GuidePaperboard

Paperboard Guide

Contents 2

Introduction 3

1. Information about Stora Enso and Consumer Boards 4

1.1 StoraEnsoinbrief 5 1.2 StoraEnsoConsumerBoards 6 1.3 Sustainabilityinpackaging 7

2. Paperboard making and paperboard grades 8

2.1 Paperboardmaking 9 2.2 Paperboardgrades 11

3. Barrier coating 15

4. Paperboard handling recommendations 18

5. Printing methods 19

5.1 Offsetprinting 21 5.2 Gravureprinting 22 5.3 Flexoprinting 23 5.4 Inks 24 5.5 Digitalprinting 25 5.6 Practicalprintinginstructions 26

6. Converting and Finishing 28

6.1 Varnishing 29 6.2 Embossing 31 6.3 Hot-foilstamping 31 6.4 Die-cuttingandcreasing 32 6.5 Glueing 34 6.6 Lamination 35

7. End uses 36

7.1 Graphical 39 7.2 Beverageandmultipack 40 7.3 Chocolateandconfectionery 41 7.4 Cigarette 42 7.5 Cosmeticsandluxury 43 7.6 Detergentsandhousehold 44 7.7 Food 45 7.8 Pharmaceutical 46 7.9 FoodService 47 7.10 Liquid 47

8. Stora Enso Consumer Boards production and service facilities 48

8.1 Paperboardmills 49 8.2 Extrusioncoatingplants 51 8.3 Partnerservices 52

9. Testing methods 53

10. Glossary 57

Contents

3 Paperboard Guide

Creatinginnovativepackagesandbril-

liantgraphicalproductsfromadvanced

paperboardmaterialsisbothascience

andanart.Asaruleofthumb,thesky

isthelimitastotheimplementationof

artisticdesignsordemandingprint-

ingandfinishingeffects.However,the

moreweknowaboutthebehaviourof

paperboardinvariousrefiningprocesses

andindividualenduseenvironments,

thebettertheresult.

ThisPaperboardGuidehasbeen

compiledtothatveryend–toserve

ourpartnersandtheircustomerswith

accurateinformationthathelpsmake

excellenceoutoftheordinary.

Asischaracteristicofeducational

material,alotofthesubjectmatter

dealswithconcepts,definitions,ab-

breviationsandprinciples.Inaddition

toexplainingthebasicvocabulary,the

Guidepresentsanoverallpictureofthe

paper-boardworldandclarifiessomeof

thekeyissuesrelatedtoit.

Introduction

Welcome to the enchanting world of paperboard.

PasiAhokasVP,GraphicalBoards

<< Contents

Information

andConsumerBoards

aboutStoraEnso

Stora Enso Consumer Boards 4<< Contents

StoraEnso’ssalestotalledEUR13.2billionin2005.TheGrouphassome46000employeesinmorethan40countriesonfivecontinents.StoraEnsohasanannualproductioncapacityof16.9milliontonnesofpaperandboardand7.7millioncubicmetresofsawnwoodproducts,including3.3millioncubicmetresofvalue-addedproducts.StoraEnso’ssharesarelistedinHelsinki,Stockholm,andNewYork.

StoraEnsoservesitsmainlybusiness-to-businesscustom-ersthroughitsownglobalsalesandmarketingnetwork.Aglobalpresenceprovideslocalcustomerservice.Customersincludepublishers,printinghouses,andmer-chants,aswellasthepackaging,joinery,andconstruc-tionindustries–andaremainlyconcentratedinEurope,NorthAmerica,andAsia.AsStoraEnsomovesintothefuture,theGroupisfocusingonexpandingitsopera-tionsinnewgrowthmarketsinChina,SouthAmerica,andRussia. TheGrouphasproductionfacilitiesinEurope,NorthandSouthAmerica,andAsia.Modernproduc-tioncapacity,combinedwithefficientrawmaterialandenergysourcingandefficientprocesses,ensureexcellentcontinuityofproduction.

StoraEnsoiscommittedtosustainability–economic,environmental,andsocialresponsibilityunderpinsourthinkingandourapproachtoeveryaspectofdoingbusi-ness.TheGroupbuildsaccountabilityintoitsoperationsbybeingtransparentandengaginginopendialoguewithitsstakeholders.Group-widetargetsandcleargovernanceareusedtomonitorandmeasurehowwellStoraEnsoperformsintermsofsustainability.

1.1 Stora Enso in brief

Information

andConsumerBoards

aboutStoraEnso

StoraEnsoisanintegratedpaper,

packaging,andforestproductscompany,

producingpublicationandfinepaper,

packagingboard,andwoodproducts

–allareasinwhichtheGroupisaglobal

marketleader.

5 Stora Enso in Brief

committed to

sustainability

<< Contents

1.2 Stora Enso Consumer Boards– providing packaging solutions worldwide

Fibre-basedmaterialsenjoyastrongandwell-deservedstatusinthepackagingworld.Paperboardissmoothandstrong,lightandbright,versatileandcost-effective.Agenerousprintingsurfaceandsuperbprintqualitymakespaperboardcartonsidealinformationcarriersandbrandbuilders.Reliabilityinhigh-speedfillinglinessavesmoneyandminimizesproductiondowntime.Renew-ablefibresalsomakeaparticularlywell-foundedchoiceenvironmentally.

Theultimatechallenge,however,liesinusingthefullpotentialofthematerialintelligentlyandinnovativelytocreatesolutionsandconceptsthatwillhaveacom-petitiveedge–inproductprotection,materialsavings,productionandlogisticscosts,tradepreference,con-

sumeracceptance,shelfpresenceorrecyclingefficiency.Suchsolutionsdonotmaterializeoutofthinair.Theystemfromactiveinteractionwiththewholepackagingcommunity.AndthatiswheretheofferingofStoraEnsoConsumerBoardsreallycomesintoitsown.Weproduceawideselectionofpaperboardsineverycategoryandprovidethelargestvarietyofpolymercoat-ings.Wehavestrongandmodernpulpandboardmillsthat,togetherwithoursalesstaffandServiceCentrefa-cilities,ensureconsistentquality,fastserviceandreliabledeliveries.Butevenmorethanthat,wearecommittedtoverticalinnovationinthewaywecooperatewithourpartnersacrosstheboardtopromotetheefficiencyandsustainabilityoffibre-basedpackaging.

Information

andConsumerBoards

aboutStoraEnso

Liquid FreshLiquid Ambient

Stora Enso Consumer Boards 6

Stora Enso Consumer Boards

<< Contents

Information

and Consumer Boards

about Stora Enso

1.3 Sustainability in packaging

Sustainable development in packaging means solutions that satisfy present needs in an optimal way without compromising the ability of future generations to meet their own needs. Fibre-based boards provide a powerful means of achieving those goals throughout the pack-age’s life-cycle. Here are some of the basic issues:

Wood, a renewable and recyclable resource, is the main raw material in our packaging boards. We apply the prin-ciples of environmental and social responsibility for wood procurement and sustainable forest management.

Paperboard is produced at an integrated mill, using mainly renewable energy derived from the wood in the pulping process.

Versatile and light paperboard packages prevent product loss by effectively protecting packed materials against

physical damage, contamination and light. Product in-formation can be printed directly onto the surface of the paperboard, so no extra labels are needed.

Space-saving designs are particularly economical in transportation. Efficient logistics reduce fuel consump-tion and emissions to the atmosphere.

Paperboard packaging is a valuable resource in itself, with many potential uses. Packaging boards are made from fibres with good strength properties and can be recycled for a number of paper and paperboard grades. In the case of polymer-coated boards, the plastic fraction can be used for energy production, replacing fossil fuels, or can be recycled when appropriate.

For a more detailed presentation of sustainability in pack-aging, view the multimedia.

7 Sustainability in Packaging << Contents

Paperboard

paperboardgrades

makingand

Paperboard making and paperboard grades 8<< Contents

Paperboard

paperboardgrades

makingand

2.1 Paperboard Making

Thebasicprinciplesofpaperandpaperboardmakinghavenotchangedformorethantwothousandyears.Fibresgainedfromtimberareevenlydistributedinwater.Multiplelayersoffurnishareapplied,oneaftertheother,onawire.Thewaterisdrainedfromthepulpand

thelayersareformedintoastrongfibremat.Asmoothsurfaceisachievedbycoatingandcalendering.TheexcellentqualityofStoraEnsopaperboardsistheresultofadvancedtechnologyandtheuseofhigh-qualityrawmaterials.

Raw Materials used for Paperboard Production

Chemical PulpWoodchipsarecookedwithappropri-atechemicalsinanaqueoussolutionathightemperatureandpressure.Theobjectiveistodissolvetheligninandseparatethefibresintact.Thepulpcanbeusedunbleachedorbleachedtothebrightnessneeded.

HardwoodPulpmadeofdeciduousbroad-leavedtreessuchasbirch,oak,beech,aspenoreucalyptus.Characteristicaretheshortfibres.

SoftwoodPulpproducedofpine,spruce,orotherconifers.Thefibresarelong.

Watermeansoftrans-portandsolvent.

PigmentsNaturalcoatingpigmentsandfillers.GroundCalsiumCarbonate(GCC)andKaolinClay.

LatexWaterdispersionoforganicbinderforthecoatingpigment.

Components Coating Colourrheologymodifiers

Sizing Agentssuchasnaturalresinorsyntheticsizesareaddedtoincreasestrengthanddecreaseabsorbance.

Wet-end Additivesand Retention Aide.g.starchandaluminiumsulphate.

Secondary fibresaregainedfromsortedrecoveredpaperorboardbypurifyingandsometimesdeinkingandbleaching.

CTMP (Chemi Thermo Mechanical Pulp)Woodchipsareimpregnatedwithappropriatechemicalsandheatedbeforeseparatingthefibresbyamechanicalrefiningprocess.Thepulpisbleachedandwashedinseveralsteps.

GroundwoodLogsofdebarkedsoftwoodarepressedagainstarotatinggrindingstonewhilewaterisaddedinordertoseparatethefibres.

Mechanical Pulp

9 Paperboard making and paperboard grades << Contents

Paperboard

paperboardgrades

makingand

Paperboard ProductionThepicturebelowillustratesonetypicalexampleofpaperboardmachinelay-out.

Wire Section Press Section Pre-Drying Section

Wire Section:Thewebisformedinthewiresectionbypumpingamixtureofwaterandpulpfromtheheadboxesontothewire.Thewatercontentisover99%,whichiswhythispartofapaperboardmachineisalsoknownasthewetend.Thewaterisdrainedoffandthefibresbondtogether.Theindividuallayersoffibrearecouched.Anevenfibreformationisvitaltoensureoptimumstrength,surfacesmoothnessanduniformity.Afterthewiresectionwatercontentis80%.

Press Section:Inthepresssection,waterisremovedfromthewetwebbymechanicalcompressioninthenipsformedbytworolls.Theremovedwaterisreceivedbyafelt.Afterpresssectionwatercontentisapproximately60%.

Pre-Drying Section:Thepaperboardwebisfurtherdriedbyaseriesofsteam-heateddryingcylinders.

Pre-Drying Section

Glazing Cylinder

Post-Drying Section 1 Coating Section

Post-Drying Section 2Shoe Calender

Glazing Cylinder:ThetopsideofthewebcanbesmoothedbycontactwithaYankeecylinderhavingahighlypolishedsurfaceorwithsocalledshoecalender.Noteverypaperboardmachinehastheseoptions.

Post-Drying Section 1 and 2:Additionalreductionofmoisturecontent.

Coating Section:Dependingonthequalityrequired,thewebcanbecoatedwithone,twoorthreecoatingstationsperside.

Reeler Section Winding Paperboard Reel

Gloss Calender

Calendering: Thesmoothingcalenderfurtherregulatesthesurfacequality.Dependingonthegrade,thesurfaceisadditionallycalend-eredwiththehotsurfaceoftheglosscalender.

Winding:Thefinishedpaperboardiswounduptoajumboreelwhichisthenrewoundintonarrowerreelsandaccordingtocustomerrequirements,eithersenttocustomersinreelsorcutintosheets.

Paperboard making and paperboard grades 10

Extrusion coatingForsomeend-usespaperboardcanbeextrusioncoated.Extrusioncoatingisaseparateprocessafterthepaper-boardproduction.Formoreinformationonthebarriercoatingoptionsseechapter3.0.

<< Contents

Paperboard

paperboardgrades

makingand

2.2 Paperboard Grades

Agreatvarietyofgradesarecommerciallyavailableandthetermsusedtodescribethemvaryfrommarkettomarket.Belowthegradecategoriesarebasedonfibregradesandproductiontechnology.Eachgrademaybetailoredformanyendusesandforindividualcustomerneeds.

Paperandpaperboardaremadewiththesamebasetechnology.Paperprovidesmainlytheprintingsurface,paperboardbothprintingsurface,stiffness,strengthandotherpropertiesnecessaryinpackagingandgraphicenduses.Usuallybasisweight,caliperandstiffnessarehigherthanthoseofpaperandalsomostofthepaperboardgradesaremultiplyproducts.

FBB (Folding Boxboard)

Alayerorlayersmadeofmechanicalpulpisbetweenlayersofchemicalpulp.Mechanicalpulpmaybestone-groundwood(GW),pressurizedgroundwood(PGW),thermomechanicalpulp(TMP)orchemi-ther-momechanicalpulp(CTMP).Thetoplayerisbleachedchemicalpulpandthereverselayercanbebleachedorunbleachedchemicalpulp.Thetopandreversesidemaybecoatedwithmineralorsyntheticpigments.

SBS (Solid Bleached Sulphate)

Paperboardentirelymadeofbleachedchemicalpulp.Thetopsideandreversemaybecoatedwithmineralorsyntheticpigments.

