PERFORMANCE EVALUATION OF CORRUGATED PACKAGING - A KEY TO SUCCESS FOR PAPERMAKERS AND CORRUGATORS...
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PERFORMANCE EVALUATION OF CORRUGATED PACKAGING - A KEY TO SUCCESS FOR PAPERMAKERS AND CORRUGATORS
Sanjay Tyagi, B. P. Thapliyal, R. D. Godiyal, Prachi Kaushik and Manoj Kumar
CENTRAL PULP AND PAPER RESEARCH INSTITUTE SAHARANPUR- 247001
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• Pulp & Paper industry is one of the largest industrial sector in world producing 404 million MT of paper & paper board annually.
• Asia contributes highest production with 182 Mmt followed by Europe (106 Mmt) and North America (85Mmt)
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Asia Europe North America
Latin America
Oceania Africa0
5
10
15
20
25
30
35
40
45
50
Pap
er a
nd
Pap
erB
oar
d P
rod
uct
ion
(%
)
Region-wise Production of Paper and Paperboard
(Source: Compendium of Census Survey of Indian Paper Industry, CPPRI (2015))
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Global Production Trends
• Global Pulp & Paper industry shows positive growth despite a decline in production in graphic paper in North America and Europe.
• Positive growth of tissue and packaging grades has offset the retreat of graphic paper.
• According to FAO, paper and board packaging product will continue to represent industry’s largest segment with contribution of more than 50% of worldwide paper production.
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37%
26%
14%
8% 8% 7%
0%
5%
10%
15%
20%
25%
30%
35%
40%
Corrugated Material
Printing and Writing
Paper
Paper Board for Packaging
Tissue Paper
Otherpaper Newsprint
Pape
r and
pap
er b
oard
Pr
oduc
tion
(%)
Grade-wise Global Production of Paper
(Source: Compendium of Census Survey of Indian Paper Industry, CPPRI (2015) )
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Global Paper Consumption
• Highest consumption of paper is registered for Asia, Europe & North America
• China accounts for 25% of world demand against 26% of global production of paper and board.
• Europe consumes 24% of paper against the contribution of 27% of global paper production.
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46%
24%20%
7%2% 1%
0%5%
10%15%
20%25%
30%35%
40%45%
50%
Asia Europe NorthAmerica
LatinAmerica
Africa Oceania
Con
sum
ptio
n of
Pap
er (%
)
Region- wise Global Consumption of Paper
(Source: Compendium of Census Survey of Indian Paper Industry, CPPRI, 2015)
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221
156
50
215
75
159
23
126
47
13.2 8
0
50
100
150
200
250
Per
Cap
ita C
onsu
mpt
ion
Paper Consumption kg/capita
(Source: Compendium of Census Survey of Indian Paper Industry, CPPRI (2015))
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Fact sheet of Indian Paper industryNumber of Mills 813
Total installed capacity, MMT 22.15
Operating Installed capacity, MMT 19.27
Production of Paper, board & newsprint, Mtpa 14.99
Capacity utilization, % 80
Per capita consumption (kg) 13.2
Contribution to exchequer, Rs. crores 4500
Employment Direct, million people 0.5
Indirect Employment, million people 1.5
Indian share in world’s production 3.7
(Source: Compendium of Census Survey of Indian Paper Industry, CPPRI (2015))
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Variety Raw Material Production (Mtpa)
Total production Mtpa
% Contribution
Writing Printing Grade
Wood Based 2.675.21 35*Agro Based 0.54
Recycled Fibre Based
2.00
Packaging Grade
Wood Based 0.858.29 55*Agro Based 1.07
Recycled Fibre Based
6.37
Newsprint Grade
Wood Based 0.02`1.49 10*Agro Based Nil
Recycled Fibre Based
1.47
Total Production 14.99 100
Indian Paper Industry segment based on Products
(Source: Compendium of Census Survey of Indian Paper Industry, CPPRI (20150))
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Projected requirement of different varieties of Paper
• It is estimated that production of paper will reach 21.94 million tons in 2025 against present production of 14.99 million tons.
