CORRUGATED BOARD & BOX MAKING

Process, Raw Material Properties, Testing & Specification

CONTENT:

 Brief Background
 Application

 Process of Board & Box Making

 Fundamentals of Bonding & Warp Control.

 Important Paper Properties

 Testing & Specifications

A presentation by:
THE USER INDUSTRY....

 Fast Moving Consumers Goods

 Processed Food & Beverages
 Non-Food (Pharmaceuticals, Home & Personal Care)
 Consumer Durables
 White Goods
 Electronic Gadgets
 Garments & Footwear
 Fruits & Vegetables
 Engineering Products
 E-Commerce
THE USER INDUSTRY...
▪ The largest segment of Demand for Corrugated
Boxes is the FMCG Sector. (60-65%)

▪ Demand for Corrugated Boxes in this segment

is growing at 8-10% per year.

▪ Demand for Corrugated Boxes for E-Commerce

is ‘add-on’ packaging and is growing
exponentially
 The Raw Material to Produce
Corrugated Box / Board is Liner
Paper and Fluting Paper

– Commonly referred to as
“Container Board”
What is a Corrugated Board ?
Corrugated Boards are Converted into Boxes or
Die-cut Blanks based on the method of Packing,
Storage & Delivery…..
Various Box Styles………
Corrugated Boxes & Application………
Corrugated Boxes & Application………
Corrugated Boxes & Application………

Promotes Brands
EXPECTATIONS FROM A “GOOD BOX” .....
 Protects its Contents
 Against Damage
 Against Pilferage

 Promotes the Brand

 Allows Productive Packing

 Case Dispensing /Extraction **
 Case Forming **
 Auto Case Filling **/ Manual Case Filling **
 Case Closure (Sealing)
 Batch Identification (Ink Jet/Dot Matrix Printing)
Components of Corrugated Board
Corrugated Board making Process (Wet-End)
Production of Fluted Web

Single Application of Adhesive to Flute Tips without “fluff out”

Facer Joining of Liner & Fluted paper & formation of “Green Bond”
Transport of Single face web to the Bridge
Bridge Stock Control (to maintain a constant dwell time)
Automatic
Bridge Allow Green Bond Curing
Control &
Web Aligner
Maintain Web Tension & Alignment

Pre-heating of Single Face Web & Liner paper for Bonding

Glue
Machine & Application of Adhesive to Flute Tips of Single Face Web
Double Joining of Single Face Web & Liner to create Bond
Backer
Removal of Excessive Moisture from Corrugated Board
Corrugated Board making Process (Dry-End)

Slitting & Scoring of Continuous Corrugated Board

Slitter
Scorer
Side Trim Evacuation, Shredding & Removal

NC Cut - Off Chopping of Corrugated Board

Auto Down Continuous Stacking & Ejecting Lots of Corrugated Boards

Stacker

Wet – End Order Change

Auto Order
Change
Dry – End Order Change
 CRITICAL PROCESSES IN BOARD MAKING &
IMPORTANT PAPER PROPERTIES

➢ Bonding on the Corrugator

➢ Board Warp Control

THE BONDING MECHANISM…..
➢ By in-situ Gelatinization of Suspended Starch Granules to create a
Bridge between the Bonding Substrates (Flute & Liner Papers)
BONDING AT THE CORRUGATOR…..

 The Single Face Bond

➢ Joins the Corrugated Medium to a Liner to create
Single Face Sheet. ( “Two Ply Sheet” )

Three Stage Bonding Mechanism

1. Creation of Green Bond with ungelled but
deformed Starch Granules partially combined in
high intensity nip of Pressure Roll & Corrugating
Roll.
2. Bridging of gelatinized adhesive between flute
shoulder & liner surface.
3. Bond strengthening by dewatering of gelled
adhesive film created in step 2.
BONDING AT THE CORRUGATOR…..

 The Double Face Bond

➢ Joining the flute tips of Single Face Web to Liner
paper to create a Combined Corrugated Board.
Double Face Bond
Four Stage Process
1. Creating the Green Bond.
2. Dewatering the Double face joint to create a strong
Bond.
3. Removing excess moisture from the Combined
Board while avoiding board warp.
4. Cooling of Combined Board.
BONDING AT THE CORRUGATOR…..
The Role of Starch in creating Adhesive Bonds on the Corrugator

➢ Starch granules do not impart adhesion

between two substrates unless they are
gelatinized.

