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Handbook of Paper and Paperboard
Packaging Technology
Handbook of Paper and Paperboard
Packaging Technology
Second Edition

Edited by
Mark J. Kirwan
Paper and Paperboard Specialist,
Fellow of the Packaging Society,
London, UK

A John Wiley & Sons, Ltd., Publication

This edition first published 2013 © 2013 by John Wiley & Sons, Ltd

Wiley-Blackwell is an imprint of John Wiley & Sons, formed by the merger of Wiley’s global Scientific,
Technical and Medical business with Blackwell Publishing.

Registered Office
John Wiley & Sons, Ltd, The Atrium, Southern Gate, Chichester, West Sussex, PO19 8SQ, UK

Editorial Offices
9600 Garsington Road, Oxford, OX4 2DQ, UK
The Atrium, Southern Gate, Chichester, West Sussex, PO19 8SQ, UK
2121 State Avenue, Ames, Iowa 50014-8300, USA

For details of our global editorial offices, for customer services and for information about how
to apply for permission to reuse the copyright material in this book please see our website at
www.wiley.com/wiley-blackwell.

The right of the authors to be identified as the authors of this work has been asserted in accordance
with the UK Copyright, Designs and Patents Act 1988.

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted,
in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, except as permitted
by the UK Copyright, Designs and Patents Act 1988, without the prior permission of the publisher.

Designations used by companies to distinguish their products are often claimed as trademarks. All brand names
and product names used in this book are trade names, service marks, trademarks or registered trademarks of their
respective owners. The publisher is not associated with any product or vendor mentioned in this book. This
publication is designed to provide accurate and authoritative information in regard to the subject matter covered.
It is sold on the understanding that the publisher is not engaged in rendering professional services. If professional
advice or other expert assistance is required, the services of a competent professional should be sought.

Library of Congress Cataloging-in-Publication Data

Handbook of paper and paperboard packaging technology / edited by Mark J. Kirwan. – 2nd ed.
p. cm.
Earlier edition has title: Paper and paperboard packaging technology.
Includes bibliographical references and index.
ISBN 978-0-470-67066-8 (hardback : alk. paper) – ISBN 978-1-118-47091-6 (epdf/ebook) –
ISBN 978-1-118-47089-3 (emobi) – ISBN 978-1-118-47092-3 (epub) – ISBN 978-1-118-47093-0 (obook)
1. Paper containers. 2. Paperboard. 3. Packaging. I. Kirwan, Mark J.
TS198.3.P3P37 2013
658.7′85–dc23
2012024778
A catalogue record for this book is available from the British Library.

Wiley also publishes its books in a variety of electronic formats. Some content that appears in print may not be
available in electronic books.

Front cover illustration courtesy of Smurfit Kappa Group plc.

Cover design by Meaden Creative

Set in 10/12pt Times by SPi Publisher Services, Pondicherry, India

1 2013
Contents

Contributors xv
Preface xvii
Acknowledgements xix

1 Paper and paperboard – raw materials, processing and properties 1

Daven Chamberlain and Mark J. Kirwan
1.1 Introduction – quantities, pack types and uses 1
1.2 Choice of raw materials and manufacture of paper and paperboard 6
1.2.1 Introduction to raw materials and processing 6
1.2.2 Sources of fibre 7
1.2.3 Fibre separation from wood (pulping) 8
1.2.4 Whitening (bleaching) 10
1.2.5 Recovered fibre 10
1.2.6 Other raw materials 11
1.2.7 Processing of fibre at the paper mill 12
1.2.8 Manufacture on the paper or paperboard machine 13
1.2.9 Finishing 19
1.3 Packaging papers and paperboards 20
1.3.1 Introduction 20
1.3.2 Tissues 20
1.3.3 Greaseproof 20
1.3.4 Glassine 21
1.3.5 Vegetable parchment 21
1.3.6 Label paper 21
1.3.7 Bag papers 21
1.3.8 Sack kraft 22
1.3.9 Impregnated papers 22
1.3.10 Laminating papers 22
1.3.11 Solid bleached board (SBB) 22
1.3.12 Solid unbleached board (SUB) 23
1.3.13 Folding boxboard (FBB) 23
1.3.14 White-lined chipboard (WLC) 24
1.4 Packaging requirements 25
1.5 Technical requirements of paper and paperboard for packaging 26
1.5.1 Requirements of appearance and performance 26
1.5.2 Appearance properties 26
1.5.3 Performance properties 34
1.6 Specifications and quality standards 48
1.7 Conversion factors for substance (basis weight)
and thickness measurements 48
References 49
vi Contents

