Boxes on IndustryNet

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Corrugated cardboard is a stiff, strong, and light-weight material made up of three layers of brown kraft paper. In 1884, Swedish chemist, Carl F. Dahl, developed a process for pulping wood chips into a strong paper that resists specific damages - tearing, splitting, and bursting. Boxes provide some measure of product protection by themselves, but often require inner components such as cushioning, bracing and blocking to help protect fragile contents.

The manufacturing process of boxes includes:

First, machine rolls out a whole lot of recycled paper to be split up into one wavy sheet of paper called a flute, which sits between two flat sheets called liners. They form a corrugated board.Then the paper goes through two rollers called a corrogater. Hot steam is sprayed on the cardboard while another roller glues one side of the flute.A machine then adheres two liners to hold the box together and strengthen the board. Next, a razor thin circular saw cuts each side of the cardboard. After this process, the corrogater machine cuts the board as many as nine times, depending on the size of the box. The corrogater's final use is to separate the boards into layers using these aluminum tongs.

The next machine stacks the boards in quantities of between 25 and 80 boards. The machine then feeds the next machine at a rapid rate of 8,000 boards per hour; a trimmer cuts through the cardboard withexpert precision to make the flaps and handles. Rubber blades ensure that this machine cuts only the parts. The boxes are processed at an amazing rate of 90 boxes per minute. The unused, cut off paper goes down below,where it is recycled as many as six more times.

Then a bending machine folded the boxes along lines already made by the corrogater. Glue is then applied to the places which will come together to form the box. Another machine, then, folds the glued sections.The boxes are then put in large piles and then sent off to be shipped away. To put the proper writing on these boxes, there's an ink kitchen were over 5,000 colors are systematically poured into these containers. They're then mixed perfectly in just the right color combinations on the cardboard boxes. The boxes are finally ready to ship and carry nearly anything you could imagine.

Quality control begins with the suppliers of the kraft paper used to make corrugated cardboard; kraft paper must be smooth and strong. The Cobb test measures moisture in the liner and medium.Glue strength, bursting strength, compression, and highly accurate dimensional tests determine the quality of the manufacturing process. A warp test determines the flatness of the box blank, insuring that each blank will travel smoothly through the flexor machines. Trimming, cutting, and scoring must be correct.No damage to the cardboard is allowed. Also, the different layers of colored ink used in color printing must be perfectly aligned.

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