GABLE TOP

PACKAGE
QUALITY
Testing Formed
Juice and Milk Cartons
 This training manual provides an overview
of quality checks for gable top packaging TABLE OF
MANUAL systems as manufactured by Evergreen CONTENTS
OVERVIEW Packaging. The manual is designed to
be used in conjunction with instructor led Tools Required .................................................. 3
classroom training.
Safety Considerations .................................... 3

Carton Layout ................................................... 4

Course Objectives Bottom Pad Register ........................................... 6

Pyramid Bottom ................................................. 8

Upon completion of this training course,
you should be able to: Heat Seal Fundamentals .................................. 12

Dye Stain Tests ................................................ 15

Understand Carton Layout. Carton Bottoms ............................................... 17

Standard Bottom ......................................... 25

Properly Perform Dye Check Procedure.
J Bottom ..................................................... 28
Check Carton Bottoms.
Carton Tops .................................................... 30
– Bottom Pad Registration
– Squareness Pressure Management Jaws ......................... 30
– Heat Patterns Bar Dam Jaws ............................................. 32
– Seal Integrity
Spouts
– J Bottoms
Duckbills/Ducktails .......................................... 42
Check Carton Tops. Abhesive ........................................................ 44
– Sealer Jaw Registration
Carton Defects Diagram .................................. 46
– Squareness
– Heat Patterns Storage Considerations.................................... 47
– Seal Integrity
Glossary of Terms............................................ 50

Check Spout Seal Quality. Review ........................................................... 61

Contact Information ......................................... 68

1 2
 TOOLS CARTON
GABLE TOP CARTON
REQUIRED LAYOUT

Scarlett Moo Dye Stain

– 4 grams Scarlett Moo Powder
– 2 milliliters aerosol OT Wetting Agent
– 1 quart warm distilled or demineralized water

Add aerosol wetting agent to a quart of warm water

(180ºF). Shake and stir vigorously for 2 minutes. Add
Scarlett Moo powder and shake again, vigorously. Dye
stain must be cooled to room temperature before using.

Store the dye stain solution in a covered container at all

times. Label the covered container with an HMIS label
containing the correct information for the solution.

When the dye stain solution becomes diluted or weak it

must be discarded in compliance with your facility
environmental policies and procedures and a new The above drawing depicts a half gallon spout carton. Actual
solution must be mixed. customer cartons may be configured differently.

Utility Knife

Gloves (chemical resistant and cut resistant)

Safety Glasses

Safety Considerations

Wear gloves and safety glasses when mixing dye

stain solution.

Cut resistant gloves should be worn when using a

utility knife.

The above drawing depicts a half gallon non-spout carton.

3 Actual customer cartons may be configured differently. 4
 CARTON CARTON
LAYOUT GABLE TOP CARTON BOTTOM PAD REGISTER
BOTTOMS

The following procedure should be used to check the position of the

reliefs (register) of the bottom pressure pad. This procedure is to be
performed after rinsing out dye stained bottom samples and before
tear down. It can also be performed on non-dyed carton samples.

A Style or Standard Top

Bottom stake pad impression. Insert knife point into
Chevron reliefs as shown.

Insert knife point into the Insert knife point into fifth
center of the inner stake panel relief as shown.
reliefs as shown.

B Style or Half Gallon Top

5 6
 BOTTOM PAD REGISTER
CARTON
PYRAMID BOTTOMS
BOTTOMS

The pyramid bottom was invented to prevent the “rocking”, “tipping”

or “leaning” of a filled carton on the store shelf.

Insert knife point into Now you are ready to

J bottom relief as shown. inspect bottom pad register.

Visually inspect the pressure relief marks to ensure they are

vertical and horizontal and not skewed.

1. Tear open gusset flaps.

2. Make sure the chevron cuts are equal distance This is an example of a pyramid bottom on a 59 oz. carton,
between the two gusset flaps. which is a half gallon cross-section.

3. Make sure the inner stake cuts do not ride up the tuck
in flap. Cut must not exceed 1/32” from the tuck in
flap.

4. Make sure the fifth panel cut does not ride up onto the
fifth panel. Cut must not exceed 1/32 ” from fifth panel.

NOTE: This procedure is for skived fifth panels. A

non-skived panel will show the cut in the fifth
panel at tear down. Evergreen Packaging
manufactures bottom pressure pads which are
universal and capable of sealing both
configurations.

5. Make sure J bottom cuts are as close to J score as This is an example of a pyramid bottom on a quart carton.
possible without touching.

7 8
 PYRAMID BOTTOM REGISTER
CARTON
BOTTOMS PYRAMID BOTTOM REGISTER
Alignment Verification

1. Select one sealed bottom sample that has the excess removed
The following procedure should be used to check the position of from the carton side walls.
the reliefs (register) of the pyramid bottom pressure pad. This 2. Locate panel #1 on the carton bottom.
procedure is to be performed after rinsing out dye stained 3. Looking at the outside of the carton bottom, rotate the carton
bottom samples and before tear down. It can also be performed bottom so that panel #1 is at the top. (Position North based
on non-dyed carton samples. on a compass reading).

In order for the pyramid bottom pad to be registered on the Panel 1 Panel 1
carton, both “squares” or indentations should be centered on
the carton bottom. The register of the bottom pad in relationship
to the tuck flap and the 5th panel are important to containing
product. Follow the procedure below for checking pyramid
bottom register.

Alignment Procedure – Carbon Paper

Take one carton and cut two squares out of the carton that
are the same size as the pyramid bottom seal pad. (2 7/8”
square for quarts; 3 ½” square for half gallon). Pyramid Bottom stake pad Insert knife point into relief
impression. lines as shown. These cuts
Insert a piece of carbon paper between the two pieces of will identify the north to
paper with the carbon side facing upward. south position of the pad.
Insure that the filling machine is at the proper IES/ZES state
for your facility and place the stack of paper between the
seal pad and the mandrel. Close the seal pad. Panel 1 Panel 1

Remove the paper stack and view the carbon image on

the paper. The bottom seal pad should be centered on the
square. If it is not centered, adjust the bottom seal pad to
center it.

