Corrugated Fiberboard Design

Design of Corrugated Fiberboard
Boxes
- by tech team (JR
Packages)
Historical perspective
Corrugated Board Corrugated Board
Properties and Tests Properties and Tests
Corrugated Boxes Corrugated Boxes
Carrier Rules Carrier Rules
Stacking and Compression Stacking and Compression
Historical perspective
Appearance of corrugated paper and the development
First patents Ior making were recorded in England in 1856.
First patents in US were granted to A.L.Jones in 1871
Unlined corrugated sheet---packing lamp chimneys and Iragile objects.
The Iirst user double-lined corrugated boxes was a cereal manuIacturer
(obtained acceptance in 1903)
Figures reversed Irom 20 to 80 between the world War I and
2. The specialized produce
Sheet plants buy combined board only printing and cutting.
About 2000 plants produce more than 3 billion worth in India
3. Rules for constructing corrugated containers
To enhance the quality
Rule oI UFC and NMFC
. Corrugated Board Corrugated Board
Construction : linerboard and medium
Material heavy paper ---containerboard
Facings---kraIt linerboard
Medium---one-ply sheet, hardwood or recycled Iiber
Linerboard
(flat facing)
Medium
(fluted wavy)
Four types combined board
b Single Wall
(Double Face)
one medium
two liner boards
a Single Face
one medium
one liner board
(Ior protective wrapping)
c Double Wall
two mediums
three liner boards
d Triple Wall
three mediums
Iour liner boards
Direction: Machine Direction
Cross Direction ----Ilute direction

3. FIutes
!roIile arches with proper curve---- the strongest way to span space
Flutes as arches--- resist bending and pressure, support weight, as cushion.
!roper curve between U and V (Also has its advantages)
Flutes also as a insulator to protect sudden temperature changes
Vertical linerboard provides strength; protects Irom damage.
Several standard shapes
(A,B,C,E,F.) ,
Contrast
A-Ilute ---- the largest proIile
B-Ilute ----smaller than A
C-Ilute ----between A and B
E-Ilute ---- smaller than B
F-Ilute ---- micro-Ilute
New Ilute---Macro-Ilute
Combined board ---DiIIerent Ilute proIiles combined in one board
one layer oI medium might be A-Ilute while the other C-Ilute
Manipulate the compression and cushioning strength, total thickness oI the board.
Standard flute configurations
Flute Flutes/ m Flutes/ ft
1hickness

Factor
A = 3=36 467 mm 4
B 4=6 44= 46 mm 3
C =4 36=4 363 mm 4
E =3 6=4 mm 7
ot including facings;
foot 347m
~Take-up factor is the
length of medium per
length of finished
corrugated board
Described: the component oI grammage or basis weight, Irom outside to inside
eg. corrugated board '205/127C/161----Outside liner 205grams;
Medium 127 grams, Iormed to C-Ilute;
Inside liner 161grams
4 Fiberboard Grades : Weight ; Thickness ; Material
Grammage: the mass in
grams per square meter.
Basis weight: the weight in
pounds per 1,000 square Ieet
( abbreviated lb/MSF)
The most commonly used
corrugating medium weights
Grammage/g Basis Weight/b
7 6
47 3
6 33
4
MeteriaI :
W Linerboard --- natural kraIt ;Solid bleached white kraIt ; Mottled white ; Oyserboard
Linerboard with a whiter surIace provide better graphics.
Recycled or secondary Iiber ---producing both two components
Recycled board ---smoother surIace Iinish ;low CoF; excellent printing surIace.
