Corrugated box design is a design factor matching process for corrugated fiberboard boxes with physical, functional, and functional end-use requirements. The packaging engineer works to meet box performance requirements while controlling the total cost across the system.
In addition to the structural designs discussed in this article, bar codes printed, labels, and graphic design are also important.
Video Corrugated box design
Function
Corrugated boxes are often used as shipping containers. Boxes need to contain products from manufacturing through distribution to sales and sometimes end use. The boxes provide some measure of product protection by themselves but often require inner components such as pads, supports and blocking to help protect fragile contents. The dangers of delivery depend heavily on the particular logistics system used. For example, boxes that are incorporated into the unit load on the palette do not experience individual handling while the boxes are sorted and sent through a part of their distribution cycle because the mixed load or express operator can receive shocks, kicks, etc...
Regular delivery containers require printing and labels to identify content, provide legal and regulatory information, and barcodes for routing. Boxes used for marketing, merchandising, and point-of-sale often have high graphs to help communicate their content. Some boxes are designed to display the contents on the shelf. Others are designed to help get rid of the contents. Popular for its strength, durability, lightweight, recyclable, and cost-effective, corrugated boxes are used for the delivery of various items. Due to the quality and safety of packaging goods in corrugated boxes, they are widely used in the food industry. The boxes handle the pressure that comes with the stack, making it ideal for easy transport.
More than 95% of all products in the United States are shipped in corrugated boxes. Corrugated paperboard accounts for more than half of all recycled paper in the US.
String strength
One important function of the corrugated box is to provide hatch resistance (product protection) and adequate strength to accumulate in the warehouse.
Boxes can be designed by optimizing corrugated board level, box design, flange direction, and internal support. Support from the product also provides "load sharing" and can be an important factor. Closing the box can sometimes have an effect on the stacking strength of the box.
If long-term storage of corrugated boxes in high humidity is expected, extra strength and moisture resistance are required.
The method of loading the boxes on the palette greatly affects the buildup. Vertical columns provide the best box performance while interlocking box patterns significantly reduce performance. Box and palette interactions are also important.
The box compression test is a means to evaluate boxes, stack boxes, and load units under controlled conditions. The stacking and dynamic compression field conditions do not have the same level of control. Compression strength can be estimated based on container construction, size, and usage parameters: actual packet testing is often done to verify these estimates.
Many packaging engineers find it useful to periodically audit the warehouse and visit the customer's receipt operation. When field performance is observed or documented has problems, a new design and testing cycle may be justified. for corrugated boxes to withstand deformation during accumulation or storage (pile load = compressive strength 1/3). where stack load = gross weight box * heap height.
Estimating compression
Fiber Box Association has a method to estimate the compression power that includes the following factors:
- Time
- Humidity
- Type of palettization
- Pattern palette
- Type palette
- Handling
Maps Corrugated box design
Process
Packaging engineers design corrugated boxes to meet the specific needs of shipped products, environmental dangers of delivery, (shock, vibration, compression, moisture, etc.), and the needs of retailers and consumers
Engineers and designers begin with specific project needs: cost constraints, machine capabilities, product characteristics, logistics requirements, applicable regulations, consumer requirements, etc. Often the design is made with a Computer Aided Design program connected to the automated sample creation table. Some design and construction options may be considered.
Samples are often sent to performance testing based on ASTM or other standard test protocols such as the International Safe Transit Association. The structural design is adapted to the graphic design. For consumer-based design, marketing personnel sometimes use Focus groups or more quantitative ways to assess acceptance. The test market is used for the main program.
The process begins by making corrugated boards on wavy lines, a long series of connected machines that may be in the size of a soccer field. The single piece of single wavy board is a single wavy layer flanked between two liners.
Skilled workers prepare job tickets for each stack of empty boxes and route the blanks to the fabrication machine. Dead printing and patterning are prepared on large, flexible, rubber or tin sheets. They are loaded onto rollers and empty boxes are inserted through it, where each is trimmed, printed, cut, printed, folded, and glued to form a box. The finished boxes are then stacked and sent to a milkfish machine to be wrapped and shipped.
Design
The most common box style is Regular Slotted Container (RSC). All flaps have the same length from score to edge. Usually the main flaps meet in the middle and the minor flap does not, except the width is equal to its length. Box styles in Europe are typically determined by a 4-digit code provided by the European Corrugated Steel Manufacturer Federation (FEFCO): An irregularly lined container is coded 0201.
The manufacturer's connections are most often combined with adhesives but may also be embedded or stitched. The box is sent flat (torn down) to the package maker who prepares the box, fills it out, and closes it for delivery. Closing of the box may be with tape, adhesive, staples, strapping, etc.
Many other styles of corrugated boxes and structures are available:
- FOL (Full Overlap): A Full Overlap Box is similar to RSC unless the main flaps are completely overlapped. Overflow full-overlap gives extra stacking power and edge protection.
- HSC (Half Slotted Container): Half-Slotted Containers (HSC) is similar to RSC, but with just one set of flaps. They are useful when the top open container is desired. HSC can be used to make a telescope box.