2 Environmental and resource management issues 51

Daven Chamberlain and Mark J. Kirwan

2.1 Introduction 51
2.2 Sustainable development 53
2.3 Forestry 54
2.4 Environmental impact of manufacture and use of paper
and paperboard 61
2.4.1 Issues giving rise to environmental concern 61
2.4.2 Energy 62
2.4.3 Water 66
2.4.4 Chemicals 67
2.4.5 Transport 68
2.4.6 Manufacturing emissions to air, water and solid waste 68
2.5 Used packaging in the environment 73
2.5.1 Introduction 73
2.5.2 Waste minimisation 74
2.5.3 Waste management options 74
2.6 Life cycle assessment 79
2.7 Carbon footprint 81
2.7.1 Carbon sequestration in forests 81
2.7.2 Carbon stored in forest products 82
2.7.3 Greenhouse gas emissions from forest product
manufacturing facilities 82
2.7.4 Greenhouse gas emissions associated with producing fibre 83
2.7.5 Greenhouse gas emissions associated with producing
other raw materials/fuels 83
2.7.6 Greenhouse gas emissions associated with purchased electricity,
steam and heat, and hot and cold water 83
2.7.7 Transport-related greenhouse gas emissions 83
2.7.8 Emissions associated with product use 83
2.7.9 Emissions associated with product end of life 83
2.7.10 Avoided emissions and offsets 83
2.8 Conclusion 84
References 86

3 Paper-based flexible packaging 91

Jonathan Fowle and Mark J. Kirwan

3.1 Introduction 91
3.2 Packaging needs which are met by paper-based flexible packaging 94
3.2.1 Printing 94
3.2.2 Provision of a sealing system 95
3.2.3 Provision of barrier properties 95
3.3 Manufacture of paper-based flexible packaging 99
3.3.1 Printing and varnishing 99
3.3.2 Coating 100
3.3.3 Lamination 105
 Contents vii

3.4 Medical packaging 109

3.4.1 Introduction to paper-based medical flexible packaging 109
3.4.2 Sealing systems 112
3.4.3 Typical paper-based medical packaging structures 113
3.5 Packaging machinery used with paper-based flexible packaging 114
3.6 Paper-based cap liners (wads) and diaphragms 118
3.6.1 Pulpboard disc 119
3.6.2 Induction-sealed disc 119
3.7 Tea and coffee packaging 119
3.8 Sealing tapes 121
3.9 Paper cushioning 121
References 123
Websites 123

4 Paper labels 125

Michael Fairley
4.1 Introduction 125
4.2 Types of labels 128
4.2.1 Glue-applied paper labels 128
4.2.2 Pressure-sensitive labels 130
4.2.3 In-mould labels 133
4.2.4 Plastic shrink-sleeve labels 134
4.2.5 Stretch-sleeve labels 135
4.2.6 Wrap-around film labels 135
4.2.7 Other labelling techniques 136
4.3 Label adhesives 136
4.3.1 Adhesive types 137
4.3.2 Label adhesive performance 138
4.4 Factors in the selection of labels 139
4.5 Nature and function of labels 140
4.5.1 Primary labels 140
4.5.2 Secondary labels 141
4.5.3 Logistics labels 141
4.5.4 Special application or purpose labels 142
4.5.5 Smart, smart-active and smart-intelligent labels 142
4.5.6 Functional labels 144
4.5.7 Recent developments 144
4.6 Label printing and production 145
4.6.1 Letterpress printing 146
4.6.2 Flexography 148
4.6.3 Lithography 149
4.6.4 Gravure 150
4.6.5 Screen process 151
4.6.6 Hot-foil blocking/stamping process 152
4.6.7 Variable information printing (VIP),
electronically originated 153
4.6.8 Digital printing 155
viii Contents

4.7 Print finishing techniques 156

4.7.1 Lacquering 156
4.7.2 Bronzing 156
4.7.3 Embossing 156
4.8 Label finishing 156
4.8.1 Introduction 156
4.8.2 Straight cutting 157
4.8.3 Die-cutting 157
4.8.4 Handling and storage 159
4.9 Label application, labelling and overprinting 159
4.9.1 Introduction 159
4.9.2 Glue-applied label applicators 160
4.9.3 Self-adhesive label applicators 160
4.9.4 Shrink-sleeve label applicators 161
4.9.5 Stretch-sleeve label applicators 162
4.9.6 In-mould label applicators 162
4.9.7 Modular label applicators 163
4.10 Label legislation, regulations and standards 163
4.10.1 Acts of Parliament 163
4.10.2 EC regulations and directives 163
4.10.3 Standards 164
4.11 Specifications, quality control and testing 164
4.11.1 Introduction 164
4.11.2 Testing methods for self-adhesive labels 165
4.11.3 Testing methods for wet-glue labels 165
4.12 Waste and environmental issues 167
Websites 168

