Professional Documents
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Linerboard
(flat
facing)
Medium
(fluted
wavy)
二 . Corrugated Board
a. Single Face
one medium
one liner board
(for protective wrapping)
b. Single Wall
(Double Face)
one medium
two liner boards
二 . Corrugated Board
c. Double Wall
two mediums
three liner boards
d. Triple Wall
three mediums
four liner boards
动画
Direction: Machine Direction
Cross Direction ----flute direction
二 . Corrugated Board
3. Flutes
Profile: arches with proper curve---- the strongest way to span space
Flutes as arches--- resist bending and pressure, support weight, as cushion.
Proper curve: between U and V (Also has its advantages)
Flutes also as a insulator to protect sudden temperature changes
Vertical linerboard provides strength; protects from damage.
Several standard shapes
(A,B,C,E,F…) ,
Contrast:
A-flute ---- the largest profile
B-flute ----smaller than A
C-flute ----between A and B
E-flute ---- smaller than B
F-flute ---- micro-flute
New flute---Macro-flute
二 . Corrugated Board
Thickness
Flute Flutes/ m Flutes/ ft Factor *Not including facings;
*
A 100~120 30~36 4.67 mm 1.54 1foot = 0.3047999m
“Take-up factor” is the
B 145~165 44~50 2.46 mm 1.32
length of medium per
C 120~140 36~42 3.63 mm 1.42 length of finished
E 280~310 86~94 1.19 mm 1.27 corrugated board
The most commonly used linerboard grades, based on Mullen burst test grading.
5. Corrugating Adhesive
The corrugating machine forms the medium into a fluted pattern and bonds
it to the linerboard facings , 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 modified or
supplemented by the addition of various polymeric materials.
4) Weather-resistant adhesive would maintain box properties at a somewhat
higher level for a longer period.
5) Water-resistant adhesive would be required for those applications where
the finished container will be in actual contact with water for periods of
time, and the coating or waxed should be treated
二 . Corrugated Board
6. Broad Manufacture
Corrugating machine is made up of a set of stations that take the appropriate
linerboards and mediums, shape the flutes, join fluted medium to linerboards.
Precondition
medium with heat
and steam
Pretreated
linerboards to the
same temperature
and moisture
Brass fingers
Flute tips adhesive
The single-facer of a corrugating machine is where the flutes are formed
and bonded to the inside liner
二 . Corrugated Board
Manufacture:
Adhesive --- On the other side of the medium to glue outer linerboard.
Final heating and cooling section --- Between two long , flat 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 performance.
Unbalanced constructions --- more problems with board wrappage.
Heavier liner is placed on the outside for better printing and on the insi
de for better compression strength.
三 . Properties and Tests
Measures the time it takes for a given volume of air to pass through
a paper. The lower the number, the more porous the paper. The porosity
of paper is sometimes the culprit when problems occur at vacuum-cup tra
nsfer points.
7. Flexural Stiffness (TAPPI T 820)
Rrelated to box compression strength. Reduced stiffness is a good indica
tor of damage during fabrication.
8. Water Take-up Tests (TAPPI T 441)
The Cobb size test, measures the amount of water absorbed by the facing
in a given time, used to measure water absorption for materials specified
to be used for hazardous product containers
三 . Properties and Tests
B-flute is used where box stacking strength is not required. B-flute's has high flat
crush strength when supporting heavy goods.
C-flute --- 10% better stacking strength than the same weights of B-flute
2. Box Style
Many standard box styles can be identified in three ways: by a descriptive name,
by an acronym based on that name, or by an international code number. For exa
mple, a Regular Slotted Container could also be referred to as an RSC or as #02
01.
There are many standard corrugated box styles: Slotted Boxes, Telescope Boxes
, Folders, Rigid Boxes (Bliss Boxes), Self-Erecting Boxes and Interior Forms
“Regular Slotted Container”(RSC or #0201) is the workhorse corrugated b
ox style (Figure 4.10). All his flaps have the same length, and the two o
uter flaps (normally the lengthwise flaps) are one-half the container's wi
dth, so that they meet at the center of the box when folded. If the produc
t requires a flat, even bottom surface, or the protection of two full layers
, a fill-in pad can be placed between the two inner flaps.
四 . Corrugated Boxes
3. Manufacturer's joint
A flat piece of corrugated fiberboard, which has been cut, slotted and
scored, is called box blank. For some box styles, in order to make a box,
the two ends of the box blank must be fastened together with tape,
staples or glue. The place where these two ends meet is known as the
manufacturer's joint.