➢ Gelatinization is the swelling & bursting of

granular Starch to form a tacky Adhesive.

➢ Gelatinization requires water to penetrate the

Starch granules with adequate heat (Heat of
Gelatinization).
BONDING AT THE CORRUGATOR…..
The Role of Starch in creating Adhesive Bonds on the Corrugator

➢ Moisture for gelatinization is available in the

suspension of granular Starch in the Water.

➢ Heat is supplied for gelatinization primarily by

heating the Substrates being Bonded together
(Liners & Fluting papers)
ADHESIVE DELIVERY TO THE BONDING POINT
 Granular, Un-geletinized Starch granules suspended in water do not form a ‘good’
film of adhesive
 A ‘Carrier’ Component is required to create a film

Creating Adhesive Film on Transfer Rollers in Single Facer & Glue Machine
GLUE PREPARATION
 Preparing the Adhesive by Stein-Hall Process
Two Component Adhesive

➢ Carrier Component :- Partially Gelatinised Starch

Granules (about 25% of Adhesive Quantity)- these
help to form a film by ‘carrying’ un-gelled granules.

➢ Non Gelatinised Starch Granules (about 75% of

Adhesive Quantity)

➢ Required Gel-Point & Viscosity is achieved by

Controlled addition of Caustic & Borax
BONDING AT THE CORRUGATOR…..

Role of Heat on the Corrugator

➢ To Create Adhesive Bonds between the different

Paper Components of the Board using an adhesive
comprising of a suspension of Starch granules in
Water.

➢ To Remove the Excess Moisture induced into the

Board Structure by the Adhesive.
BONDING AT THE CORRUGATOR…..
The Role of Heat in creating Adhesive Bonds on the Corrugator

* Source: Corrugator Bonding – A TAPPI PRESS Anthology of Published Papers

BONDING AT THE CORRUGATOR…..

➢Adequate Heat & Pressure is Critical

for the Single face Green Bond.

➢Adequate Heat is required for the

Double face bond & for removing
excess moisture induced by
Adhesives in the combined board.
HOW IS THE HEAT REQUIRED FOR BONDING
IMPARTED TO THE POINT OF ADHESION ?
 HEAT CARRIAGE & DISSIPATION

Paper has two major components

➢ Fiber – Low Specific Heat (0.33kcal / kg /

OC)

➢Water – High Specific Heat (1.0kcal / kg /

OC)
 HEAT CARRIAGE & DISSIPATION

➢When paper is heated by 1 OC the

moisture component carries 3 times the
amount of Heat than the Fiber
component.

➢Paper with higher moisture content

carries more heat than dryer paper at the
same temperature.
 HEAT CARRIAGE & DISSIPATION

➢The heat required to raise the adhesive

temperature to the Gel-point & beyond is
imparted by Pre-heaters & Pre-
conditioners to the Fluting / Liner.
IMPORTANT PAPER PROPERTIES FOR GOOD
BONDING…..

➢Higher Moisture Papers Bond better

& are less prone to cracking during
scoring due to their inherent
flexibility

➢At Low Moisture content papers have

to be heated more to carry adequate
heat for bonding This tends to
increase their Brittleness.
BONDING AT THE CORRUGATOR…..
Paper Properties must facilitate Anchoring of Adhesive Bridge
to both Substrates:

* Source: Corrugator Bonding – A TAPPI PRESS Anthology of Published Papers

IMPORTANT PAPER PROPERTIES FOR BONDING:

 Moisture – Critical for carrying adequate heat

to the bond site
 Cobb – Should be appropriate for Speed of
Operation.
 Porosity – Too much or too little are both bad.
The adhesive has to form a proper “Bridge”
between substrates and “Anchor”in each one.
BOARD WARP CONTROL AT CORRUGATOR…..

Criticality of Warp
➢ Reduction in Structural Strength of Board / Box

➢ Inaccurate Box Dimensions as due to Mis-registration

of Slots

➢ Shifting of Print Matter

➢ Productivity Loss at Converting Machines

BOARD WARP CONTROL AT CORRUGATOR…..

