There are many different types of folding boxes. The most common design is a cardboard box, the bottom and top of which are not adjacent to a common side; when assembling it, the cardboard development is bent along four parallel lines, one of which separates a narrow flap (forming a factory seam), which is glued, and the workpiece takes the shape of a sleeve. The edges are cut out in the form of valves, and scoring lines are applied to them; these flaps are then closed and secured at the edge of the sleeve, resulting in a closed package.
Rice. 6.2. The basic types of folding cardboard boxes shown here come in many varieties. The figure shows flat blanks that are carved; Scoring lines are applied to them, and then the box is assembled and glued together. The glue flap is usually die cut along with the back of the box so that the open cut of the cardboard will face the rear after gluing (the outside side is shown, also called the die side)
A box with a glued bottom is very similar to the type described above, but both bottoms are sealed after packaging. In Fig. Figure 6.2 shows the different shapes of the bottom valves. Bottom flaps are often equipped with special locks to prevent heavy goods from falling out when the box is lifted. Parcel boxes have additional slots and tabs that prevent the package from opening during transit.
We have given only the main varieties, on the basis of which a talented designer can create many new modifications. Packaging may have various cutouts and protruding parts, which allow the consumer to better see the product or provide a certain location of the product inside the box. When additional parts are included (perforations and hinges, tongues and slots, music stands and cuffs), the cost increases slightly or does not change at all. It is this variety of design that makes the folding box so convenient.
The choice of box design and materials is determined by the type of product and marketing considerations for the specific product. If packaging performs exclusively utilitarian functions (for example, serves to store products) or is supplied to industrial enterprises or organizations, then cost is primarily taken into account when making decisions. In this case, the problem comes down to using the thinnest grade of cardboard that is acceptable in this case and calculating the minimum area for the development.
The increase or decrease in the strength of cardboard depending on its thickness is given in table. 6.2, as well as on the graphs presented in Fig. 6.3, 6.4 and 6.5. Once the technical requirements have been formulated, tests must be carried out to confirm the suitability of the selected design. Drop and vibration tests are especially important; they should be carried out under conditions as close as possible to operational ones, that is, by placing the contents for which it is intended in a box and packing as many boxes into a transport container as are planned to be transported in it in practice.
| Box volume, cubic meters inches | Contents Weight, lbs. | Cardboard thickness, inches |
| up to 20 | up to 0.25 | 0,018 |
| from 20 to 40 | from 0.25 to 0.50 | 0,020 |
| from 40 to 60 | from 0.50 to 0.75 | 0,022 |
| from 60 to 80 | from 0.75 to 1.00 | 0,024 |
| from 80 to 100 | from 1.00 to 1.25 | 0,026 |
| from 100 to 150 | from 1.25 to 1.50 | 0,028 |
| from 150 to 200 | from 1.50 to 2.00 | 0,030 |
| from 200 to 250 | from 2.00 to 2.50 | 0,032 |
| from 250 to 300 | from 2.50 to 3.75 | 0,036 |
| from 300 to 375 | from 3.75 to 5.00 | 0,040 |
Rice. 6.3. The stiffness of cardboard is determined by the modulus of elasticity (Young's modulus), the length of the fibers and the cross-section of the sheet. Single fibers of wood pulp have an elastic modulus of about 500,000 psi (pounds per square inch) (3.448 MPa). Since most of the fibers are parallel to the paper's casting direction (longitudinal direction), the stiffness is higher in this direction. As the sheet thickness increases, the moment of inertia increases in proportion to the square of the distance from the center of the sheet to its outer surface. Consequently, the rigidity is determined to the greatest extent by the outer layers
Rice. 6.4. When packaging bulk products in large boxes, their walls are deformed and swell under the internal pressure of the contents. The most important factor is the side area. The graph shows that increasing the thickness of the cardboard only slightly reduces the swelling of the walls
One of the requirements for a folding cardboard box is its attractiveness to the buyer, but there are other factors to consider. First of all, you should consider the method of displaying products. The packaging must be stable and not fall off the store shelf. The front side of the box should look good even when there are many boxes displayed on the shelves in the retail chain. It is necessary that the packaging size (compared to the size of the product) is substantial, but does not mislead the consumer. In Fig. 6.6 shows an example of a cardboard box for a soft tube, how to determine the most suitable size for it.
Rice. 6.5. During transportation, the cardboard box is mainly affected by compressive forces. The graph shows how the strength of cardboard increases as its thickness increases. As an example, consider the maximum load (in pounds) from top to bottom that a cardboard box measuring 210 x 76 x 279 mm can support
The size of the cardboard box should correspond to the standard height of the shelves in the store. If in a retail chain the product in question is usually hung on consoles, then the box must be equipped with a hanging loop or one of the sides must be extended and a hole of the appropriate size must be made in it. It should be easy for the consumer to take the packaged product from the shelf and hold it in his hands. A heavy cardboard box can be equipped with a handle cut from the same ream. A window on the box, through which its contents or a high-quality image of the packaged product can be seen, can help ensure a good level of sales.