SUB (Solid Unbleached Board) / SUS (Solid Unbleached

Sulphate)

Paperboardmademainlyofunbleachedchemicalpulp.Toachieveawhitesurface,itmaybecoatedwithminer-alorsyntheticpigments,sometimesincombinationwithalayerofbleachedfibresunderthislayer.SomeCTMPorrecycledfibresmaypartlyreplacetheunbleachedsulphatepulp.

Double/triplecoating

Bleachedchemicalpulp

Bleachedmechanicalpulp

Bleachedchemicalpulp

(Coating)

Double/triplecoating

Bleachedchemicalpulp

Bleachedchemicalpulp

Bleachedchemicalpulp

Single/doublecoating

Double/triplecoating

Bleachedorunbleachedchemicalpulp

Unbleachedchemicalpulp(mixedwithCTMP/recycledfibres)

Unbleachedchemicalpulp(mixedwithCTMP/recycledfibres)

(Coating)

11 Paperboard making and paperboard grades << Contents

Paperboard

paperboardgrades

makingand

Paperboard making and paperboard grades 12

WLC (White Lined Chipboard)

Multi-layerpaperboardcomprisingatleastonemid-dlelayerofmainlyrecoveredfibres.Thetoplayerisbleachedvirginchemicalpulporwhiterecoveredpulps.Betweenthetoplayerandthemiddlelayer(s)therecanbealayerofchemical,mechanicalordeinkedrecycledfibres.Thereverselayercanbemadefromselectedrecy-cledfibresorbleachedand/orunbleachedvirginfibres.Thetopandreversesidemaybecoatedwithmineralorsyntheticpigments.

LPB (Liquid Packaging Board)

LiquidPackagingBoards(LPB)areusedforthepackag-ingofliquidfoods,suchasmilkorjuice.ThebaseboardmaybeeithercoatedoruncoatedFBB,SBSorSUB.Thepaperboardisplasticcoated–oftenwithPE(Poly-ethylene),high-barrier-orfoil-laminatedforlong-lifebeverages.

Two-sidedPEcoating

PECoating

Board

PECoating

PEcoating

Board

Barrierlayer

PEcoating

Double/triplecoating

Bleachedchemicalpulp/whiterecoveredpulps

Recoveredpaperorpaperboardbrown/grey

Bleachedchemicalpulp/

anyofthepulpsabove

(Coating)

<< Contents

13 Paperboard making and paperboard grades

Definition (DIN 19303) Type Description Pulp Stock

uncoated coated

AZ SBS Cast-coatedsolidbleachedboardwithwhiteback Fullybleachedchemicalpulp

AC1 FBB Cast-coatedfoldingboxboardwithwhiteback Chemicalandmechanicalpulp

AC2 FBB Cast-coatedfoldingboxboardwithcreamback Chemicalandmechanicalpulp

UZ GZ SBS Solidbleachedboard Fullybleachedchemicalpulp

GN1 SUS/SUB/CNK Solidunbleachedboardwithwhiteback Unbleachedchemicalpulp

GN4 SUS Solidunbleachedboardwithbrownback Unbleachedchemicalpulp

UC1 GC1 FBB FoldingBoxboardwithwhiteback Chemicalandmechanicalpulp

UC2 GC2 FBB FoldingBoxboardwithcreamback Chemicalandmechanicalpulp

UT1 GT1 WLC Whitelinedchipboardwithwhiteback Secondaryfibres

UT2 GT2 WLC Whitelinedchipboardwithcreamback Secondaryfibres

UT4 GT4 WLC Whitelinedchipboardwithbrownback Secondaryfibres

UD1 GD1 WLC Whitelinedchipboardhighbulk≥1,45cm3/g Secondaryfibres

UD2 GD2 WLC Whitelinedchipboardhighbulk<1,45cm3/g,>1,3cm3/g Secondaryfibres

UD3 GD3 WLC Whitelinedchipboardhighbulk≤1,3cm3/g Secondaryfibres

Overview of Paperboard Nomenclature

AccordingtoDIN19303,anypaperboardcanbedescribedbyacombinedcodeoftwolettersortwolettersandonefigure.

The first letter describes the type of surface treatment:

A=cast-coated G=pigment-coated U=uncoated

The second letter stands for the main furnish:

Z=bleachedchemicalpulp N=unbleachedchemicalpulp C=mechanicalpulp T= secondary-fibrepulpwithwhite, creamorbrownreverse D=secondary-fibrepulpwithgreyreverse

Except for the D grades the figure defines the colour

of the reverse side:

1=white 2=cream 3=brown

For the D grades, the figure describes the bulk

of the paperboard:

1=≥1.45cm3/g 2=<1.45cm3/g,>1.3cm3/g 3=≤1.3cm3/g

Paperboard

paperboardgrades

makingand

<< Contents

BarrierCoating

Barrier Coating 14<< Contents

BarrierCoating

3. Barrier Coating – Optimal Packaging Solutions using Barrier Coatings

StoraEnso’sbarriercoatingrangeisthewidestonthemarket,offeringsolutionsforpracticallyallpackagingneeds.Theroleofcoatinginthepackagingboardsistoproducethedesiredbarrierpropertiesforthepack-age,resultinginsuperiorproductqualityandprolongedshelf-life.Creativeuseofdifferentcoatings,togetherwithindividualmatchingofthemostsuitablebaseboardsforthepurpose,optimizespackageperformance,ensureshighvisualquality,savesmaterials,simplifiesconvertingandpackaging,andreduceswaste.

Barriercoatingstypicallyformatightfilmonthepaper-boardinordertoprovidethedesiredbarrierandotherfunctions.Generally,barriercoatinginpackagingboardsreferstotheuseofpolymersasextremelythinlayersonthebaseboard.Thesepolymersgiveexcellentproductprotectionpropertiesplussubstantialeconomicalandecologicalbenefits.Polymercoatingsproduceeffectivebarriersforawidevarietyofproducts,includingperish-ablefoodstuffs.

Themainpurposeofcoatingistoprotecttheproductfromtheundesirableeffectsofsuchfactorsaslight,oxy-gen,humidity,andmicrobes.Dependingontheapplica-tion,coatingfunctionsalsoincludeimprovedgrease-proofness,heatresistanceorpeelability,orenhancedprintingandfinishingproperties.

Application of coating polymers

Extrusionisthemostcommonlyusedbarriercoatingtechnologyforpolymerssuchas:

• PE(polyethylene),PP(polypropylene) andotherpolyolefins

• EVOH(ethylenevinylalcohol)andPA(polyamide) ashigh-barriermultilayercoatings

• specialpolymerssuchasPET(polyethylenetereph- thalate)andPBT(polybutyleneterephthalate).

Polymerscanalsobeappliedaswaterdispersionsbyusingtraditionalpigmentcoatingmethods.Anewgrouprapidlygaininggroundconsistsofbiopolymerstailoredforfullbiodegradability.

Structure of polymers e.g. polyethylene:

Polyolefin coatings

PolyolefinbarrierssuchasPE-LD,PE-HDandPPpolymersgivegoodhumidityprotection.Forheatresistance,PPcoatingissuperiorcomparedtothePEgrades.

Typicaluses:PEcoatedpackagesandcupsforbeverages,frozenfood,icecreamandyoghurt;PPcoatedpackages,traysandplatesforpreparedorsemi-preparedfoodssuitableformicrowaveheating;PE-HDcoatedpackagesformoisture-sensitivedryfoods.

15 Barrier Coating << Contents

Polyolefin coatings:

High-barrier coatings

PatentedEnsobarrhigh-barriercoatingsconsistofmulti-layerEVOHand/orPApolymerstructures.Theyprovideexcellentlight,oxygen,humidityandaromaprotection.EnsobarrSilvergradehasanadditionalsilver-colouredlayertoprovidemaximumprotectionagainstlight.Thehigh-barriercoatedboardsarealsogreaseproof.

Typicaluses:variousdelicatefoods,includingchocolate,cerealsanddairyproducts;dryfoods,suchascandy,savouryandprocessedsnacks,coffeeandtea,milkandcocoapowders;liquidproductssuchasjuices,softdrinks,greentea,water,soupsanddesserts,aswellaslight-sensitivebeveragessuchaswinesandlongshelf-lifejuices;non-foodproductssuchasliquiddetergentsandfabricsofteners.

High-barrier coatings:

Special Polymer Coatings

Specialcoatingscanperformbothbarrierandotherfunctions.TypicalexamplesarePETcoatingsthatprovideheatresistancetogetherwithexcellentgreasebarrierfea-turesandgoodWVTR(WaterVapourTransmissionRate)properties.PBTpolymersaresimilartoPETintheirfunc-tions,butenhancedwithexcellentreleaseproperties.

Typicaluses:Oven-usabletraysandreheatableproductpackages,andnon-sticktraysforbakeryproducts.

Special barrier coatings:

Biopolymer Coatings

Biodegradablecoatingsaretailor-madepolymersprovid-inghumidityandoxygenbarriersaswellassealability.Thecoatingcanbecompostedintohumusinorganicrecycling.

Biopolymer coatings:

BarrierCoating

Light

Oxygen

HumidityHeat,peelability

Grease

3

2

1

0

Light

Oxygen

HumidityHeat,peelability

Grease

3

2

1

0

Light

Oxygen

HumidityHeat,peelability

Grease

3

2

1

0

Light

Oxygen

HumidityHeat,peelability

Grease

3

2

1

0

Barrier Coating 16

Performance:1.Moderate2.Good3.Excellent

<< Contents

Paperboard

Recommendations

Handling

Paperboard Handling Recommendations 17<< Contents

Paperboard

Recommendations

Handling

4. Paperboard Handling Recommendations

Duetotheirstructure,allboardsare‘living’material.Anunwrappedsheetofpaperboardreactswiththeairveryquickly.Beforeprinting,youmustmakesurethattheinternalrelativehumidityandtemperatureofthesheetsareinbalancewiththeconditionsofthepressroom.Largedifferencesintheseparameterscanleadtoprob-lemssuchascurlingofthesheetsandslowinkdrying.

Makesurethatthepaperboardisacclimatizedtowhereitisgoingtobeprinted.Thenecessarytimeforsettlingcanbefoundonourpalletlabels.

Example:Ifthesize(volume)ofthepalletis1m3(1mx1mx1m)andthetemperaturedifferencebe-tweenthepalletandthepressroomis20°C,thesettlingtimeneedstobe46hoursinthepressroom.

Forpaperboard,theidealhumidityofboththeware-houseandthepressroomis50-55%relativehumidityandtheidealtemperature20-23°C.

Increasedrelativehumiditycancausedryingandrub-resistanceproblemsintheprintedsurface.Anotherpossiblereasonforslowdryingmaybeashortageoftheoxygenthatisneededforinkpolymerization.

Removethewrappingjustbeforeprinting.Thiswillensureevenandsmoothsettlingofthepallet.Thewrap-pingalsoprotectsthesheetsfromdirtanddamage.

pallet m3 Difference in temperature between the press room and pallet

5°C 10°C 15°C 20°C 25°C 30°0.3 7h 14h 21h 31h 43h 60h0.4 7h 17h 26h 36h 41h 64h0.6 9h 20h 31h 42h 55h 76h0.7 11h 21h 31h 44h 58h 79h1 12h 23h 33h 46h 62h 87h2 13h 24h 35h 49h 66h 90h

18 Paperboard Handling Recommendations << Contents

PrintingMethods

Printing Methods 19<< Contents

PrintingMethods

5. Printing Methods

Thefinalprintqualityisinfluencedbymanyvariables,suchaspaperboardproperties,printingpressandproc-essparameters,andinkproperties.Foroptimalresults,itisimportanttounderstandtheinteractionbetweenvitalpaperboardpropertiesandthechosenprintingprocess.

Thischapterdescribesthemostcommonprintingmeth-ods,althoughtheinformationbelowfocusesmainly

onthesheet-fedoffsetprocess,whichisthedominantprintingtechniqueforpaperboards.Theinformationwillfacilitatetheprocessingofourpaperboardsandenhancethequalityoftheprintwork.Moreover,theseguidelinesmayserveasatokenofourongoingendeavourstoaddourmanufacturingexperiencetotheexpertiseoftheprintingandconvertingindustries.

20 Printing Methods << Contents

Thedominantprintingmethodisoffset,whichisdividedintothreedifferentprocesses:

•sheet-fed(sheets)SFO forpaperandpaperboard •heatsetweboffset(reels)HSWO forpaperand low-grammagepaperboard •coldsetweboffset(reels)CSWO fornewsprint

Offsetprintingisbasedonphysicochemicalreactionsbetweentheink,fountainsolution,printingplateandblanket.

Theprintingplateismadeofaluminium.Theplateischemicallytreatedsothatimageareasacceptgreasyink(oleophilic)andarewater-repellent.Thenon-printingareasarehydrophilic,meaningthattheyrepelinkbutacceptfountainsolution.

Theaveragethicknessoftheinklayercarriedbytheplateis2-3µmandthatofthewaterlayer1-2µm.

Theinkistransferredfromtheprintingplatetotheprint-ingblanket,thenontothesurfaceofthepaperboard.

Thestructureoftheprintingblanketisatextureof2-4layerscoveredwithrubberlayers.Theblankethasdiffer-enthardnesslevels(70-85ShoreD),theharderblanketsbeingmoredurableandmeantforhigherprintingspeeds.Byusingasoftblanket,bettercontactwiththepaperboardcanbeachieved.Theblanketisnotallowedtoreactwithinksolventsduringtheprintingprocess.

Theprintingblankettransferstheprintingimagefromtheprintingplatetothesurfaceoftheprintingmaterial.