• Industry requires an addition of 6.95 million ton production capacity over a period of 10 years i.e an addition of 0.69 million ton /annum.
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Projected Growth of different varieties of Paper
Paper Grade Growth rate in %Writing/Printing Paper
• Coated Paper 10
• High grade maplitho 08
• Copier Paper 15
• Cream wove 05
Industrial Paper and Board
• Container and Corrugated board 10
• Carton Board 08
Newsprint 06
Specialty Paper 05
(Source: Compendium of Census Survey of Indian Paper Industry, CPPRI (2015))
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Use of Paper and Paperboard for Packaging
• Bags, wrapping and infusible tissues e.g. Tea and coffee bags, sachets,
pouches, over wrap, sugar and flour bags, carrier bags
• Multiwall paper sacks
• Folding car tins and rigid boxes
• Corrugated and solid fiberboards boxes
• Paper based tubes, tubes and composite containers
• Fiber drums
• Liquid packaging
• Labels
• Sealing tapes
• Cap liners (sealing wads) and diaphragms (membranes)
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• Contain the product.• Protect goods from mechanical damage• Preserve products from deterioration.• Information to customer / consumer.• Provide visual impact through graphical and
structural design.
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Technical Requirement of Paper and Paper Board for Packaging
• All papers and paper board properties depend on the ingredients used e.g. type and amount of fiber and other materials, together with the manufacturing process.
• These related to the visual appearance and technical performance of packaging incorporating such materials.
• Appearance that relates to color, visual impression and the needs of any processes such as printing which have a major impact on the appearance of the packaging.
• Performance that relates to strength, product/consumer protection and the efficiency of all the production operations involved in making and using the packaging.
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Corrugated fiber board packaging
• Corrugated fiber board packaging in terms of weight, is the commonest type of paper and paper board based packaging.
• It function is mainly the protection of products during distribution.
• Popularity of corrugated board as packaging material is primarily because of its high strength- to- weight ratio
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Relative price verses relative strength of various packaging materials
Source: Alf dr Ruvo, “Development trends in packaging”, PRIMA supplement in Paper Europe, volume3, number 4, July 1991)
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Structure of Corrugated Board
• Corrugated board has a sandwich material structure.
• It comprises a central paper (called the corrugating medium or simply the medium) which has been formed using heat, moisture and pressure in a corrugated i.e. fluted, shape on a corrugators and one or two flat papers (called liners) have been glued to the tips of the corrugations
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Structure of Corrugated board
a Single Face
b Single wall
c Double wall
d Triple wall
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Corrugating Flutes ProfilesFlutes Average
Number of flutes / m
Pitch (mm) Take up factor
D 75 14.96 1.48
K 95 1.70 1.50
A 110 8.60 1.53
C 129 7.95 1.42
B 154 6.50 1.31
E 295 3.50 1.24
F 310 2.40 1.22
G 350 1.80 1.21
O 360 1.25 1.14
(Sourse: ‘Technical Corrugating Roll Data’,BHS Corrugated brochure by Edmund Bradatsch and Lothar Jobst – July 2000)
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Properties of corrugated paper board and their test procedure
• Weight per unit area (grammage) • Thickness (caliper)• Bursting Strength• Rigidly or bending stiffness• Edge Crush test• Flat crush test and hardness• Concora Medium Test• Puncture Test• Adhesion Test and Score cracking• Box Compression Test
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Weight per unit area (grammage) and thickness (caliper)
• Grammage = L1 + (a x F) + L2
where L1 and L2 are the liners, F is the medium and ‘a’ is take-
up factor. • The take- up factor defines the length of the
medium (fluting) material used in a corrugated fiberboard structure compared with the length of the facings.
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Thickness or Caliper• The thickness (caliper) is measured under 20 kPa pressure
Average value of thickness for different flutes in given below
Flute Caliper or Thickness (mm)
D 8.0
K 6.5
A 4.8
C 4.2
B 2.8
E 1.7
F 1.2
G 1.0
O 0.7
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Why measuring the corrugated caliper is important?