5 Paper bags 169

Smith Anderson Group Ltd, Fife, UK, and Welton Bibby &
Baron Ltd, Radstock, Somerset, UK
5.1 Introduction 169
5.1.1 Paper bags and the environment 170
5.2 Types of paper bags and their uses 170
5.2.1 Types of paper bag 170
5.2.2 Flat and satchel 170
5.2.3 Strip window bags 172
5.2.4 Self-opening satchel bags (SOS bags) 172
5.2.5 SOS carrier bags with or without handles 174
5.3 Types of paper used 175
5.3.1 Kraft paper – the basic grades 175
5.3.2 Grease-resistant and greaseproof papers 176
5.3.3 Vacuum dust bag papers 176
5.3.4 Paper for medical use and
sterilisation bags 176
5.3.5 Wet-strength kraft 176
5.3.6 Recycled kraft 176
5.3.7 Coated papers 176
 Contents ix

5.3.8 Laminations 177

5.3.9 Speciality papers 177
5.3.10 Weights of paper 177
5.4 Principles of manufacture 177
5.4.1 Glue-seal bags 177
5.4.2 Heat-seal bags 178
5.4.3 Printing on bag-making machines 178
5.4.4 Additional processes on bag-making machines 178
5.4.5 Additional operations after bag making 179
5.5 Performance testing 179
5.5.1 Paper 179
5.5.2 Paper bags 179
5.6 Printing methods and inks 180
5.6.1 Printing methods 180
5.6.2 Inks 181
5.7 Conclusion 181
5.7.1 Development of the paper bag industry 181
5.7.2 The future 181
Reference 182
Websites 182

6 Composite cans 183

Catherine Romaine Henderson
6.1 Introduction 183
6.2 Composite can (container) 185
6.2.1 Definition 185
6.2.2 Manufacturing methods 185
6.3 Historical background 187
6.4 Early applications 189
6.5 Applications today by market segmentation 189
6.6 Designs available 190
6.6.1 Shape 190
6.6.2 Size 190
6.6.3 Consumer preferences 190
6.6.4 Clubstore/institutional 190
6.6.5 Other features 191
6.6.6 Opening/closing systems 191
6.7 Materials and methods of construction 194
6.7.1 The liner 195
6.7.2 The paperboard body 196
6.7.3 Labels 197
6.7.4 Nitrogen flushing 197
6.8 Printing and labelling options 197
6.8.1 Introduction 197
6.8.2 Flexographic 197
6.8.3 Rotogravure 198
6.8.4 Lithography (litho/offset) printing 199
6.8.5 Labelling options 199
x Contents

6.9 Environment and waste management issues 200

6.9.1 Introduction 200
6.9.2 Local recycling considerations 200
6.10 Future trends in design and application 200
6.10.1 Introduction 200
6.10.2 Increase barrier performance of
paper-bottom canisters 201
6.10.3 Totally repulpable can 201
6.10.4 Non-paper-backed liner 201
6.10.5 Film label 201
6.10.6 Killer paper 201
6.11 Glossary of composite can-related terms 201
References 203
Websites 203

7 Fibre drums 205

Fibrestar Drums Ltd., Cheshire, UK
7.1 Introduction 205
7.2 Raw material 207
7.3 Production 208
7.3.1 Sidewall 208
7.3.2 Drum base 210
7.3.3 Lid 210
7.4 Performance 212
7.5 Decoration, stacking and handling 214
7.6 Waste management 215
7.7 Summary of the advantages of fibre drums 215
7.8 Specifications and standards 216
References 216
Websites 216

8 Multiwall paper sacks 217

Mondi Industrial Bags, Vienna, Austria
8.1 Introduction 217
8.2 Sack designs 218
8.2.1 Types of sacks 218
8.2.2 Valve design 223
8.2.3 Sewn closures 225
8.3 Sack materials 226
8.3.1 Sack body material 226
8.3.2 Ancillary materials 230
8.4 Testing and test methods 232
8.4.1 Sack materials 232
8.4.2 Sack testing 235
8.5 Weighing, filling and closing systems 237
8.5.1 Open mouth sacks 238
8.5.2 Valve sacks 241
 Contents xi

8.5.3 Sack identification 245

8.5.4 Sack flattening and shaping 247
8.5.5 Baling systems 247
8.6 Standards and manufacturing tolerances 248
8.6.1 Standards 248
8.6.2 Manufacturing tolerances 248
8.7 Environmental position 250
References 251
Useful contacts 251
Websites 251