Theoffsetinksareverytackyandrequirehighsurfacestrengthintheprintmaterial.Thesheet-fedinksdrybyabsorptionandoxidation,heatsetinksbyevaporation(aidedbydryers).UV(Ultraviolet)offsetinksneedUVlighttodrybypolymerization.

Theinkingunittransfersaneveninklayertotheprintingplate,makestheinkfluidandflexibleandkeepsitatthecorrecttemperature.

Thefountainsolutionformsathinwaterlayeronnon-printingareasoftheprintingplate.ThepH,hard-nessandconductivityareimportantpropertiesforthe

fountainsolution.ThepHshouldbebetween4.8and5.3,hardnessbetween7and15°dHandconductivity50-200mS/mtoachievethebestprintingresult.

Sheet-fed offset printing unit

Waterless offset (dry offset)

Inwaterlessoffsetprinting,nowaterisinvolvedintheprintingprocess.

Inthedryoffset(waterlessoffset)process,moretackyinksareusedandspecialprintingplatestreatedwithsiliconeareneeded.Thesiliconematerialoftheprintingplatehasaverylowsurfaceenergyandmakesupthenon-printingareaoftheplate.Thismaterialwillresisttheink,providedtheink’sviscosityissuchthatithasagreateraffinityforitselfthanitdoesforthesilicone.

5.1 Offset printing

PrintingMethods

-dotsareuniformlycoveredwithink-edgesareragged

Printing Methods 21

Impressioncylinder/roller

Offsetblanketcylinder

Paper

Lithoplatecylinder

Waterrollers

Water

Inkrollers

<< Contents

-brokenshapeofdots-missingdots

-donutshapeddots

Temperaturecontrolofprintinginksisveryimportant.Thetemperatureshouldbestable.Theoptimumtem-peraturerangefordryoffsetinksisnarrowerthanforconventionaloffsetinks.Ifthetemperatureistoolow,theviscosityoftheinkincreases,resultinginpoorfluid-ity/rheologyoftheinkandinferiorinktransfer.Inprintedareas,thisresultsinpicking,ghosting,mottling(uneven-ness),lowprintedglossandproblemsresultingfrompoorinktransfer.Ifthetemperatureistoohigh,theinkviscositydecreases,causingsomeoftheinktobetrans-ferredtotheunprintedareasoftheprintingplate,result-ingindoublingproblems(dyetoning:weakerghostdotsnexttotruedotswhosepositionisoutofregister).

Theoperatingtemperaturerangesfordryoffsetinksare26-35°Cforblack,24-31°Cforcyan,22-28°Cforma-gentaand20-29°Cforyellow.Theexacttemperaturesdependonthemanufactureroftheinkandtheambientconditions.

WaterlessoffsetprintingisenvironmentallyfriendlierduetotheabsenceofwastewaterandresiduesfromIPA(isopropylalcohol)oradditives.

5.2 Gravure printingGravureisusedforlongprintrunsonpaperboard,mag-azinepaperandplasticfilms,andforsecurityprinting.

Theprintinginkistransferredfromtheprintingcylindercellstothesurfaceoftheprintingmaterial.

Gravure printing

Themetallicprintingcylinderandsoftrubberbackingrollformtheprintingnip.Thepressureattheprintingnipishightoensureoptimalinktransfer.

Themostimportantrequirementfortheprintmate-rialissmoothnesstoensuregoodcontactbetweenthepaperboard,theinkandtheprintingcylinder.Becauseofthehighpressureattheprintingnip,thecompressibilityofthepaperboardisalsoimportant.

Theprintinginkissolvent-orwater-basedwithaverylowviscositylevel.Theinksdrybyevaporationinthedryingunit.

PrintingMethods

Imageelementsareequallyspacedbutdifferinareaandvolume(variabledepthandvariablearea)

Impressioncylinder/roller

Blade

Inkfountain

Gravurecylinder

Gravurecylinder

Impressioncylinder/roller

22 Printing Methods << Contents

PrintingMethods

Theprintinginkistransferredbyananiloxrolltotheprintingplate.Thesurfaceoftheaniloxrollisfullofsmall,engravedcellsandextrainkiswipedawaybyusinganoscillatingdoctorbladeorachamberdoctorblade.

Theprintingplateismadeofphotopolymerorrubber.Theupliftingpartsoftheprintingplatetransfertheinkfromtheplatetotheprintingmaterial.

Thesoftprintingplateandhardsteelbackingrollformtheprintingnip.Thepressureattheprintingnipshouldbeverylight(“kiss”).

Theflexoinksarewater-orsolvent-basedwithaverylowviscositylevel.UVinkscanalsobeused.

Water-andsolvent-basedinksdrybyevaporationinadryingunitthatnormallyfollowseachprintingunit.UVinksneedUVlighttodrybypolymerization.

Thesurfaceenergyplaysanimportantroleinflexoprinting.Thesurfaceenergyshouldincreaseinprintingorder(lowerforinkthanforprintingmaterial)toensureoptimalinktransferandadhesion.

Flexoprintingismainlyusedforprintingonflexiblepackaging,labels,paperboardandflutingboard,plasticbagsandnewsprint.

-inkispressedtoedges-shadowintheedgeoftext

Flexo printing

Impressioncylinder(hard)

Printingplate(soft)

Elasticprintingplatewithraisedimageelements

Printingsubstrate

Aniloxroller

Inksupply(Chambereddoctorbladesystem)

InkedupimageelementCellsoftheaniloxrollerfilledwithink

5.3 Flexo printing

Printing Methods 23<< Contents

The main components in a printing ink are:

• Pigmentthatcreatesthecolourandcolour strengthandgivestheinkitsopticalproperties • Binderthatbindsthepigmentsintotheprinting materialandaffectsinkdryingandinkgloss • Solventthatadjustsinkviscosityandhasanef- fectoninksettinganddrying.Thesolventdissolves thebinder • Additives(dryer,wax,antiskinningagent,anti- foamingagentandsurfactants/flexo,gravure)

Sheet-fedoffsetinksdrybyoxidation+absorptionandheatsetoffsetinksdrybyevaporation.

OffsetUVinksdrybypolymerization.TheinkcontainsphotoinitiatorsthatabsorbUVemission.Theinkmono-merhastoreactwithUVemission.Dryingprogressesthroughtheinklayerfromtoptobottomandisdepend-entoninklayerthicknessandinktype(darkorlightinkshade).

OffsetUVinksareslightlytackierthantheconventionalinks,whichmeansthatthepaperboardneedsahigherdegreeofpickingresistance.NoodourortaintproblemsnormallyoccurwithUVinksifthedryingcapacityandtimeareoptimal.TheUV-printedsurfaceisnowreadyforfurtherprocessing.

Flexoandgravureinkscanbesolvent-orwater-basedandbothinksdrybyevaporation.

Metallic inks for offset

Theamountofmetalpigmentinsilverinksis25-30%andingoldmetallicinksupto50%.Themetalsusedingoldinksarecopperandzinc.Thegoldcolourshade(copperredtogreenishyellow)isdependentontheproportionsofcopperandzinc.Aluminiumisusedinsilverinks.

Theplatymetalpigmentsareproducedusingtheballmillprocess(goldandsilver)orthefoilprocess(silver).Theparticlesizeofthemetallicpigmentislargerthanthatofconventionalinkpigments.

Allmetallicinkshavegoodcoverage.Themetallicinkdriesthroughabsorptionandoxidation.Thesettingof

theinkdoesnotdifferfromconventionalinks.Whenmetallicinksareused,thefountainsolutioncanbethesamekindasforconventionalinks.

Theadhesionofmetallicinkstotheprintedbaseisweakerduetothelowerbinderamountandhigherpig-mentamountintheink.However,theseareknownfactswhenusingmetallicinks,andanyproblemsarecausedbytheinks,notbythepaperboardtobeprinted.

Ifthebaseboardisveryroughorhasveryhighporos-ity,itshouldbesealedbeforeprintingwithmetallicinks.Thetechniqueknownasunderprintingcanalsobeused.Underprintingwithyellow,redororangeinkcanbeusedundergoldink,andcyaninkundersilverinks.Theshadeoftheinkwillremainunchangedandtherub-offresistancewillbeimproved.

Thebestpaperboardgradeformetallicprintingispro-ducedinneutraloralkaliprocessestoavoidinkshadedifferences.Printingwithmetallicinksisbestdoneinthelastprintingunit.

Therubresistanceofmetallicinksislowerthanwithconventionalinksbutcanbeimprovedbyvarnishingtheprintedsurface.

A typical procedure when using metallicinks is as follows:

• metallicink+varnish • sealingofbaseboard+metallicink+varnish (whenthebaseboardisveryrough) • underprintingofbaseboard+metallicink+ varnish(shadeofinkandrub-resistance willbebetter)

Theadhesionofvarnishtothesurfaceofthemetallicinklayerispoor,partlybecausetheinklayerisslippery.Themetallicinkshouldnotcontainwax–oratanyrateaslittleaspossible.Theinklayershouldbethoroughlydrybeforevarnishing,toimproveadhesion.Theamountofvarnishusedshouldalsobeaslowaspossible.

Thebestvarnishingprocessforametallicinklayeris:metallicink+water-basedvarnish+UVvarnish.

5.4 Inks

PrintingMethods

24 Printing Methods << Contents

PrintingMethods

5.5 Digital Printing

Traditional and Digital Production Printing Technologies

Page description file

Ripping (Raster Image Processing)

Film processing

Plate making Plate/master manufacturing

Printing using a non-variable master

Offset, Gravure, Flexo

ElectrophotographyInkjet

ElectrocoagulationIonography

Magnetography

Computer to film Computer to plate/master Computer to plate

on pressComputer to press

Digital Printing

Adigitalprintingsystemcanbedefinedasasystemthatprintsimagesdirectlyfromrippedinformationwithoutastaticmaster,sothateveryconsecutiveprintcanbedifferent.Untilrecently,electrophotographywastheonlytechnologyusedinproduction-typecolourdigitalprint-ingmachines,butnewsolutionsforproduction-speeddigitalcolourprintingarebeingdeveloped,basedontechnologiessuchasink-jetandelectrocoagulation.

Digitalprintingisgraduallyenteringthefieldofcon-sumergoodspackaging.Promisingnewtechnologiesarebeingdiscoveredandexistingtechnologiesarebeingrefined.Here,twoofthemostcommondigitalprint-ingmethodsarediscussedbrieflyandsomecommentsaregivenregardingthespecialrequirementsforeachmethod.

Electrophotography

Paperboardgradesworksatisfactorilyinavarietyofsheet-orweb-fedelectrophotographicproductionma-chines.Eitherdirectorindirectdrytoner,oralternativelyindirectliquidtoner,canbeused.MachinesuppliersinthedrytonercategoryarePunchGraphix(Xeikon),Xer-ox(DocuColor,iGen3)ande.g.Kodak(NexPress),andintheliquidtonercategory,Hewlett-Packard(Indigo).

Ingeneral,itcanbesaidthatpaperboardrunsbetterindrytonermachinesinwhicheitherindirectorsingle-stepdirecttonertransferisusedandthepathfortheboardinsidetheprintingmachineisasstraightaspossible.Mostproductionprintingmachinesareincludedinthiscategory.Moreproblemscanarisewithsomehome,smallofficeornetworkprintersinwhichtoneristrans-ferredtotheboardinseveralseparatestepsandthepathfortheboardisnotasstraight.Inthiscategory,compat-ibilityshouldbeevaluatedineachseparatecase.

FortheHPIndigopress(liquidtoner),theboardsurfaceneedstobetreatedwithprimerpriortoprinting.Thetreatmentcanbeappliedwithaflexographiccoat-ingorprintingunitorwithanoffsetprintingmachine.Theprimersolutionshouldbeusedasreceived.Thetreatmentlastsfor2-3months.Excessivelyhighprimerconcentrationsreducethedurabilityandimpairliquidtonercompatibility,whichmaycauseyellowing.

Inkjet

PaperboardsarehighlysuitableforprintingwithUVinkjetinksandforone-colourinkjetprinting(black).Thecompatibilitywithotherinkjetinksdependsontheinkcompositionandshouldbeevaluatedcasebycase.

Printing Methods 25

Oneclassificationofthetraditionalanddigitalproductionprintingtechnologies.

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5.6 Practical printing instructions

PrintingMethods

Choose the right inkChoosingtherighttypeofinkisimportant.Thefollow-ingcriteriamustbetakenintoconsideration:

• desiredprintgloss • processing/convertingoftheproduct • dryingtimeoftheink • desiredscuffresistance • numberofcolourunits • possibilityofIR/UVdrying • tack • specialfeaturesrequiredfromthejob (odour/taintetc.) • subsequentUVvarnishing

Certainpropertiesoftheinkdependoneachother.Themostimportantoftheseareprintgloss,settingspeed,scuffresistanceandageinginthepress.Thesepropertiesarecloselyinterrelated.Forinstance,ifahigh-glossinkischosen,moretimehastobereservedfordrying.Formoredetailedinformation,itisbesttocontacttheinksupplier.

Amount of fountain solution during printing

Theentireoffsetprocessisbasedonthebalancebe-tweeninkandwater.However,asmuchas30%ofthefountainsolutionmayemulsifyintotheinkinnormalprintingcircumstances.

Thereisnobenefittousinganexcessiveamountoffoun-tainsolutioninthepress.Itquicklyaffectsthequalityoftheendproduct,causing,forexample,dryingproblems,printglossreductionandweakercolours.Whentheamountoffountainsolutionisincreasedduringprint-ing,italsoincreasestheamountofwateronthesurfaceofthepaperboard,eitherintheinkorontheunprintedareas.Thecorrectfountainsolutionlevelexistsonthepresswhenthereistheminimumpossibleamountofwaterontheplatestoachieveanoptimumprintingresult(adequateinkfilm)andwhenthefountainsolu-tionpHiscorrect,i.e.4.8-5.3.Undertheseconditions,thepaperboarddoesnotabsorbanexcessoffountainsolution,fromeitherunprintedorprintedsurfaces.

