PAPERBOARD
PAPERBOARD
Commonly known as “Pulp
board”, it is board manufactured
in one thickness or by bringing
two or more plies of the same,
furnish into a single structure in
the wet state without adhesive.
PAPERBOARD
– virgin and/or recycled fibre
– specially processed
• For better appeal and printability
• For imparting barrier properties
• For rigidity and protection
• For meeting Legal & Health demands
Types of Paper board
1. SOLID BLEACHED SULPHATE BOARD
(SBS)
2. FOLDING BOX BOARD (FBB)
3. RECYCLED BOARD / WHITELINE CHIP
BOARD
Solid Bleached Board
– Produced entirely of bleached chemical pulp.
– The number of solid homogeneous fibre layers
varies from two to four
– Both long and short fibre are used
– Surface is double coated and back is either
uncoated or lightly coated.
– Available in 200 to 600 GSM
– Suitable for all types of Printing Process
– Considered as premium grades for packaging
and graphical purposes
Folding box board
– Folding box board consists of three layers
– The top layer is of bleached chemical pulp.
– The middle layer consist of mechanical pulps: stone
ground wood pulp, pressurised ground wood ,
thermomechanical pulp or chemi thermo
mechanical pulp. This layer gives stiffness and bulk.
– The back of FBB is either manilla or white in colour
– A good substitute for SBS in applications where
runnability and a virgin fibre base are required
– Visual properties slightly inferior to SBS
– The basis weight ranges from 200 to 450
– Ideal for Food packaging, cigarettes cosmetics,
pharmaceuticals and graphical applications.
Recycled fiber based
– Multi layer boards consisting of 60 to 100 % of
recycled fibre
– Top layer produced either with high grade
white preprint waste paper or bleached chemical
pulp.
– The middle layer and the back layer are made
from waste paper
– The basis weight ranges from 200 to 600 GSM
– Surface Brightness is 80 to 85 %
– Cost effective substrate for gravure and offset
printing process
What Makes paperboard a
popular packaging medium
• Safe ,easy to handle,easy to use and
easy to dispose material
• Conversion technology advanced and
easy to master
• Tremendous flexibility in terms of size
shape properties .
• Easy to impart barrier
• Made from renewable source /
recyclable
CARTON BOARD - TYPES:
• GREY - MILL BOARD.
• DUPLEX BOARD.
• TRIPLEX BOARD.
• FOOD BOARD.
PAPER CARTONS
• MILL BOARD - A BOARD MADE
FROM MIXED WASTE PAPER IN
THICKNESS GREATER THAN 1 MM.
• DUPLEX BOARD - PAPER OR
BOARD CONSISTING OF TWO
FURNISH LAYERS FELTED
TOGETHER BY PRESSURE WHILE
STILL MOIST , WITHOUT ADHESIVE.
PAPER CARTONS
• TRIPLEX BOARD - BOARD
CONSISTING OF THREE FURNISH
LAYERS FELTED TOGETHER,
WHILE STILL MOIST, WITHOUT
USING ADHESIVE.
PAPER BOARD TO CARTON --
PROCESS
• BOARD PRODUCTION AND
COATING.
• PRINTING & CONDITIONING
• CONVERSION TO CARTON
LIMITATIONS:
• NO BARRIER PROPERTIES.
• SUSCEPTIBLE TO HUMIDITY /
MOISTURE ABSORBTION.
• THUS NEED TO BE COATED OR
LAMINATED WITH APPROPRIATE
MATERIALS
CARTONS
THERE ARE BASICALLY THREE
TYPE OF CARTONS:
• CONVENTIONAL CARTONS.
• CEKALINE CARTONS.
• EXPRESSO CARTONS.
CONVENTIONAL CARTONS
FEATURES BENEFITS
SIZE FLEXIBILITY BETTER LOGISTICS,
(30G-5KG). EASE OF USAGE.
VARIETY IN SHAPE CONVENIENCE AND
POSSIBLE. LOGISTICS.
CEKALINE CARTONS
FEATURES BENEFITS
MORE COMPACT THAN BAG REDUCES FREIGHT
IN BOX. COST.
SIZE RANGE POSSIBLE. 100 G - 1 KG.
CAN BE MACHINE OR HAND CHOICE ACCORDING
PACKED. TO REQUIREMENTS.
WIDE CHOICE OF LINERS LOGISTIC
ADVANTAGE
ACCORDING TO THE NATURE LEADING TO REDUCED
OF PRODUCTS. FREIGHT COSTS.
FEATURES BENEFITS
LINER RANGE:
PAPER/POLY LOGISTIC ADVANTAGE
LEADING TO REDUCED
FREIGHT COSTS.
PAPER/FOIL/POLY INCREASED PRODUCT LIFE.
PET/FOIL/POLY INCREASED SHELF LIFE
(6-8 MONTHS).
METPET/PAPER/POLY GOOD BARRIER MATERIAL,
IMPROVES SHELF LIFE
UPTO
6 MONTHS.
PET/LDPE/HDPE/LLDPE/ FOR SPECIALIZED PACKING
PRIMACOR E.G. OIL.
