pi

What is the "flute" of a corrugated box?

"Flute" is the term that describes the wavy medium between the two faces of liner board that makeup corrugated. Flutes range from A, the thickest/tallest to E, the thinnest or even F or Micro, which have hardly any "wavy" to them.

What three material characteristics might be important for some machinability on a VF/F/S machine?

Coefficient of friction, yield point, and sealability

What do we mean by the term "fragility" when describing a product? Give specific examples.

"Fragility" describes a product's susceptibility to damage and addresses the following question: What is the safe working load? What is the critical drop and "G" level? What are resonance frequencies and their response to random vibrations? What are the critical temperatures? What is the critical humidity? What is the projected shelf-life? What is the critical discharge voltage?

What are "Mil-Spec" boxes or packages?

"Mil-Spec" denotes a package proscribed by the US-UN military procurement process. These specs are usually for special handling, extended storage, extreme conditions or other demanding requirements. Mil-Spec packaging must be made as defined by the procurement documents, and must be exactly as defined: no substitutions without prior permission (difficult to obtain). Mil-Spec packaging usually requires special materials and-or components not generally readily available.

How thick is a 150-gauge film in thousandths of an in.? How many mils is that?

.0015" = 1.5 mils

What do we mean when we say that a load is 87% are efficient?

13% free space exists within the pallet envelope.

What should be the minimum storage capability of a pallet load according to the Food Marketing Institute?

30 days at 32 degrees C (92 degrees F) and 80% relative humidity, stacked two loads high

What is the standard pallet size set by the Grocery Manufacturers of America?

48 in x 40 in

What is the typical shunting speed go a rail boxcar?

8.4 kilometers per hour or 5.2 miles per hour.

What is a die-cutter?

A die-cutter is a machine or an attachment to a flex o that uses a sharp blade set into a wood block or form to cut the box blank into special shapes. It can cut holes, angles and angled scores, and do perforations to make heavy box board fold easier. Die-cutters come in rotary that can be a station on flex or a standalone machine. A "flat bed" die-cutter has the blade set into a large board, and the corrugated is placed between the "die" and a flat plate to do the cutting. The flatbed is more manual and slower than a rotary, but the tooling is much more economical.

Which is easier to make, a fin seal or a lap seal? Why?

A fin-style vertical seal might nit be able to resist peeling apart. even though it is still hot.

Under what distribution circumstances might the planned shipping container not be used?

A household toaster many be packed in a primary paperboard carton; six toasters may be packed into a corrugated box. However, the study corrugated box may go only as far as the local distribution warehouse. From that point, the actual distribution container many become the carton that houses each toaster.

Why might a heat seal's poor hot-tack performance slow down a filling operation?

A poor hot-tack seal might not be able to resist peeling apart, even though it is still hot.

What is the difference between a printer-spotter and a flex folder-gluer?

A printer-spotter can print out onto the box board, add scores (creases) and other minor operations. A flex folder gluer can print, slot, fold, glue, and stack completed boxes for delivery. Some flex machines even have rotary die-cutting sections.

What are the other flutes used for?

A, E, F and Micro flutes are used in niche markets and for special-purpose packaging where volume justifies the different board type.

At what point in a package design should distribution packaging be considered?

At the inception of a product's design.

What are the predominant flutes used in box making?

B and C flutes and BC double wall comprise the bulk of corrugated boxes.

Why is it always necessary to specify the permeant(s) when discussing barrier properties?

Barrier is a nonspecific word that describes a material's ability to prevent gases from permeating through the volume of material. The barrier qualities of a given material vary, depending on the gas being permeated. It is not enough to say, " We need a high-barrier material." The gas to which a barrier is required must be specific.

What does "basis weight" mean for paper?

Basis Weight is how paper grades are listed. It is the weight of 1,000 square feet of paper (U.S.) or the "grams per square meter" for Europe and other foreign markets.

Why is corrugated glue called starch?

Because the main ingredient in corrugated glue is FDA-approved food grade corn starch. Corn starch plus water makes glue that adheres the medium to the liner board.

What is "converting equipment"?

Box board comes from the corrugated as a flat sheet, perhaps containing some scores. "Converting equipment," such as printer-slotters, flex folder gluers, tapers, gluers, stitchers, die-cutters (flat bed and/or rotary) transform the flat sheet of corrugated board.

Can boxes be made "waterproof"?

Boxes can be made moisture resistant and water resistant, but not fully waterproof.

