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 DEStech Pub li ca tions, Inc. 439 North Duke Street Lanc as ter, Penns ylv an ia 17602 U.S.A. Copy right © 2015 by DEStech Pub li ca tions, Inc. All rights res erved No part of this pub lic at ion may be re prod uced, stored in a ret rieval sys tem, or transm itt ed, in any form or by any means, elec tronic, me chani c al, phot oc opyi ng, rec ordi ng, or oth erw ise, witho ut the prior writt en perm iss ion of the publ isher. Printed in the United States of Ameri ca 10 9 8 7 6 5 4 3 2 1 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 HOW TO ORDER THIS BOOK BY PHONE: 877-500-4337 or 717-290-1660, 9AM–5PM Eastern Time BY FAX: 717-509-6100 BY MAIL: Order Department DEStech Publications, Inc. 439 North Duke Street Lancaster, PA 17602, U.S.A. BY CREDIT CARD: American Express, VISA, MasterCard, Discover BY WWW SITE: http://www.destechpub.com 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