Cartons, Crates and Corrugated Board: Handbook of Paper and Wood Packaging Technology

585 Pages·2014·24.78 MB·English

by  Diana Twede

SECOND EDITION
CARTONS,
CRATES and
CORRUGATED
BOARD
Handbook of Paper
and Wood Packaging Technology

Diana Twede, Ph.D.,
School of Packaging, Michigan State University
Susan E. M. Selke, Ph.D.,
School of Packaging, Michigan State University
Donatien-Pascal Kamdem, Ph.D.,
School of Packaging, Michigan State University
David Shires, BA (Hons)
Smithers Pira
Cartons, Crates and Corrugated Board, Second Edition
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Main ent ry un der tit le:
Cartons, Crates and Corrugated Board: Handbook of Paper and Wood Packaging Technology, Second Edition
A DEStech Pub lic at ions book
Bib lio gr ap hy: p.
Inc ludes in dex p. 561
Library of Congress Control Number: 2014958357
ISBN No. 978-1-60595-135-5
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TABLE OF CONTENTS
Preface ix
Chapter 1: Introduction and Historical Background . . . . . . . . . . . . . . . . . 1
1.1 Wood Packaging History 3
1.2 Paper-based Packaging History 15
1.3 Wood and Paper Packaging Statistics Today 60
1.4 References 63
Chapter 2: From Trees to Lumber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.1 Hardwoods 72
2.2 Softwoods 73
2.3 Resource Base and Wood Production 73
2.4 Production of Lumber 78
2.5 Engineered Wood Products 87
2.6 Wood Cost Estimation 91
2.7 Trees, Wood and Sustainability 92
2.8 References 93
2.9 Review Questions 94
Chapter 3: Structure and Properties of Wood . . . . . . . . . . . . . . . . . . . . . . 97
3.1 Chemical Structure of Wood 97
3.2 Tree Growth and the Physical Structure
of Wood 101
3.3 Interaction with Water 105
3.4 Strength 116
3.5 Coefficient of Friction 122
iii
iv Table of Contents
3.6 Relevance of Wood Properties to
Packaging 123
3.7 References 123
3.8 Review Questions 124
Chapter 4: Wooden Containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.1 Commercial Box Woods 127
4.2 Fasteners and Fastening 129
4.3 Wooden Boxes 135
4.4 Crates 141
4.5 Baskets 149
4.6 Barrels 150
4.7 Corks 153
4.8 References 154
4.9 Review Questions 155
Chapter 5: Wooden Pallets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
5.1 Pallet Terminology and Types 159
5.2 Pallet Construction 162
5.3 Alternative Pallet Materials 169
5.4 Palletization and Unitization 171
5.5 Pallet Exchange and Rental Programs 171
5.6 Pallet Performance Prediction and Testing 172
5.7 References 173
5.8 Review Questions 174
Chapter 6: Making Pulp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
6.1 Debarking and Chipping 178
6.2 Pulping 179
6.3 Defibering, Washing, and Screening 191
6.4 Bleaching 192
6.5 Recycling and Repulping 193
6.6 Wood versus Non-wood Pulps 197
6.7 Stock Preparation at the Paper Mill 199
6.8 References 203
6.9 Review Questions 204
Chapter 7: Fabrication of Paper and Paperboard . . . . . . . . . . . . . . . . . . 207
7.1 Fourdrinier Process 207
7.2 Cylinder Multi-ply Paperboard Process 215
Table of Contents v
7.3 Machine Direction Comparison of cylinder
and Fourdrinier Multi-ply Boards 218
7.4 Paper Coating and Surface Treatment 219
7.5 References 221
7.6 Review Questions 222
Chapter 8: Paper, Paperboard, and Corrugated Board
Properties and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
8.1 Basis Weight (Grammage) 228
8.2 Caliper (Thickness) 233
8.3 Moisture: Measurement and Effect 234
8.4 Physical/Mechanical Properties 241
8.5 Porosity: Resistance to Air, Grease, and
Water Vapor 262
8.6 Surface and Optical Properties 266
8.7 References 270
8.8 Review Questions 271
Chapter 9: Types of Paper, Paperboard, Laminations,
and Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
9.1 Kraft Paper 275
9.2 Greaseproof/Resistant Papers 276
9.3 Waxed Paper and Corrugated Board 278
9.4 Cellophane and Other Cellulose-based Films 279
9.5 Specialty Wrapping Papers: Butcher, Baker, Tissue,
and Acid-free Paper 280
9.6 Newsprint, Book, and Office Papers 281
9.7 Paperboards: Recycled and Kraft 282
9.8 Containerboard, Corrugated Board, and
Solid Fiberboard 283
9.9 Molded Fiber 284
9.10 Clay-coated Paper and Paperboard 284
9.11 Extrusion Coating and Lamination 285
9.12 Adhesives Used for Paper-based Packaging 288
9.13 Food Contact Considerations: Migration of
Indirect Additives 295
9.14 Paper-based Packaging Sustainability Issues 297
9.15 References 299
9.16 Review Questions 300
vi Table of Contents
Chapter 10: Printing on Paper and Paperboard . . . . . . . . . . . . . . . . . . . 303
10.1 Text and Other (Mostly) Black Printing 304
10.2 Images and Colors 311
10.3 Inks 314
10.4 Printing Methods 316
10.5 Preparation for Printing and Quality
Control 330
10.6 Print Quality Control and Testing 332
10.7 References 332
10.8 Review Questions 333
Chapter 11: Labels, Bags, and Other Flexible Paper-based
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
11.1 Labels 337
11.2 Paper-based Form-fill-seal Packaging 348
11.3 Wraps and Void Filler 353
11.4 Bags and Sacks 355
11.5 References 371
11.6 Review Questions 372
Chapter 12: Paperboard: Folding Cartons, Set-up Boxes,
and Beverage Carriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
12.1 Paperboard Types and Their Properties 376
12.2 Folding Cartons 383
12.3 Beverage Carriers 410
12.4 Rigid, Set-up Boxes 412
12.5 References 414
12.6 Review Questions 415
Chapter 13: Liquid-Filled Cartons and Other Specialized
Paperboard Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
13.1 Liquid-filled Cartons 419
13.2 Cylindrical Shapes: Composite Cans,
Fiber Tubes, and Drums 426
13.3 Carded Packaging 433
13.4 Molded Forms 437
13.5 References 442
13.6 Review Questions 443
Table of Contents vii
Chapter 14: Corrugated Fiberboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
14.1 Combining Corrugated Board 449
14.2 Corrugated Board Structure 453
14.3 Corrugated Board Grades and Specification 464
14.4 Choosing an ECT Grade Based on Its
Relationship to BCT 471
14.5 References 486
14.6 Review Questions 488
Chapter 15: Corrugated Fiberboard Shipping Containers . . . . . . . . . . 493
15.1 Box Converting 493
15.2 Common Corrugated Box Styles 503
15.3 Solid Fiberboard Boxes and Slipsheets 519
15.4 Other Corrugated Fiberboard Packaging
Applications 521
15.5 Box Specifications 523
15.6 Box Cost Estimation 525
15.7 Case Packing and Sealing 526
15.8 Beyond Material Properties: Distribution
Dynamics Performance Testing 527
15.9 Substitutes for Corrugated Fiberboard Boxes 531
15.10 Distribution Packaging Functions
Beyond Protection 532
15.11 References 533
15.12 Review Questions 534
Chapter 16: The Future of Wood, Paper, and Paperboard
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 539
16.1 Strengths 540
16.2 Weaknesses 541
16.3 Threats 542
16.4 Opportunities for the Future 543
16.5 At Last 557
16.6 References 557
16.7 Questions for the Future 558
Index 561