Can you look at a box and tell how it is made?

Boxes have a "right hand" and a "left hand". The first liner medium combination of the corrugated is the "single face" side, and an observer can determine that by looking fir faint lines in the surface. The other liner, known as the "double back" liner, is much smoother.

How can boxes be made for fruit, vegetables, fish, and chicken be kept from coming apart when wet?

Chemicals can be added to the starch to increase moisture or water resistance. Also, boxes can be wax coated or plastic coated inside or outside to help them hold together. Some box styles add to the ability to hold ice or or wet product without the box coming apart.

Describe the co-extrusion process and explain its advantages, compared with alternate systems.

Co-extrusion combines the outputs of two or more extruders so that a curtain of material exiting the extruder is actually multiple materials fused together. It is solvent-less

How would you ensure that you distribution packages are neither over designed nor under designed?

Compare packaging and damage cost and balance them with a desired acceptable damage rate.

What is the difference between compression strength and stacking strength?

Compression strength is a dynamic value measured over a short time Stacking strength is measured s a static volume over time

What is "Conditioning"?

Conditioning is the act of bringing a package, prior to testing, to a set of "standard conditions": 73 degrees F (+/- 1 degree) (23 degrees C +/- 1 degree C) and % RH for 24 hours prior to testing.

Why are there so many popular grades?

Differences in their fiber source, manufacturing processes and even geographic location influence the quality; also, the intended end use of the paper is taken into consideration in the making paper.

Vibration is described as a spring/mass relationship. What are the three conditions that can result from a vibrational input?

Direct coupling, where output equals the input Resonance, where output is greater then the input Isolation, where output is less than the input

You want a transparent package with a high oxygen barrier. What two polymeric materials are candidates for adding barrier properties to the laminate structure? If the package did not need transparency, what other options might you consider?

EVOH and OPP. EVOH is used as a high oxygen barrier. However, EVOH absorbs water and must be sandwiched between materials that will keep moisture away from it. Oriented polypropylene's (OPP) combination of excellent base properties at a economical cost make it one of the most popular materials for wraps and laminates having sparkling clarity. Foil and metaled film are other non-transparent.

What provision would I need to make if I were designing an EVAL-based barrier laminate for an organic soup product?

Ensure that the EVAL film selected is a barrier to the organics in the soup, and also assure that a very good moisture barrier is used in the laminate.

What is "Preconditioning"?

For consistency, prior to testing package samples should be "oven-dried" (warm, dry atmosphere) for 24 hours prior to the conditioning cycle.

Is the single face side ever placed on the outside of a box, or is this an error?

For special reasons, a box can be made with the smoother surface on the inside. This is easy to do, but not commonly done.

What vibration frequency range is of the greatest concern to packagers?

Frequencies below 30 Hz.

What is the advantage of a HF/F/S machine over a VF/F/S machine?

HF/F/S machines can have many operating stations grouped along the horizontal travel path of the pouch. This allows for multiple filling heads, steam purges and other activities.

Drops resulting from manual handling are influenced by the nature of the package. Describe five relationships between the package and manual handling drops.

Heavier products have slower probable drop height, unitized loads will experience fewer drops, handholds reduce the probable drop height, address labels will orient the drop to a label-up position, unitized loads will experience fewer drops than individual packages and cautionary labels have only a minor effect on either drop height or the number of drops

What are two units or measurement most commonly used to describe vibration?

Hert and Frequency

Define "distribution environment".

How will the product be handled? How will it be stored? How will it be transported? How high will it be stacked? What will the temperature and humidity range be? How many times will it be transferred and handled? What kind of pallets will be used? Will it be united or containerized?

A 25-micrometer-thick plastic film has a moisture permeability that is 840 mg/100 square in./ 24 hours. What is a likely permeability if we go to a 12.5 micrometer film of the same material?

It will increase to 1680 mb/100 sq in/24 hrs

What are the three main types of box making paper?

Kraft Liner Board (KLB), Performance Graders for ECT board and Corrugated Medium

Describe the laminate structure of a juice box container and explain the purpose of each layer.

Laminates for aseptic packages usually consist of seven material layers. Paper provides body, while aluminum foil provides a barrier. The ionomer provides a superior bond to the aluminum metal.

Are chemicals used to make boxes? Why or why not?

