.
B is smaller than the C size and bigger than the E size.
A is the largest flute size and most commonly used on the market.
While there are a number of new specialized flute sizes currently being
worked on for production, the ones listed above are the most common ones
available and as noted above, already on the market for purchase. The
largest and larger flutes tend to be used for handling boxes since it can
handle more pressure on top of it and the smaller flutes are used mostly for
smaller retail cardboard box purposes.
Depending on the purpose the cardboard box is used for, various sizes of
flutes can be combined in creating the particular box in such a manner as to
cause the box to adjust its handling ability as a result of the particular
37
Corrugated Packaging
Box Dimensions
Dimensions are given in the sequence of length,
width and depth. Internationally, the words
length, breadth and height may be used to
express these dimensions. The dimensions of a
box are described based on the opening of an
assembled box, which can be located on the top or the side, depending on
how it is to be filled. The opening of a box is a rectangle; that is, it has two
sets of parallel sides. The longer of the two sides is considered its length, the
shorter of the two sides is considered its width. The side perpendicular to
length and width is considered the depth of the box.
Dimensions can be specified for either the inside or the outside of the box.
Accurate inside dimensions must be
determined to ensure the proper fit for
the product being shipped or stored. At
the same time, palletizing and
distributing the boxes depends on the
outside dimensions. The box
manufacturer should be informed as to which dimension is most important
to the customer.
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Corrugated Packaging
Chapter VII
Production Process of Corrugated
Packaging
39
Corrugated Packaging
Production Process
Paper for Corrugated Board
Fluting Paper
(a)Recycled:
Made from recycled paper. The fibre content, quality and hygiene is vary.
With certain process this recycled paper could match the semi-chemical
fluting
it
is
more
abrasive.
(b)Semi-Chemical:
Made from virgin fibre hardwood & mixed with recycled paper (<35%).
More expensive than recycled fluting, but higher quality.All recycled paper
is recommended to be used within 7 days - 6 months. While Kraft Liner &
Semi Chemical Fluting is recommended to be used within 11 days - 12
months
LinerPaper
TestLiner(Recycled):
Made from recycled paper and processed with water sothat it become pulp.
Afterward cleaned and process again. The fibre than mixed with chemical
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Corrugated Packaging
and
starch
a)Brown
Test
glued
b)Brown
become
Liner
new
c)Coated
Test
paper,
d)White
such
as:
Top
Test
Liner(Kraft):
Made from pine trees with long and strong fibre and heated ntil become
soft.Then rinse. Aferward process become paper with smoother surface,such
as:
a)Brown Kraft b)White Kraft c)White Top Kraft d)Coated Kraft
The details of the production process along with diagrammatic
representation are followed on the next page.
Corrugator Machine
Wet End :
1. Mill Roll Stand - liner
2. Pre-heater
3. Single Facer
4. Preconditioner
5. Mill Roll Stand - medium
6. Bridge
7. Mill Roll Stand - based liner
8. Web Break
9. Web Guide
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Corrugated Packaging
Dry End :
Rotary Shear
Slitter Scorer
Cutoff
Stacker
Converting Process :
1. Flexo Printing
2. Slotting / Die Cutting (Rotary & Flat Bed)
3. Folding, Gluing / Stitching
4. Bundling
1. Flexo Printing
a. Printing can be made with Top or Bottom Printing
b. Printing Plate could be rubber or Photopolymer
c. Printing unit depend on the needs, from 2 to 6 colors
Flexo printing process
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Corrugated Packaging
Most of simple job using only 2 solid colors, but for the high quality printing
they have used up to 6 colors - though it is rare in this region.
a) Printing Machine
Most of the printing machine always combine with Slotter to make RSC
Boxes (Regular Slotted Container).
Prefeeder
Printing Unit
Creaser/Slotter
Delivery/Stacker
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Corrugated Packaging
2. Folder Gluer
Offline
3. Diecutting
Die cut is used for Wrap around boxes, There are 2 kind of die cutting
machine :
Rotary and
Flat Bed
44
Corrugated Packaging
45
Corrugated Packaging
Flute Type :
46
Corrugated Packaging
Chapter VIII
47
Corrugated Packaging
48
Corrugated Packaging
Telescope Boxes
Trays
49
Corrugated Packaging
Chapter IX
Corrugated Recycling Process
50
Corrugated Packaging
Recycling Process
Corrugated is a highly useful, cost-efficient, versatile packaging material
that is used to ship just about every product under the sun, all around the
world. But it doesn't stop there: corrugated is also the most-recycled
packaging material on earth, with a recovery rate of about 73 percent.
Businesses, retailers and consumers at home collect and return their used
corrugated containers to be recycled into new ones. While almost
everyone contributes to corrugated's recycling success, fewer people may
know where those boxes go from the collection point, or how they are
processed to produce new corrugated material.
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Corrugated Packaging
pulled
out
of
the
repulper.
