Professional Documents
Culture Documents
Dr Gordon L. Robertson
University of Queensland &
FoodPackagingEnvironment
Brisbane
Australia
MODULE I: CHAPTER 2: PAPER-BASED PACKAGING
2.1 Learning Objectives
2.2 Introduction
2.3 Raw Material
2.4 Pulping
2.4.1
2.4.2
2.4.3
2.4.4
2.4.5
Mechanical Pulps
Chemical Pulps
Semichemical Pulps
Digestion
Bleaching
2.5 Paper
2.5.1
2.5.2
2.5.3
2.5.4
Stock Preparation
Beating, Refining and Sizing
Papermaking
Converting
Kraft Paper
Bleached Paper
Greaseproof Paper
Glassine Paper
Vegetable Parchment
Waxed Paper
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Paper-based Packaging
Coniferous forest
2.4 Pulping
The purpose of pulping is to separate
the fibers without damaging them so
that they can then be reformed into a
paper sheet in the papermaking
process. The intercellular substances
(primarily lignin) must be softened or
dissolved to free individual fibers.
Commercial pulping methods take
advantage of the differences between
the properties of cellulose and lignin in
order to separate fibers, but breaking
and weakening of the fibers does
occur to a greater or lesser degree at
various stages during the pulping
process.
Pulps that retain most of the wood
lignin consist of stiff fibers that do not
produce strong papers; they
deteriorate in color and strength quite
rapidly. These properties can be
improved by removing most or all of
the lignin by cooking wood with
solutions of various chemicals, the
pulps so produced being known as
chemical pulps. In contrast,
mechanical pulps are produced by
pressing logs on to a grindstone, when
the heat generated by friction softens
the lignin so that the fibers separate
with very little damage. Mechanical
pulps can also be formed by grinding
wood chips between two rotating
refiner plates. In addition, there are
some processes which are categorized
as semi-chemical and chemimechanical.
2.4.1 Mechanical Pulps
Wood fibers
Paper-based Packaging
Refiner
Chemithermomechanical pulping
(CTMP) increases the strength
properties of TMP pulps even further
by a comparatively mild chemical
treatment followed by pressurized
refining. In general, CTMP pulps have
a greater long fiber fraction and lower
fines fraction than comparable TMP
pulps. CTMP is suitable for the middle
layer of multiply boards where it adds
bulk and rigidity (stiffness) at lower
cost than kraft pulp.
2.4.2 Chemical Pulps
There are several chemical pulping
methods, each based either directly or
indirectly on the use of sodium
hydroxide. The objective is to degrade
and dissolve away the lignin to allow
the fibers to separate with little, if any,
mechanical action. The nature of the
pulping chemicals influences the
properties of the residual lignin and
the residual carbohydrates. For
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Paper-based Packaging
Paper-based Packaging
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Twin-wire former
Twin-wire formers have replaced the
fourdrinier wet-ends on many
machines, particularly for lightweight
sheets, corrugated media and
linerboard grades.
Cylinder machine
The advantage of the cylinder machine
for the manufacture of boards is that a
number of cylinder units can be
arranged so that the fiber mat from
each is deposited as a layer and all the
layers can be combined to make a
multiply paperboard (see photo
above).
The twin-wire former method for
making paper and paperboard was
developed in the UK in the 1950s. The
paper web is formed between two
converging forming screens by means
of a flow box, and the water is drained
from the slurry by pressure and later
by vacuum. Successive layers of fiber
are laid down sequentially on the felt,
water being removed upwardly,
overcoming the difficulty experienced
in the conventional downward
removal of water through several
Paper-based Packaging
Calender
Surface treatments such as sizing and
coating are extensively applied to
improve the appearance of products.
Paper may be coated either on
equipment that is an integral part of
the paper machine (i.e. on-machine
coating), or on separate converting
equipment. The most common
method for the application of
chemicals to the surface of a paper
Paper-based Packaging
Paper-based Packaging
Glassine paper
2.7.5 Vegetable Parchment
Paper-based Packaging
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Paper-based Packaging
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Paper-based Packaging
Triple-wall construction
In addition to the various weights of
linerboard and corrugating medium
used and the different form of
construction of corrugated board,
there are five different flute sizes,
each varying primarily in the height of
the flute and the number of flutes
used per unit length of the board.
Common flute sizes are A, B, C, E and F
or microflute. The letter designation
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in
Number of
Flutes per
meter foot
4.70 0.185
110
33.5
2.46 0.097
154
47
3.61 0.142
128
39
1.14 0.045
278
85
0.75 0.030
420 128
0.58 0.023
503 153
0.45 0.018
558 170
Paper-based Packaging
Box Manufacture
Boxes can be formed in the same plant
as the corrugator. Alternatively, sheets
of corrugated board may be sent to a
different manufacturing facility for box
fabrication. The corrugated board is
creased or scored to provide
controlled bending of the board. Most
often, slots are cut to provide flaps on
the box. Scoring and slotting can also
be accomplished by die-cutting.
Although there are a wide variety of
styles of corrugated fiberboard
containers, the most common box
style is the regular slotted container
(RSC), due mainly to its simple
construction and economical board
usage in terms of board area to
volume ratio of the fabricated
container. All flaps are the same
length and the major flaps meet in the
center of the box. However, its poor
stacking strength is its major
disadvantage, i.e. it rates poorly in
terms of volume over strength of
fabricated containers. Therefore,
when the product can be relied upon
to carry most of the static and
dynamic stacking load forces (as is the
case for canned foods for example), or
when internal partitions can carry a
significant proportion, the economy of
the RSC is unbeatable. However, when
the container has to provide
protection in addition to simple
containment, other less economical
container styles must be resorted to.
The dimensions of a corrugated box
are always measured from the inside
of the box and are expressed as length
x width x height. The length is always
the first dimension to be expressed
and should always be the highest
number of the three.
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Paper-based Packaging
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2.9 Exercise
a. Obtain samples of paperboard
packaging and carefully
separate the plies so that you
can identify both the number
of plies and their likely
composition.
b. Gather as many different
corrugated boxes as you can
and measure their dimensions.
Paper-based Packaging
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