Furthermore,thisensuresquickinkdrying,thedesiredprintglossandthecorrectcolourbalanceontheprintedsurface.

Amount of inkInkdensityisoneofthemostimportantfeaturesmeas-uredfromtheprintedsurface.Rememberthatprintcontrastisreducedifexcessiveinkiscarried.Inkfilmthicknessalsohasaninfluenceontheinkdryingtimeandontheriskofset-off.Duringprinting,thecontrastofeachcolourshouldbemaximizedbyattainingtheopti-maldensitylevel.Thesmallertheamountofinkneededtoachievemaximumcontrast,thefinerthescreenthatcanbeusedinreproduction,resultinginthesharpestpossibleimageinthefinalproduct.

Drying of the ink

Dryingofstandardsheetfedoffsetcoloursisaffectedbyachemicalreaction.Ifyouwanttospeedupdrying,theprintedsheetscanbeacclimatizedbyturningthem,eithermanuallyorusingapileturner.

The reason for a drying problem may be:

• toohighhumidityinthepressroom • temperaturechangesinthepressroom • tooshortasettlingtimeofpalletsbeforeprinting (thematerialiscoldormoist) • unsuitableinkorinkseriesforthepaperboard beingused • excessiveamountofwaterorink • fountainsolutiontooacid • IR(infrared)dryertemperaturetoohigh

ThedryingofUVinksstartswithinafractionofasecondduetopolymerization.Thesheetsarereadyforfurtherprocessingimmediatelyafterprinting.

26 Printing Methods << Contents

PrintingMethods

Grain direction (Machine direction)

Thedirectioninwhichmostfiberslayinafinishedsheetofpaperboardisreferredtoasgrain.Fibersflowparalleltothedirectioninwhichthepaperboardtravelsontheboardmachineduringmanufacture.

Theenduseoftheproductmustbetakenintoconsider-ationwhenchoosingthegraindirection.Itisimportanttoknowhowtheendproductwillbeusedandwhatrequirementsarerelatedtoitsfunction.Forexample,thedirectionofascoreorfoldortherequiredsturdinessoftheendproductshoulddeterminethegraindirectionwhenthesheetsareordered.

Anotherimportantfactorforchoosinggraindirectionistheprintingpress.Almostwithoutexception,therun-nabilityofthepaperboardisbetterifprintedwiththegraindirectionparalleltothecylinders.Thepaperboardismoreflexibleinthesharpcurvesofthepressandproblemscanbeavoidedevenathighspeeds.Thisfac-torbecomesevenmoreimportantwhenthegrammageofthepaperboardishigher.

Moisture

Rememberalsothatthemoistureappliedinthepressincreasesthedimensionsofthesheet.Becauseofthestructureofthepaperboard,thefibresgenerallyexpandmoreindiameterthaninlength.Itisobviousthatifthegraindirectionofthesheetisthesameasthedirectionofprint,aregisterproblemcanoccur.Thelikelihoodofthisproblemoccurringisgreateriflargeformatsaretobeprintedwithaverypreciseregister.Toavoidsuchproblems,theorientationofthesheetshouldbeplannedbytakingintoconsiderationboththeendproductandtheprintingpress.

Printing Methods 27<< Contents

Converting

Converting and Finishing 28

andFinishing

<< Contents

6. Converting and Finishing

Paperboardpackagingoffersmarketersand

theirdesignersanincomparablecreative

medium.Thisisimportantwhenitcomes

tocommunication,positioningandbranding.

Astrongconstructionacceptsattention-

grabbingembossingwithoutcracksorbreaks

andapolishedfinishmeldswithfoilsand

hologramsforvibrancyanddepth.Theskillful

useoftheseprintingenhancementsin

paperboarddesignhelpstoattractconsumers

andoftenaddsvaluetotheproducts.

6.1. Varnishing

Varnishingimprovesthevisualappearanceoftheprintedsurface.Varnishesmaybemattorglossy.Spot-varnish-ingcanalsobeusedtohighlightcertainareasandmakethemmoreprominent.

Thevarnishshouldberesistanttomechanicalrubbingandsolvents.Aglossyvarnishlowersthefrictioncoef-ficient(COF)ofthepaperboardwhichshouldbehighenoughinordertosecuregoodrunnabilityofthepa-perboardinthefollowingconvertingprocess.NormallywhenhavingmattvarnishtheCOFlevelishigh.

Thefinalglosslevelofthevarnishedsurfaceisdepen-dentonpaperboardproperties,thethicknessofthevarnishlayerandthechemistryofthevarnishused.Iftheporesinthecoatinglayeraresmall,thevarnishhasdifficultypenetratingintothecoatinglayerandtendstoremainonthesurface.

Ifthesurfaceisveryrough,twovarnishlayersareneeded;thefirstoneclosesthesurfaceandthesecondonesmoothesouttheroughness.

Solventsinthevarnishshouldnotreactwiththecoatingbinderortheinkbinder,sincesuchareactionmayresultinsofteningofthevarnishedlayer.

Yellowingofthevarnishedlayercanbepreventedbychoosingtherightbindersystemforthevarnish.Varnish-ingwillimprovetherub-resistanceoftheprintedsurface.Varnishingcanbecarriedoutbyusinganinkunit(offsetvarnish),onlinevarnishunit(flexounitforwater-basedvarnish)oraseparatevarnishunit.Glueingshouldbecarriedoutonunvarnishedareas.

On-line varnishing can be divided into three main methods:

Offset varnish • composedlikeoffsetinks,butwithoutpigment • 1-2g/m2asdry • approximately75%solidcontent • chemicaldrying(oxidation)

Water-based varnish • approximately40-50%solidsacryldispersion • 2-5g/m2asdry • physicaldrying(IR,air=>evaporation+ penetration)

UV varnish • driesbyUVradiation • 3-8g/m2asdry • virtuallytheentirecoatingsubstancepolymerizes intoasolidfilm

29 Converting and Finishing

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The advantages and disadvantages of each method are as follows:

+processedlikeink,+easytodospotvarnishing,+goodmoistureprotection

-slowdrying,-thinlayer,-riskofyellowing,-requirespowdering,-lowgloss,-odourandtasteproblemsmayoccur

Offset varnish

+goodgloss

+verygoodabrasionresistance

+fastdrying

+littleornoset-offpowderneeded

+highpilingstability

+noyellowing

+neutralodour

(dependentondryingconditions)

- spotapplicationmorecomplicated

- riskofsheetstretchorshrinkagewithlower

grammagesduetothehighwatercontent

- smearingbecauseoftoohighvarnishamount

ortooeffectivedryingpower

Water-based varnish

+processedlikeink

+easytodospotvarnishing

+goodmoistureprotection

-slowdrying

-thinlayer

-riskofyellowing

-requirespowdering

-lowgloss

-odourandtaintproblemsmayoccur

Offset varnish

+ thehighestgloss

+ veryhardandresistant

+ instantlydry

+ noset-offpowderneeded

+ veryhighabrasionresistance

- highcostofvarnishandenergy

- nottotallyodourless

(dependentondryingconditions)

- difficulttoprocessonlinewithconventional

inks(->adhesionproblems)

- yellowingofvarnishovertime(canbeavoided

byusingwaterbasedvarnishasprimerand

increasingtheviscosityofUVvarnish)

- varnishmayirritateeyesandskin

UV varnish

IfUVcoatingisappliedoverconventionaloffsetinks,theinksurfacemustbeabsolutelydrybeforecoating,and/orthe

inksmustbecarefullyselected.Otherwise,theresultmaybealowercoatingglossorflakingofthecoatedsurface.

Converting and Finishing 30

Convertingand Finishing

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6.2 Embossing

Embossingisdonetoemphasizeprintedareaorprintimpressionorevenunprintedsurface.

Required paperboard properties,if all other properties are the same, then

• chemicalfibreisbetterthanmechanicalfibre • longfibresarebetterthanshortfibres • highermoistureisabenefit(inhibitscracking) • thickpaperboardisbetterthanthin • strengthproperties,especiallyburstingstrength, areimportant • thecoatingshouldbeflexibletoavoidcracking • multi-layerboardsarebetterthansingle-layer boards

Althoughabulkypaperboardmightseemeasiertoemboss,theaimisusuallytoachieveacertainheightsothattheembossingismorepronounced.Abulkypaper-boardwillrespondinamorespongyway.High-densityboardsgivemorepronouncedembossing(atthesametoolheight).

Theembossingmachinemustbecorrectlyadjustedforthepaperboardgradetobeprocessed.

Hot-foilisatechniqueusingverythinaluminiumfoilinavarietyofmetalliccolours,suchasred,blue,silverorgold.Themetallicfoilis(loosely)fixedtoacarrierfilm.Atoolbearingtheimagetobehot-foiledstrikesthisweb.Throughheatandpressure,theimageistransferredtothepaperboard.

Careshouldbetakenwhenapplyinghot-foilstampingonvarnishedpaperboard.Forbestresultsthefoilneedstoadherestronglytothesubstrate.Thepresenceofanykindofdebrisordirtwillhaveanegativeinfluenceontheendresult.Theprintingandcoatingthereforeneedtobeflawlessandadherestronglytothepaperboard.

31 Converting and Finishing

6.3 Hot-foil Stamping

Convertingand Finishing

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6.4 Die-cutting and creasing

Introduction

Characteristicsdifferbetweendifferenttypesofpaper-boards,suchassolidbleachedpaperboard(SBS),foldingboxboard(FBB)orwhitelinedchipboard(WLC).Allgradescanbecutandcreased,buttoobtainthebestresultforeachapplicationitisimportanttofine-tunethetreatment.Theoperatingwindowofdie-cuttingandcreasingvariesaccordingtothetypeofpaperboardanditsindividualproperties.

Itistrueofallpaperboardtypesthatresultsdifferdependingonthegraindirection,moisturecontent,thickness,andtheamountandtypeofsurfacetreatment(pigment,plastic,foil,etc.).Moisturecontentandthick-nessarethemostimportantfactors.Toollifewillalsobeaffectedbythepaperboardtypechosen.

Forcuttingandcreasing,therearebasicallytwometh-odsinuse:RotaryorFlat-bed.Thesedifferentmethodsplacedifferentdemandsonthepaperboard.Themaindifferencebetweenthemis:

- In rotary cutting, the knife does not meet the “anvil.” There is a gap of some 5 microns.

- In flat-bed cutting, the knife should just touch the counter plate for best results.

Inaddition,flat-bedcuttingcanbeperformedeitherin-lineoroff-line.Allofthesevariableswilltosomeextentplacedifferentdemandsonthepaperboard.Forrotarycutting,thewebmuststicktogether,ratherthanfallapart,untiltheblanksenterthesplitter/collector/stacker.Atthesametime,cleancutsaredesired.Thiscanbeachievedbyusingspeciallyadaptedqualities,butspeedofthedie-cuttingequipmentisofcoursealsoimportant.

Inoff-lineflat-bedcutting,almosttheoppositecouldbesaidtobetrue.Whilecleancutsarestilldesired,thepaperboardshouldseparateeasilyinthepuncher.Thefollowingdescriptionmainlyfocusesonflat-bedcutting.

Die-cutting

Agoodcutshouldbecleanandfreefromloosefibresandparticles.

Themostimportantstrengthpropertiesofthepaper-boardaretearandtensilestrength.Thesepropertiesdifferbetweendifferentpaperboardtypesandthedie-cuttingprocesshastobeadjustedaccordingtothoseproperties.

Thecorrectmoisturecontentisessentialforbothrun-nabilityandqualityduringthedie-cuttingprocess.Toohighalevelwillmakethepaperboardstronger,tougherandmoredifficulttocut.Toolowamoisturelevelwillmakethepaperboardmorebrittleanddifficulttotrans-fer,andmaycausedusting.Difficultiesincuttingmaybecausedbythepaperboardthickness,moisturevariationortoolwearandadjustments.Itisimportanttocontroltheclimatetokeepthemoisturecontentunchanged.Controlledclimatehelpstoachieveapreciseregisterbetweentheworkstages.

Ifthecuttingknivesaresharpandmeetthecounterdiecorrectly,thecuttingoccursasdesired.Aproblemmayoccurifthesheetmovesduringtheprocess.Thisisoftenduetoincorrectrubberingandresultsinflakingandpre-maturetearingofthebacklayerofthepaperboard.Thisisobservableasatornareanexttothecut.Damagewillalsooccurtotheknifeifitpressestooheavilyagainstthemetalplate.Theknifewearsandbecomesblunt,leadingtodustandhairy-cutedges.

Plastic-coatedorlaminatedproductswithanextratoughlayer(forinstancePET)shouldpreferablybedie-cutfromtheplastic-coatedside.

Creasing

Acreaseformswhenpaperboardispressedintoagroovewitharule.Thiscausesaplasticdeformationinthepa-perboard,allowingthepaperboardtofoldeasilywithoutcracking.Agoodcreaseissufficientlydeepandnarrowtoenableprecisefolding.Themainfactorforsettingtheadjustmentsisthethicknessofthepaperboard.Thetypeofthepaperboardisalsoimportant.Obviouslythepres-sureofthedie-cutteralsoaffectsthecreasing.

Converting and Finishing 32

Convertingand Finishing

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Duringcreasing,thepaperboardisweakenedinwell-de-finedfoldinglines,whichthenactashingesforfoldingpackagingandgraphicalproducts.Creasingiscarriedoutbyusingathinstripofsteelwitharoundsmoothedgeandanaccuratelycutgrooveinathinhardmate-rialknownasthecounterplate.Thecreasingrulepushesthepaperboardintothegrooveofthecounterplate,locatedunderthepaperboard,creatingapermanentcrease.