9 Rigid boxes 253

Michael Jukes
9.1 Overview 253
9.2 Rigid box styles (design freedom) 254
9.3 Markets for rigid boxes 256
9.4 Materials 256
9.4.1 Board and paper 256
9.4.2 Adhesives 257
9.4.3 Print 257
9.5 Design principles 257
9.6 Material preparation 258
9.7 Construction 259
9.7.1 Four-drawer box 261
9.8 Conclusion 263
References 263
Websites 263

10 Folding cartons 265

Mark J. Kirwan
10.1 Introduction 265
10.2 Paperboard used to make folding cartons 267
10.3 Carton design 268
10.3.1 Surface design 268
10.3.2 Structural design 269
10.4 Manufacture of folding cartons 277
10.4.1 Printing 277
10.4.2 Cutting and creasing 280
10.4.3 Creasing and folding 287
10.4.4 Embossing 292
10.4.5 Hot-foil stamping 293
10.4.6 Gluing 294
10.4.7 Specialist conversion operations 295
10.5 Packaging operation 296
10.5.1 Speed and efficiency 296
10.5.2 Side seam-glued cartons 297
10.5.3 Erection of flat carton blanks 298
xii Contents

10.5.4 Carton storage 300

10.5.5 Runnability and packaging line efficiency 300
10.6 Distribution and storage 303
10.7 Point of sale, dispensing, etc. 306
10.8 Consumer use 307
10.9 Conclusion 311
References 311
Suggested further reading 312
Websites 312

11 Corrugated fibreboard packaging 313

Arnoud Dekker
11.1 Introduction 313
11.1.1 Overview 313
11.1.2 Structure of corrugated fibreboard 313
11.1.3 Types of corrugated fibreboard packaging 315
11.1.4 History of corrugated fibreboard 317
11.2 Functions 318
11.2.1 Overview functions 318
11.2.2 Corrugated fibreboard packaging production 318
11.2.3 Packing lines 319
11.2.4 Palletisation and logistic chain 319
11.2.5 Communication 320
11.2.6 Retail-ready 320
11.2.7 Product safety 320
11.2.8 Recycling and sustainability 321
11.3 Board properties and test methods 321
11.3.1 Overview of board properties and test methods 321
11.3.2 Box tests 323
11.3.3 Pallet tests 324
11.3.4 Predictions 324
11.4 Manufacturing 326
11.4.1 Overview 326
11.4.2 Paper production 326
11.4.3 Corrugated board production 328
11.4.4 Corrugated fibreboard converting 330
11.4.5 Corrugated fibreboard printing 333
11.4.6 Customer packing lines 335
11.4.7 Good manufacturing practice 335
11.5 Corrugated fibreboard and sustainability 335
11.5.1 Sustainable sourcing of raw materials 336
11.5.2 Sustainable production 337
11.5.3 Sustainable packaging design 337
11.5.4 Sustainable supply chain 338
References 338
Websites 338
Suggested further reading 339
 Contents xiii

12 Solid board packaging 341

Mark J. Kirwan
12.1 Overview 341
12.2 Pack design 342
12.3 Applications 345
12.3.1 Horticultural produce 345
12.3.2 Meat and poultry 346
12.3.3 Fish 346
12.3.4 Beer (glass bottles and cans) 346
12.3.5 Dairy products 346
12.3.6 Footwear 346
12.3.7 Laundry 346
12.3.8 Engineering 346
12.3.9 Export packaging 347
12.3.10 Luxury packaging 347
12.3.11 Slip sheets 347
12.3.12 Partitions (divisions, fitments and pads) 348
12.3.13 Recycling boxes 350
12.3.14 Bag-in-box liquid containers 350
12.3.15 Shelf-ready packaging 350
12.4 Materials 350
12.5 Water and water-vapour resistance 350
12.6 Printing and conversion 351
12.6.1 Printing 351
12.6.2 Cutting and creasing 352
12.7 Packaging operation 352
12.8 Waste management 352
12.9 Good manufacturing practice 352
Reference 352
Websites 352

13 Paperboard-based liquid packaging 353

Mark J. Kirwan
13.1 Introduction 353
13.2 Packaging materials 357
13.2.1 Paperboard 357
13.2.2 Barriers and heat-sealing layers 358
13.3 Printing and converting 360
13.3.1 Reel-to-reel converting for reel-fed form, fill,
seal packaging 360
13.3.2 Reel-to-sheet converting for supplying printed carton
blanks for packing 361
13.3.3 Sheet-fed for bag-in-box 361
13.4 Carton designs 361
13.4.1 Gable top 362
13.4.2 Pyramid shape 362
13.4.3 Brick shape 363
xiv Contents