Changes are also taking place in the placement of packaged products on store shelves. For a long time, in retail, cardboard boxes were positioned (and printed accordingly) where possible with the consumer facing outwards and upwards, thereby drawing more attention to the product on display. Sometimes the box is designed to be placed horizontally on the shelf (the reason may be that the product looks better in this case, or sometimes the possibility of stacking the boxes in two layers), and it even happens that savvy packaging designers use a ready-made type of box used by some or another company for vertically displayed products. But at the same time, the variety of products offered in stores, especially supermarkets, is increasing, and many store managers prefer a smaller front area, as this allows more products to be displayed on the shelf. There is constant competition for shelf space.
The use of fifth-sided boxes should be approached with extreme caution. They are really effective in terms of drawing attention to the product on the shelf, but they require more cardboard to produce and can create problems on the production line and when packed into shipping crates. At the same time, such boxes may be absolutely necessary for packaging small items that otherwise risk simply going unnoticed.
Rice. 6.6. Bristol-Lund formula (Bristol-Lund) used to calculate the most suitable size of cardboard box for a soft tube (in this case, as a rule, the rule about the inadmissibility of packaging that creates misconceptions about the product is also observed)
In some cases, to prevent petty theft, it is necessary to make the box large enough that it cannot be hidden in the hand or placed inside another box. For the same reason, it is preferable to glue the flaps of the box, since otherwise the thief will be able to remove the product and return the empty packaging to the shelf.
The good appearance of retail packaging is determined by the strength of the box itself, the quality of the cardboard used and the type of printing. It is not advisable to save by using lower quality material, which will quickly lose its presentation.
Once marketing considerations have been taken into account, further decisions about the choice of materials and box design should be made based on consideration of the packaging's purpose and cost requirements; the analysis of individual aspects should be carried out in stages.
Since different mills produce different types of board, it makes sense for the packaging engineer to first determine the marketing and technical requirements for the box being developed, and then select the type of board that best meets them.
Rice. 6.7. Under the influence of weather conditions and storage conditions, the strength of cardboard can be halved
Next, you need to find out whether this material will be available in the required quantity and within a certain period of time. For example, heavy grades of waste paperboard with a thickness of more than 30 points (0.8 mm), as well as especially heavy grades of solid bleached sulphate board, are gradually being phased out. (SBS) currently used only for the production of milk cartons. Other materials, such as 10-point (0.25 mm) cardboard and corrugated profile cardboard E And F(which is sometimes used to make heavy-duty folding boxes) may be very difficult to obtain in some areas. Another factor is weather conditions. For example, the rigidity of boxboard and the strength of the box are affected by humidity (Fig. 6.7).
If recycled cardboard is selected, the packaging technologist should also consider the costs of printing the waste cardboard and making boxes out of it, and also consider the possibility that the productivity of the packaging equipment will be lower as quality decreases at higher speeds. In addition, chipboard may not be strong enough to produce some complex designs, such as end clamps and pull-tab clamps. As a result, you may find that a thicker grade of recycled paperboard may be required to provide the required packaging performance, but this will require you to transport heavier loads and use larger shipping boxes.
In cases where it is expected that packaging operations will be carried out manually or on semi-automatic equipment in the near future, it is advisable to evaluate the long-term prospects and determine whether a transition to automatic equipment will be made in the future. For example, a box with a locking latch on the bottom is ideal for manual loading and cannot be closed using automatic equipment. Operational cards should be developed, packaging and packaging equipment parts should be designed in such a way that when switching to more complex technologies, there is no need to replace die-cutting dies and printing forms, and especially all the packaging equipment used.
Cost is always an important consideration and is largely determined by the choice of design and type of material used. As a rule, any improvement in the characteristics of cardboard or improvement in the appearance of its surface leads to an increase in cost. This is where a packaging technologist can provide important assistance to the marketing department when decisions are made about product packaging. There are no immutable rules here, and the final choice is made on a compromise basis. Using the data in table. 6.3, a decision can be made as to whether to use cardboard with inner layers made from recycled materials or consisting entirely of virgin fibres.
Table 63. Comparison of the characteristics of cardboard made from virgin material and cardboard with inner layers of another (recycled) material
| Characteristics | Solid bleached sulphate board | Cardboard with inner layers of recycled fibers |
| Wall deformation (swelling) | When opening the box, the walls are deformed due to less rigidity in the longitudinal direction | Higher longitudinal rigidity |
| Rilevka | The scoring lines are held securely | Scoring lines lose shape over time |
| Creep | Low creep rates; Less fatigue when compressed | High creep rate; greater fatigue when compressed |
| Gluing | Requires expensive synthetic glue | It is acceptable to use inexpensive dextrin glue |
| Uniformity of processing | More uniform machining | Processes less evenly |
After all these issues have been considered, an important factor such as economic efficiency is taken into account. Although sustainability has received a lot of attention lately, most packaging experts agree that the choice is always made in favor of the most functional and most cost-effective option.
The packaging designer needs to collaborate with the designer of the manufacturing company that supplies the boxes. Recently, there has been a desire to determine technical characteristics by mutual agreement between the supplier and the customer; The box development plan is also made acceptable to both parties. Material suppliers and packaging manufacturers know that this takes a lot of time, but the effort is well worth it.