Many chemicals are used throughout in box making. The "starch" that holds the corrugated board together may have chemicals to improve strength, moisture resistance. Surface treatments contain chemicals to meet special needs, such as cold storage or slip protection.

In what order are the components of a laminate specified?

Material plies are properly listed from the outside of the package to the inside.

What are the extracts incurred when a product has poor pallet area utilization?

More pallets are needed more stretch wrapping is needed more storage pieces are needed in warehouse more tractor-trailer loads are needed to transport products forklift trucks operate longer

What problem is inherent to odd-shaped shipping containers?

Odd shapes do not pack well in a mixed-product pallet load.

What is paper made from?

Paper for boxes is made from any plant, including trees that contain woody cellulose fibers.

How long have paper making and box making been around?

Papermaking has existed for centuries. Paper box making has existed for a little more than 100 years.

Why are there so many different grades within the three major types of box making paper?

Performance vs. cost and other economic factors drive the variety of different paper weights and finishes for box linerboard paper.

What is the most common box closure method?

Poly film tape is the predominant closure, followed closely by glue. Glue is a favorite in automatic machines, while tape is common in semiautomatic operations. Stitches are rarely used due to the special equipment required and are limited to applications where specifically required, such as some government or military packages.

From an appearance and marketing point of view, what might be the advantages of a pouch made on an HF/F/S machine?

Pouches made on HF/F/S machines are characterized by a three-sided edge seal. An advantage for graphics is that both front and back panels are free of seals. HF/F/S pouches can be easily accommodated to produce gusseted stand-up pouches to provide an attractive billboard for a product.

How might you recognize whether a pouch was made on a VF/F/S machine or a HF/F/S machine?

Pouches made on a VF/F/S machine feature a seal across the pouch top and bottom and a vertical seal across the center of the back. Pouches made on HF/F/S machines are characterized by a three-sided edge seal.

What are the advantages of using ASTM D4169 or an ISTA General Simulation test over ship tests?

Pre-shipment testing reveals inadequate product design or packaging long before it starts costing money

How is preprinted liner utilized?

Preprinted liner is applied to corrugated board at the double back station. the preprint contains a registration mark that is read by other converting machines to assure proper alignment. Preprint provides a premium appearance at a premium cost, and also produces additional waste.

Is it possible to print a picture on a box?

Prior to the 1970s, the answer was no, but with preprinted liner board, spot labels and halftone flexographic plates, some surprisingly sharp graphics are being printed on corrugated board. Board quality is the biggest factor in achieving an acceptable image.

List some of the considerations you would take into account when designing a distribution package.

Product design (fragility), the distribution environment, the primary container could become the shipping container, complementary primary and shipping containers, dimensions for maximum efficiency, ease of (package) assembly and disassembly, multiple use and reuse, compliance with legal and /or carrier requirements, disposal of packaging waste material, efficient materials handling.

Where are the scores (creases) put on a box?

Scores for the top and bottom of the box are applied at the corrugator and scores for the other four edges are applied either at the printer -flexo or die-cut machine.

Define the terms "shock" and "resonance."

Shock is an impact characterized by a short-duration, relatively high intensity dynamic event with a sudden change in velocity. Resonance describes the condition in which a vibration input is amplified.

Name three methods of unitized load handling, and comment on the advantages and disadvantages of each.

Slip sheets are economical, take up little space and are light. However, the equipment is not universally available and is more expensive and is slower to operate. Pallets are universally available to a variety of handling situations and locations. However, they are costly and take up space, and disposal can be difficult. Clamp trucks use no added materials, but the geometry and character of the load must be such that it can be squeezed between truck clamps.

How do you know a box meets all applicable regulations and requirements?

Some regulations spell out requirements for the manufacture of the box and all components of the package. Others require the manufacturer to know and comply with the regulations. The ensure compliance, myriad tests can and sometimes should be performed. These tests are prescribed and detailed by the applicable agency, such as ASTM, ANSI, DOT, IATA, ISTA, ISO, FDA, USDA, EPA and many others. All are published.

Describe how stack resonance occurs.

Stack resonance occurs when the bottom container goes into resonance and passes that input to the container above it. This happens in succession for all containers in the stack until the top container bounces off the top of the head.

Shock and vibration are typical distribution environment hazards. List six more.

Static compression, dynamic compression, piercing and puncturing, racking and deformation, elevated temperature, reduced temperature, low pressure, light, moisture/water, biological hazards, time, contamination

List methods of increasing the shipping stability of a palleted unit load.

