Corrugated fiberboard

Corrugated cardboard is a mainly used in the packaging industry, pulp product, which is easy and relatively stable. Corrugated board is one of the most widespread packing material in the world. It is mainly used for transport packaging: In Germany, their market share is 68 percent ( as of 2010). The production of corrugated cardboard is a complex industrial process; the main raw material for this is paper.

Corrugated board is produced by gluing together of at least one smooth and one corrugated paper web (one-sided or one-sided corrugated cardboard glued ). Up to seven paper webs are used to form corrugated board ( three -wave corrugated cardboard ). The shaft is its crucial feature: Lightweight paper receives an extraordinary strength when it is wavy or serrated and glued paper webs forming with smooth hollow volume. So is caused by a type of lightweight construction made ​​of paper, a stable packing containers.

Depending on the need and field of many different types of corrugated board and corrugated packaging are produced.

The term ' board ' is because you ' paperboard ' the expression for the sticking together of formerly used.

History

Curled paper has already been patented in 1856 in England and used as inlay for high repellent. It was not until 15 years later, on December 19, 1871 was granted by the U.S. Patent Office Albert Jones of New York a patent for "Improvement of paper for packaging purposes ." Jones used so curled paper for the first time for packaging purposes, namely for wrapping and sending bottles and glass vials. True corrugated presented for the first time ago by Oliver Long, bonded by a smooth paper web with proprietary Jones corrugated paper web. The result was three years after Jones ' development unilaterally glued (or short: one-sided ) corrugated cardboard. Long received a U.S. patent for this invention on August 25, 1874. Double-sided (now say: single-wall ) corrugated cardboard, with ceiling papers on both sides, who patented the first Robert H. Thompson on January 17, 1882 in the United States.

The company Thompson & Norris founded in 1875, bought the patents of Jones and Long and developed an industrial production of corrugated board, first in the U.S., in 1883, in addition to London. The first production facility in continental Europe was also established in 1886 at Jülich in the Rhineland by Thompson & Norris. Only after the Jones patent had expired in America, the American patent holders was competition. For the first time machines for the production of corrugated board were also developed on the European continent.

The first independent German corrugated board plant was founded in 1892 by Fedor Schoen (paper and corrugated factories Fedor Schoen, Cologne). This could be by the machine manufacturer Wilhelm Richter in Wroclaw to your own specifications build machines and produced there in rooms that were his brothers, one-sided corrugated cardboard. 1894 moved to the production in the German main industrial area to Cologne to soon produce double-sided corrugated board there. In the following years were more Wellpappwerke and paper mills in Stuttgart, founded in Vaihingen ( Enz ), Berlin, Dresden ( 1911), Gittersee, Neuss (1919) and Dohna. ( Relocated in 1976 to Pulheim ) at the Cologne and Dresden corrugated board is also produced today.

Wilhelm Richter, in 1895 built a single corrugated machine for the first time, was the first producer of corrugated machines (and not CF Langston, as alleged in American publications). However, judges are not built for the general market, but had to undertake to supply only to Fedor Schoen or only with its permission.

Early 20th century began the corrugated box until then usual custom-made wooden crates and containers in the commercial, freight and transportation gradually replaced.

The first procedure ( Mullen burst index ) was introduced in 1907 in the United States for corrugated board after it has been previously used for paper checks. In 1959, the Mullen tester was officially recognized in Germany. In Indiana in 1916 for the first time two wall corrugated board was produced (double - double ). 1929 came to the A wave known to date, add the B- wave.

Pay

Worldwide, around 275,000 people are employed in the production, processing and distribution of corrugated cardboard; in Germany, there were 2010, around 18,000 people.

In 1991, there were 1650 corrugated plants in the Western world, of which 661 in Europe and 97 in Germany; 2010, there were 39 companies in Germany with 114 works. In Europe, Germany is due in 2010, with sales of approximately 9 billion m² (equivalent to about 4.8 million tonnes) in the first place.

The corrugated consumption per person in 2007 was in kg:

Varieties

Generally

There are different varieties, types of waves and wave combinations with corrugated board. The most common types of waves in the single-wave range are C- wave (medium wave ) and B - wave ( B-flute ) and E wave ( superfine or microwave).

In the double -wavelength wave combinations of BC- shaft ( fine and medium wave), EB -wave or EE- wave are mainly used. For three -wall corrugated board ACA ( rough wave medium wave rough wave ), BAA (fine wave rough wave rough wave), EBC ( extra thin fine wave medium wave) or BBC are (fine wave - fine shaft - medium wave) common shaft combinations.

The choice of wave combinations in conjunction with the basis weight and the type of Wellpappenrohpapiers (eg kraft liner or test liner than linerboard and, for example, semi-chemical pulp or chip board as a paper for the shaft ) are dependent on the product to be packaged and the shipping route and the resulting stresses.