PREFACE
This book is intended to be a textbook for students in graduate and under-
graduate university packaging courses . It describes the properties, manufactur-
ing processes, function, specification, and design of wood, paper, paperboard,
and corrugated fiberboard packages, beginning with the trees. It reviews the
history of wood and paper-based packaging, and it explores the opportunities
and threats of the future. The book’s description and discussion of commonly-
used tests and terminology make it a useful reference for practicing packaging
professionals as well.
The book began in the lecture notes of some legendary MSU professors:
Gary Burgess, Don Abbott, Dennis Young, Ruben Hernandez, Bruce Harte,
Tee Downes, Hugh Lockhart, Gunilla Jonson, Pete Rafael, and Jim Goff. It
reflects the School of Packaging’s creation in 1952 in the MSU Department
of Forest Products. It draws from the current literature of our field and from
the assistance of MSU packaging alumni and others in the packaging industry.
All chapters in the first edition (2005) were thoroughly reviewed by leading
practitioners who are acknowledged there.
Ten years later, this second edition has updated chapters, more science, and
two new co-authors. Dr. Pascal Kamdem, a scholar of Forest Products, adds
depth to our understanding of the science behind the applications of wood in
packaging. David Shires adds an international perspective from his experience
(consulting and testing) in the British packaging industry and as Editor-in-
Chief of the international research journal, Packaging Technology and Science .
Recent research is cited to provide a route for the reader who wants to learn
more .
We have also incorporated feedback from previous students in the two MSU
courses for which the textbook is used, Packaging with Paper and Paperboard
and Packaging Materials, and from instructors in other packaging education
ix