How to create a folding carton What is cardboard [Paperboard] • Paperboard is usually 0,254 mm [0.01 inch] thicker than paper. ISO standards designate paperboard as 2 paper with more than a 224 g/m basis weight, with exceptions. Paperboard can be single ply or multi-ply and is lightweight and easy to form and cut. Since it is strong, it is useful as packaging material. • The first carton made from paperboard was produced in England in 1817. By the 1860s, folding cartons were available and by 1974, oven able paperboard had been discovered. • Article Source: http://EzineArticles.com/6152841 Invention and development • In the 1840s, cartons were made by hand and held together with tacks and string, and used only for expensive items (such as jewelry). • Although Charles Henry Foyle is described by some as the "inventor" of the paper carton, mass production of the cartons was invented, partly by accident, at the Robert Gair Company in Brooklyn, New York. Machinery at the end of the press had been set up carelessly by a pressman, and the machinery cut through the material. This ruined the press but gave them an idea: printing and cutting could be done with one machine. • Previously, cutting of printed cardboard had been done manually. From the mistake in 1879, Gair developed a process for mass production of boxes. • In 1897, the National Biscuit Company (Nabisco) became the first large company to adopt the new cartons, for biscuits. Other manufacturers soon followed. With inexpensive packaging now even common items could be placed in a showy carton and each carton became its own advertisement. The product was also protected, and the contents had a longer shelf life. Types of creasing • Single side creasing • Multi-Score creasing • Male / Female Flexible Dies • Male / Female Solid Dies Single side creasing Single side creasing • Poor alternative to ”real creasing” • More like a compression of the paper • Not a creasing line that is easy to bend • Can be used for low quality products, like hangers for socks etc. Multi-Score Flexible Dies Multi-Score Flexible Die Multi-Score Flexible Die Multi-Score Flexible Dies • Three cutting lines close together • Very good for simple boxes • Must run in anvil position • Engraving must be turned 3 – 5 degrees, due to the forces from the creasing lines Male / Female Flexible Dies Male / Female Flexible Dies Male / Female Flexible Dies • Low cost alternative to solid dies • Female plate is acting as an anvil for cutting, as well as for creasing • Exact location is therefore required • Pin mounting system used Male / Female Solid Rotary Dies Male / Female Solid Dies Male / Female Solid Dies • EDM made solid dies • Engraved cutting and creasing lines on top position die • Grooves engraved into the die in anvil position • Anti-backlash gears Male / Female Solid Dies • Discs to control lateral movement • Timing marks on gears Waste removal • Small pointed pins in anvil • Counter holes in solid die • Bars with a slot ”tears” (comb) the waste away from the pins • Often used in Flip Top Cigarette boxes, due to nesting of boxes Pin Picker and Comb Anvil Roll Anvil Roll Pins Pin Comb Comb Waste material is removed off the pins by the comb Waste Pin picker and comb Pin stripping • Pin stripping works by impaling die cut waste on a series of pins, then “combing” the waste off and into a vacuum • Pin stripping allows for the maximum degree of carton nesting and efficiency Creases • Zero Clearance • Interfering Zero Clearance Male Male does not enter female 0 Female Interference Male enters female to create a more pronounced crease Male .005” or .013mm Female Board • Recycled • Virgin Solid Bleached Board Solid Unbleached Board Folding Boxboard White Lined Chipboard Cutting angles Forces when cutting • Big angle = big forces • Small angle = small forces Deflection of a Solid Die Udbøjning - skærevalse Web width : 330 mm [13”] 288 mm cutting line across web [10 N/mm] [mm] Udbøjning 0,0250 0,0200 0,0150 Udbøjning Deflection 0,0100 0,0050 [Z, 1/8” CP] 0,0000 60 65 70 75 80 85 90 95 100 105 110 115 120 Cardboard Folding Techniques Automatic folding and glueing Testing • Test the creasing lines in a real production environment • Discuss the product with your customer Packaging Market • Folding cartons will see an average annual growth rate of 7.9% in BRIC (Brazil, Russia, India, China) between 2010 and 2016. •The majority of this growth comes from the food, healthcare and electronics industries. •Global actual consumption of carton-board will grow by an average of 4.4% annually from 2010 to 2016, •Asia accounted for 45% of the total volume, followed by America and Europe with a combined total of 52%. •It is estimated the Global board product market will be worth $210B by 2016 • Most types of folding cartons can be converted using a rotative conversion process, but are currently converted flat bed General Box Carton product. • RotoMetrics already produces tooling for various OEMs throughout the world • Can be cut using either solid tooling or flexible dies MARKETS •Pharmaceuticals •Cosmetics •Sleeves •Hot and cold beverages •Flexible Packaging Packaging – Food To Go • Food to Go has been a major success for RotoMetrics • Environmental drivers force a move away from 100% plastic to box carton • Sandwiches, Pasta, Rice, Noodle trays, Tortillas, Wraps and Pita bread BENEFITS • Box carton out sells the plastic packaging by a factor or 3-1 • Created from 95% card with a 5% lining. Shelf life is longer Food to go Digital press • Dries out the cardboard • ”Cracking” can appear • Avoid black colors on creasing lines • Avoid 180 degrees bend • Run fully rotary, not semi rotary Thank you for listening! Any questions please ?