DJP6052 PRINTING FOR PACKAGING

CORRUGATED BOARD REPORT

DMP4B

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NO CONTENT PAGE

1. INTRODUCTION FOR PACKAGING 3

2. PACKAGING INDUSTRY 3

3. TYPES OF LINERS 4

4. FLUTED PATTERN AND BONDS 6

5. BASIC COMPONENTS 8

6. MANUFACTURING PROCESS
8. CONCLUSION
9. REFERENCES

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INTRODUCTION FOR PACKAGING

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
designing, evaluating, and producing packages. Packaging can be described as a
coordinated system of preparing goods for transport, warehousing, logistics, sale, and
end use. Packaging contains, protects, preserves, transports, informs, and sells. In
many countries it is fully integrated into government, business, institutional,
industrial, and personal use.

PACKAGING INDUSTRY

Nowadays,in packaging industry almost 70% use of plastic for their packaging.
While the rest for their transportation and etc. There are several material packaging
used for example paper, aluminum, plastic and so on. The main purpose of packaging
is to protect the content of a product. To ensure a product is sold, a medium of
communication between the customer and the product must be present. A product's
design will come with an attractive design. The question is how is it designed and able
to attract customer attention?

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TYPES OF LINERS CORRUGATED FIBER BOARD

CORRUGATED FIBER BOARD IS THE MOST WIDELY USED SECONDARY

PACKAGING MATERIAL.

SINGLE WALL
- (One fluted medium with two liner plies) a standard type for most product types.

DOUBLE WALL
-(two fluted medium plies and three liner plies) used for heavier or more bulky
products such as machinery, large appliances or furniture, or for display stands or for
products which are stored for extended time periods

TRIPLE WALL
-(three fluted medium plies and four liner plies) used for particularly heavy duty
applications, as a subtitude for wooden containers for palletboxes or bilk bins.

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A CORRUGATING MACHINE FORMS THE MEDIUM INTO A FLUTED
PATTERN AND BONDS IT TO THE LINERS USING ADHESIVE.

FLUTE A
-A kind of wrinkled paper is wrinkled paper very strong in terms of durability and
paper type has a great flute

FLUTE B
-This type of paper is wrinkled paper that both have strength in terms of durability as
well as the largest flute after wrinkled paper type A

FLUTE C

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-This kind of wrinkled paper is the third highest durability and also the third largest
flute after type B. Wrinkled paper type known as the medium paper

FLUTE E
-This kind of wrinkled paper has less resistance because this paper has the smallest
flute of three types of flute available. Wrinkled paper type known as microflute paper

FLUTE F
- F-flute, the newest flute, is nearly half of the thickness of E-flute and is popular
choice in the corrugated industry. The ideas for F-flute originated in Europe to reduce
the fibre content in packaging

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BASIC COMPONENT REQUIRED FOR CORRUGATED BOARD:

1.LINER OR FACING MATERIALS(FROM KRAF PAPER)

 The liners and medium that make up the corrugated sheet are both forms of
paperboard
 Linerboard is the paperboard used as the inner and outer facing of corrugated
sheet.
 It is made primarily through the chemical process and usully made from
softwoods like Pine trees that longest fibers and produce the strongest board
 Linerboard and medium are also made from recycled resources.

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-Flute materials

2.ADHESIVES

 As the second,most important material has gaines significance importance

 Usually starch based adhesives are used for joining the outer liner(This has
relation to printing) Sodium Silicate (near to natural)also is used
 The silicate can give a rigid board but they can render the box brittle or lend to
de-lamination depending upon the humidity

3.FLUTES MATERIAL

Flutes cardboard is the wavy pieces of board sandwiched between the liners and gives
a box its strength and protection from knocks and impact damage

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PROCESS FOR CORRUGATED BOX
• 1 Manufacturing a corrugated cardboard box begins with the pulping of wood
chips in the kraft (sulfate) process. First, tree trunks are stripped of bark and torn into
small chips. Next, these chips are placed in a large, high-pressure tank called a batch
digester, where they are cooked in a solution, or liquor, made of sodium hydroxide
(NaOH) and several other ionic compounds such as sulfates, sulfides, and sulfites.
These strongly alkaline chemicals dissolve the lignin, the glue-like substance that
holds the individual wood fibers together in a tree trunk.
• 2 When the pressure is released after several hours, the wood chips explode like
popcorn into fluffy masses of fiber.
Making kraft paper
• 3 After additional cleaning and refining steps, a consistent slurry of wood pulp is
pumped to the paper-making machine, also known as a Fourdrinier machine.
Gigantic, square structures up to 600 feet long (182.88 meters), these machines
contain a wire mesh in which the paper is initially formed. Next, the paper is fed into
massive, steam-heated rollers and wide felt blankets that remove the water. At the
end, the finished medium, or liner, is rolled for shipment.
Shipping and storing the kraft paper
• 4 Rolls of kraft paper for corrugating are available in many sizes to fit the
production equipment at different corrugating plants. The most common roll sizes are
67 inches (170.18 centimeters) wide and 87 inches (220.98 centimeters) wide. An 87-
inch roll of heavier paper can weigh up to 6,000 pounds (2,724 kilograms). As many
as 22 rolls of 87-inch paper can be loaded into one railroad boxcar for shipment to a
corrugating plant.
• 5 At the plant, the kraft paper is separated into different grades, which will be
used for the medium and the liner. These different grades of corrugated cardboard can
be made by combining different grades of kraft paper. A knowledgeable packaging
specialist works with a customer to determine the strength required for the corrugated
cardboard container being planned. Then, when a plant receives an order for
containers, a product engineer specifies the combination of medium and liner to
produce a cardboard to match the customer's requirement.
• Corrugating the cardboard
• 6 Using powerful fork-lifts, skilled equipment operators select, move, and load
rolls of kraft paper at one end of the corrugator.
• Corrugated cardboard manufacture includes two key steps: making kraft paper
and corrugating the cardboard. Kraft paper involves pulping wood chips and then
feeding the resulting paper substance through massive steam rollers that remove the
water.