Check the density of the carbon impression. If the

impression is darker on one side than the other, it may
indicate that the clearance between the pad and the
mandrel needs to be checked.
Insert knife point into Chevron Insert knife point into fifth
relief as shown. These cuts panel relief as shown.
will identify the east to west
position of the pad.
9 10
 PYRAMID BOTTOM REGISTER CARTON
FILLING MACHINE HEAT SEAL FUNDAMENTALS BOTTOM SEAL
Panel 1 INTEGRITY

There are three basic fundamentals necessary to obtain good

carton top and bottom seals on a filling machine.

Heat (polyethylene activation)

Pressure
Cooling

A good carton seal is accomplished when you apply the

proper amount of heat to the carton and then add the
proper amount of pressure and cooling. This squeezes the
Now you are ready to activated surfaces together and removes enough heat from
inspect bottom pad register. the carton so it will form a bond.

Heat
Visually inspect the pressure relief marks to ensure they are
vertical and horizontal and not skewed. Heat is used to activate the polyethylene coating on both the
inside and outside surfaces of the carton. Proper amounts of
1. Tear open gusset flaps. heat are required to activate the polyethylene coating to a
molten state. When squeezed together both surfaces will bond
2. Make sure the Chevron cuts are equal distance or stick together creating a seal. The molten poly is utilized to
between the two gusset flaps. create the seal between two surfaces and it helps to fill in any
small channels that may be present.
3. Make sure the inner relief cuts are centered from
north to south on the bottom and do not ride up the When not enough heat is being applied to the carton surfaces,
tuck in flap. the poly coatings will be “under-activated.” This condition will
not allow for proper bonding of the two poly-coated surfaces.
4. Make sure the fifth panel cut does not ride up onto This will result in a non-sealed area.
the skived fifth panel.
Applying too much heat will overactivate the poly coating
5. Cut must not exceed 1/32” from fifth panel. which will not allow for a good seal. In some cases, the poly
is actually removed or broken down to the point where there
NOTE: This procedure is for skived fifth panels. A is not enough poly left for adhesion. NOTE: Sometimes the
non-skived fifth panel will show the cut in the temperature of the heaters are turned up in an effort to correct
fifth panel at tear down. another problem and overactivation is usually the result. It is
better to find the true cause of a problem and correct it rather
than just turning up the heat to improve the seal.

11 12
 FILLING MACHINE HEAT SEAL FUNDAMENTALS FILLING MACHINE HEAT SEAL FUNDAMENTALS

Pressure and Cooling

Too much heat will create pinholes in the polyethylene which
can lead to spoilage, leaks and bulge. Too much heat can also The pressure and cooling are combined because it is
open up the 5th panel (factory seal) and create leaks at the difficult to explain these as individual steps in the process.
5th panel, especially on the carton tops. Overactivation can
burn off the abhesive which is applied to the pour spout areas After the polyethylene on the carton has been activated
of the carton. Abhesive is applied to the pour spout area on by the correct amount of heat, the carton is transferred
non-fitment cartons to prohibit a poly to poly bond and make to the pressure pad (bottom) or the sealer jaws (top). The
the carton easy to open for the consumer. activated surfaces are exposed to extreme pressure which
creates the poly to poly bond required for a good seal.
Even with correct filling machine temperatures, there is a
possibility you will not get a correct seal if the ovens are Cooling water is circulated through the pressure pads and
not properly aligned with the carton. (Oven temperatures sealer jaws in order to remove the heat from the cartons
may be increased in order to correct this problem and while under pressure. If the heat is not removed, the carton
this is not the proper solution). Heater heads can be may stick to the bottom pressure pad or may begin to tent
too low, too high or misaligned with the carton. This top in the case of the top sealer jaws.
misalignment results in incorrect heat distribution on the
carton. Proper alignment of all components on a filling It is important to make sure that your machine has the
machine, especially the ovens is critical to producing a correct cooling water temperature, flow and correct
gable top carton with a good seal. pressure.

Pressure pad and sealer jaw clearances are also critical to

producing good seals. If there is too much clearance, not
enough pressure is applied and a poor seal will result. If
there is not enough clearance, machine damage will occur.

Air pressure should be maintained at 95 psi. Air should

also be clean and dry. Bottom pressure pads and top
sealers should be timed according to the machine
specifications. Cylinders should be inspected and rebuilt as
required.

13 14
 DYE DYE
STAIN SAMPLE PREPARATION/TEST FREQUENCY SAMPLE PREPARATION/TEST FREQUENCY STAIN
TESTS TESTS

Bottom Samples NOTE:

• Form and seal empty cartons
Pinholing and dye penetration on non-barrier board is
and retrieve from discharge of
expected.
filling machine.
• Label each carton with the
corresponding mandrel number. The carton tops of milk cartons and non-barrier cartons
This will be helpful if are often checked through the inspection of fiber tear and
troubleshooting is required. not using the dye stain method.
• Open carton tops.
Frequency Dye penetration at the bottom horizontal score is normal
3/hour/line following however, the dye should not exit the carton to the outside
machine start-up. corner.
Run one per mandrel
position at machine start-up. Separation of the interior top shoulder at the fifth panel
Run 3/hour/line following is normal on standard top cartons. This separation is
machine start-up. inherent to the carton top design and is caused when the
fifth panel is folded backwards during top formation.
Top Samples
Top sample checks are performed on
juice and specialty packages ONLY.

• Form and seal filled cartons and

retrieve from discharge of filling
machine.
• Cut off carton tops 1 inch below
top major horizontal score line.
• Invert top and place in carton
bottom.
Frequency
Run one per mandrel
position at machine start-up.
Run 3/hour/line following
machine start-up.

Dye Stain Test Procedure

Pour 1 inch of Scarlett Moo solution into carton samples and
hold for 1 minute (see recipe on page 3). Empty contents.
Rinse and dry thoroughly. Cut off excess side panels from
top and bottom samples. Inspect for excessive heat damage.
15
Perform tear down and leak inspection.
16
 CARTON HEAT PATTERN AND PINHOLES
BOTTOM SEAL HEAT PATTERN AND PINHOLES
INTEGRITY

Heat application is critical to the bottom seal integrity of the

gable top carton.

To perform this check you will need your rinsed, dye stained
carton bottom samples.

Sample Prep: This is an example of low heat.

Cut out carton bottoms by removing carton panels.
Fold back gusset flaps from center of carton bottom samples.