- A Complete Telescope Box has two fully telescoping sections. Parts can be formed by staples, cut keys, adhesives, etc.
- The Partial Telescope Box has two parts. The upper telescope partially covers the bottom. Commonly used for holding printed paper.
- Corrugated tray is often used for display purposes or used with shrink wrap
- Wavy corner bearings can be used for product support and cushioning
- The special die-cut shape has almost unlimited design and usage.
- etc.
Box size can be measured for internal dimensions (for the appropriate product) or external (for machine handling or palletizing). Boxes are usually specified and ordered by internal dimensions.
Sending individual blends
Many items are shipped separately (partially or completely) with express delivery, mail, or other mixed logistics systems. The demands of some manual handling, automatic sorting, and uncontrolled buildup in trucks or air containers put heavy pressure on boxes, sealed boxes, and contents. Boxes designed for the handling and storage of unit loads may not be suitable for mixed logistic systems.
Less than delivery of trucks makes more pressure on delivery of undulating shipments than shipping by uniform load of pallets in trucks or intermodal containers. Boxes sometimes need heavier construction to fit the needs of the distribution system.
Government, military and export
Many of the items supplied to the government are handled very well: boxes are put together, shipped in closed trucks or intermodal containers, and storage is in a warehouse. Normal "domestic box" and commercial packaging acceptable.
Military supplies, field supplies, and humanitarian aid often experience severe handling and uncontrolled storage. The special box specifications for government shipping often apply. Weatherproof fiberboard, box construction, closing box, and unitization are required.
Export
Many international shipments are handled very well: boxes are put together, shipped with closed trucks or intermodal containers, and storage is in the warehouse. Normal "domestic box" is usually used.
Break bulk cargo needs waterproof and heavy duty. Even deliveries originally delivered via intermodal freight transport may have subsequent logistical operations that are extreme and uncontrollable. Specific conditions in destination ports and usage countries need to be considered for export box design.
Dangerous and dangerous items
Delivery of dangerous goods or hazardous materials is highly regulated. Based on the UN recommendation on the Transportation of Dangerous Goods model rules, each country has a coordinated design and performance requirements for delivery. For example, in the US, the Department of Transportation has jurisdiction and requirements published in Title 49 of the Code of Federal Regulations. The corrugated box is described in the 4G requirements. Performance (weight loss test, etc.) Must be certified for boxes and content.
Some operators have additional requirements.
Closing box
How to close the box is an important aspect of the design. This affects the types of equipment available for production lines, measurable laboratory performance, field performance, and end-user capabilities to open the box easily and safely.
Closing boxes include:
- Adhesive adhesives, water-based or hot-melt adhesives applied either manually or by machine.starch-based adhesives are the corrugator option because it is economically.starch works as a medium for molds, litchens & amp; fungus so to prevent the antifungal added in it before use.
- Staples- staples are used to close the box so that the effective cover staples should be applied in a 45 deg angle.
pins made of steel, nickel, brass etc.
- The sealing tape box, pressure-sensitive-taps are available in widths of 36, 48, and 72 mm and some thickness. BOPP and PET are used as backing. Recording is done manually or with semi automatic machine.
- Filament tape, pressure sensitive
- Paper attached with active water - this paper consists of a thick paper in which adhesive is applied and dried, when water is applied to the adhesive and the binding ability is reproduced.
- Water reinforced adhesive tape attached
- The straps are generally used to hold together, made of plastic (PP, PE, PET, PVC), metal (SS steel) etc. and available wide range.
- Shrink wrap - this is a thin film LLDPE, LDPE etc. which shrinks with hot applications that produce box wrappers from all sides. It's more expensive among all because it requires a hot tunnel and more material consumption. However, the packaged box will be protected from the environment as it will serve as a barrier.
References
Books, general reference
- "Fiber Box Handbook", Fiber Box Association, Chicago IL
- Koning, J., "Corrugated Crossroads, Reference Guide for Corrugated Industry", TAPPI Press, 1995, ISBNÃ, 0-89852-299-4
- The European Corrugated Board Industry
- Good Manufacture Wrapping for Solid and Compact Board Packs
- Soroka, W, "The Basics of Packaging Technology", IoPP, 2002, ISBNÃ, 1-930268-25-4
- "Guide to Packaging for Small Parcel Shipping", 2005, IoPP
- Yam, K. L., "Encyclopedia of Packaging Technology", John Wiley & amp; Children, 2009, ISBN 978-0-470-08704-6
ASTM Standard
- The D642 Test Method for Determining Resistance Presses Delivery, Component, and Unit Expense Barriers.
- Standard Practice D1974 for Closure, Sealing, and Reinforcing Fiberboard Box
- D4577 Test Method for Compressed Container Endurance under Constant Load
- D5118 Standard Practices for Fiberboard Box Fiberboard Fabrication
- D5168 Standard Practices for Fabrication and Closing Fiberglass Corrugated Fiberglass Triple-Wall Containers
- D5639 Standard Practices for Corrugated Fiberboard Material Selection and Box Construction Based on Performance Requirements
- The D6804 Standard Handbook for Handwashing Designs in Corrugated Box
Source of the article : Wikipedia
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