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Manufacturing of Corrugated Board

Corrugated board is a packaging material made from a fluted paper layer glued between two flat paper layers. It is lightweight yet robust. The fluted layer provides cushioning and support, making corrugated board stable and able to withstand pressure and impacts during shipping. It can be manufactured in various designs and formats to meet different packaging needs.

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98 views

Manufacturing of Corrugated Board

Corrugated board is a packaging material made from a fluted paper layer glued between two flat paper layers. It is lightweight yet robust. The fluted layer provides cushioning and support, making corrugated board stable and able to withstand pressure and impacts during shipping. It can be manufactured in various designs and formats to meet different packaging needs.

Uploaded by

Paul Philip Labitoria
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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MANUFACTURING OF CORRUGATED BOARD

Corrugated Board
- Packaging material formed by gluing one or more fluted sheets of paperboard (corrugating medium) to one or more
flat sheets (called facings) of linerboard

Design Principle

Corrugated cardboard is a stable and lightweight construction made of air and paper. The secret lies in its stability, where the
paper wave is glued to one or several layers of paper. This principle corresponds to the arches seen in the construction of
bridges and cathedrals which, in terms of corrugated board, reflects the cushioning effect causing great stability and immense
load-bearing capacity.

Characteristics of Corrugated Board

1. Renewable
Corrugated board is made from papers made up from cellulose fibres, which are virgin or recycled. This makes
corrugated a renewable natural resource.

2. Versatile
Aside from its various applications, corrugated board accommodates a wide variety of printing options such as
Flexographic, litho and silk screen printing.

3. Light

4. Robust
This construction forms a series of connected arches which are well known for their ability to support strong weights.
This structure gives corrugated board considerable rigidity and resistance. The air circulating in the flutes also serves
as an insulator which provides excellent protection against temperature variations.

Corrugated board is engineered for stack ability. It withstands pressure, is crush-resistant and passes burst-strength
tests. Corrugated Board offers tear, tensile and burst strength to withstand shipping pressures. Corrugated Board
resists impact, drop and vibration damage and offers uniform stacking and weight distribution.

When arranged in this way, the flutes would collapse when exposed to pressure from above. Carton
strength is then compromised and entire stacks may collapse.

5. Flexible to Different Design Specifications


Corrugated board is a rigid shipping and packaging medium that can be cut and folded into an infinite variety of
shapes and sizes, constructed to an almost scientific specification, even allowing direct print with high resolution
graphics.
History
The American Albert L. Jones is known as the "father of the corrugated board". It is said, that whilst producing ruffs and
frills, he came up with the idea of sending paper instead of textile through the rollers to produce a flexible packaging material.
In December of 1871, he filed the paper application for it. In 1874, the American Oliver Long achieved a major improvement:
He glued the corrugated paper line to a smooth paper and thus created the one-sided corrugated cardboard.

Patents
*1856: Edward C. Healey and Edward E. Allen
The material patented was a form of fluted material for the sweatbands of hats.

*1871: Albert L. Jones


Use of unlined corrugated paper, formed with tubes and small boxes, for packaging small fragile articles such as
glass vials and bottle

Manufacturing
*Thompson and Norris Co. (New York, USA) *Robert Gair Co. (Boston, USA)

Manufacturing Process

1. Single-facer Station
a. Fluting medium and liner are preconditioned with steam to make them pliable for processing.
b. The medium is fluted through large rolls with surface pattern.
Vacuum pressure is used to hold the medium in place, reducing potential indentations and improving
compression strength.
c. Adhesive is applied to flute tips.
d. The liner is pressed against the tips, where a combination of heat and pressure bonds the two surfaces together.

2. Bridge Store Station


The flexible single-faced material is draped in an overlapping wave pattern. Its purpose is to separate the single-facer
and double-backer stations, allowing for different operating speeds and reel changes.

3. Double-backer Station
Adhesive is applied to the flute tips on the other side of the medium and the outer liner is glued on.

4. Finishing Station
a. The stiff corrugated board is passed between two long flat belts for final heat setting and cooling.
b. The edges are trimmed and slit to required widths and lengths.
c. The machine then scores the board along the planned flaps for folding.
d. The finished sheets are stacked ready for assembly.

*Scores

1. Three-point Score used where the case flaps will be folded in one direction to close the container
2. Off-set Point-to-point Score
3. Five-point Score
- used where flaps need to be first bent outwards (may produce an uneven break when heavy materials are used)
*Ways of Operating Joints

1. Gluing
- Simple and fast, offers strong joint
- Most common technique
- Double-gluing can be used to reinforce corners

2. Wire Stitching
- Commonly used on triple-wall constructions and where treatments such as waxing prohibit normal gluing
- Slower and semi-automatic operation

3. Taping
- Slower and semi-automatic operation
- Used for oversized cases not able to be put through a gluer
- For applications where the overlap of the normal glue tab is undesirable
- Pressure-sensitive and heat-activated tapes replaced gummed tapes due to ease of application
- For reinforcing containers

4. Stapling
- Slower and semi-automatic operation

Standard and Common Styles of Corrugated Board

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