This is an example of correct heat. There is a slight gloss, This is an example of excessive pinholing caused by too
very slight dye penetration and no leaks. much heat or improper bottom oven height.

18
17
 CARTON BOTTOM LEAK CHECKS CARTON BOTTOM LEAK CHECKS

Sample Prep:
To perform the following checks you will need your rinsed, Fold back gusset flaps from center of carton bottom samples.
dye stained carton bottom samples. Lift fifth panel from gusset. Use a knife to cut along side of fifth panel
to make a separation and pry fifth panel upward.

This is an example of a This is an example of a

good bottom seal. good bottom seal although
dye has penetrated slightly
underneath gusset flap.

Fifth Panel Leaks

This illustration highlights the area of the carton bottom where
fifth panel leaks will be found.

This is an example of a This is an example of a

weak bottom seal. leaking bottom seal.
STOP machine and STOP machine and
do not run. do not run.

19 20
 GUSSET LEAKS CHANNEL LEAKS

This illustration highlights the area of the carton This illustration highlights the area of the carton
bottom where gusset leaks will be found. bottom where corner channel leaks will be found.

Sample Prep: Sample Prep:

Fold back gusset flaps from center of carton bottom samples. Fold back gusset flaps from center of carton bottom samples.
Lift fifth panel from gusset. Use a knife to cut along side of Lift fifth panel from gusset. Use a knife to cut along side of
fifth panel to make a separation and pry fifth panel upward. fifth panel to make a separation and pry fifth panel upward.

This is an example of a gusset leak. This is an example of corner channel leaks.

STOP machine and do not run. STOP machine and do not run.
21
22
 TUCK FLAP LEAKS TUCK FLAP LEAKS

This is an example of a tuck flap leak.

This illustration highlights the area of the carton STOP machine and do not run.
bottom where tuck flap leaks will be found.

Sample Prep:
Fold back gusset flaps from center of carton bottom samples.
Lift fifth panel from gusset. Use a knife to cut along side of
fifth panel to make a separation and pry fifth panel upward.

Tear open tuck flap seal.

This is an example of a tuck flap leak.

STOP machine and do not run.

23 24
 COMPLETE CARTON BOTTOM TEAR DOWN COMPLETE CARTON BOTTOM TEAR DOWN

Fold gusset flaps (on both sides of bottom) at center Pull the right inside half of the gusset triangle (fifth
and tear open. Inspect both sides of carton bottom panel facing side) apart. Pull open the remainder
for fiber tear. All sealed areas must have 100% of the gusset flap. Check for dye penetration
fiber tear.

Lift fifth panel from gusset. Use a knife to cut along Pull the tuck flap apart from the bottom major flap.
side of fifth panel to make a separation and pry Check for dye penetration.
fifth panel upward. Check for dye penetration.

25 26
 COMPLETE CARTON BOTTOM TEAR DOWN J BOTTOMS

Sample Prep:
Use torn down sample from Bottom Tear Down procedure to
inspect J bottom seal. Lift J bottom flap from panel 1 bottom
and inspect for fiber tear underneath.

Pull apart remaining gusset flap by pulling upward on the

tuck flap. Separate the other side of the gusset triangle by
pulling apart. All sealed areas must have 100% fiber tear.
Check for dye penetration.

This illustration highlights the area of the carton

bottom where J bottom leaks will be found.

Turn carton bottom over. All sealed areas must have 100%
fiber tear. Check for dye penetration.

27 J Bottom 28
 J BOTTOMS
PRESSURE MANAGEMENT CARTON
TOP SEAL JAW REGISTER TOP

This illustration shows the “H” pattern on the carton

top. The “H” pattern should be centered on the
This is an example of a J bottom leak. carton top.
STOP machine and do not run.

Pull up J bottom tab from carton bottom. Sealed

area must have 100% fiber tear. Check for dye
penetration.

This illustration shows the proper sealer/Dater

relief position.

29 30
 PRESSURE MANAGEMENT TOP SEAL JAW REGISTER BAR DAM JAWS

This illustration shows the proper position for

knife points for checking the fifth panel dam
register.

This illustration shows the position for knife NOTE: Knife points should fall within 1/32 ” of
points when checking the height of the top fifth panel edge.
seal dater jaws. Knife points should be within
1/ ” of the top of the gable which creates the
32
4 paper thickness.

This illustration shows the proper position for

knife points for checking the bar dam height.

NOTE: Knife points should be as close to the top

of the gable (which creates the 4 paper
thickness) as possible without touching.

31 32
 FITMENT FITMENT CARTON TOP SEAL INTEGRITY
CARTON FITMENT CARTON TOP SEAL INTEGRITY
TOP

Sample Prep:
To perform the following checks you will need your
rinsed, dye stained carton top samples.
Note:
This test is for fitment cartons only.
Side View of Carton Top

This illustration highlights the area of the

carton top where channel leaks will be found.

Flange
Mark

Mark fitment flange at bottom center using a knife.

Remove fitment cap and look for dye inside cap
and in pull ring area.

33 Open gables on both ends. 34

 FITMENT CARTON TOP SEAL INTEGRITY FITMENT CARTON TOP SEAL INTEGRITY

This is an example of a good top seal. This is an example of a weak top seal.
STOP machine and do not run.

This is an example of a good top seal with This is an example of a leaking top seal.
slight dye penetration. STOP machine and do not run.

35 36
 FITMENT CARTON TOP SEAL INTEGRITY FITMENT CARTON TOP SEAL INTEGRITY

This is an example of excessive pinholing caused by

too much heat or improper top oven height.

Pull open top holding at opposite corners.

This is an example of good fiber tear

Fiber tear must be present on the inside of the

carton top in all the corners. (Exception: Cartons
with abhesive will not have fiber tear in all corners
Separate fifth panel from first panel by as depicted above.)
tearing apart.
Fiber tear must be 100% above the top minor
horizontal score lines.

Fiber tear must be 100% in the 4 paper thickness

area on the outside of the carton top.

37
38
 FITMENT CARTON TOP SEAL INTEGRITY FITMENT CARTON TOP SEAL INTEGRITY

This is an example of proper energy ring impressions. This is an example of good fiber tear.

Peel fitment flange from carton.

This is an example of poor fiber tear.

