PKG 315: Paper and Board Economics

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Paperboard

Thick, paper-based material, made from wood pulp, commonly used in packaging; ≥ 12 points (0.012 in.)

Clay Coated Kraftback (CCKB)

Produced from 100% recycled paperboard. Tan Kraft on the inside, white clay coating on the outside for a printable surface

Great for heavier products where strength and a printable surface is required

Clay Coated Newsback (CCNB)

Produced from 100% recycled paperboard. Plain chip on the inside, white clay coating on the outside for an improved printing surface

Cartons and mailers where high quality printing is required. Used in rigid mailers and reverse tuck product lines.

Solid Bleached Sulfate (SBS)

Premium paperboard grade produced from at least 80% virgin-bleached wood (chemical) pulp. White on both sides and has a thin layer of clay coating on one side to provide an ideal printing surface.

Ideal for pharmaceuticals, cosmetics, etc. where quality printing and clean surfaces are required

Solid Unbleached Sulfate (SUS)

Unbleached paperboard produced from at least 80% virgin unbleached, natural wood (chemical) pulp. White on one side with superior strength, designed to withstand temperature fluctuations.

Kraftpack

Unbleached, uncoated virgin paperboard (brown kraft) that is moisture resistant and durable when wet.

Tan Bending Chip

Uncoated, plain brown chipboard made from 100% recycled materials that is noticed for its strength, while being both economical and eco-friendly.

Ideal for hardware, automotive, and mechanical parts where extra strength is required.

Uncoated Recycle Board/Bending Chipboard (URB/BC)

Usually brown with specs throughout and contains post-consumer waste. It is typically the most economical option.

Clay Coated Kraft board/Coated Unbleached Kraft board (CCK/CUK)

Virgin paperboard that is not bleached. One side is clay coated white and the other side is brown kraft. Heavy duty packaging, frozen food packaging, beverage carrying containers, pharmaceutical packaging are major markets.

Clay Coated Newsboard/Clay Coated Recycled Board (CCNB/CCRB/CRB)

One side is clay coated white for printability and the other side has a grey tone. An economical option. Soap and laundry detergent packaging, paper goods packaging (facial tissue and napkins), cereal cartons, light bulbs, dry food items (FDA compliant) are major markets.

Kraft

Unbleached virgin paperboard that is brown throughout

Folding Box Board (FBB)

Made using chemical pulp with mechanical or (B)CTMP middle; higher end and general packaging, healthcare, cosmetics, greeting cards

Coated Kraft Back (CKB/CUB)

Coated unbleached chemical pulp (some mechanical); heavy consumer products, food

Liquid Packaging Board (LPB)

Bleached chemical pulp, some CTMP; milk, juices, etc.

White Lined Chipboard (WLC/CRB)

1 or more layer of recycled fiber; recycled fiber, lower-end packaging

What is driving the paperboard market?

Sustainability

Consumer preferences

Adaptability

Corrugated Board

Packaging material consisting of a fluted medium and 1-2 flat linerboards

Clay coating

Part of the board manufacturing process; should not be confused with poly coating (applied for grease resistance after the board is made)

How is corrugated board specified?

Construction, flute size, burst strength, edge crush strength, flat crush, basis weights of components (lb/1000 ft², g/m², etc.), surface treatments and coatings, etc.

Corrugated material

Comprised of three fiberboard layers; two linerboards with a medium in the middle

Flutes

Form rigid columns, are capable of supporting a great deal of weight, act as a cushion to protect the container’s contents, serve as an insulator and provide protection from sudden temperature changes

Linerboard

Provides additional strength and protects the flutes from damage

A-flute

Flutes/foot: 33±3

Greatest cushioning for fragile products

C-flute

Flutes/foot: 47±3

Commonly used for shipping cases

B-flute

Flutes/foot: 39±3

Flatter surface for higher quality printing and die cutting

E-flute

Flutes/foot: 90±4

A strong alternative for paperboard folding cartons

F-flute

Flutes/foot: 125±3

A more rigid box with less solid waste

N-flute

Flutes/foot: 170

Enhanced printability and more accurate folding capabilities

Mailer box

Efficient, protective, and stylish; come with dust flaps that seal and protect the package’s contents

Frequently used by e-commerce and subscription businesses

One-piece folder box

Comprised of a single piece of corrugated cardboard; can be quickly assembled to ship items like books or artwork

Regular Slotted Case (RSC)

Popular shipping container for consumer products

Inner (end) flaps do not meet on rectangular cases

Center Special Slotted Case (CSSC)

End and side flaps meet

Provides extra layer of top/bottom protection

Overlap Slotted Case

Side flaps overlap when closed; can be sealed with staples, stitches, or straps

End flaps do not meet on rectangular cases

Lithographic printing

Perfect for bulk printing —> uses customized plates to guide the printing process; offers high-resolution print quality —> suitable for high-end packaging and displays

Flexographic printing

The most common type of printing; quick, easy, and cost-efficient

Suitable for a wide range of packaging needs

Digital Printing

Ideal for small-scale printing jobs since there’s no need for customized plates

Low setup costs and quick turnaround times —> custom or short-run print jobs

Multiwall Shipping Sacks

Used to package a wide variety of food, agricultural building materials, and are cost-efficient options for shippers that offer a better degree of customization

Can be designed to meet exact requirements and provide the highest degree of product quality protection at the lowest cost that meets normal handling, shipping, and service requirements

How is paperboard priced?

$/1000 ft²

How is paper priced?

$/3000 ft²

Basis Weight

The weight in 1000 ft² of paperboard; the weight of a specified area of paper or paperboard

Brightness

The amount of blue-white light that a paper reflects

Grammage

Expresses mass/unit area and is measured in g/m²

Stiffness

Affects the ability of cartons to run smoothly through the machine that makes, fills, and closes them; gives strength and reduces the tendency of a carton to bulge under the weight of settling flowable contents

Caliper

Expressed in thousandths of an inch (0.001”) or points; 0.024” = 24 points

Thickness

Measured in microns (µm)

Determine the cost of a paperboard carton

1. Find the cost/blank (carton)

   • Determine the area (convert to ft² if necessary)

   • Multiply the area by the basis weight (or density*point/thickness)

   • Multiply by cost/ton

   • Multiply by 3

   • Add printing

2. Multiply by 1000 cartons

3. Units: $/1000 cartons

Folding Carton Trade-Offs

Tuck flaps and automatic bottoms do not require glue (take more board though)

Plan size and arrangement in die to reduce scrap

Cartoning operation speed depends on board quality

Aseptic Coated Cartons

Solid bleached sulfate (SBS) with PE coating; milk cartons, juice boxes, etc.

“Tied good” relationship to machinery supplier (Tetra Pak, Pure Pak) —> Low cost (or no cost) machine, high level of service, only runs their material (can charge what they want)

Ways to enhance the value of folding cartons

Windows, divided cartons, pour spouts, coatings, special effects, new styles (e.g. origami)