13.4.4 Pouch 364

13.4.5 Wedge 364
13.4.6 Multifaceted design 365
13.4.7 Bottle shapes 365
13.4.8 Round cross section 365
13.4.9 Bottom profile for gable top carton 367
13.4.10 Bag-in-box 368
13.5 Opening, reclosure and tamper evidence 369
13.6 Aseptic processing 374
13.7 Post-packaging sterilisation 375
13.8 Transit packaging 376
13.9 Applications for paperboard-based liquid packaging 378
13.10 Environmental issues 378
13.10.1 Resource reduction 379
13.10.2 Life-cycle assessment 379
13.10.3 Recovery and recycling 381
13.11 Systems approach 382
References 382
Suggested further reading 383
Websites 383

14 Moulded pulp packaging 385

Cullen Packaging Ltd, Glasgow, UK
14.1 Introduction 385
14.2 Applications 385
14.3 Raw materials 388
14.4 Production 389
14.5 Product drying 391
14.6 Printing/decoration 392
14.7 Conclusion 392
Website 392

Appendix: Checklist for a packaging development brief 393

Reference 398
Further reading 398
Index 399
Contributors

Smith Anderson Group Fibrestar Drums Ltd

Anderson Group Ltd Cheshire, UK
Fife, UK
Jonathan Fowle
Welton Bibby & Baron Ltd Innovati Partners, Shepton Mallet,
Radstock, Somerset, UK Somerset, UK

Cullen Packaging Ltd Catherine Romaine Henderson

Glasgow, UK Integrated Communication Consultants
Greer, SC, USA
Daven Chamberlain
Editor Michael Jukes
Paper Technology London Fancy Box Company
Bury, Lancashire, UK Kent, UK
Arnoud Dekker Mark J. Kirwan
InnoTools Manager Paper and Paperboard Specialist
Smurfit Kappa Development Centre Fellow of the Packaging Society
Hoogeveen, The Netherlands London, UK
Michael Fairley Mondi Industrial Bags
Labels & Labelling Consultancy Vienna, Austria
Hertfordshire, UK
Preface

This book discusses all the main types of packaging based on paper and paperboard. It
considers the raw materials and manufacture of paper and paperboard, and the basic proper-
ties and features on which packaging made from these materials depends for its appearance
and performance. The manufacture of 12 of the main types of paper- and paperboard-based
packaging is described, together with their end-use applications and the packaging machin-
ery involved. The importance of pack design is stressed, including how these materials offer
packaging designers opportunities for imaginative and innovative design solutions.
Authors have been drawn from major manufacturers of paper- and paperboard-based
packaging in the UK, the Netherlands, Austria and the USA, and companies over a much
wider area have helped with information and illustrations. The editor has wide experience in
industry having spent his career in technical roles in the manufacture, printing, conversion
and use of paper, paperboard and packaging.
Packaging represents the largest usage of paper and paperboard and therefore both influ-
ences and is influenced by the worldwide paper industry. Paper is based mainly on cellulose
fibres derived from wood, which in turn is obtained from forestry. The paper industry is a
major user of energy and other resources. The industry is therefore in the forefront of current
environmental debates. This book discusses these issues and indicates how the industry
stands in relation to the current requirement to be environmentally sound and the need to be
sustainable in the long term. Other related issues discussed are packaging reduction, life-
cycle analysis and assessment, and the options for waste management.
The book is directed at those joining companies which manufacture packaging grades of
paper and paperboard, companies involved in the design, printing and production of packag-
ing and companies which manufacture inks, coatings, adhesives and packaging machinery.
It will be essential reading for students of packaging technology in the design and use of
paper- and paperboard-based packaging as well as those working in the associated media.
The ‘packaging chain’ mainly comprises:

● Those responsible for sourcing and manufacturing packaging raw materials.

● Printers and manufacturers of packaging, including manufacturers of inks, adhesives,
coatings of all kinds and the equipment required for printing and conversion.
● Packers of goods, for example within the food industry, including manufacturers of pack-
aging machinery and those involved in distribution.
● The retail sector, supermarkets, high street shops, etc., together with the service sector,
hospitals, catering, education, etc.

The packaging chain creates a large number of supplier/customer interfaces, both between
and within companies, which require knowledge and understanding. The papermaker needs
to understand the requirements of printing, conversion and use. Equally, those involved in
printing conversion and use need to understand the technology and logistics of papermaking
together with the packaging needs of their customers and society. Whatever your position
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