The most commonly used linerboard grades, based on Mullen burst test grading
North American Grades European Grades
Grammage Basis Weight Grammage
127g 26b 125g
161g 33b 150g
186g 38b --
205g 42b 200g
-- -- 225g
-- -- 250g
337g 69b 300g
Other grades -- 400g
-- -- 440g
1 kg 2.2046 b
1 meter 3.28084 Ioot
1 g/m
2
0.205 b/MSF
A generation oI newer linerboards has high-perIormance boards, meeting ECT rather
than Mullen burst test and basis weight requirements.
lighter grades oI the high-perIormance boards to get satisIactory perIormance
Corrugating Adhesive
The corrugating machine Iorms the medium into a Iluted pattern and bonds it
to the linerboard Iacings , usually with a starch-based adhesive
1) A starch-based adhesive applied at about 10 to 14 grams per square meter.
2) Requirements not tolerant high moisture and loses strength quickly.
3) When higher resistance is needed, starches can be modiIied or
supplemented by the addition oI various polymeric materials.
4) Weather-resistant adhesive would maintain box properties at a somewhat
higher level Ior a longer period.
5) Water-resistant adhesive would be required Ior those applications where
the Iinished container will be in actual contact with water Ior periods oI time,
and the coating or waxed should be treated
6. Broad Manufacture
Corrugating machine is made up oI a set oI stations that take the appropriate
linerboards and mediums, shape the Ilutes, join Iluted medium to linerboards.
!recondition
medium with heat
and steam
!retreated
linerboards to the
same temperature
and moisture
Brass Iingers
Flute tips adhesive
The single-facer of a corrugating machine is where the flutes are formed
and bonded to the inside liner
Bridge ---Draped in an overlapping wave pattern to the double-backer station
!urpose---Isolating the two ends oI the corrugating machine; balance; slow down
The double-backer section of corrugating machine where a second linerboard
is applied to the single-faced material coming from the single-facer unit
Manufacture:
Adhesive --- On the other side oI the medium to glue outer linerboard.
Final heating and cooling section --- Between two long , Ilat belts.
Trimming edges--- Slit board to required width and length and stack
Balanced construction--- Outer and inner have identical grammage.
Upgrading only one liner may gain perIormance.
Unbalanced constructions --- more problems with board wrappage.
Heavier liner is placed on the outside Ior better printing and on the
inside Ior better compression strength.
Most board tests are described in methods provided by TAPPI
Standard corrugated board burst and crush tests
Mullen burst test (TA!!I T 810)
Forcing a rubber diaphragm against the Iacing until it bursts
ECT (TAPP T 811)
A small specimen is placed between the platens oI a compression
tester and loaded until Iailure occurs. Values are a Iunction oI the
stiIIness contributed by the Iacings and the medium. ECT values have
a direct relationship to the projected stacking strength.
3 Flat Crush Test (TAPP T 808)
Similar to the edge compression test except the specimen is
compressed in the Ilat. The test provides a measure oI Ilute rigidity.
4 Combined Weight of Facings
Describes the combined linerboard weight per 1,000 square Ieet oI
corrugated board
Thickness of Corrugated Board (TAPP T 411)
Reduced board thickness (caliper) is an excellent indicator oI reduced
compression strength; Caliper can be reduced by improper
manuIacture, excessive printing pressure, improper handling and
storage
6 Gurley Porosity (TA!!I T 460 and T 536)
Measures the time it takes Ior a given volume oI air to pass through a
paper. The lower the number, the more porous the paper. The porosity oI
paper is sometimes the culprit when problems occur at vacuum-cup
transIer points.
7 Flexural Stiffness (TA!!I T 820)
Rrelated to box compression strength. Reduced stiIIness is a good
indicator oI damage during Iabrication.
Water Take-up Tests (TA!!I T 441)
The Cobb size test, measures the amount oI water absorbed by the Iacing
in a given time, used to measure water absorption Ior materials speciIied
to be used Ior hazardous product containers
Puncture Test (TA!!I T 803)
Measures the energy required to puncture a board with a triangular
pyramidal point aIIixed to a pendulum arm.