Common Types of Warp

➢ Upward Warp

➢ Downward Warp

➢ S-Warp

➢ Machine Direction Warp, etc.

BOARD WARP CONTROL AT CORRUGATOR…..

Reason of Board Warpage

Single Facer Double Facer
BOARD WARP CONTROL AT CORRUGATOR…..

Control Mechanism of Warp (Manual Mode)

➢ Increase or Decrease the Paper Wrapping of Pre-heaters at SF
Liner or DF Liner

➢ Check the Glue Application & Control if Abnormal at SF or at

Glue Machine

➢ Adjust DF Liner Paper Tension or 2 Ply Web Tension to Control

Machine Direction Warp or Long Warp

➢ There is no Operational Solution to “S Warp” & “Twist Warp”as

it occurs due to Profile Moisture Variation.
BOARD WARP CONTROL AT CORRUGATOR…..

Control Mechanism of Warp (Auto Mode)

The Corrugating Machine...
Corrugated Box making Process
Board Feeding
Printing by Flexographic Process

Regular Creasing & Slotting

Slotted Folding & Glueing
Cartons
Counting & Ejecting
Strapping
Pallet Load Forming

Printing by Flexographic Process

Die-Cut
Boxes & Die-Cutting Process
Wrap
Around Ejection of Scrap, Counting & Stacking of Blanks
Blanks
Palletizing of Blanks
DIFFERENT PRINTING TECHNOLOGIES

 All high speed printing is impression based

Printing

 Offset Printing

 Flexographic Printing
OFFSET PRINTING TECHNOLOGY

Schematic representation of Offset Printing Press

FLEXOGRAPHIC PRINTING TECHNOLOGY
The Flexo Folder Gluer...
Testing of Corrugated Board & Boxes

Currently Bursting Strength is the most

popular measure for the strength of a
corrugated paper box in India.

Is Bursting Strength the best/most

appropriate measure of the strength of a
Corrugated Box ?
 BS – ORIGIN & RELEVANCE

 Originated as a test for virgin Kraft paper used for

bag and sack applications- relevant measure was
rupture- appropriate for the application

 Could be successfully extended to corrugating raw

materials as long as paper manufacturing
technology and raw materials were homogenous –
Softwood pulp, Single ply, light pressing etc.
 BS – ORIGIN & RELEVANCE (CONTD.)

 Major Factors contributing to the gradual

obsolescence of the BS as a measure:
 Research information on the nature of box failure and
contributing factors
 New raw materials for paper making – waste paper and
other non-conventional materials
 Evolution of paper making technology- particularly
Forming and Wet Pressing
 Evolution of High Density/High Performance Liners
The Mechanism of Bursting;
What does it measure?
Measures inter fiber bonding strength through failure under
tensile forces
The Box handling Environment is harsh !

Any solutions for this ?

How does a box actually fail in protecting the goods
being stored /transported ?
What should an appropriate
measure look like?
 The ability of the box
to withstand top–down
loading ( Stacking
strength ) is critical.
What is the role of individual components of the board in
imparting stacking strength ?
 BCT/ECT – A RATIONAL MEASURE OF BOX
QUALITY

 This test measures an important box parameter

that is relevant to the success of the box as a
protective container in transit and storage.
 A ECT specification can be set to dovetail with
tests for the raw material and the corrugated
board
 RCT/SCT, ECT & BCT

 RCT/SCT – Tests the Raw Material

 ECT – Tests the efficiency of Board Making
 BCT – Tests the efficiency of Box Making

SCT BCT
SHORT SPAN COMPRESSION (STFI) TEST
MORE APPROPRIATE FOR LIGHT
WEIGHT LINERS AND FLUTING

SIPM
 BCT or BS ?
What’s appropriate ?

Others have walked this path before…

 CEPI European Containerboard Standard –
specifies SCT Index OR Mullen Equivalent

 Uniform Freight Classification Standard USA –

Alternate Rule 41 – Specifies Alternate ECT
Specification for Mullen + Combined Substance
of Liners.
HIGH PERFORMANCE LINERS & FLUTING

 Developed to meet the high strength - low weight

requirements for cost effective Box designs.

 New High RCT, low Substance (GSM) grade.

