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Corrugated board is essentially a paper sandwich consisting _____________ __________ layered between inside and outside ________________
corrugated medium, linerboard
What are the three arrows? (top to bottom)
outer liner
fluted medium
inner liner
_______________ is the most widely used kind of shipping container
corrugated
Corrugated is best known for its ________ _______ that offers _____________ to packaged products throughout the transportation cycle
structural strength, protection
What is this?
Single Face
What is this?
Single Wall
What is this?
Double Wall
What is this?
Triple Wall
What are the three typical substrates used for corrugate
kraft
mottled
bleach
What is the index for Kraft?
100 Index
What is the index for Mottled?
105 Index
What is the index for Bleach?
109 - 115 Index
The ______ combines rolls of linerboard and medium into sheets of corrugated board
corrugator
The typical corrugator is equipped to run both _____ _____ and ____ ____ in a variety of flute heights
single wall, double wall
Modern corrugators can also be equipped with enhancements that offer a range of value added features such as:
functional coatings
color coating
tear tape or internal strings
water resistant adhesives
Which part of the corrugated manufacturing process is this?
Mini Roll Stands
Which part of the corrugated manufacturing process is this?
Single Facer
This is the inside the single facer, what do the arrows point to? (Top to bottom)
Medium
Adhesive
Liner
Typically the glue used to make corrugated fiberboard is ______ ______
starch based
What does this show?
Bridge
What does this show?
Preheaters
What does this show
Glue (starch) machine
What does this show
Double backer
What is this showing?
Slitter/scorer
Scoring, slitting, and trim removal take place in the _______ ______ and ________ section in the combining process
Triplex slitting and scoring section
What does this show
cut off
What does this show?
Downstacker
What are some package design considerations?
What type of product will the package contain?
Orientation of the product to the shipping case
How many products will the package contain including is size and weight?
Package environmental needs
Handing and distribution needs
Will the product be packed by hand or machine filled and closed?
What are some equipment considerations
box erecting system
loading considerations
palletization
use of manual to robotics
What is the distribution methodology?
Distribution center
Retail
E-commerce
Direct to consumer
What are the three sets of dimensions?
Inside Dimensions
Outside Dimensions
Score to Score Dimensions
Size is typically given as ________ ________
inside dimensions
Inside dimensions are determined by the ______ of the item you wish to fit in the box
size
Outside dimensions are determined by the inside dimensions required plus the _____ _____ selected
board grade
Some customers give size in outside dimensions based on ______ allotted by the retailer or a desired _____ footprint
space, pallet
Score to score dimensions are determined by the ______ of the box and the _____ _____ selected
style, board grade
What type of dimension is shown? (top to bottom)
Outside Dimension
Inside Dimension
Score to Score Dimension
Length is ____ to _______
left to right
Width is _____ to ______
front to back
Depth is _____ to _____
top to bottom
E flute is used for what?
Cosmetics and high end small items
B flute is used for what?
High end and heavier items such as wine and liquor
C flute is used for what?
More protection for shipping
B/C Double Wall flute is used for what?
Very heavy items (industrial/sporting goods)
What are the factors for choice of fluting?
size of product
weight of product
environmental
shipping requirements
stacking requirements
What are the corrugated box styles?
RSC - Regular Slotted Container
HSC - Half Slitted Container
FOL - Full Overlap
Die Cuts - Specialized Designs/Use
What is the most common style of box utilized?
RSC - Regular Slotted Carton
In the design of an RSC the outer top and bottom flaps meet in the ______ of the _____ dimension of the container
middle, width
In the design of an HSC the outer flaps meet in the ______ of the _____ dimension of the container
middle, width
Typically, two HSC containers will be sized to allow for placement over each other to create a _______ case
telescoping
In the design of an FOL the outer top and bottom flaps ____ ____ each other in the ____ dimension of the container allowing for the major and minor flaps to fold over each other
fold over, width
In the design of a straight tuck top and bottom corrugated container the tuck top and bottom panels are ____ _____ with each other
in line
In the design of a _____ _____ corrugated container the bottom panels lock into each other to form a non-glued bottom
Tuck Top
______ _____ packaging refers to a box, tray, sleeve, bin, or other display that product is shipped in that can be set on the shelf upon arrival at a store
Retail ready
What are things to keep in mind for display manufacturing?
Will the display design be able to fit on the converter’s machinery?
Can it be glued?
Will it require manual folding and stitching or special gluing?
What are things to keep in mind for display assembly?
Will the display be prone to tearing in the assembly to loading process?
Can the loaded display it be lifted?