Remove excess paper from fitment flange.

This is an example of a good VE3 weld.

39 40
 FITMENT CARTON TOP SEAL INTEGRITY DUCKBILLS Carton
Malformations

Operating Procedures

Top Seal Alignment

This illustration highlights the area of the carton

top where duckbills will be found.

A “duckbill” is found on the leading side of the

carton as it sits in the conveyor. A “ducktail”
328–3930b
is the back or trailing side of the carton in the
conveyor.
Sealer Jaw Alignment
Carton Top Misalignment Condition (Cartons with Spouts Trailing) Corrective Action
(Turning Top Sealer Jaw
On Line 1O 1On Line 2 Alignment Knobs)
To Decrease
Dimension A

A A LR LR

To Decrease
Dimension B

B B LR LR

To Decrease
Dimensions A and B

B A B A
LR LR

To Decrease
Dimensions A and B

A B A B LR LR This is an example of a duckbill.

41 42
 DUCKTAILS Non-Spout Carton Tops
Carton ABHESIVE
Malformations

Abhesive aids in the opening of non-spout gable top

cartons. Cartons with spouts will not have abhesive.

This illustration highlights the area of the

carton bottom where ducktails will be found.

This illustration shows the proper location of abhesive.

This is an example of a ducktail. This illustration shows the proper heat application to
the carton top.

43 44
 Carton CARTON DEFECT DIAGRAM CARTON DEFECT DIAGRAM
Defects
Formed carton defects can be grouped into two
categories, carton and machine. Carton defects are
those that are caused by the paperboard or during Carton Defect List
the conversion of paper into the carton. Machine
defects are caused by improper settings on a filling
5th Panel Shoulder (side seam)
machine.
5th Panel Bottom (side seam)
The diagram below identifies the most common Horizontal Top Score
carton and machine defects found on formed, Horizontal Bottom Score
filled cartons.
Vertical Score
Bad Side Seam (other)
5th Panel Pinholes
Bottom Corner other than 2C Corner
Bottom Tuck-in Flap Wet Spot(s)
Bottom Overlap Flap Wet Spot(s)
Top Shoulder other than C1 Corner
Top Channel Leak
Top Score Pinholes
Bottom Diagonal Pinholes
5th Panel Blowout
Bottom Channel Leak
J-Bottom Mistuck
Spout Fitment Hard To Open
Fitment Leak
Spout Foil Removal Problem
Hard To Open Board Spout
Raw Edge Wicking, Bottom Side Seam
Raw Edge Wicking, Overlap Flap

C = Carton Defect M = Machine Defect

45 46
 CARTON STORAGE REQUIREMENTS
CARTON
REQUIREMENTS
STORAGE
carton is constant and the temperature required to activate
the poly coating is constant, the three factors that control
the heating of the carton are the original temperature of the
The conditions under which poly coated cartons are stored cartons, the temperature of the air used to heat the poly and
has an effect on the forming and sealing of the cartons. The the thickness of the paper.
information that follows will serve as a guideline for storage.
If cartons run one day are 75oF and the temperature is set
Evergreen Packaging recommends the following:
so that a satisfactory activation is obtained, and then the
next day cartons that have been stored at 60o are placed
STORAGE ROOM in the machine, it would be very likely that a machine
1. Temperature: 70o to 80o Fahrenheit. adjustment would be necessary. The oven temperature would
2. Relative humidity: 50%. have to be raised to obtain the same degree of activation as
3. Do not double stack pallets the day before.
4. Keep cartons 12” from walls of storage room.
RELATIVE HUMIDITY AND MOISTURE CONTENT OF THE
5. Cases should be stored in an upright position, never on
BOARD AND ITS EFFECT ON FORMING AND SEALING
the ends or sides.
6. Cases should be on pallets, never sitting on the storage The relative humidity (% of moisture in the air) in the storage
room floor. room should be held as low as possible to prevent moisture
7. Inventory should be rotated, using the older cartons first. from entering the board along the raw edges. If moisture
8. All partial cases left at the end of the production day enters the raw edges of the board, it may travel transversely
should be closed securely and returned to the storage between the poly faces and weaken the board.
room.
9. Damaged cartons should not be loaded into magazines. When cartons with a high moisture content are run in the
machine, infeed problems may occur—such as cartons
TEMPERATURE EFFECT ON FORMING AND SEALING
dropping from the magazine into the pocket when the
The ideal carton temperature is between 70o and 80oF. magazine is full. It can cause the cartons to bow down in the
Cartons should be held in this range if possible. It is equally middle and be pulled from the magazine in an “L” shape
important to have the same temperature cartons in the instead of opening square.
machine from day to day. Poly coated cartons become
stiffer with a drop in temperature and more flexible at A good indication of high moisture content is the activation
higher temperatures. This variation can make it necessary of the poly coating as it is heated and of the carton itself
to adjust the filler infeed to compensate for the difference. when heat is applied. The activated poly on a normal
If the temperature is held in the 70o to 80oF range, these carton will have a sugary or roughened uniform texture.
adjustments should not be necessary. On a carton where too much moisture is present, the poly
will blister or bubble and uneven activation will occur. The
The temperature of the carton in the magazine determines blisters or bubbles are caused by the expansion of the
how much heat must be applied by the oven to activate the moisture as it is heated and changed to vapor.
poly for sealing. Since the time that the ovens are on the
47 48
 CARTON STORAGE REQUIREMENTS
GLOSSARY REFERENCES

When heat is applied to a carton that contains excessive “A” STYLE CARTON TOP
moisture, the carton will blow up and lose its squareness. This Gable is on the second and fourth panels. “A” Style tops feature top
can be observed by watching the carton on the mandrel as and bottom in-fold gusset scores on first and third carton panels. (See
heat is applied in the oven. drawing pg. 5).
ABHESIVE
STACKING OF CASES IN EXCESS OF THE RECOMMENDED Material placed on the inside sealing surface of carton top-seal area
HEIGHT AND THE EFFECT ON FORMING AND SEALING. to prevent activation and sealing of the poly; thus providing an easy
Stacking of cases in excess of the recommended number of open top-seal feature.
cases can cause the cartons to be deformed. As the machines ABRASION
are designed to handle the cartons as they normally come Damage caused to the surfaces of a carton by friction or rubbing of
from the converting plants, any damage or deformation adjacent cartons against each other, or against machinery parts.
that occurs from improper stacking can cause cartons to be ACTIVATION
dropped by the pickoff unit or be jammed going onto the When heat is applied to sealing surfaces of a carton top, bottom, or
mandrels. side seam area and the poly becomes molten; activation occurs.
ASEPTIC PROCESSING AND PACKAGING
The process in which the product and the container are sterilized
separately. Then the container is filled and sealed in a sterile
environment.
“B” STYLE CARTON TOP
Gable is on the first and third panels. “B” Style tops features top in-fold
gusset scores on the second and fourth panels. (See Drawing pg. 5).
BASIS WEIGHT
Density measurement of weight per unit area measured in pounds per
3000 sq. ft. (US) and grams per square meter (Europe and Asia).