The main points that need to be indicated in the technical characteristics of folding cardboard boxes are:
- dimensions;
- materials used;
- scoring scheme.
Dimensions are always given in the following order: length, width, depth; they are measured from the middle of one scoring line to the middle of the other. Length is measured along the hinge joint of the lid, width is measured from the hinge joint to the fold flap, and depth is measured parallel to the adhesive flap. In the case of a complex structure, it makes sense to provide a detailed diagram.
It is necessary to accurately indicate the thickness of the cardboard, its density, coating and gloss. The characteristics of both the front and back surfaces are given, for example: white cardboard with machine coating, gray cardboard, kink-resistant box cardboard, etc. The type of printing must also be indicated. All colors and shades must be designated using standard coding systems or presented as samples; in addition, permissible deviations from established standards are indicated. If it is necessary to use glossy paints or varnish the entire surface of the box or its individual sections, this should be indicated in the technical specifications. It is necessary to specify in detail which sampling methods will be adopted, as well as the level of quality required during acceptance inspection.
When developing a specific package, first of all, you should establish the internal dimensions of the container, determined by the size of the packaged product. The length of each size is increased slightly - typically by 1/32 to 1/16 inch (0.8 to 1.6 mm) - to provide clearance between it and the box. Then the thickness of the cardboard is selected; the most commonly used material is 18 and 20 point thick (0.457 and 0.51 mm). To ensure that the selected dimensions are correct, it is advisable to make a packaging sample at this stage.
Most large carton manufacturing plants, and even some packaging plants, have a design office; Job
carried out on a computer. Using a computer-aided design system and a graphics tablet, a diagram of the critical points of the box drawing is made, which are then entered into the database. The computer then connects these points with lines. A plotter is connected to the computer, which transfers the resulting drawing onto a sheet of cardboard or vinyl plastic. If the image is applied to cardboard, then using the same plotter the scoring and cutting of the workpiece can be carried out in strict compliance with the technical conditions. The sample is then evaluated by both the packaging plant and the box supplier and receives their approval.
If the plotter plots the image on vinyl, then the layout can be printed on transparent polyester film, which is then used as a mounting sheet to ensure the correct placement of the images in relation to the box parts.
In small packaging plants, it is preferable to make samples by hand. The cardboard fibers are almost always horizontal, that is, they run around the sides of the box, perpendicular to the main scoring lines; This direction of the fibers helps avoid warping (bulging) along the top edge and helps the main sides remain flat (Fig. 6.8).
To make a sample box, the development is cut along the outline with scissors or a knife, and scoring lines are applied by laying the blank face down on a long piece of scoring ruler, which can be provided by the box supplier. This steel ruler is mounted on a wooden stand with the rounded edge facing up. The workpiece is pressed against the scoring ruler from above using a block with a forked surface, which is drawn along the cardboard along the lines drawn with a pencil. The block is made from hard wood; a groove 1/16 inch wide and 1/32 inch deep (1.6 by 0.8 mm) is made on its end surface. In this way, a roller is formed along the scoring lines, breaking the rigidity of the boxboard in this area, making it possible to make neat folds (see Fig. 6.9).
Rice. 6.8. Cardboard fibers most often run in the direction around the box, perpendicular to the main scoring lines. Thanks to this, the material has greater rigidity in the interval from one scoring line to another. Folded edges provide rigidity in the opposite direction
Rice. 6.9. The cardboard is bent in the direction from the scoring line. The roller formed using the groove of the scoring and die-cutting press breaks the bond between the layers of paper. When the sheet is folded, the cardboard at the fold line delaminates and protrudes outwards in the form of a bead, thereby reducing the stress on the outer layer of cardboard. If this did not happen, the outer surface would rupture
Rice. 6.10. Basic dimensions (in inches) based on the development of a typical folding box. There are no general standards, and the number of varieties produced is quite large
Further, if we are talking about a glued box, then regardless of how the sample was made, the workpiece is folded, glue is applied, and then the box is laid flat under the load and held until the glue dries. Provided that the cutting and scoring are carried out correctly, the sides should be exactly at right angles to each other, and the flaps that form the end walls and secure them are inserted into the slots or positioned in the required position without unnecessary friction. In rare cases, edges may need to be trimmed or new scoring lines applied to ensure a more correct fit. This sample can then be used to check whether the originally chosen dimensions of the box are suitable, that is, whether the contents are positioned as intended. The most common sizes can be found in Fig. 6.10; The exact terminology for describing the parts of a cardboard box is given in Fig. 6.11.
If the type of boxes being tested are intended to be processed on automatic equipment, then it is necessary for the box supplier to produce a die-cutting die. A minimum of 500 samples should be made, which are glued together using an industrial gluing machine; they are tested on box production equipment. Samples are not required to be printed, but they must be made from the appropriate material.