 Acceptance criteria – Ring Crush Test (RCT)

– Short Span Compression Test (SCT)
– Concora Medium Test (CMT)

SIPM
HIGH PERFORMANCE LINER ( HPL) &
HIGH PERFORMANCE FLUTING .

DEVELOPMENT:
 Superior Fibre .

 Improved formation with appropriate fibre orientation.

 High intensity Web Pressing.

 Use of strength enhancing polymers.

SIPM
 THE ADVANTAGE OF USING THE
NEW GRADES

 An Example to put performance

in perspective

SIPM
 Consider a box that has a BS specification of 18 kg/cm2
L W H
Box Dimension (mm) 600 400 300
Perimeter 2000

Consider the following 2 options that meet the BS specification

Top Liner Fluting Bottom Liner

Option 1: 250 gsm(28 BF) 150 gsm (20 BF) 250 gsm(28BF)
Option 2: 400 gsm(40 BF) 120 gsm (16 BF) 120 gsm (16 BF)

Also consider a 3rd option that does not meet the BS specification
Top Liner Fluting Bottom Liner
Option 3: 220 gsm HPL -2.6kN/m 150 gsm HPF-1.7kN/m 220 gsm HPL-2.6kN/m

SIPM
The Comparison…
GSM BCT BS BCT Cost

Option 1: 803 372 kgf 149% 85% 118%

Option 2: 682 348 kgf 153% 79% 108%

Option 3: 658 438 kgf 100% 100% 100%

Option 3 which does not meet the BS criterion has

the highest Compression Strength and the lowest
Cost.

SIPM
 Desired Paper Quality & Other Functional Properties

➢ High Compressive Strength with Lower Basis Weight

➢ Odour Free

➢ Crack Free

➢ Breakage & Tear Free

SIPM
A FEW FACTS OF CORRUGATING INDUSTRY...
THE INDUSTRY....

▪ The Corrugated Box Industry converts about

5.5 million MT of Paper into about 8 to8.5
billion square meters of Corrugated Boxes
every year.
THE INDUSTRY....
▪ The Corrugated Box Industry is highly
fragmented and currently comprises of about
13,000* mainly Small Scale Enterprises
scattered across the country.
* Guesstimates vary between 12,000 and 14,000 active units.
THE INDUSTRY....
▪ The Corrugated Box Making Industry has been
changing rapidly in terms of Scale and
Technology after its “De-reservation” in 2007

▪ Prior to 2007, the caps on investments in the

industry ensured that the industry comprised of
small, low productivity, poor quality capacities
THE INDUSTRY....
 Prior to 2007, the Industry was completely dominated by
“Semi-Auto” ** (Litho Lam) Board making facilities

 There has been rapid increase in number of “Automatic

Plants” (Continuous Board making)

 Within the set of “Auto Plants” the degree of automation

of control varies considerably & there is even a larger
variation in the sophistication of converting equipment
(Corrugated Boards to Boxes)
SIZE OF INDUSTRY SEGMENTS BY NUMBERS,
OUTPUT & LOCATION

40% 35%
60% 2.7 million MT
35%
Box Makers with “Semi 30%
30%
Automatic” Litho-Lam
Type
25%
25%
12,000 to Board Making Geographic
14,000 20%
Distrubution
15% of
40% - 2.0 million MT Box Makers
10% with
Box Makers with 6% 4%
Continuous
Continuous Corrugated 5%
Corrugated
Board lines -“ Automatic Board Lines
0%
Plants”
375
Number of Box Makers Output in MT
TRENDS IN THE USER INDUSTRY...
▪ New Geographic locations based on changes in
Taxation Policies & Logistical Advantage.

▪ Higher Capacity, more Productive, Automated,

Brand-Owned manufacturing facilities coming up.

▪ Frequent Product/SKU changes on Manufacturing

Lines.

▪ Shorter Lead Times.

TRENDS IN THE USER INDUSTRY...

 Shift in Board construction from Double wall (5

ply) to Single Wall (3 ply) for most FMCG products.

3 ply Construction is Cost Effective and

adequate for most FMCG cases.
 Case Sealing using Hot-melt Gluing systems
tends to increase the overall rigidity of 3 ply
(single wall) boxes & contributes to better in-
transit performance
 Thank you
for a patient hearing

Recycle –Its good for all of us.