BIAS SIDE SEAM

A misalignment or skew of the 1st panel carton edge to the #4 vertical
score of a side seamed gable top carton. Bias can be caused by
defective cutting knives, cut-to-score misregister, sharp scores, and the
side seaming process.
BLANK
A carton post side seaming that is ready to be shipped to the customer
for filling.
BLANKET
A rubber or polymer surfaced fabric used in offset lithography that is
clamped around the cylinder and transfers the image from the plate to
the substrate.
49 50
 GLOSSARY GLOSSARY

BLEACHED PAPERBOARD COOLING

A general term covering any paperboard comprised of 100% Cooling is used to remove the heat and create a seal after a carton
bleached fiber. Also referred to as “Solid Bleached Sulfate” or SBS. has been activated and pressure has been applied at the sealing
station.
BLEACHING
The process of chemically treating pulp fibers to reduce or remove CROSS SECTION
coloring matter so that the brightness of the pulp is increased. Package bottom inside dimensions, expressed in terms of width and
breadth. (Not the same as footprint).
BRIGHTNESS
CUTTING/CREASING
The quality of white intensity defined as the percent of reflectance of
The process of die-cutting, embossing, debossing, or scoring of
the paperboard surface, as measured using a standardized testing
material into carton flats.
method such as TAPPI Standard T 452m. (Often confused with
whiteness). DAM
(See Tufts).
BULGE
Carton bulge is the gradual progression of a filled carton with a DEBOSSING
square carton cross section to a round one by the bowing out of the Debossing is when the paperboard is crushed or compressed by the
carton sides. Bulge occurs because moisture migrates through the dies. Opposite of embossing.
sidewalls of the carton thus decreasing board stiffness during storage.
DELAMINATION
Important factors for bulge resistance include board stiffness, type
Describes the separation of the poly from the board.
and thickness of polymer layers, carton blank storage conditions,
filling machine setup, carton packing in cases and distribution abuse. DIAGONAL SCORE
Generally, skived cartons have less bulge than non-skived cartons. Describes the lines running diagonally on the top and bottom of a
carton.
CHANNELING
Seepage of liquid along score lines or package seal interfaces. DIE
A sharp steel rule (tooling)used for cutting, shaping, embossing,
COATING scoring or otherwise finishing or stamping carton blanks.
A substance applied in a liquid form to the surface of paperboard to DIE CUTTING
enhance or protect printing or to impart special functional properties. (See Cutting/Creasing).
COLOR SEPARATION DRAWINGS
Reducing full color images to single color images for process color Package engineering diagrams positioned print side up.
printing.
ECO-PAK® CARTON
COLOR SEQUENCE Package cross section: 2.2405” x 2.2405”
The order in which colors of ink are printed, Sizes: 4, 6, 8, 10 ounces
yellow+magenta+cyan+black. Carton top: A and B style
Opening features: Debossed, “X” cut, Thumb Punch, and spout.
CONDENSATION Side seam: Standard (Non Skived).
Liquid water that forms when a filled carton is placed in an area ELECTRON BEAM CURING (EB)
where the outside temperature is greater than the product inside. Method of drying or curing inks and protective coatings using electron
radiation.
CONVERTER
A manufacturer who fabricates packaging materials from various raw EMBOSSING
materials. Raising the paperboard above the surface of the carton by applying
pressure with a male and female die or engraved rollers.
51 52
 GLOSSARY GLOSSARY

FACINGS GUSSET
A marketing term indicating the outwardly visible panel of a carton at The triangular sections on the top and bottom of a gable
retail display. top carton.
FIBER TEAR HALF GALLON CROSS SECTION CARTON
The percent of a sealed area that exhibits fiber exposure (not poly) Package cross section: 3.764” x 3.764”
after a sealed carton has been torn down. Sizes: Half Gallon, 2 liter, 40oz and 60oz
FITMENT Carton top: B style
Spout and cap applied to gable top cartons to provide for ease of Carton bottom: Regular and J-bottom
opening and reclosing. (See Spout Closure). Opening features: Spout Hole
Side seam: Standard, and Pre-Sealed, Skived.
FLEXOGRAPHY
Flexo or Flexography is a method of direct-rotary printing, using HALF GALLON TOP
resilient raised-image printing plates, affixed to variable-repeat plate (See “B” Style top).
cylinders inked by a roll or doctor blade-wiped engraved metal roll
carrying fluid type inks to the paperboard. HEAT SEAL
The joining of two or more surfaces by the fusion of coatings and
FLAT base materials (like poly) under controlled conditions of temperature,
A carton before side seaming as the carton is stacked off of the die pressure and time.
cutter.
HIGH DEFINITION FLEXOGRAPHY
FOOTPRINT BHS Printing Press with 115 line screen max (versus 55 lpi for flexo
Package bottom outside dimensions, relative to width and breadth. or 135-150lpi for litho), colors: CMYK plus one spot color, varnish
(not the same as cross section). finish.
GABLE HORIZONTAL SCORE
A term used to describe the top of a carton. Describes the scores that run across a carton.
GALLON CARTON HYDROGEN PEROXIDE (H2O2)
Package cross section: 5.531 X 5.531 Chemical, which is atomized and heated to sanitize the inside of
Sizes: gallon, 5 lb. Squat, 7 lb., and 10 lb. Imperial cartons and equipment.
Carton top: A or B Style IMPERIAL GALLON CARTON
Carton bottom: Tuck Bottom Package cross section: 5.531” x 5.531”
Opening features: none Sizes: 10 lb.
Side seam: Standard Carton top: B style
Can be Skived Carton bottom: Standard Tuck
10 lb. – has tufts Opening features: none
GLOSS Side seam: Standard
The property of a surface that causes it to directly reflect light. Also No Skive.
used to describe the exterior printed surface of a carton (gloss side)
as opposed to the interior surface (matte side). IMPRESSION
The image left by an inked press printing plate or blanket when it
GRADE comes in contact with a substrate.
A class or level of quality of paperboard which is ranked or
distinguishable from other paperboards on the basis of use, IMPRINT
appearance, quality, manufacturing history, materials, or a The trademark or legend reproduced on a carton during the printing
combination of these factors. process to identify the manufacturer.
53 54
 GLOSSARY GLOSSARY