• Caliper is an indirect measure of the compression stacking of corrugated boxes.
• Low caliper is usually the result of poorly formed flutes or crushed flutes and often results in poor corrugated box performance.
• Whenever the caliper of given grade of board is less than the target value, it failed to achieve the maximum strength potential.
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How to maximize caliper?
• From the flutes to the maximum potential of the corrugated rolls
• Do not to crush the flutes after we have formed them.
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Strength Properties
• The strength and durability of corrugated board lies in the strength of the components it made up of.
• A 20 x 20 x 20 – 200 lbs (976g/m2) test C- flute corrugated box can withstand almost 408 kg of weight before failing, yet it weighs only 1.02 kg.
• Reason lies in the fact that fluted medium separating two liners act as columns.
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Bursting Strength
• It is indication of the character of the materials used in the manufacturer of the box.
• Depending on nature and grammage of the liners, large range of quantities from 800 to 8000 kPa is available.
• This test gives no direct information regarding the ultimate performance of the design or construction of a finished container.
• Burst strength test is of critical importance as a control test in the paper board mill.
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• Triple wall corrugated board can not be tested suitably by the burst test method.
• Testing of double wall is of questionable accuracy since it is rarely possible to get sufficiently simultaneous burst of the multiple facing.
• For single wall corrugated board, the following equation is applied
Burst Strength = L1 + L2 + 100
Where L1 & L2 are the burst strength of the liners in kPa.
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Rigidly or Flexural bending stiffness
• Relates the force required to deflect a flat specimen of corrugated board through a given angle.
• Capacity of structural members to resist bending. • Greater the flexural stiffness, greater is the load
required to produce a given deflection.• Combined board flexural stiffness in each direction
is summing the product of elastic modulus of each component.
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• Combined board Stiffness S = EtH2/2 where E = Elastic modulus of liners t = liner thickness H = combined board caliper
• Combined board stiffness is sensitive to caliper of combined board, thus it is necessary to avoid crushing the board during conversion.
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• C Flute has higher bending stiffness than B Flute
• Corrugated fiber board based on kraft liner has a higher bending stiffness than test liner of same grammage
• Bending stiffness increases with increasingly liner grammage.
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Edge Crush test
• Evaluate the compression strength of the corrugated board as
per ISO 3037. Expressed as the breaking force divided by the
sample width (kN/m).
• Relates directly to the top to bottom compressive strength of
corrugated shipping container.
• Method is used for comparing the edge wise compression
strength of different lots of similar board or for comparing
different materials combinations
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Maltenfort Equation
• ECT = k(σ CL1 + σ CL2 + α σ CF )
where σ C = compression strength of liners & flutting medium paper measured by any method SCT, RCT, CLT, CCT
α = take – up factor k = constant depending on manufacturing variables of
corrugated board
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• 15 – 20% of ECT potential of corrugated board is lost during fluting process due to high bending and tension stresses induced in medium paper during fluting.
• Application of steaming operation though relieved stresses but it reduces elastic modulus and compressive strength of sheet by 5 – 15%.
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Edge Crush Test piecesEdge Crush Test pieces
100 mm
25 mm
paraffin
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Flat crush test and hardness
• Evaluate and classify the performance of the fluting in accordance with the type and basis weight.
• Measure of the resistance of the flutes in corrugated board to crushing force applied perpendicular to the surface of the board under prescribed conditions (ISO 3035)
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• Measures the flute rigidity of the corrugated board.
• High FCT value indicates a good combination of the flute formation and at least adequate medium strength.
• A low flat crush value indicates a number of faulty conditions.
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Flat Crush TestFlat Crush Test
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• FCT test is satisfactory for single faced or single wall corrugated board but should not be used for double wall or triple wall board.
• This test gives the intrinsic performance of the flutes predicted by the Concora Medium Test (CMT) and by basis weight
• The FCT thus records how appropriate the fluting medium is for processing on the corrugators
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Hardness
• In order to evaluate properly the performance of soft board, the hardness of corrugated board is other important criterion.