Will the retailer be able to put the display together properly?
What are the types of corrugated display types?
Counter Unit
Power wing (sidekick)
Floor Display
¼ Pallet to ½ Pallet
Full Pallet 40 × 48
Pull Pallet 48 × 48
Once an order has been placed, the _______ ________ ______ can create an instruction sheet to be packed with the display
Corrugated display vendor
This will allow the retail location on how to assemble to ________ ______ correctly
Corrugated Display
What are the main corrugated printing methods?
Flexo
Flexo preprint
Flexo lamination
Offset lamination
Digital
Describe the flexo printing process:
Flexible printing plates are mounted to a cylinder and pick up a fast drying water based ink from an anilox cylinder that is metered by a rubber roll or doctor blade system
In flexo printing sheets are fed through the ______ and _______ are transferred to the corrugated board
cylinders, grapics
What are the two ways that litho quality graphics can be incorporated into corrugated packaging?
Single Face Laminating
Labeling the combined board
With ______ ______ _______ a printed “top sheet” can be laminated directly to the medium as the outside liner
single face laminating
Which tyle of printing uses solvent based inks?
Litho Liner Printing
______ _______ is the most recently developed printing technology
digital printing
Graphics from a digital computer file are transmitting ______ to a printer that plots the graphics onto the corrugated board which eliminates the need for _______ ______
directly, printing plates
What is used in secondary labeling and coding?
Non contact ink jet printing
Pressure sensitive on demand label printing and application equipment from manual to auto print and apply
The horizontal scores shown by the BLUE arrows are typically accomplished on what?
corrugator/combiner
The vertical scores shown by the green arrows are typically accomplished on what?
flexo, folder & gluing machine
The slots shown by the red arrows are typically accomplished on what?
flexo, folder & gluing machine
The glue lap shown by the yellow arrows are typically accomplished on what?
flexo, folder & gluing machine
An RSC can also be run utilizing ______ ______ to allow for further accurate finished corrugated container
die cutting
_______ _____ systems provide random length pattern control and simplifies the glue lap bonding process in the corrugated box manufacturing process
cold adhesive
What are the two methods of corrugated die cutting?
Rotary
Platen (flat bed)
What tests are completed on the delivered containers before the corrugated containers are released to manufacturing?
Dimensional Quality
Squaring and Folding Qualities
Print Accuracy & Quality
Board and Glute Specifications
_____ _____ is a multiplier used to convert a known dead weight storage load to a compression requirement
safety factor
What determines safety factor?
time
humidity
abuse
What are other factors to consider in safety factor?
the number of times the package is handled
product support
case alignment
environment
stretch wrap
printing
The area within ____ ____ of each corner of an RSC contributes to approx 65% of its stacking strength
3 inches
_______ _______ testing tells us the weights of the liner and medium components used to make corrugated board
basis weight
Basis weights are in __________
lb./MSF - pounds per thousand square feet
______ testing is a compression test on a sample of board that is directly related to the compression strength of a corrugated case
ECT
ECT units are in _______
lb./in
The ______ ________ of a corrugated case is directly related to the edgewise compression strength (ECT) of the corrugated board used to construct the case
stacking strength
_______ _______ measures the amount of force that it takes to puncture through corrugated board with a rubber diaphragm
Mullen Burst
_______ _______ measures resistance to flexing of corrugated board
Bending stiffness
______ _______ is directly related to corrugated case compression strength
Bending stiffness
Bending Stiffness results are given in _______
lbf/in
________ relates to the compression strength of a case
caliper
Increased board caliper yields ________ case compression strength
increased
If flutes of corrugated board are crushed significantly during manufacture, ECT, Bending Stiffness, and Box Compression are _________ affected
negatively
______ _______ measures the amount of force required to pull the corrugated medium away from the linerboard on a sheet of corrugated board
Pin adhesion
_______ _______n testing measures the amount of resistance the flutes provide to crushing force applied perpendicular to the surface of the sheet of board
flat crush
________ _______ is the water absorptiveness of sized paper, paperboard, and corrugated fiberboard
Cobb Test
What are the two methods of liner and medium compression strength testing are used to predict the ECT of combined board?
Ring Crush Test
Short Span Compression Strength
________ is a compression test on a short span (.0276”) of a strip of linerboard or medium
STFI
STFI strength of liners and mediums ________ to ECT strength of corrugated board
correlates
_________ _________ testing is a compression test on a strip of linerboard or medium formed into a circle
ring crush
Ring crush strength of liners and mediums _______ to ECT strength of corrugated board
correlates
Note 
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