Rice. 6.11. To ensure mutual understanding with supplier companies, parts of folding cartons should be named correctly
Nowadays, a growing number of different software applications are available, and box images are increasingly being prepared on a computer. When using a computer-aided design system, the development of the box design can be carried out in conjunction with the work on the printed image, and thus the entire package is immediately developed in accordance with the exact specifications. However, computer printouts should not be used as a reference for color selection when printing. The proofing system used to validate the print sample and ink used should be as close as possible to the selected printing process technology, as printing methods vary widely.
In small businesses and printing houses where packaging is made by hand, a printed test sheet is prepared. This stamped sheet allows you to check whether the stamp is positioned correctly on each side of the cardboard box.
Cardboard boxes should be packed in strong shipping crates with approximately 15% free space to avoid damage to the notched folds. If the boxes are packed too tightly, the opposite sides will be pressed against each other, when it is preferable for them to curve outward slightly, as this makes it easier to open the box before packaging. It is preferable to pack small boxes on trays, but in large boxes the contents can simply be separated with sheets of cardboard. All boxes in the stack must be stacked in the same direction, which is especially important if the assembly will be carried out using automatic equipment. Transport boxes for these purposes are usually made from corrugated cardboard; they must be strong enough to withstand stacking heights of 5 to 6 feet (1.5 to 1.8 m) without deformation. It is not advisable to store glued and assembled boxes for more than 6 months, as the cardboard may warp or harden.
It's 2012 outside the window. New Year's holidays are over. But doesn't the symbol of 2011 look like the Easter bunny?
New Years is soon! And if you need to give a lot of gifts c, this article will be interesting to you.
because it contains the most diverse New Year's boxes))
You can put any little thing in these (like candy or cookies) to make a nice warm gift!
It seems like a little effort, but the gift is handmade and pleasant.
Find out what else you can put in a small box at the end of the article.
Let's see!
By the way. We recently printed several boxes here and I’ll tell you, a gift in a box looks much more interesting than one packed in paper.
Maybe just because it’s unusual))
Since 2011 is considered the year of the rabbit, let's start with rabbits!
Source ,
download printable box template
and here is another rabbit - a funny gift box with long ears:
Source ideem, download outline vector template
(to download, check the box next to "I have read and accepted" Ideam's Terms of use.")
Photos, templates can be downloaded in vector and jpeg
but here is a more complicated box:
Photo by ustamp4fun, download template
Photo donteatthepaste, download outline template or
* * *
and this is actually not quite a box...
But if you wish, you can use it exactly like this:
All! While the hares and rabbits are over, let's go through the rest of the characters))
Gift box "Snowman"!
Photo by dianaevans, download template
another one:
Christmas tree box:
Photo rubberstamping, download template
and now a small selection of pyramidal boxes.
Such boxes look very advantageous and can also serve as Christmas tree decorations:
Photo accucut, you can download the template
Photo by polkadotprintsstudio, you can download the template
Photo mariestamps, you can download the template, watch the lesson
Photo rubberstamping, you can download the template
And in the year of the rabbit it’s good to give gifts in carrot boxes))
What's the main thing in the new year? So that there are enough carrots! And carrots are something different for everyone:
luck, happy occasions, romantic encounters, money or something else))
and here is another package, which (as Nastya suggested in the comment) is well suited for carrots
And finally, the funniest thing, otherwise we are all about rabbits and Christmas trees...
What do you think of the idea of giving a gift in a hat box?
Or number all the gifts, put leaves with numbers in a hat and invite guests to pull them out))
Or arrange a New Year's fortune telling, as described at the beginning of this article))
or make a hat and get gifts from it for everyone...
In general, what an idea! Rich!
The source was given in a jar, you can also give it in a box,
having previously poured it all into a transparent bag
and as always ( if you like surprises) photo of any large gift (along with instructions on where to look for it)
can be rolled up and hidden among candies small box!
Enjoy your gift-giving and have a good New Year's mood!
Based on the type of assembly, cardboard boxes are divided into 2 main classes:
Fully assembled cardboard boxes(the unfolding of the entire package represents a single whole)
Typical examples of this type of packaging are:
- packaging for various electronic devices,
- cameras,
- spare parts for cars.
Cardboard box type<крышка-дно> (packaging unfolding consists of 2 parts: lid unfolding, bottom unfolding).
An example of this type of box is:
- chocolate box,
- cake box.
By design, cardboard packaging is also divided into 2 main classes:
1 - self-assembled cardboard boxes(assembly without glue)
Most often, the assembly of boxes of this type and the packaging of goods in them is done manually.
2 - glued cardboard boxes(with 1,2,3 or more gluing points). The assembly of this type of boxes and the packaging of goods in them can be carried out manually and on special conveyors.
Glued cardboard boxes can be flat-folded (packaging of this type is delivered flat)
The most typical examples of such packaging
- packaging for medicines,
- tea cardboard packaging,
- pizza.
Rigid glued: boxes of this type after gluing have a three-dimensional appearance; most often gluing of such boxes is done either on special machines or manually.
A rigid glued box, for example, is packaging for washing powder.