Liquid adhesives are most often used to join the two surfaces. Often there
is a glue tab, extending along one end of the box blank. The tab can be
joined to either the inside or the outside of the box. If there is no tab, the
box must be joined using tape. Not all boxes have manufacturers joints;
for example, the bliss box does not.
四 . Corrugated Boxes
1. Application
The Uniform Freight Classification (UFC) and National Motor
Freight Classification (NMFC) were established to categorize articles
for shipment via common carrier with respect to value, density,
fragility, and potential for damage to other freight.
The classifications specify the conditions under which specific
articles can be shipped and at what rates. When shipping by rail, refer to
UFC. When shipping by truck, refer to NMFC. UFC rule 41 and NMFC
item 222 are the most frequently used in describing corrugated
packaging.
There are four basic steps for determining authorized packaging:
1. Fully identify the product.
2. Select the proper governing classification.
3. Use the "Index to Articles" to find the applicable item number.
4. Consult the proper article to find the required packaging.
五 . Carrier Rules
Figure 4.11 Box manufacturer's certificates using burst test and ECT values
五 . Carrier Rules
1. McKee formula
Stacking strength is defined as the maximum compressive load (pounds
or kilograms) that a container can bear over a given length of time, under
given environmental/ distribution conditions without failing.
The ability to carry a top load is affected by the structure of the containe
r and the environment it encounters, and the ability of the inner (primary)
packages and the dividers, corner posts, etc. to sustain the load.
The simplest and most common corrugated transport packages are regul
ar slotted containers (RSCs, Box Style 0201) in which the corrugation dir
ection is typically vertical-parallel to top- bottom stacking forces.
Compression strength of regular slotted containers is a function of:
·Perimeter of the box (two times length plus two times width)
·Edge crush test of the combined board
·Bending resistance of the combined board
·Aspect ratio (L:W) and other factors
六 . Stacking and Compression
Where:
BCT = RSC top-to-bottom box compression strength, kN/m2(lbf/in.2 or p.s.
i)
ECT = edge crush test, kN/m (lbf/in.)
Dx,Dy = flexural stiffnesses of combined board in the machine direction an
d cross direction, kN/m(lbf/in.)
BP = inside box perimeter, m (in.)
六 . Stacking and Compression
The McKee formula can only be applied to RSCs, and only those with a
perimeter-to-depth ratio no greater than 7:1.
McKee also created a simpler formula based on caliper of the combin
ed board instead of bending stiffness:
BCT=5.87×ECT× (T×BP)1/2 (4.2)
Where: T = caliper of combined board, m (in.)
Solving for ECT, the simplified McKee formula is:
ECT = BCT /[5.87× (T ×BP)1/2] (4.3 )
六 . Stacking and Compression
3. Compression Requirement
If the compression strength and distribution environment is known, the effe
ctive stacking strength of any given RSC can be reasonably estimated.
If the distribution environment, container dimensions and flute profile are kn
own, a compression requirement can be estimated. This can be of great value,
because once a compression requirement is determined, the ECT requirement
can be determined (and, therefore, board combination options as well).
[Example] A box of 0.5 m × 0.25 m× 0.30 m ( outside dimensions ) will h
ave 12 kg, stacked 3 m high in the warehouse. Boxes will be arranged in an in
terlock pattern and will be required to hold the load for 180 days at 80% R.H..
The pallets are in good condition; there will be no overhang. What should the
required compression strength of the box be ?
六 . Stacking and Compression
1). Determine maximum number of boxes above bottom box: 3 /0.30 -1=
8
2). Determine load on bottom box: 8×12 kg = 96 kg
3). Determine Environmental Factor by multiplying together all factors th
at 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 factor=96 kg/0.17=564 kg
Now that the actual compression strength is know, this value can be plug
ged into the McKee formula (4.3), and the required edge crush test (EC
T) value of the corrugated board can be calculated.
六 . Stacking and Compression
4. Compression Solutions
Following are a variety of approaches to increase compression and stac
king strength. The most efficient and cost-effective approach will depen
d on the product, package size and distribution environment.
·Stronger liners and medium(s)
·Load sharing
·Increase the number of corners
·Change corrugation direction
·Dimensions: Depth, Length to width, Perimeter, Panel size
·Multiwall corrugated fiberboard
·Partitions, inserts and interior packaging
·Lamination
·Treatments, impregnations and coatings