Test the resistance and stiIIness oI triple wall corrugated
The box maker`s stamp on triple wall containers calls Ior a puncture test
Pin Adhesion (TA!!I T 821)
!in adhesion quantiIies the strength oI the bond between the
medium's Ilute tips and the linerboard Iacings.
Ply Separation (TA!!I T 812)
Evaluates the board's resistance to ply separation when exposed to water.
Coefficient of Friction (TA!!I T 815 and ASTM 04521).
CoF can aIIect machinability and load stability. A stress/strain machine
method will give both static and dynamic CoF values
MM Corrugated Boxes Corrugated Boxes
1. 1. SeIecting the Correct FIute
use a carrier classiIication and C-Ilute as good starting points.
aracteristic A-Flute* B-Flute -Flute E-Flute
Stack strength best* fair good poor
Printing poor good fair best
Die cutting poor good fair best
Puncture good fair best poor
Storage space most good fair least
Score/bend poor good fair best
Cushioning best fair good poor
FIat crush poor good fair fair
Comparison of corrugated board characteristics
E- and F-fIutes are not used in shipping containers but rather are
replacements Ior thicker grades oI solid paperboard. Can be considered iI a
Iolding carton design calls Ior boards thicker than 750(30 point). Also be used
to replace paperboard Ior heavier or special protective primary packs as
primary container while in distribution.
Such as small tools, hardware, small appliances, and housewares.
A-fIute originally speciIied, not commonly use . almost 5 mm (1/4 in.)
Occupies more space ,has signiIicantly greater deIlection beIore bearing a load
when compressed. The thicker section give it the highest top-to-bottom
compression strength. A-Ilute has the lowest Ilat crush resistance
B-fIute is used where box stacking strength is not required. B-Ilute's has high Ilat
crush strength when supporting heavy goods.
C-fIute --- 10 better stacking strength than the same weights oI B-Ilute
edium Grammage A- FIute - FIute B- FIute
127g 0.70 1.00 1.15
161g 0.90 1.25 1.45
195g 1.10 1.50 N.A
Relative flute flat crush values
Box Box Style
Many standard box styles can be identiIied in three ways by a descriptive name,
by an acronym based on that name, or by an international code number. For
example, a Regular Slotted Container could also be reIerred to as an RSC or as
#0201.
There are many standard corrugated box styles Slotted Boxes, Telescope Boxes,
Folders, Rigid Boxes (Bliss Boxes), SelI-Erecting Boxes and Interior Forms
Regular Slotted Container(RSC or #0201) is the workhorse corrugated
box style (Figure 4.10). All his Ilaps have the same length, and the two
outer Ilaps (normally the lengthwise Ilaps) are one-halI the container's
width, so that they meet at the center oI the box when Iolded. II the
product requires a Ilat, even bottom surIace, or the protection oI two Iull
layers, a Iill-in pad can be placed between the two inner Ilaps.
Figure 4 Parts of a regular slotted container (RSC) blank
3 Manufacturer's joint
A Ilat piece oI corrugated Iiberboard, which has been cut, slotted and
scored, is called box blank. For some box styles, in order to make a box,
the two ends oI the box blank must be Iastened together with tape,
staples or glue. The place where these two ends meet is known as the
manuIacturer's joint.
Liquid adhesives are most oIten used to join the two surIaces. OIten there is
a glue tab, extending along one end oI the box blank. The tab can be
joined to either the inside or the outside oI the box. II there is no tab, the
box must be joined using tape. Not all boxes have manuIacturers joints;
Ior example, the bliss box does not.
Bliss style container
Bliss-style box design variations
4 Dimensioning
Dimensions are given in the sequence oI length, width and depth.
Dimensions can be speciIied Ior either the inside or the outside oI the
box. Accurate inside dimensions must be determined to ensure the proper
Iit Ior the product being shipped or stored. At the same time, palletizing
and distributing the boxes depends on the outside dimensions. The box
manuIacturer should be inIormed as to which
Top Loading
End Loading
Application
The UniIorm Freight ClassiIication (UFC) and National Motor
Freight ClassiIication (NMFC) were established to categorize articles
Ior shipment via common carrier with respect to value, density, Iragility,
and potential Ior damage to other Ireight.