The packaging may have several locks:
Necessary information to calculate the cost of packaging
1. Purpose of packaging;
2. Packing size (mm);
3. Development of the package (disassembled perimeter size) mm;
4. Number of gluing points; in the case of single-point gluing, the length of the side gluing (mm);
5. Circulation (copies);
6. Brand of cardboard indicating density or thickness;
7. Colorful printing (CMYK, Panton, silver, gold);
8. Varnishing - selective or continuous. Type of varnish - offset, UV varnish;
9. Indicate availability<Заказчика>:
9.1. Packaging (design) or layout file;
9.2. Box or layout design file;
9.3. A set of photographic films with a die-cut layout;
9.4. Stamping form (stamp).
This bag box is very suitable for small gifts and souvenirs, for example, cosmetics or handmade soap. This is also a good option for use as a bonbonniere at a wedding. Finished size including handles 120*80*40 mm.
For this box, I have prepared several files with templates, which you can download from the forum on our website (link at the end of the article). Once you have downloaded and unzipped the files, you will find 4 files in the folder that will help you make these cute boxes.
File called Package-bw.jpg can be used by owners of a black and white printer. This file contains a diagram of the box, which you can print on a regular A4 sheet, cut out and transfer to the colored paper from which you want to make the box. If possible, you can print this template directly on a sheet of colored paper from the wrong side (if the paper is A4 size).
For owners of a color printer and Photoshop, I have prepared special templates with which you can print ready-made color scans from the front and back sides, and then make boxes from them. Those. To do this, you only need thick paper for printing on a printer. I recommend using Lomond or Fora paper with a density of at least 180 g/m2. I use Lomond paper (matte single-sided with linen texture, 230g/m2). The files are called Package-layers-1.pdf, Package-layers-1.pdf, Package-layers-1.pdf, i.e. three developments for the boxes that you see in the photographs.
I’ll tell you in more detail how to print these scans correctly. Those who have color printers are well aware of the problem with refilling cartridges with color ink. And for those who do not have a CISS (continuous ink supply system), this becomes a whole problem. Therefore, you need to print in such a way as not to waste ink.
Thus, it is necessary to print the scan on one side and the other so that they coincide. It is very difficult to achieve an exact match, so I made the front side unfold a little wider than the back side.
So, I will describe step by step what needs to be done and how to do it for those who have never worked in Photoshop.
1.
Open any of the three files, for example Package-layers-1.pdf. If you don't have the Layers panel open, press F7. In the "Layers" panel you see two layers, in the "background" there is a pattern for the back side, on "Layer 1" - for the front side.
2. First, print the front side of the scan by inserting a sheet of paper into the printer with the front side and selecting the “File-View and Print-Print” tab from the menu. Be sure to note which edge you inserted the paper (mark with a pencil on the edge).
3.
By clicking on the “eye” button, marked in the picture with a red circle, we make the layer with the front side inactive, and the layer with the back side becomes visible.
4. Now we print the wrong side of the development. But first you need to turn the paper over and insert it into the printer with the same edge. And be sure to display the image horizontally. To do this, go to the menu “Image-Rotate canvas-Display canvas horizontally”.
5. We print the reverse side by clicking in the menu "File-View and Print-Print". That's it, our scan is ready. All that remains is to cut it out, crease the dotted lines and bend them. Glue the box together and, if desired, make the holes marked on the template.
Despite the intensive growth in the use of polymers in packaging production, cardboard and corrugated cardboard continue to be one of the most widely used packaging materials. A variety of folding boxes and crates made from these materials are currently the most common types of packaging. Their advantages include:
- low cost;
- wide range of standard sizes and designs;
- high manufacturability using highly automated equipment;
- the possibility of high-quality design using various printing and finishing technologies;
- high technology of assembly and filling with products;
- high technological efficiency of transportation and storage both in a filled and empty state: boxes made of cardboard and corrugated cardboard are collapsible containers, which allows you to significantly save space when storing and transporting empty boxes.
Today, cardboard boxes are widely used for packaging food, tobacco products, medicines, perfumes, household chemicals (washing powders), household appliances, shoes and other types of consumer goods.
Cardboard is usually used to make the inner or outer packaging of a product. Corrugated cardboard is usually used for external and transport packaging.
Design of cardboard and corrugated cardboard boxes
When developing the design of boxes made of cardboard and corrugated cardboard, it is necessary to take into account the characteristics of the products being packaged, the physical and chemical properties and price of the packaging material, as well as other factors.
The box design process usually includes the following stages:
- determination of the main characteristics of boxes: type and thickness of material, shape and overall dimensions;
- choice of printing and finishing methods;
- design of box development (cutting);
- testing of a sample box and its approval with the customer.
Material selection
When choosing a material, the following factors are taken into account:
- protective properties of the packaging material (mechanical strength, moisture, grease and gas resistance, etc.);
- technological properties of the packaging material (sealable properties of the material, manufacturability of processing in machines for the production of containers, for example, suitability for gluing and welding, manufacturability when packaging goods);
- material price.
The material of the box must ensure stability of its shape during operation, which determines the quality of the container’s protective and logistics functions, in particular the box’s ability to protect goods from damage and loss, its suitability for stacking
etc. The shape stability of a box depends on its design and the mechanical characteristics of the material from which it is made.