• Hardness is the resistance of the board in early stage of FCT. It relates to the real strength of the flutes whereas FCT is late yield point.
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Effect of crushing force on flutes
3500
3000
2500
2000
1500
1000
500
01 2 3 mm
Compression
Force
23
45
6
1
leaning flutes
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PUNCTURE TEST
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• This test illustrates the energy required to penetrate the corrugated board.
• Conducted as per ISO 3036 standard. Values are reported in mJ/m.
• This test gives better performance of corrugated box as compared to Burst test.
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Concora Medium Test
•It is a test of compression of the paper after fluting in fluting apparatus.
•The CMT value is the maximal force the sample can with stand before it breaks.
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Concora Medium TestsConcora Medium Tests
Tape
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Pin Adhesion Test (PAT) and Score cracking
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• The Pin adhesion Test (PAT) is used to evaluate the bonding between the fluting and liner.
• Adhesion resistance is the maximum force required to separate the linerboard from the fluting with the help of special sample holder.
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• In single face bonding, the adhesive is distributed on each side of the flute tip.
• In double backers, the adhesive deposit is placed on the top of the tip.
• Score cracking effect occurs during converting operation due to stress-strain occurring in folding & erecting.
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How Box Collapse?
• In conventional vertical flute boards, with progressively increasing load, side & end panels become unstable & deflect laterally.
• Having become unstable, central region of each panel suffers appreciably reduction to accept further increase in load & box bow outward or inward.
• Edges carry greatest intensity of load & rupture of box at edges triggers failure of entire box.
• Box Compression test (BCT) is the best representation to practical stacking strength of corrugated board boxes.
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Box Compression Test
• Stackability of corrugated boxes is best determined by box compression test (BCT) expressed as KN or kg.
• BCT is the top to bottom compression strength.• To conduct this test, the container is placed
between the platens of the test machine and compressed at a rate of 0.5 in/min. The maximum load and deflection at failure is recorded.
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Box Compression Tester
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• Box Compression strength = K x ECTa x FSb x Dc
where D is the dimension of box (perimeter), FS is the flexural stiffness of the board, ECT is the edge crush test of board and
K, a, b and c are empirical constants.
• ECT of combined box is a dominant factor in top load box compression strength.
• A % increase in ECT strength, contribute three times greater increase in BCT as compared to % increase in flexural stiffness & 1 – ½ times the same increase in box perimeter
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Factors negatively affecting the top load Compression strength
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Effect of relative humidity o compressive strength property of corrugated boards
Humidity
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• Corrugated box looses half or more of its short term top load compression strength when relative humidity increased by 50%.
• BCT falls from 350±50 kg (at 23°C/50% RH) to 130±15 kg (at 20°C /90%RH)
• With increasing moisture content, ultimate paper strength properties reduced due to reduction in inter fiber bondings.
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Age• With number of days the box is under
compression, compression strength of box began to loose at an alarming rate.
• This is due to creep within the cellulose fiber structure of the paper and the corrugated material itself.
• As a thumb rule, 50% of its stacking strength will be lost over six months period.
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Misalignment
• Vibration disturb system stability. • BCT value of box from 300 kg falls by 40% (170 kg) due to vibration.
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Column stack verse Interlock
Compression strength of corrugated box as a function of stackability
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Pallet Overhang
Effect of pallet overhanging on compression strength of corrugated boxes
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Rough Handling
• Mishandling including dented vertical edges on the container can result in as much as 50% decrease in the box compression strength when compared to the virgin container.
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Conclusion
• Growing market has placed demands upon the corrugated case producers for better quality both in terms of strength and visual apperance.
• For achieving above points it become very essential to evaluate the performance parameters of corrugated boxes at every stage of production and converting.
• This should be done by adopting the correct procedure of testing of liner, medium and corrugated box with state of art equipments by following standard test methods.
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THANKS