The classiIications speciIy the conditions under which speciIic
articles can be shipped and at what rates. When shipping by rail, reIer to
UFC. When shipping by truck, reIer to NMFC. UFC rule 41 and NMFC
item 222 are the most Irequently used in describing corrugated
packaging.
There are Iour basic steps Ior determining authorized packaging
1. Fully identiIy the product.
2. Select the proper governing classiIication.
3. Use the "Index to Articles" to Iind the applicable item number.
4. Consult the proper article to Iind the required packaging.
Failure to comply with regulations can subject the shipper to penalties
such as higher Ireight rates, reIusal oI acceptance by the carrier, or
nonpayment oI damage claims.
Summary of Rules for Corrugated Box Construction
Carrier rules Ior corrugated box construction can be summarized as
Iollows
SpeciIied boards (using either Mullen burst test or ECT values) shall
be used Ior a given product weight, providing the box does not exceed a
speciIied dimensional limit. The dimensional size limit Ior a box is
determined by adding an outside length, width, and depth.
Table 4.6 summarizes the construction requirements Ior corrugated
boxes. The rules also require that a box manuIacturer`s certiIicate (BMC)
on the bottom oI the container ( Figure 4.11).
Figure 4 Box manufacturer's certificates using burst test and ECT values
!ART A* !ART B*
Maximum
weight oI
Box and
Contents(l
bs.)
Maximum
Outside
Dimension,
Length,
Width and
Depth
Added(in.)
Minimum Burst Test,
Single Wall, Double
Wall or Solid
Fiberboard(lbs.per sq.in.)
or
Minimum !uncture Test,
Triple Wall
Board(in.oz.per in.oI
tear)
Minimum
Combined Weight
oI
Facings,including
Center Facing(s) oI
Double Wall and
Triple Wall Board
or
Minimum
Combined Weight
oI !liers, Solid
Fiberboard,
Excluding
Adhesives(lbs.per
1,000 sq.It.)
Minimum Edge
Crush Test
(ECT)
(lbs. per in.
width)
Table 46 Summary of carrier rules for corrugated boxes
Single Wall Corrugated Fiberboard Boxes
20
35
50
65
80
95
120
40
50
60
75
85
95
105
125
150
175
200
250
275
350
52
66
75
84
111
138
180
23
26
29
32
40
44
55
Double Wall Corrugated Fiberboard Boxes
80
100
120
140
160
180
85
95
105
110
115
120
200
275
350
400
500
600
92
110
126
180
222
270
42
48
51
61
71
82
Triple Wall Corrugated Fiberboard Boxes
240
260
280
300
110
115
120
125
700
900
1100
1300
168
222
264
360
67
80
90
112
Solid Fiberboard Boxes
20
40
65
90
120
40
60
75
90
100
125
175
200
275
350
114
149
190
237
283
* Mullen(!art A) and ECT(!art B) are presented side-by-side,
but there is no correlation between the values
33 Stacking and Compression Stacking and Compression
McKee formula
Stacking strength is deIined as the maximum compressive load (pounds
or kilograms) that a container can bear over a given length oI time, under
given environmental/ distribution conditions without Iailing.
The ability to carry a top load is aIIected by the structure oI the
container and the environment it encounters, and the ability oI the inner
(primary) packages and the dividers, corner posts, etc. to sustain the load.
The simplest and most common corrugated transport packages are
regular slotted containers (RSCs, Box Style 0201) in which the
corrugation direction is typically vertical-parallel to top- bottom stacking
Iorces.