Strapping, stretch wrapping, high friction inks/coatings and high tack packing adhesives.

Discuss the dangers of using a sequential approach to package design.

Such a product, designed only with its end use in mind, is like to add to the manufacture's protective packaging costs. More costs will be incurred if the product cannot be efficiently fitted into a standard distribution system.

What is the Box Makers Certificate?

The Box Makers Certificate is a stamp printed on the box that tells the end user and shipper-freight carrier that the box meets or exceeds requirements for the rules (tariffs) for that particular box. "Standard" BMCs exist for regular boxes, particularly hazardous material boxes, require special markings. These markings supersede or even replace the regular BMC. UN-marked boxes have very stringent regulations and penalties for failure to comply with regulations. Failure to comply with a standard BMC rule may result in freight carrier refusing to accept shipment.

Why should pallet overhang be avoided?

The Food Marketing Institute holds pallet issues responsible for about half of all observed damage and cities poor pallet footprint as the single largest cause of shipping damage. Of this damage 50% is attributed to poor pallet stability and 35% is attributed to poor pallet overhang.

What are some tests associated with the regulations and requirements?

The Mullen Test determines the burst strength of a box, ECT determines the stacking strength. The Cobb test determines the ability of boxes and box board to resist moisture and water absorption. The Pin Adhesion Test determines the quality of the corrugated board. In addition, performance criteria have been developed by multiple agencies, especially the UN fo Haz-MAt the require cyclic impact (vibrations), drop and stacking strength testing. Some packages must be manufactured to exact requirements specified and tested for verification of the box's quality.

Packaging damage and loss is normally greater in the summer than in winter. Explain why.

The damage and loss is mostly attributable to higher humidity.

A box falls off a conveyor. What orientation will cause the greatest damage to the container, and what orientation is likely to cause the greatest damage to the contents? Why?

The greatest damage to the container is from edge or corner drops and greatest to damage to the contents is a flat drop on one of faces. There may be a need for greater cushioning protection for the product.

What effect does address label location tend to have on the orientation of a package?

The label tends to orient the drop to a label-up position.

You are investing a product that has a poor shipping history. There are three things that might be changed to improve the shipping experience. What are they?

The product, package and distribution environment

Is there any correlation between the different types of paper?

There are similarities, but no direct correlation. Each type has a different end use purpose and properties.

Raising the temperature or increasing the pressure of heat-sealing jaws in some instances can decrease bond strength. Why?

Time/temperature/pressure data should be developed for all heat-sealing systems. Excessive combinations of time, temperature and pressure tend to force melt from the seal area and create a weaker seal.

What is the objective of combining various materials into a laminated packaging material?

To combine the best of all material properties into a single package structure.

The distribution packaging cost is not just the cost of the distribution package. Explain.

To find the minimum system costs, the Toal distribution costs-Including packaging cost and damage cost-must be established.

A product arrives damaged. Inspection of the shipping container reveals no marks or clues that the package had been dropped or otherwise mishandled. Describe two mechanisms by which the damage could have been caused.

Vibration damage from relation motion and vibration resonance.

What are the two basic mechanisms by which vibration can damage goods?

Vibration damage from relative motion and vibration resonance.

Describe the difference between dry-bond laminating and wet-bond laminating.

Wet bonding requires that at least one substrate be porous enough to allow adhesive solvent or water to escape. Almost invariably, this substrate is paper. Adhesive is applied to one substrate, the two substrates are nipped together and the whole sent through an oven to set the adhesive. In dry bonding, adhesive is applied to the substrate and then dried of solvents. The resinous adhesive is either tacky or can be activated and set by heat. The second substrate is joined by a heated nip against the first to create a bond.

When designing a laminate, what material: a.) tolerates the highest use temperature? b.) is an economical way of adding stiffness or bulk? c.) is a good oxygen barrier and can be thermoformed? d.) heat-seals through grease and bonds well to aluminum?

a.) PET and polycarbonate have the highest use temperatures. b.) Paper c.) Meat or cheese packs that have one part of the web drawn to a product-conforming tray require easy formability of the web stock. The web stock also needs to have clarity to show off the product, and it must have good oxygen-barrier properties. This combination of properties is best found in nylon-based laminates. d.) Ionomers are used when high melt strength is needed. Ionomers tolerate contaminants and create adequate heat seals across greasy contaminants and have superior adhesion capability on metal surfaces.