Place for lighter goods i.d.R. single-and double -wall corrugated board use, typical for products in the food and beverage industries (consumer goods ). Three wall corrugated board can be used for heavy and fragile goods, such as for shipping overseas and serve as a replacement of wooden packaging. When the goods to be packaged are frequently capital goods with high weights and special requirements due to unfavorable climatic conditions during the route and at the receiver position.

In addition to the choice of the wave combination and the Rohpapiersorte with the corresponding basis weight, package design is a decisive factor for the stability of the packaging and product protection.

The FEFCO ESBO code gives an overview of constructions of standardized shipping containers. In addition, the companies of the corrugated industry individual constructions are developed alone or in cooperation with their customers.

The corrugated board is built up in several layers. For single wall corrugated board are:

To achieve the required strength values ​​for the respective use different types of paper for ceiling and wave train can be used. These papers differ in their content of fresh and recycled fibers, as well as its mass per unit area, called basis weight. A better strength can be achieved through the use of papers with a high fiber content fresh, but also by higher basis weights.

Species

(* For the wave types N and O is a standard does not exist or is in preparation. )

Waveform

The produced in Germany waveform is the sine wave, referred to as " round- corrugated form." The so-called V- profile is in Germany less common.

Double shaft ( duplex)

With double wall corrugated board (eg BC- wave), the structure is as follows:

In the double- wave two -sided corrugated cardboard are assembled in a laminating ( gluing ) and provided with a final cover sheet

Production

Corrugated cardboard ( engl. = wavy corrugated ) with so-called " Corrugatern " or simply German corrugated board plants ( WPA ) was prepared. With such systems it is possible to single-layer (simplex ), double layered (duplex ) or three-layer ( Triplex ) to produce corrugated cardboard. The paper of the wave train is put under pressure by means of fluted rollers and hot water vapor in the form and at first, then glued to the inside cover with the outer cover; for bonding starch is used. A fluted roller looks in cross-section similar to a gear. The curve on the fluted roller determines the waveform and height. Most EPA have a working width of 2,500 mm. Modern WPA, there are now also available with working widths of up to 3,300 mm; they can produce at a production speed of up to 400 m / min corrugated cardboard under the most favorable circumstances. That means over 1,300 m² / min or 79,000 m² / h

World leader in the field of development and installation of corrugated cardboard layers is the BHS Corrugated Machinery and Plant GmbH, which is located in the Upper Palatinate community pond hammer. It is close to the Italian firm Agnati, the Italian- American competitor Fosber and active in numerous industries, Mitsubishi Heavy Industries.

Offset corrugated packaging

As an offset corrugated packaging offset printed corrugated packaging are called. A printed sheet is adhered to a final corrugated web, consisting of the inner cover and the shaft and is cut simultaneously in the sheet pieces. The result is so-called laminated sheet goods. The printed sheet acts as an outer cover. One finds offset corrugated packaging often in the supermarket (POS ) because they sold products very appealing. From 1980 to 2009, a development of the trays is (4-8 cm high, open-top cartons, where cans, bottles [ possibly shrunk with film ] or Product cartons are available ) and outer boxes observed in food discounters: from throughout brown on the outside, then white inside and later printed outside, first one, now often have two colors.

Curvature of corrugated cardboard ( Warp )

The curvature of corrugated board, also called Warp ( from the English verb to warp - bend, deform or noun Warp -. Chain leash), is a common problem in the corrugated board production. It may occur mainly at two points in time:

The so-called Corrugator Warp (English corrugator: corrugator ) occurs directly after the production of corrugated cardboard. It is caused by incorrect machine settings, machine defects and faulty raw materials ( base paper ). For the post Corrugator Warp ( deformation after the corrugator ) turn an incorrect storage of the finished material is the cause: the finished sheets leave the corrugator lying flat and bulge out after a few hours to days. Triggers are false or prolonged storage and climatic conditions here.

The so-called warps also be classified according to their shape:

• Up - Warp

Two or four edges of the ( underlying ) arches rise and form the cross-section of the arc in the direction of "U".

• Down Warp

The edges fall downwards. The stack is similar to a hill.

• Side - to-side Warp

Runs the curvature of the arcs transverse to the machine direction, one speaks of the side-to -side warp. This form has its roots in different moisture contents of the ceiling tracks.

• End-to -end warp

Referred crooked arcs in the machine direction. The reasons for end-to -end Warp are different moisture contents of the ceiling tracks or different web tensions.

• S- Warp

Is characterized by the reversal of the orientation of the warps to the machine direction. Causes can be local moisture differences of ceiling tracks or improper storage.

• Twist Warp

Has the shape of a corkscrew and can have several of the above-mentioned causes.

The curvature of the corrugated board can be (consisting of several corrugated sheets ) minimized and / or introduction of interim management boards or prevented during stacking by alternately turning of corrugated packages.