Agood,functionalfoldoccurswhenthepaperboarddelaminatesinthecreaseintoasmanythin,undamagedlayersaspossible.Plybondstrengthmustbeacompro-mise,sothatdelaminationoccurseasilyinacreasewhilethestructureholdstogetherinotherareas.

Thickerboardsrequireawiderruleandgroove.Bulkyboardsareeasytocrease.Creasingrequiresaflexiblecoatingandstrongsurfacelayers.Thefibrecomposi-tionandnumberoflayersareimportant.Amultilayerstructureincreasingisdesirable.Becausethickmaterialcannotfoldwithoutbreakingthestructure,thefibrelayersdelaminateinacrease.Thebondingbetweenthelayersweakensincreasing,causingthemtoloosenfromeachothermoreeasilyinfolding.

Thecreasabilitypropertiesdependonthefibreorienta-tion.Acreaseinthemachinedirectionusuallyhasworsefoldingproperties,becausethestiffnessislowerinthecross-fibredirection.Stablemoisturecontentisimpor-tant,becausedrypaperboardcancrackmoreeasily,whilemoistpaperboardhasalowerstiffness,resultingindifficultieswithdelamination.

Thecreasingpropertiescanalsobeanalyzedbymakinga“creasingwindow.”Atlaboratoryscale,theMarbachequipmentisusedbychangingthegroovewidthanddepth,blade/rulewidthandthepenetrationofthecreas-ingruleintothegroove.Thebendingforcesofcreasesaremeasured.Thecreasesshouldhavecertainstiffnessafterbending–inMD(machinedirection),45-60%andinCD(crossdirection),55-65%.

Avisualjudgmentofcreasesisalsomade.Ifthepaper-boardhasalargeoperatingwindow,thecreasabilityisgood.

Ingeneral,plasticsurfacelayersimprovethecreasability,becausetheyhaveverygoodelongationbeforetheybreakandtendtoreducetheriskofsurfacecrackinginthecreases,comparedwithplainpaperboard.

a=creasinggroovewidthb=creasinggroovedepthc=boardthicknessd=creasingruletipthicknesse=creasingruleheightf= thicknessofgroovebottom

creasingcounterpart

creasingplate

c

d

e

a

f

b

Creasing

33 Converting and Finishing

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6.5 Glueing

Sideseamorpointglueingisoftenthefinaloperationinthecarton-makingprocess.

Themostcommongluetypesusedforpackagingpur-posesarewaterbaseddispersionandhot-meltglues.Set-tingofthegluesproceedsbychemicalreaction,coolingdownorreductionofsolvent.

Thegluecanbeappliedusingagluewheel/diskoranozzlesystem.Water-basedgluesareappliedusingbothsystems,whilehot-meltglueisappliedbynozzles.

Whenthedelamination(breakdownoftheseam)occursinthefibrelayer,theseamisacceptableassumingthein-ternalstrengthofthepaperboardisonacceptablelevel.Ifitbreaksinthecoatinglayer,theremaybeaproblemduringuse.Delaminationinthegluelayerisatheoreticalpossibility.

Thesmoothnessandporosityofthepaperboardsurfacehaveaneffectonthemechanicaladhesionoftheglue.Theglueshouldbeanchoredtothepaperboardsurface.Theabsorptionofthetopandreverselayersmustnotbetoodifferentsincethiswouldresultinpenetrationofthegluemostlytothehighlyabsorbentside.Thegluemustwetthesurfacesproperly.Forprintedandvarnishedsur-faces,theseamareasareoftendevoidofinkandvarnishtoassistadhesion.Itisimportanttocorrectlyadjusttheglueingmachinesettingstothemostsuitableopentime,compressiontimeandforce.

Normallythegluesarewater-baseddispersionsofpoly-vinylacetate(PVAc).Themostimportantparametersforglueabilityarethepaperboardandthegluetype.Surfaceenergyandsmoothnessplayanimportantrole.Thesurfaceenergyofthepaperboardsurfacemustbehigherthanthatofthegluetoensuregoodadhesion.

Withplastic-coatedsurfaces,thecoronatreatmentisusedtoincreasethesurfaceenergyofthesurface.Thelowerlimitforsurfaceenergyofthepaperboardsurfaceseemstobe38mN/m–anythinglowermaycauseproblems.

Theamountofglueappliedisdependentonthepaper-boardandgluetypes–varyingwiththeglue’sviscosityforexample–aswellasontheapplicationsystem(diskornozzle).

Thegluedriesasthewaterpenetratesintothepaper-boardsurface.Penetrationisdependentonthemoistureandporosityofthepaperboardsurface.Aportionoftheglueitselfshouldalsopenetrateintothepaperboard.Therecommendedpenetrationdepthis1-3timesthefibrediameter.

Hot-meltgluesareusedtogluematerialswithalowporositylevel(plasticcoatingsandmetalliclaminates)orinprocessesthatrequireshortsettingtimeoftheglue(e.g.in-lineglueinginpackagingmachines).Hot-meltgluecontainsresin(affectingadhesion),wax(creatingasuitablerheologyforthemeltedglue)andpolymer(forcohesion).Hot-meltglueismeltedandappliedtothesurfaceatatemperatureof120-200°C.Whenglueingplastic-coatedboard,thegluemustbesohotthatitwillmelttheplastictosomedegree.Careshouldbetakenwhenusinghot-meltgluesincoldsurroundingsorundercoldconditions.

Converting and Finishing 34

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6.6 Lamination

Itistosomedegreeincorrecttotalkaboutlaminationasacomponentoffinishing.Paperboardisoftenboughtbyaconverterandlaminated,thensoldtoaprinter.Ifthisisthecase,therearebasicallytwomainapplicationsforlamination.Bothofthemtypicallyinvolvepaperboardinreels:

• Laminationofpolypropylene,aluminiumfoilor metallizedpolyesterfilmontoapaperboard • Laminationofoneormoreboardstoacore-web ofpaperboard,foamorsimilar

Theideaofthefirstprocessisoftentogivealuxuriouslookafterprintingonthepack.Theotherapplicationismoretypicallyintendedtoproduceadisplaypaperboardforadvertisingpurposes.Inthissecondlaminationproc-ess,twoormorewebsaregluedandpressedtogethertoobtainapaperboardgradewithahighergrammagelevel.Asdescribedabove,acentrelayerofsometypeisoftenincludedtogiveathickproduct.

The lamination may be:

• waxlamination (moltenwaxisappliedtothepaperboardsurface) • gluelamination (twoormorewebsaregluedtogether) -wetlamination -drylamination -solventlesslamination • extrusionlamination • hotmelt

Waxorresin-modifiedwaxisusedasahot-meltadhesiveinwaxlamination.Thewaxisheated,appliedtothesurfaceandcooled. Inwetlamination,oneofthewebsmustbeporoustoensureabsorptionofthesolvent,whiletheotherwebmaybeporousmaterial,aluminiumfoilorplasticweb.

Indrylamination,thegluelayerisdriedafterapplica-tion.Drylaminationcanbecarriedoutbyhotlamina-tion.Thedriedgluelayerisstickyathightemperaturesafteremergingfromadryingunit.Extrusionandhot-meltlaminationarehotlaminationprocesses.

Nosolventsandnodryingareusedinsolventlesslami-nation.Theadhesivesare100%solidmaterials,usedinsingle-componentortwo-componentsystems.

Theglueinwetlaminationisnormallywater-basedPVAcglue(solidcontentabout50%).Thegluedriesthroughabsorptionofthewaterbythepaperboardsurface.Nodryingunitisneeded.

Itisrecommendedthatthepaperboardbesheet-cuton-linejustafterthelaminationtoavoidcurlingproblems.

Itisalsoimportantthatthewebstobegluedtogetherhavesimilarcaliperandgrammageprofiles.Smooth-nessofthepaperboardisoftenveryimportantintheseprocesses.Otherfactors,suchastheglue,willalsoaffecttheendresult,butasmoothpaperboardhasahigherchanceofdeliveringthedesiredresult.

Thepaperboardsurfacemustbesufficientlyabsorbenttoensurethepenetrationofthegluesolvent.

Paperboardcanalsobegluedontoamedium(otherpaperboard,foam,etc.)assheets.Thisisnormallydoneafterprintingandtheprocessisknownaspastingorpaper-lining.Inotherwords,theprocessisdifferentbuttheendresultmaylooksimilar.

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Enduses

End uses 36<< Contents

Enduses

7. End uses

StoraEnsoConsumerBoardsisthemarketleaderinitsfield.Weproduceawideselectionofpremiumboardsineverycategoryandprovidethelargestvarietyofbarriercoatings.

Top-qualitymaterialsandinnovativesolutionsopti-mizetheperformanceofeachindividualpackageinitsparticularuserenvironmentandmarketingsituation.ConsumerBoards’offeringisbasedonend-useorientedbusinesscompetence,backedupbyinnovationandlo-gisticssupportthroughourInnoCentrefacilityandotherpartnerservices.

Forthebrandowner,designer,converterorprinter,thesuperiorityofpaperboardassuchisnottheheartofthematter.Thepackagingrequirementsforluxurycosmeticsarequiteunlikethoseforoven-to-tablefrozenfoods.Itisaquestionoffindingthecombinationofpaperboardproperties,gradeandgrammagethatwilloptimizetheperformanceofeachindividualpackage,whethertherequirementsaresuperiorstiffness,creasability,odourandtaintneutrality,ageingresistanceorsuperiorhotfoilstamping.

Product NamesBeverage &Multipack

Chocolate &Confectionery Cigarette

Cosmetics & Luxury

Detergent & Household

Aurocard

Chromocard

CKB

CosmocartT

Cupforma

Ensocard

Ensocoat

Ensogloss

Koppargloss

Kopparprint

Kopparwhite

Microliner

Natura

Neocart

Performa

Printocart

Tambrite

Tamfold

Tamwhite

Trayforma

TriplexBlanco

TriplexGris

TriplexMadera

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End uses 38

Understandingthecustomer’sbusinessismorethanaubiquitousbusinessphrase.Itisthemostimportantsinglecatalystbehindinnovativepackagingsolutionsandproactivepartnerservice.Therefore,theorganiza-tionofStoraEnsoConsumerBoardsisbasedontheBusi-nessSegmentManagementprinciple,whichcombinesproductionefficiencyandproductstreamliningwithend-user-drivenbusinessconcepts.

Allourcustomersareservedbydedicatedteams.ThemajorendusesservedbyStoraEnsoConsumerBoardsarepresentedbelow.Byclickingonaspecificproductinthetable,youcandownloadthelatestproductspecifica-tions(requiresinternetconnection).YoucanalsoaccessthesameinformationbygoingdirectlytoConsumerBoards’websiteatwww.storaenso.com/consumerboards.

Product Names Food Food Service Graphical Liquid Media Pharmaceutical

Aurocard

Chromocard

CKB

CosmocartT

Cupforma

Ensocard

Ensocoat

Ensogloss

Koppargloss

Kopparprint

Kopparwhite

Microliner

Natura

Neocart

Performa

Printocart

Tambrite

Tamfold

Tamwhite

Trayforma

TriplexBlanco

TriplexGris

TriplexMadera

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Enduses

7.1 Graphical

Workingwiththegraphicalindustryisauniqueexperi-ence.Youenteranenvironmentwheretheprinter’sex-actingprofessionalismismatchedonlybythedesigner’sboundlessimaginationincreatingevernewsolutionstocapturetheinterestandacceptanceofthetargetaudi-ence.

More strength and durabilityStoraEnso’sgraphicalboardsaremadebycombiningvariouspulpsintomultilayerconstructionsinordertoutilizethebestpropertiesofindividualpulps.Thistech-nologygivestheboardstheirsturdyandrigidstructure,unattainableincorrespondingwood-freecoatedpapers.Asaresult,ourgraphicalboardshavepreciselytherightstrengthandstiffnessforoptimalperformanceduringtheprintingandsubsequentfinishingstages.Sturdyboardsalsogivesuperiordurabilityinfinaluse.

Thisexcellentperformanceisfullycompatiblewithim-provedeconomy.Comparedwithalternativesolutions,StoraEnsoGraphicalBoardsproducesafinalproductwithconsiderablylesstotalweight,resultinginmoreproductsfromlessrawmaterial.

Smooth and efficient finishingOurgraphicalboardsarefullycompatiblewiththemate-rialrequirementsofvariousfinishingmethods.Theyaresuitedtovarnishingtreatments,aswellasdie-cutting,embossingandcreasing.

Wide spectrum of paperboard optionsStoraEnsooffersacomprehensiverangeofproductsforthegraphicalindustry,fromWLC(white-linedchip-board)throughFBB(foldingboxboards)andadvancedmultilayerCTMP(chemi-thermomechanicalpulp)boardstoSBS(solidbleachedsulphate)boards.Whatevertheapplication,thereisanoptimalchoiceavailable,de-signedforthebestinsmoothnessandbrightness,print-abilityandrunnability,andconsistenthighqualityfrombatchtobatch.

Applications

End uses of Stora Enso Graphical Boards

• Coversformagazines,books,brochures, annualreports,maps,notepads,andmanuals

• Cards:greetingcards,postcards,collectingcards, recipecards

• Media:audioandvideoCD/DVDpacks,display boards,ticketsandtags,calendars,folders

BackedupbyServiceCentreswithhighsheetingcapacityandavailableviaanactivenetworkofspecializedmer-chants,StoraEnsographicalboardsarefullyequippedtomeetthedemandsoftoday’sfast-movingandrapidlydevelopinggraphicalindustry.