EXPRESSO CARTONS
FEATURES BENEFITS
UNIQUE TUCK IN DESIGN TAMPER PROOF AND
AND INSIDE MEMBRANE POSSIBILITY MINIMI-
ON TOP AND BOTTOM. ZED.
MACHINE PACKING. AUTOMATION AND
REDUCED COSTS.
FLEXIBILITY IN CARTON LARGER SIZE RANGE
SIZE. POSSIBLE.
CHOICE OF MEMBRANE TRANSPARENT/
MATERIALS. OPAQUE.
FOLDING CARTONS
• AS A PRIMARY CONTAINER.
• AS A SECONDARY PACKAGING.
MERITS:
• MULTICOLOUR GRAPHICS.
• SALES APPEAL - ON SHELF.
• LOW COST, EASY AVAILABILITY.
• ECO FRIENDLY.
Role of the Folding
Cartons…..
• An Integral part of our daily life.
• Most preferred consumer packaging
Worldwide.
• Covers wide range of FMCG items:
> Bulbs to Printers Cartridges.
> Cereals to C Ds.
>Personal Products to Pharmaceuticals.
> Toys to Tobaccos.
>Milk to Machine Spare Parts.
VALUE ADDITIONS
-Water based Varnish
-UV Varnish
-Lamination
-Foil Stamping
-Embossing
-Window Patching
Characteristics of Paper board
For Folding Carton Conversion
A. SURFACE PROPERTIES
B. OPTICAL PROPERTIES
C. MECHANICAL PROPERTIES
D. PACKING PROPERTIES
Surface Properties
a. Paper Squareness
b. Paper Flatness (Even Moisture)
c. Even Caliper
d. PH (5 TO 5.5)
e. Cobb Value (Porosity)
f. Smoothness
g. Coeff. of Friction
Optical Properties
a. Whiteness
b. Brightness
c. Gloss
d. Color Shade
Mechanical Properties
a. GSM
b. Tensile Strength
c. Bursting Strength
d. Stiffness
e. Grain Direction (MD and CD)
KEY PROPERTIES
• STIFFNESS
• GRAIN DIRECTION
• SURFACE / PRINTABILITY.
PAPER BOARDS -Factors
which determine performance
• Good stiffness and bulk enables a package to
travel better
• Higher Crease resistance ensures better carton
openability -However it makes gluing difficult!
• Properties need to be prioritized
GRAIN DIRECTION
• NORMALLY ACROSS THE MAIN
SCORES.
• FOR BETTER PERFORMANCE ON
AUTOMATIC CARTONING
MACHINE.
• LESS CHANCE FOR CORNER
BREAKING.
COMPRESSION STRENGTH
• INFLUENCED BY GRAIN DIRECTON.
• BOARD STIFFNESS IS IMPORTANT.
• CONTRIBUTION OF MFG’S JOINT (SIDE
SEAM) POSITIVE.
LATEST DEVELOPMENTS IN
PAPERBOARDS
• Ovenable paperboards
Base board is SBS or FBB
Extruded with PET to withstand temperatures suitable for
microwave ovens.
• Barrier coatings
Nanotechnology. Durethan KU-2 is a polyamide with silicate nano
particles which increases barrier properties and can replace
aluminium
Barrier boards with EVOH and PA
• Mold resistance thru. special additives for soaps- this gives
antifungal properties and soap can be directly packed without
any inside liner or stiffener.
Demands from end users
• Foods • Key properties
– frozen foods and desired
ice creams - hygiene, hard sizing
– bakery products
– breakfast cereals - grease proof
– confectioneries - protection,print
appeal
-odour, taste and taint
..end users
• Foods
– dairy products,juices - reqts of system
and oil packaging
– beverages and spirits - protection and reqts
of system
packaging,print
appeal,embossing,
foil stamping
– fast foods - ovenable boards
Barrier boards
…end users
• FMCG products • Print appeal and
and toiletries aesthetics, perf. in
packing systems,crush
strength, economy,pack
variants
• Pharma products • Hygiene,whiteness,
perf. in packing
systems,crush strength
• Detergents • Moisture resistance and
crush strength
…end users
• Engg. products • Stiffness and glue ability
• Cigarettes • Print appeal,tactile feel,perf.
in hi speed converting and
packing systems
• stiffness,edge crush, e-
fluting reqt.
• Toys and games
• shade/whiteness,print
appeal,perf. with
embossing/debossing
• Cultural - greeting dies,foil stamping
cards,book covers
THANK YOU
QUALITY CONTROL TESTS
PAPERBOARD .
• GRAMMAGE - SUBSTANCE - GSM .
PAPER IS BOUGHT ON
WEIGHT BUT USED ON AREA
BASIS .
• MOISTURE CONTENT - %
AFFECTS STRENGTH .
TEST & SIGNIFICANCE .