Processing, special features, accessories, subsequent uses

For processing of corrugated board boxes ( = usually rectangular boxes ) it takes after the choice of materials, the careful planning of a cutting pattern that takes into account the behavior of the box when folded, folds, straining and tearing in terms of geometry and strength. Circumcised is the edge, Einreißecken, window. Interrupted cuts facilitate folding or determining tear lines, but can also to simple marking, labeling serve. The grooves sets fold lines. Cartons are folded and glued, or generally plugged in or clipped. For storage in the unfilled state boxes left open ( Vierecköhre with top flaps ) and two high -speed top and bottom folds can be folded flat or the soil is - except for a hole - closed and yet the folding kind. Sufficient conical boxes can be plugged into each other and stacked, not square - rectangular one into each other in two. The manufacture of corrugated packaging is performed by a CAD program. For this program punching tools are made.

Climbing for fruit are formed by stacking fits: Top upstanding tabs fit into cutouts below. Slots with rounded handle by screwing bending the tab top edge allow for comfortable carrying heavier goods (such as tube TVs ). Another form for the formation of handles is the riveting of handle straps made ​​of soft PE or thin, fibrous polyester, such as on cartons for 2 to 6 kg washing. There are handles made ​​of PE, which - can be hooked up inside with a PE insert and pressed flat from the outside by gently pushing inward - inserted through two holes in the cardboard. At six-packs for half-liter beer bottles in the space between the bottle necks are two forms of handle holes: one form horizontally along in an upstanding tab for all four finger or two crushable with a click into a horizontal surface hole tabs for the death grip with thumb and forefinger.

For push-in connectors can be provided at the edge with a transverse incision, the clamped after plugging in, so the initial opening of the box leaves a tear or at least a visible kink in the package. With snap connectors can be refined molded Displays up to about two meters in height stiffen. Good to engage also connections for archival boxes and small furniture.

Cartons can be formed with removable lid (Shoes, copy paper ) that are re-used for like. A cover can be folded down and lock into place well: Examples include the packaging of glucose - coated tablets, sports shoes, cigarettes. When shaped cartons can be sealed very stiff with a dihedral cover with four lateral push-in and possibly a fifth small locking tab ( PC motherboards, expensive equipment that presents in person and again to be securely packaged ). These are suitable in replication as a dimensionally stable container for books or small items in the backpack.

From corrugated board stacks with ten or more waves ( the layers and waves stand for the highest load capacity vertical) can be very stable and non-slip pads and tie for box - wood pallets trained. Similarly, there are pallets made ​​entirely of corrugated cardboard or of mixtures of corrugated and solid board and similar characteristics ( load capacity, etc.) such as plastic, pressboard pallets or similar. have.

Low fruit crates are very stiff and are equipped with simple hand tearable adhesive dots, so they take up less space as waste. Presses compress with a stubble or a roller press die boxes in front of a plate or container to reduce storage and Transportbedaf. Because of the danger of bodily these facilities were almost completely taken in the premises. Private waste producers are advised to disassemble cartons before throwing in the waste paper bin or to fold, because while ripping or cutting a part of the valuable fibers is reduced. For manual cutting of corrugated board advantageously simple break-off or hook blades are used. If you cut only one layer of a, a crease line can be specified.

Recycling

Corrugated cardboard has a natural resource base. Manufactured in Germany corrugated board consists average of 80 percent recycled material, namely waste paper. The rest being virgin fibers of cellulose, which in turn is made ​​of wood. All containerboard produced in Germany are mainly produced from recycled paper and should therefore bear the designation ' recycled paper '. Papers on mostly virgin fiber are imported from abroad. The glue used in the manufacture of corrugated board is made ​​of potato, wheat or corn starch. Corrugated cardboard is therefore a product made ​​from renewable resources.

The in the Ordinance ( the Ordinance) uncommitted response rate of 70 percent for packaging made of paper, board and cardboard corrugated surpasses by far, because in Germany it is almost completely captured and recycled. This comes only a small proportion of households that dispose of used corrugated packaging on the waste paper bin. The vast majority of used corrugated packaging falls on mainly in the retail and industrial companies. There they are collected or pressed to save space and eventually picked up by a waste disposal company. This provides the waste paper as raw material to the paper mills, the paper that is loaded again - even base paper for corrugated board production - produce.

The closed material cycle works according to market principles, as used corrugated cardboard as well as the rest of the paper is a valuable resource for the paper industry. The recycling system RESY ensures the material recycling of all marked with the RESY symbol transport and secondary packaging of paper, cardboard and corrugated board. Behind the RESY OfW GmbH is a community of corrugated board manufacturers, waste paper disposal companies and producers of containerboard. The imprinted on most corrugated packaging RESY sign with the three arrows confirmed that this material is recyclable and is utilized by the partners of RESY OfW GmbH.

Since 2009, the Association of corrugated board industry offers (VDW ) with the eco - Signet all users of corrugated packaging another marking which indicates the favorable ecological properties of this material.