The mechanical characteristics of cardboard and corrugated cardboard are determined by the following factors:
- material thickness;
- fiber orientation for cardboard and direction of corrugations for corrugated cardboard;
- moisture content of the material.
The thickness of the material is selected depending on the volume of the box and the weight of the product that will be packaged in it. As the volume of the box and the weight of the product increase, the required thickness of the material increases.
When designing boxes, it is necessary to take into account that cardboard and corrugated cardboard differ in anisotropy of mechanical properties along the length and width of the sheet (web). In the machine direction, the strength and rigidity of the cardboard sheet (web) is higher than in the transverse direction. As the cardboard thickness increases, the difference between the mechanical properties of the material in the machine and transverse directions increases. The mechanical properties of corrugated cardboard similarly depend on the direction of the corrugations.
Ambient humidity has a significant influence on the properties of cardboard and corrugated cardboard. These materials are characterized by fairly high hygroscopicity, and when moisture is absorbed, their mechanical properties deteriorate significantly. To protect boxes from moisture, a protective coating can be applied to their surface.
Determining the shape and overall dimensions of the box
When determining the shape and overall dimensions of the box, the following requirements are taken into account:
- minimizing material consumption;
- compliance of the shape and size of the box with logistics requirements;
- manufacturability of the design of the box for assembling and packaging goods;
- convenience of the box for the consumer;
- attractive appearance.
When determining the shape and overall dimensions of the box, it is necessary to take into account the practice of their unification. The unification of cardboard containers by size and design serves to rationalize its production, transportation and storage. Unification of cardboard boxes helps reduce the costs of their development and production, and facilitates the organization of serial and continuous production on high-performance automated equipment. The costs associated with packaging goods in boxes, transporting, storing and selling packaged products are also significantly reduced.
The unification of containers by standard sizes is based on a modular system, which is based on the dimensions of group transport packaging (modular packaging) regulated by standards: pallets and containers. Currently, standard pallets for rail transport have dimensions of 800x1200 and 600x1200 mm; for sea transport, the ISO standard recommends pallets of 1000x1200 mm. The dimensions of modular packaging today are decisive when designing loading and unloading and transport vehicles, calculating the areas of warehouses, store shelving, etc.
To take advantage of the benefits of packaging unification, the overall dimensions of the boxes must be a multiple of the dimensions of the modular packaging.
An important requirement for cardboard boxes is their suitability for use with automated packaging equipment. The design of the box must provide for the possibility of its automatic assembly with subsequent packaging of goods into it and the formation of group modular packages.
Selecting printing and finishing method
High-quality printing design compensates for some monotony of standardized packaging, helps to attract the attention of buyers and thus stimulates the growth of product sales.
The choice of printing and finishing methods is determined by the properties of the box material and its purpose. Naturally, the design of consumer packaging is subject to much higher requirements than the design of transport packaging. However, due to the fact that recently in self-service stores goods are displayed on the shelves, including in transport containers, the quality of the packaging of the latter has also become of great importance.
* Symbols developed jointly by the European Federation of Corrugated Box Manufacturers (FEFCO) and the European Association of Corrugated Cardboard Manufacturers (ASSCO).
Test methods for corrugated cardboard boxesFEFCO has developed a series of tests to determine the important performance characteristics of corrugated packaging. Compressive Strength Test of Empty Corrugated Cardboard Box The test is carried out using a special test To perform the test, you need a device for determining the compression force, providing an error of no more than 2% of the measured value, as well as a measuring ruler with an error of ± 1 mm, or no more than 5% of the measured value. Before testing begins, the cardboard box is placed on the bottom plate and aligned with its center. The spatial orientation of the box is determined based on the test task. To accurately position the box on the plate, appropriate markings must be made. After turning on the mechanism for moving the plate(s), the box is subjected to compression. The test should be completed before the box is completely destroyed. The compressive resistance value (expressed in Newtons) is measured at three points. After the test is completed, a protocol is drawn up, which indicates information about the packaging, machines and devices used during testing, test conditions, and also records the results obtained. For boxes consisting of several parts (for example, telescopic), the test should be carried out for each part in turn, after which the results are summed.
Drop test of corrugated cardboard box The test is designed to test the strength of a box with goods packed in it to impact loads that occur, for example, when it falls. The test results also allow us to determine the quality of the box’s function of protecting the product. The test consists of simulating the free fall of a box with a product packed in it onto a horizontal surface. The drop height and spatial orientation of the box are determined based on the test task. Drop height is measured as the shortest distance from the bottom of the box to the surface on which it falls. To describe the spatial orientation of a box, indicate which side, edge, or corner it hits. If the blow falls on a side face or corner, they are designated by the numbers of the sides that form them. The surface on which the box falls must be flat and hard, its deformation as a result of the impact of the box must be negligible. To carry out the test, it is recommended to use a special installation that allows you to fix the box at the required height in a certain position and then ensure that it falls down without giving it acceleration or rotational impulse.