J-BOTTOM PANEL
A flap cut into the bottom of a carton, when folded properly leaves no A face, side, top or bottom of a gable top carton.
raw edge exposed on the inside of the carton.
PAPERBOARD
“L” SHAPED BOTTOM Paperboard is heavier in basis weight, and thicker and more rigid
A bottom style with an extended first panel and all other panels of the than writing papers. Sheets equal to or greater than 12 points or
same length that when folded properly leaves no raw edge exposed 0.012 inches in thickness are classified as paperboard.
on the inside of the carton.
PINHOLE
LITHOGRAPHY (OFFSET OR LITHO) A pinhole is a random small hole in the coating about the size of
Litho or Lithography is a printing process in which the image is a pin. Pinholing occurs when the coating fails to form a complete
photographically reproduced onto a thin flexible metal plate that is continuous coverage and can also occur when the sealing surfaces
fitted to a curved cylinder. The inked image is transferred, or offset, are over-activated.
from this plate to a rubber covered cylinder, which in turn transfers the
image to the substrate. PINHOLE RESISTANCE
Heat activated pinholes can be created in the polymer layer when
MANDREL
excessive heat is used to perform the carton sealing (side seam, top
Where cartons are loaded for the bottom forming, heat activation,
seal, bottom seal). Pinhole resistance is achieved in some carton
and sealing process.
structures (such as TruTaste™ Gold) by increasing polymer thickness
MATTE and/or using heat resistant polymer materials. Improved pinhole
The interior surface coating of a carton. resistance can result in increased bulge resistance (by mitigating side
MICRO PAK CARTON seam over activation), increased resistance to distribution abuse with
Package cross section: 1.810” x 1.810” aggressive products, and ease of running on filling machines at the
Sizes: 4, 6, 8 and 10 ounces customer facility.
Carton top: B style (half gallon top) POINT
Carton bottom: Pyramid Bottom A unit of paperboard thickness representing one-thousandth of an
Opening feature: Strawhole patch (foil) inch. Also describes the width of a steel die rule, where a point
Side seam: Pre-Seal Skived. equals 0.014 inch.
MIL POLYETHYLENE (PE) (Poly)
A unit of measure used to define paperboard thickness. One mil The coating used on the inside and outside of a carton.
equals one thousandth of an inch. (0.001”).
POLYPROPYLENE (PP)
OFFSET LITHOGRAPHY
The material used to manufacture the cap portion of a fitment.
(See Lithography).
OPACITY “PRE-SEAL AND SKIVE” SIDE SEAM
The extent to which light transmission is obstructed, a lack of Method to eliminate raw paperboard edges on the inside of side
transparency or translucency. seams. The skive cut is narrower than that used in making the
standard skive. The product contact polymer layer next to the skive
OVEN HEAD cut is preheated. The flap formed by the skive cut is then folded
The section of the oven housing where the sealing surfaces of a carton back and pre-sealed to the preheated area of the side seam panel
are activated. and the #1 panel of the carton is sealed over the Skive Pre-Seal to
OVERPRINT form the finished side seam. Skive Pre-Seal side seams are stronger
A transparent varnish applied over a previously than standard skive side seams. The strength differential has been
printed surface. confirmed by drop testing.

55 56
 GLOSSARY GLOSSARY

QUART CROSS-SECTION SKIVE

Package cross section: 2.764” x 2.764” Refers to the fifth panel, which is folded over and sealed
Sizes: half pint, pint, third quart, quart with no paperboard raw edge exposed on the inside of the side seam.
and 200ml, 250ml, 500ml and 1 liter
Carton top: A and B style SLEEVE
Carton bottom: Regular and J-bottom A carton post side seaming that is ready to be shipped to the customer
Opening features: Spout Hole for filling. Also called a blank.
Side seam: Standard, Standard Skive
and Pre-Seal Skived. SLIMPAK™ CARTON
Package cross section: 3.450” x 3.450”
RECYCLED FIBER Sizes: 1.75L and 1.5L
Cellulose fiber reclaimed from waste material and reused, sometimes Formed carton height: 1.75L = 10.5” 1.5L = 9.44”
mixed with a minor portion of virgin materials, to make new Carton top: B style Carton bottom: Pyramid bottom
paperboard. Not commercially used for grade A dairy products in the Opening features: spout hole (1.22” hole)
United States due to requirements for a controlled source of fiber. Side seam: Pre-Seal, Skived.
REGISTER SOLID BLEACHED SULFATE
The position of the reliefs and stake points on a sealed carton top or Paperboard made from 100% bleached fibers. May be coated with
bottom. polymer resins for food packaging applications such as milks and
REGISTRATION juices. Also used in clay coated folding cartons for such products as
The degree to which two or more printed images on the same frozen foods, butter, ice cream and cosmetics.
paperboard substrate are in alignment with each other.
SPOUT-PAK® CLOSURE
RELIEF A plastic part comprising a spout opening and a cap. Spout closures
Milled out areas on pressure pads and sealer jaws which are are described in terms of the tamper evident feature (internal – such
designed to accommodate different thicknesses of board when as a pull plug or membrane) or external – such as a break band) and
sealing. the cap size (which may correlate to the spout opening size. Also
called a fitment.
SANITIZE
Adequately treat food-contact surfaces by a process that is effective STAKE POINT
in destroying vegetative cells of microorganisms of public health Pressure points in the sealing die that create a debossment to help
significance, and in substantially reducing numbers of other prevent channeling.
undesirable microorganisms without adversely affecting the product or
its safety for the consumer. STANDARD TOP
(See “A” Style top).
SCORE
An impression creased into paperboard to facilitate folding. STIFFNESS
Resistance of board to deflection from an external source, often
SHELF LIFE
measured in Taber units. This property varies significantly between
The length of time a consumer product remains in a saleable or
grain and cross-grain direction (MD or CD) and will vary with
acceptable condition under specified conditions of storage.
moisture content of the paperboard.
SIXTH PANEL
A bottom style characterized by an extended tab on the 3rd panel, STEINE QUART
(See Wedge). A squat quart size using a half-gallon cross section (3.764” X
3.764”).
57 58
 GLOSSARY GLOSSARY