Corrugated Packaging
Chapter X
Changes In The Industry
53
Corrugated Packaging
Decades of Change
Improvements in raw materials and manufacturing processes and new
uses for corrugated boxes have been numerous.The paperboard used for
early corrugated containers was made from straw. About 100 years ago, the
kraft process was developed to make pulp from wood. Kraft pulp is
generally stronger than that made with a any other process, and corrugated
box manufacturers quickly adopted the superior kraft process. Papermaking
improvements gradually extended the range of grades. Chemical additives
were developed to improve wet strength or impart other properties. More,
recently, higher-strength containerboard, for a given weight, has been
developed thorough either mechanical or chemical procedures. Corrugators
have increased their speeds. Flying splicers permit the change of
containerboard rolls without shutdown. Triplex cutoff units permit changing
order dimensions with little delay. Computers improve the control and
adjustment of many machine functions. Printing has undergone dramatic
change. The development of rotary presses, and of flexography using water54
Corrugated Packaging
based inks, improved speed and reduced crush damage. Preprint and labeling
techniques coincide with, and provide new opportunities in, America's
changing retailing practices. Developments in adhesives, inks, waxes and
other coatings have contributed to an array of new uses for corrugated. Many
would not have been possible without the concurrent development of new
chemicals. The most, dynamic packaging developments came from simple
adaptations. Giant corrugated boxes for furniture, appliances, and bulk
products. Coatings that permit the use of corrugated for fresh fruits and
vegetables, meat, poultry and fish and bag-in-box to replace glass containers
for liquids are concepts that were never conceived by the pioneers of the
industry. Today, corrugated containers are the largest segment of the
packaging industry.
Future Trends
Inline Automatic Board and Box making plants will ease out the
present semi automatic production processes.
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Corrugated Packaging
Chapter XI
Company Profile
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Corrugated Packaging
COMPANY PROFILE
Name: Akshar Pack
Location: 119/c, Bombay talkies compound, Malad(w), Mumbai 400 064.
Telephone: 022-28813326
Hours of Operation: 9am -6pm
Line of operation:
Akshar pack is a proprietary concern who manufactures corrugated
boxes. The corrugated boxes manufactured are made to order and
customized on the basis of the specifications drawn by the customer.
The company is growing in leaps and bounds due to its steady policies of
operation and constant effort to achieve customer satisfaction.
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Corrugated Packaging
Akshar pack was incorporated in 1987 and now it has become one of
the leading producers of Cardboard Packaging to Commercial &
Agricultural Industries.
Akshar pack is an independent manufacturer and converter of
corrugated cardboard, cardboard boxes and packaging. In order to
meet any
Corrugated Packaging
Processed Foods
Wine & Beverage
Clothing & Textile
Electronics
Akshar Pack makes their own corrugated board and can supply high
volume customers. Akshar pack is experienced in supplying a range
of different customers with individual and special requirements. This
ranges from high volume - name brand customers to smaller lower
volume users. It can tailor a no obligation quotation for your current
packaging requirements, taking into account such factors as
frequency of deliveries, short lead times and long term contract
pricing.
Extensive range of corrugated board, printed boxes, Trays, die cut &
waxed cartons. The range of cardboard & corrugated products is very
diverse. Akshar Pack can manufacture corrugated board for sale to
box converting plants, a complete range of printed boxes, with
various finishes and styles. Trays for hand erect and machine
erecting, die cut cartons for counters and display stands for the
retailers. It also can produce waxed cartons and functional coated
cartons to be used in the produce and seafood industries. It has a
comprehensive range of existing designs to choose from or we can
design a custom made carton to suit your particular requirements.
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Corrugated Packaging
Case study
1] Shipping Watermelons in Corrugated Bulk Bins Offers
Dramatic Savings
The Corrugated Packaging Alliance (CPA) today released a cost-comparison
study that concludes shipping watermelons in bulk bin corrugated containers
saves nearly 20 percent of annual,
total supply-chain/distribution costs, compared with shipping in bulk bin,
reusable plastic containers (RPCs). The study also showed that the retailer
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Corrugated Packaging
saves over 10 percent, while the grower/shipper saves 45 percent of its cost
to package and ship the watermelons. The study used actual cost data
provided by a large grower/shipper of watermelons in south-central Arizona
to perform a real-world cost comparison. Total supply chain costs (including
the bulk container rental, trucking and handling, and pool maintenance of the
RPCs) came to $7 million annually in
corrugated, compared to $9.7 million in RPCs - a cost advantage of $2.7
million for using corrugated bins. Most of the difference, as in other case
scenarios previously released by the CPA, is caused by higher costs
associated with trucking and handling for RPCs. These additional costs are
primarily incurred in the
backhaul trip, when the bins must be sorted, cleaned, maintained and
shipped back for re-use. In contrast, the corrugated bins are frequently
reused right in the same store that received the watermelons, and when they
can no longer be used, they are recycled to generate additional revenue for
the retailer.
The new study is the fourth in a series of cost comparisons sponsored by the
CPA and conducted by Heads Up Systems, Inc. (West Linn, Ore.). The
research was conducted using Full Disclosure(SM), a sophisticated, activitybased cost-modeling tool to evaluate total annual costs for shipping
watermelons
2,000 miles (approximately the distance from Red Bluff, Ariz., to Cincinnati,
Ohio). Costs were examined for shipping in bulk bin corrugated (triple-wall,
800-pound capacity) and in injection-molded bulk bin RPCs (800-pound
capacity with integrated pallets). The comparative weight of each container
- 112 pounds for RPCs versus 51.5 pounds for corrugated bins
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Corrugated Packaging
Corrugated Packaging
Bibliography
Source : Internet
Websites visited :
http://edis.ifas.ufl.edu/AE206
http://en.wikipedia.org/wiki/Packaging
http://www.google.co.in/
http://www.iip-in.com/Library.htm
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Corrugated Packaging
http://www.knowthis.com/tutorials/principles-of-marketing/productdecisions/10.htm
http://www.saferpak.com/latest_220803.htm
http://www.corrugated.org/
http://www.ampackcorp.com/
http://www.directmovingboxes.com/taping-moving-boxes.html
http://www.ci.fort-collins.co.us/recycling/kids/corrugated.php
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Corrugated Packaging
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