Compression strength oI regular slotted containers is a Iunction oI
!erimeter oI the box (two times length plus two times width)
Edge crush test oI the combined board
Bending resistance oI the combined board
Aspect ratio (LW) and other Iactors
When we know the above variables, we can estimate the compression
strength through an equation known as the McKee Iormula.
BCT2.028j(ECT)0.746j((DxjDy)0.254)1/2 jB!0.492 (4.1)
Where
BCT RSC top-to-bottom box compression strength, kN/m2(lbI/in.2 or
p.s.i)
ECT edge crush test, kN/m (lbI/in.)
Dx,Dy Ilexural stiIInesses oI combined board in the machine direction and
cross direction, kN/m(lbI/in.)
B! inside box perimeter, m (in.)
The McKee Iormula can only be applied to RSCs, and only those with a
perimeter-to-depth ratio no greater than 71.
McKee also created a simpler Iormula based on caliper oI the
combined board instead oI bending stiIIness
BCT5.87jECTj(TjB!)1/2 (4.2)
Where T caliper oI combined board, m (in.)
Solving Ior ECT, the simpliIied McKee Iormula is
ECT BCT /|5.87j(T jB!)1/2| (4.3
The ability oI a container to perIorm in distribution is signiIicantly
impacted by the conditions it encounters throughout the cycle.
II the original box compression strength is known, we can Iactor it
by generally accepted multipliers to arrive at an estimated maximum
saIe stacking strength (Table 4.7)
Distribution Environment and Container Performance
Compression Loss Multifliers
Storage time under load days-37 percent loss 63
3 days-4 percent loss 6
days-4 percent loss
days- percent loss
Relative humidity, under
load(cyclical RH variation further
increase compressive loss)
days- percent loss
6 days- percent loss
7 days- percent loss
days-3 percent loss 6
days- percent loss 4
days- percent loss
Table 4.7 Environmental Stacking Factors
Pallet Patterns Best Case Worst Case
Columnar, aligned egligible loss
Columnar, misaligned - percent loss
Interlocked 4-6 percent loss 6 4
Overhang -4 percent loss 6
Overhang - percent loss 7
Excessive handling -4 percent loss 6
3 Compression Requirement
II the compression strength and distribution environment is known, the
eIIective stacking strength oI any given RSC can be reasonably estimated.
II the distribution environment, container dimensions and Ilute proIile are
known, a compression requirement can be estimated. This can be oI great
value, because once a compression requirement is determined, the ECT
requirement can be determined (and, thereIore, board combination options as
well).
|Example| A box oI 0.5 m j0.25 mj0.30 m outside dimensionswill
have 12 kg, stacked 3 m high in the warehouse. Boxes will be arranged in an
interlock pattern and will be required to hold the load Ior 180 days at 80
R.H.. The pallets are in good condition; there will be no overhang. What
should the required compression strength oI the box be ?
1). Determine maximum number oI boxes above bottom box 3 /0.30 -1 8
2). Determine load on bottom box 8j12 kg 96 kg
3). Determine Environmental Factor by multiplying together all Iactors
that apply
180 days, 0.50
80 R.H. 0.68
Interlocked stack 0.50
Multiplier product(Environmental Stacking Factors) 0.17
4). Determine required box compression strength
BCT anticipated load/stacking Iactor96 kg/0.17564 kg
Now that the actual compression strength is know, this value can be
plugged into the McKee Iormula (4.3), and the required edge crush test
(ECT) value oI the corrugated board can be calculated.
4 Compression Solutions
Following are a variety oI approaches to increase compression and
stacking strength. The most eIIicient and cost-eIIective approach will
depend on the product, package size and distribution environment.
Stronger liners and medium(s)
Load sharing
Increase the number oI corners
Change corrugation direction
Dimensions Depth, Length to width, !erimeter, !anel size
Multiwall corrugated Iiberboard
!artitions, inserts and interior packaging
Lamination
Treatments, impregnations and coatings

Corrugated Fiberboard Design

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Design of Corrugated Fiberboard

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