Formoreinformation,visitourdedicatedsiteatwww.storaenso.com/graphical.

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7.2 Beverage and Multipack

Packaging BeveragesThebasicfunctionsofpackaging–toprotect,distrib-ute,inform,attractandsell–alsoapplytobeverageproducts.However,theworldofbeveragesisuniqueinitsabundanceandvarietyofproducts,withthemostex-clusiveliquorbrands,backedbyhundredsofyearsofhis-tory,coexistingwithfashionablesportstonicslaunchedonlyyesterday.Paperboardcartonsinbeveragespackag-ingofferauniquecombinationofbrilliantimagingqual-ity,functionality,versatilityandcost-effectiveness.

ApplicationsStoraEnso’sbeverageandmultipackboardsareusedforsecondarypackaginginvariousconstructionsandset-ups,ofwhichthemainstreamvariantsare:

• Solidcartonsmadeofhigh-caliperpaperboard • Laminatedcombinationsusingtoplinersand stiffeners • Litholaminationtoasingle/doubleface corrugatedbase

Foilormetallizedfilmlaminationisemployedinalargeportionofapplications,especiallyforpremiumbrands.

Beverage cartonsTypicalproductgroupsforsingle-packcartonsarewhis-ky,spirits,liqueurs,wineandchampagne.Inindividualapplications,elaborategraphicsandfinishingtreatments(embossing,hotfoilstamping,spotvarnishing,etc.)oftenplayamajorrole.

Solidcartonsareusedforallprincipalproductgroupsofalcoholicbeverages,whilelaminatedandlitholaminatedcartonsarepredominantlyusedforcognacs,cham-pagnesandwines.

Bag-in-boxapplicationscontainingupto3litersofwinehavequicklycapturedalargeshareofsales,especiallyinthelowandmedium-pricedcategories.Thebasicconstructionhasgreatpotentialforfurtherrefinementandnewdesigns.

MultipacksBeermultipackshavefirmlyestablishedthemselvesasjustthetooltoattractsupermarketbuyersandsecuremaximumturnoverfromminimumspace.That,how-ever,isnotthewholepicture.Adaptabletoindividualneeds,distributionmethodsandmarketingstrategies,multipacksworkforamultitudeofproductsandmar-kets.Theeye-catchingpackislightandstrong,andeasytobuy,carry,openandrecycle.

Thesuitabilityofpaperboardforinnovativeconstructionsandnovelpackagingconceptsisamajormarketingas-set,evidentinsuchbestsellersasmultipacksforbeerandliquorandingeniousbag-in-boxwinepackages.

Agenerousprintingareaandexcellentfull-colourqualitymakepaperboardcartonsbothaglobalbrandingtoolandasuperbvehicleforcommunication,abletocreateenhancedshelfpresenceandlong-termcustomerloyalty.Moreimportantstill,paperboardcartonsofferawealthofoptionsforpromotionalusesandsegmentation,localizationandtestingpurposes.

Thecrucialfactoristoknowwhatpaperboardpackagingcandoandhowtoinitiatetheinnovativeprocess.

TolearnmoreabouthowStoraEnsodoesthis,accessthePartnerServicessectionatourwebsite.

Tofindclearanswerstoahostofindustry-specificpack-agingissuesvisitwww.storaenso.com/beverage.

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41 End uses

7.3 Chocolate and Confectionery

Aboxofassortedchocolatesismorethanaverypracticalcontainer.Itisasignal,apromise,apersonalmessage.Nowonder,then,thatthepackageismadeoffibre-basedpaperboard–amaterialthatcombinesrationalfunctionalitywithseductivecharm.

ApplicationsPackagingsolutionsbasedonStoraEnso’schocolateandconfectionerypackagingboardscomeinavarietyofinnovativeforms,designsandsizes,madepossiblebythematerial’suniversalapplicabilitytoawholerangeofconverting,printing,finishingandfillingmethodsandtechniques,aswellasanumberofadvancedbarriercoatingoptions.Everyindividualpackagingprojectsetsitsowndemands.Asaruleofthumb,paperboardpropertiesthatplayacrucialpartintheselectionprocessinclude:

• organolepticperformanceformaximumsafety andusersatisfaction • opticalpropertiesandprintqualityforoptimum shelfpresenceandbranddifferentiation • convertibilityandrunnabilityfortrouble-free production • per-unitcost-efficiencyforprofitablepackagingof relativelylow-pricedproducts.

Odour and Taint PerformanceThesensoricsafetyofStoraEnsopackagingboardsrestsonfourpillars:

• purityofthebaseboards • barrierpropertiesofproprietarypolymercoatings • trackrecordovermanyyears • in-housetesting,researchanddevelopment

Purity, Cleanliness, Homogenous Quality ThecoresegmentofStoraEnsochocolateandconfec-tioneryboardscomprisesSBSbrandsproducedfrompurepulp,aswellasarangeofboardswithCTMPaddedforextrastrengthandyieldandthetraditionalFBBgrades.ThechoiceisextendedbytheWLCrangemadeofrecycledfibres,elaboratelyrefinedandtestedforuseindemandingfoodpackagingapplications.

Polymer CoatingsStoraEnsobaseboardscoatedwithproprietarybarriersubstancessuchasPE,PETandHighBarrierpolymerspreservetheoriginalflavouroftheproductandprovideprotectionagainstundesirableeffectscausedbylight,oxygen,humidityorgrease.

Matchingthemostsuitablebaseboardwiththeproperbarriercoatingisaperfectwayofmaintainingsuperiorproductqualityandprolongingshelf-life.

Forconsultationontheplanningandimplementationofyourownpackagingprojects,pleasecontactus.Also,ourdedicatedInternetsiteoffersacomprehensiveviewofpackagingbasedoninnovativeuseoffibre-basedmaterials.Formoreinformationvisitwww.storaenso.com/chocolate.

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Enduses

End uses 42

7.4 Cigarette

StoraEnsoCigaretteBoardsoffersawideandcost-effec-tiverangeoftobacco-packagingsolutions.Theprod-uctofferingincludesFBB(FoldingBoxboard),CTMP(chemi-thermomechanicalpulp)andSBS(SolidBleachedSulphate)optionstomeetallneeds.Thewideselectionprovidestherightboardchooiceforthedesiredposition-ingofanindividualcigarettebrand.

Just-in-timedeliveriestoprintersaresecuredbyfourhighlyefficientmillsinthreecountries.TheservicesarebackedupbyvariousR&Dprojectswhichsupportbrandownersandprinterstocreatesuperiorproductdesignsandapplications.

Findinganoptimalboardmaterialisfacilitatedwhenalloftheoptionscanbeobtainedfromasinglesource–amajorbenefittocustomers.Astrongpartnershipbetweenbrandowners,printersandStoraEnsoenablesthemostcost-efficientsolutionstobefoundandappliedinallareasofthevaluechain.

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End uses

43 Enduses

7.5CosmeticsandLuxury

Finding an optimal carton material for packaging cos-metics and perfumes is a demanding task where general rules of thumb are not easy to find. However, some of the key points are listed below for easy reference in order to ensure that the package fulfils its major functions – protecting the contents throughout the supply chain, attracting potential customers and building distinctive brand images.

StrengthandstructureformaximumprotectionAbility to withstand mechanical stress – vibrations, impacts, blows and bumps – is an absolute necessity for cosmetics cartons. The inner structure of the material must be such that the various layers of the paperboard do not become delaminated under any circumstances. For perfume cartons, on which solid printing, heavy tints and colourful graphics are often used, the paperboard’s structure must provide excellent smoothness as well as superior cracking resistance at the fold.

HighwhitenessforsuperbvisualimageHigh whiteness ensures good contrast in printing – im-perative for top-quality results. Furthermore, whiteness associates strongly with desired product features such as purity and cleanliness. If the package design employs large unprinted areas, high whiteness of the paperboard becomes all the more important.

A significant feature relating to whiteness is the paper-board’s ability to withstand UV radiation without yellow-ing. This is a vital consideration, especially if the carton is to be exposed to sunlight for extended periods.

FullchoiceofprintingandfinishingoptionsThe quality of the carton must mirror or even enhance the quality of the contents. Printing techniques should include offset, flexo and gravure. Suitability for digital printing is also rapidly gaining weight.

More important still is the possibility to use a whole range of finishing treatments and special effects, such as pearlescent pigment printing, satin UV varnish, glossy hot-foil stamping, positive blind embossing, or laser cutting. Depending on the design, the visual appearance of the paperboard’s reverse side and its printability can also be decisive factors, taking into consideration that on cosmetics cartons there is usually a need for a lot of product information.

OdourneutralityThe carton must be very neutral in its organoleptic prop-erties to ensure that, even after extended storage, no undesired odours will be emitted from the paperboard. Only the desired fragrances, those of the product itself, must be there for the consumer to enjoy.

For more information visit our dedicated site at www.storaenso.com/cosmetics.

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Enduses

7.6 Detergents and Household

Packagingsolutionsmustservemanyends.Theproductontheshelfmustbehighlyvisibleandrepresentativeandalsocommunicatehighquality.Atthesametime,itisimportanttoproduceecologicallysoundpackagingwithoutsacrificingsuchvitalfunctionsasproductsafetyanduserconvenience.Paperboardisuniqueinitsabilitytosatisfytheseconflictingrequirements.Paperboardcartonsarelightweightandstrong,functional,eye-catchingandascost-efficientinproductionastheyareinrecycling.

StoraEnsoistheworld’sleadingproducerofpackagingpaperboardanddeveloperofnewpackagingconcepts.Ourproductrangeissecondtonone.Atoneendoftheproductspectrumarethehouseholdproductpackag-ingboards,whichcanbefoldedintoanendlessvarietyofshapes.Attheotherarethedetergentpackagingboards,whosekeydevelopmentprincipleisusersafety.Inbetweenthetwoextremesisawiderangeofprod-ucts,varyingintherawmaterials,strengths,mechanicalproperties,bleachingdegreesandsurfacefinishesused.

Allhouseholdpackagingboardsareavailablewithap-propriatepolymercoatings.MaterialoptionsalsoincludeLumiLabelflexiblepackagingpapersaswellascorru-gatedpackaging.

Forconsultationonthechoiceofmaterialorotherpack-agingissues,pleasecontactus.

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45 End uses

7.7 Food

Thereisnosubstituteforfibre-basedpaperboardasthebestmaterialforimaginative,excitingandfunctionalfoodpackaging.Paperboardissmoothandstrong,lightandbright,versatileandcost-efficient.Itlendsitselfper-fectlytoalltheshapes,sizes,designsandconstructionsthatdifferentproductsandmarketsituationscallfor.Thematerialisalsoidealtousewithmetaldetectorsandothersafetymeasures.

ApplicationsPackagingsolutionsbasedonStoraEnsofoodpackagingboardscoveramultitudeofforms,designesandsizesinallmajorproductsegments:

• Chilled Foods: Vegetablesandsalads,meatand fish,processedfood,puddingsanddressings,etc.

• Frozen foods:Readymeals,fishandseafood,ice cream,bakeryproducts,etc. • Dry foods: Biscuits,cereals,candy,drinkpowders, teas,snacksandchips,spices,etc.

• Pet foods:Wet/drycatfoodsanddogfoods,etc.

Forprimarypackagingpurposes,vitalfactorsintheselectionofthepaperboardinclude: - Organolepticperformanceofthebaseboard/poly- mercoatingcombination - Opticalproperties(brightness,printability,smooth- ness,ageingresistance) - Convertibilityandrunnability(creasability,flatness, no-dustingperformance) - Strengthinrelationtothesizeandweightofthe contents(bendingstiffness,tearresistance, glueability)

Insecondarypackaging,cost-effectiveness,sourcereductioncapacity,stiffnessand,especiallyinthecaseofpromotionalpacks,suitabilityfordigitalprintingarepropertiesthatusuallyplayamoreprominentrole.However,everyprojecthasitsownspecificdemands.Forconsultationonyourspecificpackagingtasks,pleasefeelfreetocontactus.

The essential companion: barrier coatingsInfoodpackaging,preservingthefreshnessandpalat-abilityofeventhemostdelicatefoodsisanabsolutemust.Afullrangeofpolymercoatingsmakesitpossibletocreatecups,traysandcartonswhichperformoptimal-lyinspecificenvironmentsforspecificproducts.Ingen-iouscombinationsofbaseboardandcoatingcreateafullspectrumofeffectivebarriersagainstmoisture,oxygen,light,greaseorheat.

Readmoreaboutthefoodsectorandthemanyoptionsforpackagingfoodsatourspecialsite:www.storaenso.com/food.

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End uses 46

7.8 Pharmaceutical

Therangeofpharmaceuticalproductsisenormous,fromthemostpotentprescriptiondrugstoordinaryover-the-countermedicines.Accordingly,theroleofpackagingrangesfromensuringproductsafetyandpatientcompli-ancetoprovidingaversatiletoolforcommunicationandbrandbuilding.

ApplicationsStoraEnso’spharmaceuticalboardsareusedincartonsforallformsofprimarypackaging–aluminiumandcom-positeblisters,glassandplasticbottles,rigidandcollaps-ibletubes,andpouches.Ingeneral,cartonsforprescrip-tionmedicines(antibiotics,cardiacs,potentpainkillers,etc.)usefewercoloursandmoresubdueddesigns,whileOTC(overthecounter)products(vitaminsandmicronu-trients,painkillers,coldmedicinesandskincreamsetc.)investinattentionvalue,attractivedesignsandelaboratefinishing.

Sheetoffsetwithwater-basedvarnishisthedominantprintingmethod.

Basicvariabledata(lotnumber,use-bydate)isimprintedduringthepackingprocess,usingstamping,flexo,inkjetorlasertechniques.