STRAW HOLES VARNISH

X –Debossed, X-Cut, Foil Patch, Keyhole, Circle. A thin, protective coating applied to a printed sheet for protection or
appearance.
STRETCH
VERTICAL SCORE
Elongation corresponding to the point of rupture, also known as
Describes the scores running up and down a carton.
strain.
VITASAVER™
SUBSTRATE Carton with nylon barrier structure. Produced in Litho
Paperboard or other packaging materials. and Flexo.
TEAR WARP PLATE
The force required to complete a tear, once the tear has been started. Located at the filling machine in-feed where vacuum is
The Elmendorf Tear Test is commonly used to measure this property. used to transfer the cartons from the magazine to the in-
feed chute.
TENSILE STRENGTH
A measurement of the rupture force required for a one inch wide strip WEDGE
(Y direction) of paperboard when pulled in the X direction under an A trapezoidal L bottom characterized by a tab on the third panel,
axial tension load. used to effect raw edge protection for carton bottoms.
WET STRENGTH
THICKNESS
Strength of a paperboard sample after it has been wetted by water
The height of a single sheet of paperboard measured in thousandths
under specific conditions.
of an inch or “points.”
WHITENESS
THUMBHOLD A combination of the total reflection of white light and the uniformity
A semi-circular or triangular cut made in the sides or ends of cartons of the reflectance at all wavelengths. A perfect white color has 100%
to facilitate opening of the package. reflectance.
TRAP WICKING
The ability of an ink to print onto and mask an underlying ink color. The tendency of a liquid to be absorbed by osmosis through a sheet of
paperboard. Wicking is the penetration of products into the exposed
TRU-TASTE™ GOLD
raw edge of the paperboard.
Carton barrier structure with Nylon and EVOH barriers, that is printed
in Litho or HD Flexo. WICKING RESISTANCE
For some products, such as aggressive yogurt drinks and some juices,
TUCK BOTTOM board sizing is used to prevent wicking. Some products may require
When #1 panel flap is tucked under #3 panel flap on half-gallon and skived cartons and more sophisticated carton structures to prevent
quart cross section cartons. unacceptable distribution abuse.
ULTRASONIC WINDOW
A sealing process used for welding fitments to cartons and making A die cut opening in a carton blank that provides visibility of contents,
polymer seals. usually covered with a transparent film.
ULTRAVIOLET LIGHT Sources:
Invisible, high energy light made up of wave lengths that are shorter Flexography: Principles & Practices 5th Edition, Volume 1,
than those of visible light. Used on filling machines to clean plenum of Flexographic Technical Association, 1999,
the HEPA units.
UNIVERSAL BOTTOMS 21 CFR
A tuck carton with one small piece cut off which allows the carton to
run on a filling machine with or without a fitment applicator. TAPPI Dictionary of Paper Terms

59 Evergreen Packaging Group 60

 CARTON QUALITY REVIEW
REVIEW CARTON QUALITY REVIEW

5. What causes poor top seals?

a. Tops getting wet.
b. Insufficient heat.
Name: Instructor: c. Insufficient pressure.
d. Incorrect elevator height.
Date: e. All of the above.

6. What do you call a top seal that has gotten wet from
Circle the correct answer. product, resulting in an incomplete top seal?
a. Tent top.
1. At what frequency are dye checks to be performed? b. Pitcher top.
a. Every 8 hours, at the beginning of your shift. c. A write-up.
b. Every 4 hours, and at shut downs. d. Leaker.
c. At start ups/changeovers, and every 2 hours. e. All of the above.
d. Only when you suspect a problem.
e. At start ups/changeovers, and every hour. 7. What is fifth panel blow out?
f. None of the above. a. A sudden loss of pressure.
b. A flat carton, preceded by a loud pop.
2. How much fiber tear should be present on bottom and top c. A condition requiring the fifth panel be re-lit.
seals? d. A separation of the fifth panel from the first at the top
a. 90%. seal.
b. 100%.
c. 75%. 8. What causes fifth panel blow out?
d. 50%. a. Excessive top heat.
e. Between 50 and 75%. b. Incorrect elevator height.
c. Poor manufacturer seal.
3. Which of the following items is NOT required for a good top d. Wet tops.
seal? e. All of the above.
a. Clean water.
b. Dry cartons. 9. What causes wet tops?
c. Correct heat. a. Dripping filler valves.
d. Sufficient pressure. b. Bad o-rings or springs in the discharge valves.
e. Proper cooling water temperature. c. Conveyor chains jumping or jerking.
d. Cartons not centered directly under the fill valves.
4. Poor bottom seals can be caused by: e. All of the above.
a. Insufficient heat.
b. Insufficient pressure. 10. Where should the elevator be set?
c. Insufficient cooling. a. To where the patent panel clears the valves by 1/16“
d. Poor pressure pad register. b. High enough to obtain proper top seal register.
e. All of the above. c. On the ground floor.
d. Both a & b.
e. None of the above.

