Introduction to Corrugated Packaging

Yongquan Zhou, CPP

Project EngineerFedEx Packaging Design and Development

and

Adjunct FacultyCBU School of Engineering

Corrugated fiberboard

• Construction (1, 2)

Corrugated fiberboard consists essentially of two flat parallel sheets (liners) of paperboard, with a central fluted or corrugated sheet between them. The combined board is held together with adhesive applied to the crests of the fluted sheet.

• Fiberboard grades

Linerboard - Table 15.1Corrugating medium - Table 15.2

• Corrugating adhesives

Starch-based adhesiveModified or supplemented starch-based adhesiveWeather-resistant adhesiveWater-resistant adhesive

Corrugated Fiberboard

Corrugated Fiberboard - continued

Corrugated Fiberboard - continued

Corrugated Fiberboard - continued

Corrugated Fiberboard - continued

Corrugated Fiberboard - continued

Corrugated Boxes - continued

Corrugated Boxes - continued

Corrugated boxes

• McKee formula

Box Compression Strength = 5.87 X ECT X SQRT(BP X T)

Note: Estimated RSC top-to-bottom box compression strength = , KN (lbf)

WhereECT = edge crush test, KN/m (lbf/in);BP = inside box perimeter, m (in);T = combined board thickness, m (in)

Corrugated fiberboard and box properties and tests

• Corrugated board properties and tests

Mullen burst testEdgewise compression test (ECT)

• Box compression strength

- Estimate - McKee formula

Box Compression Strength = 5.87 X ECT X SQRT(BP X T)

Note: Estimated RSC top-to-bottom box compression strength = , KN (lbf)

Where

ECT = edge crush test, KN/m (lbf/in);BP = inside box perimeter, m (in);T = combined board thickness, m (in)

- Compression test in the lab

Corrugated boxes

• Dimensioning

Length (L) Width (W) Depth (H)

• Outer dimension (OD) or inner dimension (ID)

• Loading orientation

Top-loading boxesEnd-opening boxesSide-opening boxes

• Flute direction and manufacturer's joint

Corrugated boxes

• Select the correct flute

A-fluteB-fluteC-fluteE-flute and F-flute

• Box styles and design variations

Regular slotted containers (RSC) (1, 2, 3)Die-cut (1, 2, 3, 4)Bliss box

Carrier rules and regulations and box certificate

• Carrier rules and regulations

- Carrier rules and regulations - truck, rail (1)

- Carrier rules and regulations - small parcle and express

• Box maker’s certificate (2)

Computer-aided package design programs