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Corrugating is also done in a machine that utilizes heavy rollers. One roll of
cardboard is corrugated and then glued between two other layers (liners) by the same
machine. The glue is then cured by passing the cardboard over heated rolls.
• 7 One roll of medium is loaded to run through the corrugating rolls, and a roll of
liner is fed into the corrugator to be joined with the corrugated medium. Liner from
another roll travels up over the corrugating rolls along a flat structure called the
bridge. This liner will be glued to the corrugated medium later in the process.
• 8 For a large production run, additional rolls are loaded into automatic splicers.
Sensitive detectors check the rolls of paper feeding into the corrugator. When a roll is
nearly empty, the corrugator control system starts a splicer, and paper from the new
roll is joined to the end of the paper going through the machine. Thus, production of
corrugated cardboard is continuous, and no production speed is lost.
• 9 The medium to be corrugated is fed into the giant, electrically driven rollers of
the corrugator, first through the preheating rollers and then into the corrugating rolls.
Steam at 175 to 180 pounds of pressure per square inch (psi) is forced through both
sets of rollers, and, as the paper passes through them, temperatures reach 350 to 365
degrees Fahrenheit (177 to 185 degrees Celsius).
• 10 The corrugating rolls are covered with I O flutes —horizontal, parallel ridges
like the teeth of massively wide gears. When the hot paper passes between the
corrugating rolls, the flutes trap and bend it, forming the middle part of a sheet of
corrugated cardboard. Each corrugating machine has interchangeable corrugating rolls
featuring different flute sizes. Installing a different

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• A finished piece of corrugated cardboard consists of a single corrugated layer
sandwiched between two liner layers.
• flute size in the corrugator changes the width of the corrugated medium.
• 11 The medium travels next to a set of rollers called the single-facer glue station.
Here, one layer of liner is glued to the medium. Starch glue is carefully applied to the
corrugated edges of the medium, and the first layer of liner is added. From the single-
facer, the medium and liner go to the double-backer glue station where the other layer
of liner from the bridge is added following the same procedure. Continuing through
the corrugator, the cardboard passes over steam-heated plates that cure the glue.
Forming the blanks into boxes

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• 12 At the end of corrugator, a slitter-scorer trims the cardboard and cuts it into
large sheets called box blanks. Box blanks pop out of the slitter-scorer like wide slices
of toast and slide into an automatic stacker that loads them onto a large, rolling
platform. From here, they will be transported to the other machines that will convert
them into finished containers. Skilled production workers use a computer terminal and
printer to prepare a job ticket for each stack of box blanks produced by the corrugator.
With the job ticket, workers can route the stack to the right fabrication machines,
called flexos (the name is short for flexographic machine). A flexo is a wide, flat
machine that processes box blanks.
• 13 Printing dies and die-cutting patterns I 3 are prepared in a pattern shop on
large, flexible sheets of rubber or tin. The dies and patterns are loaded onto the large
rollers in the flexo, and the box blanks are automatically fed through it. As each blank
passes through the rollers of the flexo, it is trimmed, printed, cut, scored, and, in a
printer-folder-gluer, folded and glued to form a box. From the flexo, the finished
boxes are automatically stacked and sent to a banding machine to be wrapped for
shipping. Other equipment in a corrugating plant includes stand-alone die-cutters, die-
cutters with print stations, and machines known as curtain coaters that apply a wax
coating to fruit, vegetable, and meat containers. Box blanks requiring only simple,
one-color printing and die-cutting can be run through a stand-alone die-cutter, print
station, and curtain coater to produce water- or grease-resistant containers.
Read more: http://www.madehow.com/Volume-1/Corrugated-
Cardboard.html#ixzz6HsKLe38W

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CONCLUSION…

-Corrugated Boxes are in high demand and are one of the high-growth sectors of the
Packaging Market.
There’s a loads of information available on setting up a corrugated plant and running
a business online.
The issue here is that there’re thousand of players in the market who’re producing
corrugated boxes in various stages in process.
Digital finishing and custom printing capabilities give you a few differentiators but
you’ve to really partner with them if you really want success.

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