61 62
 CARTON QUALITY REVIEW CARTON QUALITY REVIEW

11. What causes badly formed bottoms? 17. Bottom and top seal dye checks are to be performed on dry,
a. Incorrect carton stop settings. empty cartons because:
b. Loader lug damaging cartons at infeed. a. Juice and/or water left in the carton may dilute the dye.
c. Bottom heater out of alignment. b. Juice can plug up potential leak channels to the point the
d. Bottom breaker out of alignment. dye cannot penetrate.
e. All of the above. c. A filled carton will be considerably cooler.
d. All of the above.
12. How long should the scarlett moo dye be held in the cartons? e. None of the above.
a. 15 seconds.
b. 1 minute. 18. At what frequency should dye checks be taken during normal
c. 5 seconds. production?
d. 2 minutes. a. Every 8 hours, whether needed or not.
e. 5 minutes. b. Daily.
c. 3 per line per hour.
13. What should you do when experiencing problems with d. One per mandrel per line, consecutive.
bottom or top seals? e. When the cows come home.
a. Continue running. f. All of the above.
b. Shut off the problem filler line.
c. Notify supervision and maintenance. 19. Why are we encouraged to perform all of these quality
d. Go on break. checks?
e. Both b & c. a. Prevent consumer complaints.
f. None of the above. b. Keep rework costs down.
c. To ensure having the best package possible.
14. On start up, how many carton bottoms should be checked? d. Catch potential problems early.
a. One from each line. e. All of the above.
b. 3 consecutive from each line.
c. 6 consecutive from each line. 20. Label the panels of the carton.
d. One per mandrel per line, in consecutive order.
e. All of the above.

15. The completed dye check samples are to be:

a. Discarded at the end of the shift.
b. Labeled with the date, time, filler, line, and operator’s initials.
c. Stored for 2 months.
d. Both a & c.
e. Both b & c.

16. Why is it important to use fresh scarlett moo dye?

a. To help find channel leakers.
b. The dye will not penetrate well if diluted.
c. Bad dye may make leakers look good.
d. All of the above.
e. None of the above.

63 64
 CARTON QUALITY REVIEW
BIRTH OF THE PAPER MILK CARTON HISTORY

21. The matte side of a gable top carton is the side that is not
printed. True/False The very first paper-based milk containers were sold on the
streets of San Francisco and Los Angeles as early as 1906. These
cartons very quickly disappeared from the marketplace. Around
22. The coating on the outside and inside of a gable top carton
the same time another paper carton was being developed.
is polyethylene. True/False
One morning in the early 1900’s, John Van Wormer, an Ohio
toy factory owner, dropped his glass milk bottle one morning
23. The J-bottom, when properly folded, removes the raw edge shattering it and spilled milk everywhere. Annoyed about his
from the inside of the carton bottom. True/False spilt milk, Van Wormer got the idea for the paper milk carton.
Van Wormer took out a patent in 1915 on his new product that
he called “paper bottle”. The paper milk carton was later called
24. Too much heat applied to the top or bottom of a carton will “Pure-Pak” because the container could be thrown away after one use.
create pinholes. True/False
It would take Van Wormer ten years to engineer a machine
that was capable of forming, filling and sealing the paper milk
25. The gloss side of a gable top carton is the side that is not cartons. He also faced some resistance from most of America
printed. True/False because as a people, they were very attached to milk in bottles. It
wasn’t until the cost of glass increased that the “Pure-Pak” paper
milk carton gained market share.

The American Paper Bottle Company acquired Van Wormer’s

patent and in 1934 approached Ex-Cell-O Corporation, Detroit,
to manufacture machines for the Pure-Pak system. Ex-Cell-O
Corporation eventually acquired the rights to manufacture and
distribute the Pure-Pak system. One of the first enhancements
made to the package was the re-design of the carton top to create
a pour spout on one side of the gable.

Several competing systems were launched around 1930 but

none survived. Pure-Pak had a unique selling point in that the
packages were delivered flat, saving storage and transportation
costs.

From sales of 42 million units the first full year in the market, to
today’s billions of units sold, the system has come a long way.
Today, the traditional “Pure-Pak” carton is filled with milk, juice,
wine, fabric softener, soups, soy milks, pet treats, candies and fruits.

Energy-efficient production, reduction of carton weight,

improvements to sealing and opening techniques, enhanced
graphics and barrier technologies have kept the paper carton or
65 66
Pure-Pak technology alive.
 CONTACT INFORMATION
HISTORY HISTORY OF EVERGREEN PACKAGING

In 2005 Rank Group Limited purchased controlling interest in Carter Holt

Harvey (CHH) from International Paper Company (IP).

In 2006 Rank Group Limited acquired the remaining outstanding shares Evergreen Packaging
of CHH. Corporate Office
In February 2007, CHH acquired the former Beverage Packaging Division 5350 Poplar Avenue Suite 600
of International Paper and named it Evergreen Packaging Inc. (EPI).
Memphis, TN 38119
901-821-5350
In May 2007, Rank Group Limited acquired SIG, a German based liquid
www.evergreenpackaging.com
packaging company.

In July 2007, Rank Group Limited acquired Blue Ridge Paper Products
(BRPP), an ESOP company based in Canton, NC and merged BRPP with Evergreen Packaging Equipment
EPI. Main Office

The new merged company of the old IP Beverage Packaging and BRPP 2400 Sixth Street SW
organizations, now referred to as the Evergreen Packaging Group (EPG) Cedar Rapids, IA 52406
will function as one company, from an operational perspective. 319-399-3200
319-399-3543 fax
In December 2007, Rank Group Limited acquired Alcoa’s packaging and www.evergreenpackaging.com
consumer businesses.

The Rank Group Limited owned operations, SIG and Alcoa, will function
as separate entities.

Corporate office for EPG has been established in Memphis, TN.

EPG has a number of product platforms in its portfolio, including liquid
paperboards, beverage packaging, coated publication papers, and
uncoated papers.

The beverage packaging business offers total packaging solution systems

(TPSS) for juice, dairy, and specialty products. This includes gable-
top packaging equipment, gable-top cartons, spouts, and a full line of
services to support the business.

Two primary mills and three extruding locations are located in the U.S.
EPG has a Global converting business with 17 plants located in 10
countries.

EPG has an equipment manufacturing business with production facilities

in the U.S. and China.
67 68
 NOTES NOTES

69 70
 For more information on Evergreen Packaging
Systems, contact your Evergreen Packaging
Technical or Sales Representative

Photography: Don Denney

Cincinnati, OH
Design: Evergreen Packaging
Printer: RPI Graphics
Cincinnati, OH
Development: Ron DeLaurier, Al Manning &
Bobbi Wagner

Contributors: Al Murray, Tim Hughes,

Ron Ferguson, Norvie White,
Judy Zeigler, EPE Engineering,
Seth Chinnis, Lyndsey Fullen
& Julie Benesole