• GRAIN DIRECTION - MACHINE
DIRECTION & CROSS DIRECTION .
MAY AFFECT LABELLING , IMPORTANT
FOR STIFFNESS , PARTICULARLY IN
CARTONS .
• STIFFNESS - Taber . IMPORTANT FOR
COMPRESSION RESISTANCE &
MACHINABILITY OF CARTONS .
TEST & SIGNIFICANCE .
• RING STIFNESS - Kgf . GIVES
INDICATION OF THE ABILITY OF
PAPER TO PROVIDE
COMPRESSION RESISTANCE IN
THE BOX .
• TEAR STRENGTH - Gramforce .
INDICATES RESISTANCE TO
TEARING AFTER INITIAL TEARING .
TEST & SIGNIFICANCE .
• BURSTING STRENGTH - Kgs./cm. Sq.
SIMPLE TEST FOR STRENGTHWISE
RANKING OF SAMPLES.
• PUNCTURE RESISTANCE - Oz. Inch /
tear inch . INDICATES RESISTANCE
TO PUNCTURING IN TRANSIT.
TEST & SIGNIFICANCE .
• TENSILE STRENGTH . Kg./cm.
Width. IMPORTANT
CHARACTERISTICS WHEN
MATERIAL IS SUBJECTED TO
DIRECT TENSILE STRESS.
• COBB - Gms/ sq.m. INDICATES
AMOUNT OF WATER ABSORBED
WHEN EXPOSED TO WATER.
TEST & SIGNIFICANCE.
• SCUFF PROOFNESS. LOSS IN
WEIGHT AFTER 1000 REVOLUTION
& APPEARANCE. INDICATES THE
RESISTANCE TO INK LIFTING DUE
TO ABRASION .
TEST & SIGNIFICANCE.
• FOLDING ENDURANCE. - NO. OF
DOUBLE FOLDS. IT IS A MEASURE OF
ENDURANCE OF PAPER TO RAPEATED
FOLDING.
• SMOOTHNESS/ POROSITY. ML. OF AIR/
MINUTE. IMPORTANT IN PRINTING
WHERE SMOOTH SURFACE HELPS.
TEST & SIGNIFICANCE.
• BLOCKING RESISTANCE. - EXAMINED
BY SLIPPING OR PEELING TWO SHEET
APART. - NO BLOCKING , SLIGHT /
CONSIDERABLE / COMPLETE
BLOCKING.
• IMPORTANT IN HIGH SPEED MACHINES
WHERE INDIVIDUAL SHEETS / BAGS
ARE PICKED UP.
TEST & SIGNIFICANCE.
• WAX PICK UP NO. -THE
NUMBER , OF DENNISON WAX
STICK WITHOUT ANY FIBRE PICK
UP.
• AN IMPORTANT MEASURE OF
SURFACE STRENGTH OF
PAPERBOARD.
TEST & SIGNIFICANCE.
• ASH CONTENT - INDICATES % OF
ADDITIVES & FILLERS ADDED IN THE
PAPER .
A KNOWN WEIGHT OF PAPER
SAMPLE IS TAKEN IN A CRUSIBLE &
HEATED IN A FURNACE AT 700C FOR
ABOUT 6-7 HOURS & AFTER COOLING,
ASH RESIDUE IS CALCULATED AS %
OF SAMPLE WT.
OPTICAL PROPERTIES
• GLOSS.
• TRANSPARENCY.
• OPACITY.
• BRIGHTNESS.
OPTICAL PROPERTIES.
• BRIGHTNESS - IS MEASURED BY
MEASURING THE INTENSITY OF
REFLECTED LIGHT IN BLUE
REGION (400- 500 nm or 457 nm
wavelength ) AT AN ANGLE
PERPENDICULAR TO THE PAPER
SURFACE .
OPTICAL PROPERTIES.
• WHITENESS IS COMPOSED OF
ALL COLOURS OF VIBGYOR.
• LIGHT REFLECTED IN ALL
DIRECTIONS FROM THE PAPER
SURFACE IS SUMMED UP & IS
INDICATIVE OF WHITENESS .
GLOSS.
• GLOSS - IT CALCULATED BY
MEASURING THE AMOUNT OF
WHITE LIGHT REFLECTED BY A
SURFACE AT A GIVEN ANGLE ,
USUALLY 75 degrees.
OPTICAL PROPERTIES.
• OPACITY – IT IS ABILITY OF A SURFACE
TO OBSTRUCT TRANSMISSION OF
LIGHT .
• OPACITY = IT IS A RATIO OF
REFLECTANCE FROM SAMPLE PAPER
WITH WHITE BACK PAPER /(DEVIDED
BY) REFLECTANCE FROM SAMPLE
WITH BLACK BACK PAPER.
PHYSICOCHEMICAL PROPERTIES.
• WATER VAPOUR TRANSMISSION RATE.
• OXYGEN (GAS) TRANSMISSION RATE.
• MIGRATION.
• RESISTANCE TO OIL.
• CHEMICAL RESISTANCE.
