How cardboard packaging boxes are made?

Packaging professionals love to talk about their products, but more so
than the substrates used in cardboard, tape, polyethene and stretch
film.

How a cardboard box is made in Custom Printing Services.

Cardboard boxes are certainly one of the staples of the packaging
industry. But it's easy to forget that the cardboard boxes you use
regularly were once a less humble tree.
How is wooden corrugated cardboard made? Well, the wait is over!
Custom Printing Services asked their technologists to tell us exactly
how the raw materials are cleaned and processed to make the cartons
you buy every day for your business.
Why not? You can add these facts to the general knowledge in your
brain, which is for quizzes and demos in pubs.
First the basics,

A cardboard box essentially consists of a groove (made from recycled
paper) that is inserted between two liners. It is very common these
days that these liners also make up a significant amount of recycled
content made from old cartons or other sources of waste paper.
However, clean energy is still used to produce high-quality cardboard
boxes. It doesn't matter if the paper is recycled or not, however, in the
end, it always started as white paper made from shredded trees.

The trees
When making cardboard boxes, we are talking about two different
types of films.
Corrugated cardboard consists of the material located above and
below the corrugation. Cardboard boxes usually have a pulp paper
inner lining and kraft outer liner. This is because kraft paper is of
better quality than proofing paper and has a smoother surface, making
it easier to print. Kraft also has the advantage of being more resistant
to water ingress, which is an added benefit of outdoor use.

To achieve this smoothness, kraft paper should be made from
softwoods, which tend to have long fibers such as pine, spruce, and fir
trees. Most of the European paper is produced from trees from
sustainable forests owned by SCA (Svenska Cellulosa Aktiebolaget -
English: Swedish Pulp Company), which plants two trees for every
tree felled. Long fibers also have better tension, which is why kraft
paper is often described as being very resistant to tearing and
cracking.

The appearance of kraft paper can vary depending on the type of
wood. For example, kraft paper made from Scandinavian fir, pine and
silver birch is dark brown in colour, but Russian versions of the same

wood species appear brown and darker spots of brighter colours. ... In
Brazil, eucalyptus and fir are used and the potency they produce is
light brown, while Chinese trees are yellowish due to the high straw
content in their potency.

Test paper inserts are generally made from short-barreled hardwoods
or recycled paper, so they are cheaper and of more abrasive quality.
Hardwoods include oak, sycamore, birch and chestnut, and again
mostly from sustainable SCA forests. Kraft paper and pulp paper are
also used to create corrugated paper between the inserts, which
ultimately creates a stable sheet.

A brief guide to cardboard boxes by Custom Packaging Services.

Pulping
Papermaking takes a long process to keep the chopped wood chips
clean and usable. The trees are first felled and felled to get tons of
logs that go through the debarking and felling machine.
These chips then go through one of two processes: mechanical
decomposition or chemical decomposition. Mechanical digestion
involves grinding to grind the wood into individual cellulosic fibers by
pressing the clean logs against a rotating stone for digestion.
The stone is sprayed with water to remove the fibers from the pulp.
However, a small amount of lignin (a non-fibrous part of the wood) is
removed, which binds the fibers and degrades the quality of the paper.
However, the mechanical mass is inexpensive and provides a higher
yield.
During chemical fermentation, the wood chips are "boiled" to convert
the raw material into individual cellulose fibers. There are two types of
chemical roasting, sulfite and sulfate, both of which result in better
separation and reduction of lignin content for superior paper
production.
The more popular of the two methods is sulfate, in which alkaline
solutions are used to break down the wood and add sodium sulfate to
increase the strength of the pulping. So come on, because this
Swedish word means strength.
Of the two methods, kraft paper is used locally and, as noted above, is
dark brown or bleached during digestion to create white kraft paper.
However, today most of the paper products specially designed for
cardboard boxes are made from recycled waste. They come in a
variety of forms, including:
Chip: Chip liners are made from recycled fibers and are usually too
small and of poor quality. They are limited to centre skins on double-
wall panels and internal skins.

Semi-Chemical Grooving: Hardwood with up to 35% waste and other
paper fibers.
Waste-based grooves: 100% chemically reinforced waste with starch

Corrugated
Corrugated cardboard is a piece of corrugated cardboard inserted
between the inserts, which gives the box strength and protection from
bumps and blows. To achieve the striped effect, the paper rolls are
loaded into a corrugating machine. This process has existed since the
18th century and was originally used to add ruffles to shirts and hats.
More recently, the R Flute was introduced; It is an alternative to
grooved B trays with the same performance but with a lower
thickness, which can reduce supply chain costs and save space for
users. The R groove is also known as the M or S groove and offers
benefits such as a 30% improvement in print quality, a 30% increase
in the number of cartons on a pallet and a reduction of around 30% in
CO2 emissions thanks to saving truck space.
Of course, these flutes only describe single-walled boxes: if you see a
box called "Flute BC" or "Flute AB", that's the case if a double-walled
cardboard box as indicated. The first letter is the top edge and the
second letter is the bottom edge.

Production

Now that we have identified the key elements for creating corrugated
cardboard, all that remains is to glue them together! After the paper
has passed through the corrugated cardboard, where hot steam is
sprayed onto the paper so that it can be squeezed, another roll sticks
to one side of the groove.

Then the machine glues the two lids to the plate; The cardboard is
then cut on each side with a circular saw so that the cardboard has
straight sides. The corrugator then cuts the sheet up to nine times,
depending on the size of the carton. This is determined by the
management of the FEFCO.
The FEFCO (European Federation of Corrugated Board
Manufacturers) guide is a corrugated cardboard that describes every
style imaginable with different categories, including 01 for commercial
rolls and sheets, 02 for slit boxes with a piece of cardboard glue. 03
for telescopic boxes with multiple parts (usually a bottom and lid), 04
for binding boxes that look like book covers, and 05, 06, 07, 08 and
09, which are made with more complex styles.
The FEFCO manual is almost any boxing style you want. All you need
to fit is the size. Of course, if you need to add more valves, our
Custom Printing Services specialists are well versed in the instructions
and can select multiple styles that they think will work effectively for
you.
After the boards are cut, the corrugated cardboard separates them
into layers and stacks them so they can be inserted into the
lawnmower. The mower's job is to accurately sculpt the "difficult"
aspects of the table structure, such as the handles and blinds. It has
sharp rubber blades, so the lines you need to mark cannot be cut. An
older way to do this, which is still used for small prints, is to use an
awl, where the design is placed over a large "stamp" and cut out of the
sheet.
The folder then folds the boxes along the marked lines and apply glue
or dots in the places that will be joined to form the box. Glue is the
most common cardboard box adhesive and is much more hygienic,
which is important for industries such as food. The staples can also be
used as tin staples. However, these are more expensive options and
are mainly used only for heavy boxes that require a stronger adhesive.
After the tie is attached, another machine folds the sections to hold

them together and the flat boxes are folded to be sent to customers
and distributors like us.
Eventually, the waste paper will be recycled and used to make
cardboard and other paper products. Many corrugated cardboard
manufacturers are now making cartons as environmentally friendly as
possible so that their manufacturing processes do not affect the
climate.
Simple product, complex process.