Ian Chalmers

Corrugated Board is an Engineered Structure

Tappi Indianapolis 2007Tappi Atlanta 2008Tappi / USDA FPL Creep Symposium 2009

2010 – Visit Korutest at booth 219

Background – MD Torsional Stiffness

US Patent 

Corrugated Board

Engineered structureWithout the engineered integrity, it will fail prematurelyMost board currently made in the USA by anyone is crushed and has lost on average at least 33% of its strengthUnrealised by most parties is that this loss of strength is being made up by over specifying linerboards

Boxes vs Board in the USA

A large USA Company

DST (bpi) Caliper (mm) ECT (kN/m) Differences Board-Box (%)

Sample Board Box Board Box Board Box DST Caliper ECT

A 5.7 3.3 3.89 3.63 6.4 5.9 -42.2 -6.5 -7.4

B 6.9 6.0 3.81 3.78 5.9 6.0 -12.5 -0.7 0.4

C 8.3 5.5 4.14 4.09 8.5 8.7 -33.3 -1.2 2.5

D 8.5 7.5 3.96 3.99 6.6 6.0 -11.7 0.6 -8.7

E 9.2 1.5 4.04 3.73 7.2 6.6 -83.6 -7.5 -7.5

F 10.1 4.8 4.16 3.86 8.3 7.2 -51.9 -7.2 -12.5

G 10.5 7.6 4.11 3.99 8.5 7.7 -27.6 -3.1 -10.3

H 10.7 9.6 3.00 3.00 6.4 7.3 -10.5 0.0 13.7

I 11.0 7.0 4.34 4.06 11.7 8.9 -36.8 -6.4 -23.7

J 11.7 7.2 4.11 3.97 7.9 7.5 -38.0 -3.5 -5.3

K 14.3 11.6 4.17 4.19 8.8 8.8 -18.9 0.6 0.6

Ave 9.71 6.52 3.98 3.85 7.83 7.33 -33.37 -3.17 -5.28

Box performance vs crush

05

101520253035404550556065707580859095

100

0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3

Load (kN)

Perfo

rman

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- Li

fetim

eC

ompl

eted

RH

Cyc

les

befo

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ilure

24 bpi14 bpi 21 bpi

Chalmers DST

Financial model

Visit Booth 219

Korutest cost savings model © Korutest Limited 2009Cost liners /short ton 560.00$ 617.29$ Prices in $US

Cost medium /short ton 480.00$ 529.10$ Medium Offset

Actual = tested DST Use -2.057lbs to gsm x = 4.882 RF -5.057

SC -2.057

USA Board Grade - C FluteCost/1000ft² DB Medium SF Actual Theory DST

Old Board 37.00$ Now 46 33 46 15 20.9New Board 30.84$ New 35 33 35 17.5 17.8

Cost Savings 6.16$ Cost % savings 17%

Weight savings (lbs) 22Wgt % savings 16%

per tonneper tonne

ALTER board grades & prices

fin