NarrowWebflexoprintingwithinlineconvertingmaybeacost-efficientalternativeforsmallorderlotsandisalreadyappliedbyseveralconvertingcompanies.

Digitallyprintedcartonsarebeginningtogaingroundasaviablemarketingandtestingoption.

Thechoiceofpaperboardmaterialmustbemadeindi-viduallyineachcase.Typicalvariablesinclude:

• opticalproperties(brightness,printability, ageingresistance) • strength(bendingstiffness,tearresistance, glueability) • runnabililityinpackaginglines(creasability, flatness,no-dustingperformance,lasercodability) • qualityandhygieneconsiderations (materialconsistency,purity,cleanlinessand homogeneity,odourandtaintneutrality) • technicalsuitabilitytocase-specifictechnologies (digitalprinting,etc.).

Theapplicablegrammageisdeterminedbysuchfactorsasboxdimensions(biggersizesneedstifferpaperboardinordertoperformwellinthepackingprocess)andtheweightofthecontents(improvedcompressionresist-anceisneededforcartonscontainingheavyproducts,suchasliquidsinglassbottles).

Visitourwebsite,www.storaenso.com/pharmatolearnmoreaboutthepharmaceuticalpackagingmarkets,innovativepackagingconceptsandthechoiceofpaper-boardforindividualapplications.

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47 End uses

7.9 Food Service

Convenience for Food Service StoraEnsooffersafullrangeofadvancedmaterialsandintegratedsolutionsforthefoodservicemarketthatca-tertothemanydifferentneedsoftoday’sactiveconsum-ers,whetheritiseat-on-the-gooroven-to-tablemeal.

FoodServiceproductsderivetheirstrengthfromauniquematerialthatcombinesspecially-developedbase-boardsandproprietarypolymercoatingstocreatethebestqualityintermsofpurity,functionality,printabilityandconvertibility.

Formoreinformation,visitourdedicatedsiteatwww.storaenso.com/cupforma.

7.10 Liquid

Fluid Solutions, Full ProtectionTheoverridingrequirementforliquidpackagingistokeepthecontentsfreshandhygienic,unchangedand

untaintedfortheentirelifeoftheproduct.Thecartonmustalsobeattractive,buildbrandimageandboostsales.Inadditionitmustcomplywithtoday´sbestenvi-ronmentalpractices.

Readmoreaboutliquidpackagingatourspecialsitewww.storaenso.com/liquid.

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StoraEnso

Servicefacilities

ConsumerBoardsProductionand

Stora Enso Consumer Boards Production and Service facilities 48<< Contents

StoraEnso

Servicefacilities

ConsumerBoardsProductionand

8. Stora Enso Production and Service facilities

StoraEnsoConsumerBoards’productsaremanufacturedinFinland,Germany,SpainandSweden.Thetotalan-nualcapacityofthesixmodernandwell-managedmillsiscloseto2.6milliontonnesofSBS,FBB,CTMP,SUB

andWLCgrades.ExtrusioncoatingplantsinFinlandandSwedencomplementtheproductionofbaseboardswithcomprehensivefacilitiesformoistureandoxygenbarriercoatings.

8.1 Paperboard Mills

Baienfurt Mill, Germany

BaienfurtMillproducespackagingboardsforavarietyofgeneralpackagingapplicationsservingcustomersinpharma-ceutical,cosmetics,confectionery,cigaretteandothermajorindustries.Inaddition,theBaienfurtofferingincludesaselec-tionofgraphicalboards.

Annualcapacity:205000tonsofFBB*Machines: BM3,machinewidth476cm

Barcelona Mill, Spain

BarcelonaMillproducesWLCboardsbasedonrecycledfibres.Theproductsofthemillserveagreatvarietyofmarketsfromfood,confectionery,detergentandpharmapackagingtobookcoversandlabellingapplications.

Annualcapacity: 170000tonsofWLCcoatedonbothsides*Machines: BM1,machinewidth400cm

Fors Mill, Sweden

ForsMillproducesfullycoatedfoldingboxboardsforvari-ousmarketsegmentsincludingchocolate,confectioneryandcigarettepackaging.

Annualcapacity: 380000tonsofFBBandCTMPboards*Machines: BM2,machinewidth372cm BM3,machinewidth543cm

49 Stora Enso Consumer Boards Production and Service facilities *)in2006 << Contents

Imatra Mills, Finland

PaperboardproductionatImatraMillscomprisesliquidpack-agingboardsforallpackagingsystems,cupstockandotherfoodserviceboards,packagingboardsforthecosmetics,food,confectioneryandcigaretteindustriesaswellasaselectionofgraphicalboards.

Annualcapacity: 930000tonsofSBS,LPBandCTMPboards* 280000tonsofpolymercoatedboards*Machines: BM1,machinewidth440cm BM2,machinewidth560cm BM4,machinewidth630cm BM5,machinewidth490cmCoatingmachines:PE2,machinewidth230cm PE3,machinewidth230cm PE5,machinewidth280cm

Ingerois Mill, Finland

IngeroisPaperboardMilloffershigh-bulkfoldingboxboardsforfood,healthcare,pharmaceutical,liquorandhouseholdindustries.

Annualcapacity: 205000tonsofFBB*Machines: BM4,machinewidth458cm

*)in2006 Stora Enso Consumer Boards Production and Service facilities 50

StoraEnso

Servicefacilities

ConsumerBoardsProductionand

Skoghall Mill, Sweden

SkoghallMillisalarge-scaleproducerofliquidpackagingboardsandthemultilayerkraftbackCKBconcept.

Annualcapacity: 745000tonsofLPB,FBB,WTLand CKBboards*Machines: KM7,machinewidth540cm KM8,machinewidth810cm

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8.2 Extrusion Coating Plants

Forshaga Mill, Sweden

ForshagaMillproducesarangeofbarrierpolymercoatingsincludingfoilandfilmapplicationonbaseboards.Typicalendusesincludeliquidcartons,foodpackaging,lunchboxes,noodlecupsandothercartonpackaging.

Annualcapacity: 140000tonsofmultilayerpolymercoated packagingboards*Coatingmachines: BL922,machinewidth200cm BL923,machinewidth200cm

Karhula Mill, Finland

KarhulaMillisspecialisedinco-extrusiontechnologycombin-ingdifferentpolymerstoproducepolymercoatedboardsforliquidandfoodpackagingapplications.

Annualcapacity: 45000tonsofmultilayerpolymercoated packagingboards*Coatingmachine: PE4,machinewidth201cm

51 Stora Enso Consumer Boards Production and Service facilities *)in2006

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Servicefacilities

ConsumerBoardsProductionand

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8.3 Partner Services

LocationofStoraEnsoServiceCentres

StoraEnsoConsumerBoards’partnerservicesfocusonpromotinginnovativenessandenhancingtheefficiencyandprofitabilityoffibre-basedpackaging,thusaddingpermanentvaluetoourcooperationwiththepackagingcommunity.

ServiceCentres for reliability and maximum efficiencyThemissionofStoraEnsoServiceCentresistomeetcustomers’individualmaterialneedswithmaximumef-ficiency,flexibilityandreliability.MajorEuropeanmarketsaresuppliedwithpromptdeliveriesofpremiumboardsandgradescomingfromvariousStoraEnsomills.TheServiceCentresarelocatedinthemiddleofmainmarketareasandequippedwithhigh-performancesheetingmachinery.

Basedonamassivesheetingcapacityof80tonnesperday, ServiceCentre BaienfurtinGermanyofferstheconceptof2-5servicing.Thismeansex-milldeliveriesofboardsfromBaienfurtandotherEuropeanmillswithintwoworkingdaysfromstandardsheetstocksandwithinfiveworkingdaysfromreelstocks.

ServiceCentre Cartiberia inSpainservescustomersinthegeneralpackagingandgraphicalindustrieswithboardsfromtheBarcelona,Ingerois,SkoghallandImatramills.TheServiceCentrehasastandarddeliverytimeofthreetofivedaysex-factory.

OtherServiceCentres areinoperationinGermany,Swe-denandtheUK.

InnoCentreInnoCentrepresentsanewinterfacetothefutureoffibre-basedpackaging.Onthestrengthofmajorinvest-mentsmadeinpeople,machineryandequipment,InnoCentrefunctionsasavehicleforverticalinnovation,proactivelytestingnewtechnologyanddevisinginnova-tivepackagingconcepts.Theresultsofthedevelopmentworkcantakemanyforms,includingimprovedlogisticssolutionsandnovelpackagingbusinessmodels.TheservicesofInnoCentreareavailabletoallourpartnersinthepackagingvaluechain.

PartnerWebPartnerWebisStoraEnso’sdedicatedonlinereal-timesoftwaresystemformanagingthesupplychain.Theso-lutionemploysanordinaryInternetinterfacetoaccessacustomer-specificapplicationthatletstheusertrackandmanagetheentireorder-to-deliveryprocess.PartnerWebisuseddailybyanincreasingnumberofourkeypart-nersforimprovedoperationalefficiencyanddrasticallyreducedroutinework.PartnerWebalsosupportsdirectsystemintegrationpossibilitiesutilizingPapiNetXMLmessaging.

Formoreinformationvisitourdedicatedsiteatwww.storaenso.com/partnerservices.

OSKARSHAMN

LUMIPAPER

CARTIBERIA

LÜBECK

BAIENFURT

Stora Enso Consumer Boards Production and Service facilities 52

StoraEnso

Servicefacilities

ConsumerBoardsProductionand

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TestingMethods

Testing Methods 53<< Contents

TestingMethods

9. Testing Methods

Thischapterdescribesthetestingmethods

usedfordifferenttypesofpaperboards.These

measurementsaremadeinordertoguaran-

teetheconsistent,highqualityofour

products.Inthemillenvironment,testingis

conductedusingonline,autolineandmanual

laboratorymeasurements.

Themostimportantroutinequalitycon-

troltestsofdifferentproductsaredescribedin

thischapter.

Testing standards and calibration

ThetestsapplytoISO,SCANandTAPPIstandardmethods.Ifstandardsarenotavailable,themill’sownmethods,ormethodsdevelopedincooperationwithcustomers,areusedtopredictthepropertiesoftheproduct.Testingisperformedusingmoderndevicesandmostofthetestsaremadeinstandardconditions.Thestandardconditionsare:23°Ctemperatureand50%relativehumidityaccordingtothestandardISO187(SCAN-P2:75).

Testing methods

Online testing

Onlinetestingisusedtomeasurethemostimportantpropertiesofthepaperboard.Themeasuringheadoftheprocesscomputermeasuresbasisweight,caliperandmoisturecontinuouslyfromeverymachinereel.Theonlinemeasurementprovidesdatathroughouttheentiremachinereelandenablesthemachinepersonneltocontrolthebasicpropertiesofthepaperboardsimultane-ously.

Themachinepersonnelchecktheentiremachinereelvisuallyateveryreelchange.Theyalsocheckimpurities,colourandformationfromthecross-profilesample.Theonlinemeasurementproperties–grammage,caliper,moistureandbrightness–arealsocalibratedortestedinthelaboratory.

Automated laboratory testing

Thereareautomatedlaboratoryteststations(laterreferredasAutoline)inthepaperboardlaboratories.Thesetestingdevicescanbeequippedwithinstrumentssuchas:

• Two-sidedgloss • Caliper(thickness) • Two-sidedsmoothness(PPS) • Two-sidedroughness(Bendtsen) • Porosity(Bendtsen) • Burststrength(Mullen) • Basisweight • TSO(TensileStiffnessOrientation)

TheAutolinemeasuringdevicesmeasureandmove30cm-widecross-profilesamplesautomatically.Theresultsaresavedinthecomputerandtransferredautomaticallytoaquality-datahandlingsystem.

Manual laboratory testing

Sheetsacrossthemachinereelaredeliveredtothelaboratoryformanualtestingbythemachineperson-nel.Thesizeofasinglesheetis30cmx30cmandthenumberofsheetsdependsonthewidthofthepaper-boardmachine.Testingisperformedsevendaysaweekinthreeshifts.

EverymachinereelistestedaccordingtotheproceduresdescribedintheISO9001system.Someoftheproper-tiesaretestedacrossthewebinmanypositionsandsomeinonepositiononly.Inqualitycontrol,mostofthetestsareperformedimmediatelyafterproduction,withoutairconditioning.

54 Testing Methods << Contents

TestingMethods

General properties

Grammage Unit:g/m2 ISO536:1995

Grammageisdeterminedbyweighingaknownareaofasample.ThegrammageismeasuredbothonlineandbyAutoline.

Thickness Unit:µm ISO534:1988 SCAN-P7:96

Thicknessisdefinedasthedistancebetweenthetwooutersurfacesofasinglesheetmeasuredat100kPapressureandovera200mm2testarea.Inadditiontotheonlinetesting,thicknessismeasuredbyAutoline.

Moisture Unit:% ISO287:1985

Moistureismeasuredbytheonlinetesting.Themois-turecontentisalsocheckeddailyinthelaboratorywithameasuringdevicethatusesmicrowavestodeterminethemoisturelevel.Inadditiontothesemeasurements,weeklycalibrationisperformedbydeterminingthelossofweightofsamplesdriedatatemperatureof105°C.

Physical strength properties

Stiffness (L&W) Unit:mN ISO2493:92 SCAN-P29:95

Stiffnessisdeterminedbymeasuringthebendingforcerequiredtodeflectasamplefromitsoriginalpositionwhenoneendofthesamplehasbeenanchored.Stiff-nesscanbemeasuredasbendingstiffnessDIN5°,bend-ingmomentTaberorbendingresistanceL&W15°.Forexample,intheL&Wbendingresistancetest,thebend-ingdistanceis50mmforpaperboardand10mmforpaper.Testingisconductedinbothmachineandcrossdirectionsbyastiffnesstester.TaberstiffnessismeasuredaccordingtotheTAPPI489standard.