Corrugated cardboard box stability testto low frequency vibrations The test is designed to test the resistance of a box with a product packed in it to low-frequency vibrations that occur, for example, during transportation. The test can be carried out for either a single box or a stack of boxes. The amplitude and duration of the vibrations, as well as the spatial orientation of the box, are determined based on the test task. To describe the spatial orientation of the box, the same notation is used as in the drop impact test (see above). To carry out the test, it is necessary to use a vibration installation. The box is placed on the vibrating machine table, which must have a horizontal, smooth and hard surface. The drive mechanism of the vibration unit must provide table vibrations with the ability to adjust the frequency and amplitude in the range of 2-7 kHz and 5.0-12.5 mm, respectively. After the test is completed, the condition of the box and its contents are checked. Detected damage is measured and recorded in the protocol. Information about the packaging, equipment used in testing and test conditions is also provided. Impact resistance test of corrugated cardboard box The test is designed to test the strength of a box with a product packed in it to impact loads. The test results also make it possible to determine the quality of the box’s performance of the product protection function. The test consists of simulating the impact of a box with a product packed in it on an inclined surface.
To carry out the test, a setup is used that includes a trolley moving on rails on which the box is placed. The rails must be laid on a special platform at an angle of 10° to the horizontal. At the lowest point, the rail track ends with an inclined wall, forming an angle of 90° with its plane. After installing the box, the trolley, under the influence of gravity, descends down an inclined rail track. As the cart approaches the bottom point of the path, the box hits a plate mounted on the wall. The surface of the slab must be smooth and hard, its deformation as a result of the impact must be negligible. The test setup must be equipped with a device to secure the cart before starting the test at a predetermined distance from the wall, depending on the required speed of the cart with the box. The speed of the cart and the spatial orientation of the box are determined based on the test task. To describe the spatial orientation of the box, the same notation is used as in the drop impact test (see above). At the end of the test, the condition of the box and its contents are checked. Detected damage is measured and recorded in the protocol. Information about the packaging, equipment used in testing and test conditions is also provided. Determination of the strength of the hinge joints of the boxfrom corrugated cardboard The test is carried out on a rectangular test sample cut out of a box using a special test device, which is a mechanical or hydraulic press with a sample fastening device and a V-shaped pressing head. The pressing head must be driven to move at a speed of approximately 12.5 ± 2.5 mm/min. The test device must be equipped with an instrument to measure the force exerted by the head on the test piece. When testing, a test sample with a width of at least 150 mm is fixed in the installation so that its sides form an angle of 90°, and the hinge joint is located under the rib of the V-shaped head. Moving down, the head puts pressure on the hinge joint. The test allows you to determine the maximum tensile strength of a hinge joint. At the end of the test, a protocol is drawn up, which indicates information about the test sample and the hinge joint, the equipment used in testing, the test conditions, and also records the results obtained.
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Design of box development (cutting)
After selecting the material, determining the overall dimensions and shape, a development is developed - a technological drawing of the workpiece from which the box will subsequently be assembled. The development should depict the outer (sealed) side of the box and reflect the features of the technological process of its manufacture and assembly.
Elements of the box layout can be divided into main and auxiliary elements. The main elements include the side walls, as well as the bottom and lid of the box. Graphic and text information can be applied to the main elements of the scan during its manufacturing process. Auxiliary elements of the development - various valves - are used to fasten the main elements when assembling the box.
The designations used in the box layout drawings are given in the table.
The layout must indicate the overall dimensions of the box. According to established practice, when describing a box, its overall dimensions are indicated as follows:
Length (L) x Width (B) x Height (H).
Dimension values are determined by measuring the dimensions of the main elements of the scan as the distance between the scoring lines. Measurements should be made under standard climatic conditions: temperature 23 °C and humidity 50%.
For telescopic boxes, which are widely used, for example, for packaging shoes, in addition to the three overall dimensions indicated above, it is necessary to provide the height of the upper part (removable lid). In this case, the designation of overall dimensions is as follows:
Length (L) x Width (B) x Body Height (H)/Lid Height (h).
The fourth size must also be specified for boxes with overlapping external flaps. In this case, the size of the overlap area is given:
Length (L) x Width (B) x Body height (H)/Overlapping area (o).
To facilitate the design and production process of boxes, their main types are standardized.
In Europe, the most widely used standards are those developed by the European Cardboard Manufacturers Association (ECMA) and the European Federation of Corrugated Box Manufacturers (FEFCO).
According to the ECMA classification, boxes are divided into the following groups:
- group A - rectangular boxes with adhesive fastening;
- group B - rectangular boxes secured with locks of various designs;
- group C - non-rectangular boxes with adhesive fastening;
- group D - non-rectangular boxes secured with locks of various designs;
- group E - boxes that are in direct contact with the product being packaged or intended for group packaging;
- group F - boxes whose designs are not included in others
groups.
According to the FEFCO classification, boxes are divided into six more groups:
- group 02 - boxes assembled from one development and closed with valves. When assembling such boxes, adhesive fastening, sewing with staples, and also fastening with adhesive tape can be used;
- group 03 - boxes of telescopic design, assembled from several parts;
- group 04 - boxes assembled from one pattern, fastened with locks of various designs;
- group 05 - boxes, as well as parts of boxes that are closed by mutual movement of structural elements;
- group 06 - boxes assembled from three blanks: a body and two side walls;
- group 07 - boxes assembled from one development, with adhesive fastening.