Surface properties

Roughness (Bendtsen) Unit:ml/min ISO8791-2:1990

Roughnessisdefinedastheflowofairwhichleaksbe-tweenthesurfaceofasampleandametalringpressedagainstthesurfaceunderspecifiedconditions.Rough-nessismeasuredonbothsidesofthesheetandthetestiscarriedoutbyAutoline.

Smoothness (PPS) Unit:µm ISO8791-4/1992

IntheParkerPrintSurface(PPS)smoothnesstest,smoothnessisdefinedastheaveragedistancebetweenthepaperboardsurfaceandametallicringpressedagainstthesampleunderspecifiedconditions.Airflowsinsidethemetalring.Theairleakagebetweenthemetalringandthesampleismeasuredbyaflowmeter,whichconvertsthevaluetoµm.ThePPSsmoothnesstestingmethodprovidesmoreinformationaboutmicro-scaleroughnessthantheBendtsenmethod.

Porosity (Bendtsen) Unit:ml/min SCAN-P60:87 ISO5636-3:1992

Porosity(ml/min)isdeterminedbymeasuringtheamountofairthatflowsthroughagivenareaofthesample.

Testing Methods 55<< Contents

Optical properties

InEurope,theISOstandardisnormallyusedtomea-surebrightness.WhenthebrightnessisexpressedasISObrightness,C/2lightmustbeusedforthemea-surements.SinceC/2lightdoesnottakeintoaccounttheeffectsofOBA(opticalbrightener)anddyes,thismeasurementgiveslowerbrightnessvaluescomparedtomeasurementsusingD65light.D65brightnesstakesintoaccounttheeffectsofbothOBAanddyes.

TheCIEwhitenessmeasurementusesawiderwave-lengthandcorrespondsmorecloselytohowhumaneyesrecognizethewhiteness.

TAPPIbrightness,measuredwithGEequipment,isusedintheUS.

Brightness D65/10 Unit:% SCAN-P3:93

Brightness C/2° Unit:% ISO2470:99 (ISO–Brightness)

CIE Whiteness D65/10 ISO11475,SCAN-P66:93

L*a*b* D65/10 SCAN-P72

L*a*b* C/2 ISO5631

Opacity Unit:% ISO2471

Brightness(%)isdefinedastheintrinsicreflectancefactormeasuredataneffectivewavelengthof457nm.Formeasuringbrightness,D65/10°illuminationwithadefinedamountofUVlightisnormallyused.

Althoughtwosheetsmayhavethesamebrightness,therecanbealargedifferenceinvisualperception.Vis-ualdifferencescanbeestimatedfromdifferencesintheL*a*b*colourcoordinatesintheCIELABcolourspace.L*isthescaleforthewhitenessimpression,rangingfrom0(black)to100(white).a*measuresshadesinthered/greenarea.Positivea*indicatesred,whileanegativea*valueindicatesagreenshade.b*measuresshadesintheyellow/bluearea.Positiveb*indicatesyellow,whileanegativeb*valueindicatesabluishshade.

CIELAB colour space

TheL&WElrephomethodmeasuresbrightness,colourproperties,fluorescenceandmanyotheropticalproper-tiesbyusingdifferentlightsandangles.

Theamountofopticalbrighteningagentsisalsodeter-minedbycalculatingthedifferencebetweenbrightnessD65/10unfilteredandbrightnessD65/10witha420nmcut-offfilter.

Gloss (Hunter) Unit:% TAPPIT480om-99 ISO8254-1:1999

Thesurfaceglossofthecoatedpaperboardorpaperisdeterminedasthereflectanceoflightfromthesheetsurface.Thelightstrikesthesurfaceatanangleof75°andthereflectionisrecordedbyaphotoelectriccell.Theresultisexpressedasthepercentageoflightreflected.TheglossismeasuredbytheHunterGlossTesterintheAutolineandiscalibratedwithatestpieceofknownreflectivity.

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56 Testing Methods << Contents

Glossary

Glossary 57<< Contents

Technical Glossaryabsorbency: abilityofapaperboardtotakeupandretainaliquidwithwhichitisincontact

blade coating: mostwidelyusedcoatingmethod,inwhichexcesscoatingmaterialisscrapedoffbyablade

bleaching: removaland/ormodificationofcolouredcomponentsinpulptoimprovebrightness,carriedoutin

oneormoreconsecutivestages

broke: paperboarddiscardedduringmanufactureorconverting;usuallyrepulped

bulk, specific volume: reciprocalofpaperboarddensity,alsoknownasspecificvolume

calendering: operationcarriedoutbymeansofacalenderonthe,atleastpartially,driedpaperorpaperboard,

withtheaimofimprovingthefinish,theprocesspermittingsomecontrolofthethicknessofthe

paperboard

caliper, thickness: thicknessofpaperboard

chemical pulp: pulpproducedbyusingcookingchemicalswhichdissolvelignin,theglueinthewood,

toreleasethecellulosefibres

chemi-thermomechanical

pulp, CTMP: chemi-thermomechanicalpulp;pulpproducedbyrefiningchemicallyimpregnated,

preheatedwoodchips

China clay, kaolin: mineralusedinpaperboardmaking,asbothfillerandcoatingpigment

CIE whiteness: degreeofwhitenessmeasuredaccordingtorecommendationsoftheCIE

(CommissionInternationaledel’Eclairage)

CKB,

Coated Kraft Back Boards: paperboardconsistingofeitherbleachedchemicalpulporamineral-coatedtoplayerorboth,an

unbleachedbackandamiddlelayerofunbleachedchemicaland/ormechanicalpulp;usedfor

packagingfoodandnon-foodproducts

coating: processbywhichpaperboardiscoatedwithanagenttoimproveitsbrightnessand/orprinting

propertiesoritsbarrierproperties;layerofextrudedplasticonpaperboardprovidesbarrier

propertiesorgoodprintabilityforthesubstrate;layerofpigmentsandbindingmaterials,suchas

latexes,improvesprintabilityofpaperboard

CTMP, see: chemi-thermomechanicalpulp

deinked pulp, DIP: recoveredpaperpulpwhichhasbeende-inkedthroughchemicalormechanicalprocessing

digital printing machine: printingmachinethatprintsdirectlyfromacomputerdatafileontopaperboard,usingthesame

imagetransfertechniquesasareusedincopiersandprinters;oftenincludesbindingoperation

DIP, see: deinkedpulp

FBB, Folding Boxboard: multi-layerpaperboard,oftenmineral-coated,withanouterlayerofsulphate(kraft)pulpandmiddle

layerofmechanicalpulp(groundwood,pressuregroundwoodorTMP;intopgradesCTMPpulpmay

alsobeapplied);usedprimarilyforconsumercartonsforpackagingofdryormoistfoods,cigarettes

andotherconsumerproducts;alsousedinthegraphicalindustryforcataloguecovers,postcardsand

folders,etc.

Folding Boxboard, see: FBB

filler: substance(oftenwhitepigment)addedtothefurnishinordertoimprovepaperboardproperties

fully bleached pulp: pulpthathasbeenbleachedtothehighestbrightnessattainable

furnish: mixtureofpulpsandfillerswhichisprocessedbythepaperboardmachinetomakepaperboard

gloss finish: shinyandhighlyreflectivesurfacequalityofpaperboardobtainedbyglosscalendering

grade: classificationofpaperboardsdifferentiatedfromeachotheronthebasisoftheircontent,appearance,

manufacturinghistory,and/ortheirenduse

grammage, gsm: massofpaperboarddividedbyarea,typicallyexpressedasg/m2;oneofthebasicunitstospecify

apaperboardgrade

10. Glossary

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58 Glossary << Contents

gravure printing, rotogravure: printingprocesswheretheimageisengraved(electronicallyorchemically)intheformof

cellsinthesurfaceofametalcylinder

groundwood pulp, mechanical pulp: mechanicalpulpmanufacturedbygrindingwood,againstagrindstoneforexample

gsm, see: grammage

hardwood: woodfromadeciduousbroad-leavedtree(suchasbirch,oak,beech,aspenoreucalyptus)

asdistinguishedfromthatofconifers

ISO brightness,

diffuse blue reflectance factor: intrinsicreflectancefactorataneffectivewavelengthof457nm;measureforthebright

nessofpaperboard

kaolin, China clay: mineralusedinpaperboardmaking,asbothfillerandcoatingpigment

laminated: productoverlaidwithalayerofplasticfoilorveneer

lignin: polymerwhichbindsthefibresinthewoodtogetherandgivesthemstiffness

long fibre pulp: pulpproducedfromsoftwood(softwoodpulp)

matt finish: mattcalenderedsurfaceresultinginadullfinishtothesurfaceofpaperboardand

havingadiffusereflection;oppositeofglossfinish

mc, see: moisturecontent

mechanical pulp, groundwood pulp: mechanicalpulpmanufacturedbygrindingpaperboard,againstagrindstoneforexample

moisture content, mc: weightofwatercontainedinwood,expressedasapercentageoftheweightoftheoven-

drypaperboard

offset press: printingpressusinganoffsetmethod,wherebytheimageistransferredfromtheplate

cylinderontopaperboardviaablanket,plateorimpressioncylinder

opacity: propertyofpaperboardthatpreventsshow-throughofprinting,theoppositeof

transparency

optical characteristics: characteristicsoftheappearanceofpaperboard,themostimportantofwhichare

shade,brightness,opacityandgloss

permeability: abilityofasurfaceorcoatingofpaperboardtoallowpassageofagas,liquidorvapour

permeance, porosity: combinedvolumeofthepores,capillariesandothervoidsbetweenthefibresandfillersin

apaperboard

plastic coating and laminating: coatingofpaperboardbypolymers,typicallypolyethylene,and/orlaminatingwith

othermaterials,typicallyaluminiumfoil,plasticfilmorotherpaperboard

plate: anymaterialusedtomakeaprintedimpressionbyletterpress,gravureorlithography

porosity, see: permeance

press: setsofopposingparallelrollsinapaperboardmachinethroughwhichthepaperboardweb

passesduringmanufactureandbetweenwhichitissubjectedtopressure,atthesametime

increasingthedrynessofthepaperboard

primary fibre, virgin fibre: woodfibreneverbeforeusedtomakepulporpaperboard

printability: functionandinteractionofpaperboardwithothercomponents,e.g.theinkintheprinting

process;subjectiveassessmentjudgedfromtheprintingresultandcoveringallthepaper-

boardpropertiesthatinfluencetheresultsofprintinganimage.Compare:runnability

recovered paper: Usedpaperandboardseparatelycollectedforre-useasfibrerawmaterialinpaperand

paperboardmanufacture

reel-fed web offset printing: printingonacontinuousrollofpaperboardinaprintingpresswhichusesacurved

printingplatemountedontheplatecylinder(HSWO)

rotogravure, gravure printing: printingprocessinwhichtheimageisengraved(electronicallyorchemically)intheform

ofcellsinthesurfaceofametalcylinder

roughness: degreeofroughnessofthesurfaceofpaperboard;oppositeofsmoothness

Glossary

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runnability: featurecoveringallthepaperboardpropertiesthatcreateatrouble-freerunthrougha

paperboardmachineorprintingpress(alsohowwellcartonsrunonanautomatic

packagingline);seeprintability

SBS, Solid Bleached Sulphate Board: paperboardconsistingofoneorseverallayersofbleachedchemicalpulp,oftenalso

pigmentcoated,usedinthegraphicalindustryandforvariousconsumercartonsfor

packagingdryormoistfoodproductsandinthenon-foodsector,typicallyforcigarette

andluxurygoodscartons

sheet-fed offset printing: offsetprintingwhereindividualpiecesofpaperboardarefedintothepress

short fibre pulp: pulpproducedfromhardwood(hardwoodpulp;e.g.birch,oak,beech,aspen,eucalyptus)

sizing: processwhereasizingagent(e.g.starch,ASA)isaddedtothepaperboardtoincrease

strengthanddecreaseabsorbance

smoothness: degreeofevennessandregularityofthesurfaceofapaperboardsheet;oppositeof

roughness

softwood: woodofpine,spruce,orotherconifers;withtheadvantageofhavinglongfibreswhich

enhancethestrengthofpaperboard

Solid Bleached Sulphate Board, see: SBS

specific volume, bulk: reciprocalofpaperboarddensity,alsoknownasspecificvolume

SUB (Solid Unbleached Board): paperboardusedforfoodandnon-foodcartons,consistingofableachedchemicalpulp

oramineral-coatedtoplayerorboth,anunbleachedbackandunbleachedchemical

and/ormechanicalpulpmiddlelayers

sulphate pulp, kraft pulp: chemicalpulpproducedbycookingwoodchipsinanalkalinesolutionofsodiumhydroxide

andsodiumsulphide

tearing resistance: mechanicalpropertyofpaperboard,forceneededtotearpaperboard

thickness, caliper: thicknessofpaperboard

TMP, thermomechanical pulp: mechanicalpulpproducedbythepressurizedpre-steamingofwoodchipspriortodefibra-

tioninarefiner

web fed offset printing, web offset: offsetprintingonarollofanysubstratethatpassescontinuouslythroughaprintingpress

White Lined Chipboard, WLC: paperboardmademainlyorwhollyfromrecoveredfibres,oftenmineral-coated,and

usedforconsumercartonsfordryfoodandnon-foodproductsaswellasgraphical

enduses

virgin fibre, primary fibre: woodfibreneverbeforeusedtomakepulporpaperboard

WLC, see: WhiteLinedChipboard

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