Group 09 combines internal liners, bottom sheets, partitions and other internal parts of boxes.
CAD systems have found widespread use in the design of developments.
Final design stages
After developing the blank drawing, a sample box is made, which is agreed upon with the customer. The sample can be subjected to tests during which the loads that arise during operation of the box are simulated. Based on the test results, the material may be changed or the box design may be adjusted.
After approval of the box design, another sample is made to coordinate the printing design of the box with the customer.
An important stage of the technological process is the development of an optimal layout of box blanks on a sheet of cardboard or corrugated cardboard. The sheet format depends on the characteristics of the printing and finishing equipment. Optimizing the layout allows you to reduce the cost of the box by reducing material waste and increasing process productivity. The quality of the layout is characterized by the material utilization coefficient, calculated as the ratio of the total area of the workpieces to the area of the sheet.
When positioning blanks on a sheet, it is necessary to take into account the orientation of the fibers or corrugations of the material, and also try to ensure uniform distribution of pressure during printing and stamping.
Technology for manufacturing boxes from cardboard and corrugated cardboard
The process of producing boxes from cardboard and corrugated cardboard includes the following technological operations:
- seal;
- finishing;
- dancing;
- assembly.
Seal
Offset, flexographic and screen technologies are most often used for printing on cardboard and corrugated cardboard. Sheet corrugated cardboard is typically printed on sheet-fed offset or flexo presses. Both sheet-fed offset and roll-fed flexographic machines are used for printing on cardboard. Screen printing is most often combined with offset or flexographic methods, expanding the technological capabilities of the printing process.
Decorative and protective finishing
Finishing of cardboard packaging allows you to diversify the design and improves its operational functions. The most popular finishing methods include: varnishing, film pressing (lamination) and hot foil stamping.
Varnishing- the process of applying varnish compositions to the surface of a material, which, when dry, form smooth transparent films that improve the appearance of the product and perform a protective function. Rotary printing machines are used to apply varnish; varnishing is performed in the non-printing section of the printing machine or on specialized equipment.
Pressing the film- the process of creating a transparent polymer coating on the surface of a material, which primarily performs a protective function. Film pressing can be done on sheet and roll laminators using different types of adhesives.
Hot foil stamping- the process of transferring metallized or colored film to a print under pressure and high temperature. Hot foil stamping is an effective design technique and also helps to increase the degree of protection of products from counterfeiting. For hot foil stamping, crucible, flatbed and rotary presses are used. In practice, converted letterpress printing machines are often used for foil stamping.
Finishing operations are performed both on production printing and finishing lines and on operating equipment.
Dancing
Punching is a complex of technological operations that ensure the formation of structural elements of boxes. The quality of stamping determines the accuracy of the geometric dimensions of the box, their strength and durability. During the stamping process the following operations can be performed:
- cutting out the outline of the box;
- scoring of fold lines on the development;
- perforation;
- Ritsovka.
Die cutting designed to give box blanks the required configuration. Tools for cutting are flat or rotary die knives. Die-cutting is performed on crucible, flat-bed and rotary presses. In small-scale and individual production, so-called shuttle devices are widely used, in which a stamp with a workpiece laid on it is rolled through a rotary printing pair.
When producing boxes from corrugated cardboard with a rectangular layout, you can do without die cutting, since in this case the slots for forming the box flaps can be made on special cutting machines - slotters.
Creasing- applying fold lines to the material in the form of extruded grooves, along which folding will be carried out in the future. Creasing is designed to reduce the rigidity of the material along the lines of future folds. The scoring tools are a scoring knife and a scoring matrix. Creasing can be either flat or rotary.
Perforation- cutting a chain of small holes. It can serve to facilitate folding by removing excess material from the fold. Typically, perforation is performed with a serrated disk knife.
Ritsovka- an incision on the surface of the material. Ritzing is done in the places where the box parts are glued together. Thanks to the penetration of glue into the cut, an increase in the strength of the adhesive bond is achieved.
After stamping, the opening of the box remains connected to the sheet by jumpers, therefore, to completely separate it, the flash removal operation is performed automatically or manually.
Assembly
After removing the flash and separating the box blanks, they can either be packaged and sent to the customer, or they can be assembled.
Assembly consists of folding the box and fastening its parts, that is, folding a three-dimensional box from a flat blank and fixing its shape. For fastening box parts, the most widely used methods are the adhesive method, which can be easily automated, and mechanical fastening using locks of various designs.
Folder-gluer lines are currently used for automated box assembly.
As already noted, in the production of cardboard and corrugated cardboard boxes today, various automation tools are widely used. When designing boxes, CAD is used, at different stages of the technological process of manufacturing boxes, various production lines are used on which printing, finishing, stamping and assembly of boxes are performed. The use of highly automated lines can significantly increase productivity and reduce production costs. As a rule, such lines are highly flexible and allow the production of boxes in a wide range of standard sizes. The possibility of complex automation of the technological process of manufacturing boxes from cardboard and corrugated cardboard is an important advantage of this type of packaging and helps them maintain one of the leading positions in the packaging market.
