Paperboard

Paperboard
Paperboard is a thick paper-based material. While there is no rigid differentiation between paper and paperboard, paperboard is generally thicker (usually over 0.30 mm, 0.012 in, or 12 points) than paper and has certain superior attributes such as foldability and rigidity. According to ISO standards, paperboard is a paper with a grammage above 250 g/m2, but there are exceptions.[1] Paperboard
Paperboard can be single- or multi-ply. Paperboard
Paperboard can be easily cut and formed, is lightweight, and because it is strong, is used in packaging. Another end-use is high quality graphic printing, such as book and magazine covers or postcards. Paperboard
Paperboard is also used in fine arts for creating sculptures. Sometimes it is referred to as cardboard, which is a generic, lay term used to refer to any heavy paper pulp–based board, however this usage is deprecated in the paper, printing and packaging industries as it does not adequately describe each product type.

Contents

1 History 2 Terminology and classification 3 Production

3.1 Raw materials 3.2 Pulping

3.2.1 Bleaching

3.3 Plies 3.4 Coating

4 Grades 5 Common terms 6 Paperboard
Paperboard industry 7 See also 8 References 9 Further reading 10 External links

History[edit] In 1817, the first paperboard carton was produced in England. Folding cartons first emerged around the 1860s and were shipped flat to save space, ready to be set up by customers when they were required. 1879 saw the development of mechanical die cutting and creasing of blanks. In 1911 the first kraft sulphate mill was built in Florida. In 1915 the gable top milk carton was patented and in 1935 the first dairy plant was observed using them. Ovenable paperboard was introduced in 1974.[2] Terminology and classification[edit]

Crush-proof Cigarette pack
Cigarette pack made of folding boxboard.

Terminology and classifications of paperboard are not always uniform. Differences occur depending on specific industry, locale, and personal choice. In general, the following are often used:[3][4]

Boxboard or cartonboard: paperboard for folding cartons and rigid set-up boxes

Folding boxboard
Folding boxboard (FBB): a bending grade capable of being scored and bending without fracture Chipboard: a recycled, low quality board

White lined chipboard
White lined chipboard (WLC): a white, often clay-coated chipboard

Kraft board: a strong virgin fiber board often used for beverage carriers. Often clay-coated for printing Laminated board: a lamination of paperboards and other materials, for example liquid packaging board Solid bleached board
Solid bleached board (SBB) or solid bleached sulphate (SBS): clean white board used for foods etc. Sulphate refers to the kraft process Solid unbleached board
Solid unbleached board (SUB): board made from unbleached chemical pulp

Containerboard: a type of paperboard manufactured for the production of corrugated fiberboard

Corrugated medium: the inner fluted portion of corrugated fiberboard Linerboard: a strong stiff board for one or both sides of corrugated boxes. It is the flat covering over the corrugating medium.

Other

Binder's board: a paperboard used in bookbinding for making hardcovers.

Production[edit] See also: Paper
Paper machine Fibrous material is turned into pulp (paper)/pulp and bleaching of wood bleached, to create one or more layers of board, which can be optionally coated for a better surface and/or improved visual appearance. pulp board are produced on pulping machines that can handle higher grammage and several plies. Raw materials[edit] The above-mentioned fibrous material can either come from fresh (virgin) sources (e.g. wood) or from recycled waste paper. Around 90% of virgin paper is made from wood pulp.[5] Today paperboard packaging in general, and especially products from certified sustainable sources, are receiving new attention, as manufacturers dealing with environmental, health, and regulatory issues look to renewable resources to meet increasing demand. It is now mandatory in many countries for paper-based packaging to be manufactured wholly or partially from recycled material. Raw materials include:

Hardwood: C. 0.05 inches (1.3 mm) in length e.g. Birch
Birch which has short fibres. It is generally more difficult to work with; however, it does provide higher tensile strength, but lower tear and other strength properties. Although its fibres are not as long and strong as those in softwood, they make for a stiffer product defined by some stifness tests. Hardwood
Hardwood fibres fill the sheet better and therefore make a smoother paper that is more opaque and better for printing. Hardwood
Hardwood makes an excellent corrugating medium. Softwood: C. 0.13 inches (3.3 mm) in length e.g. Pine
Pine and spruce which have typically long fibres and make superior paperboard in services where strength is important. Softwood
Softwood makes excellent linerboard. Recycled: Used paper is collected and sorted and usually mixed with virgin fibres in order to make new material. This is necessary as the recycled fibre often loses strength when reused; the added virgin fibres enhance strength. Mixed waste paper is not usually deinked (skipping the deinking stage) for paperboard manufacture and hence the pulp may contain traces of inks, adhesives, and other residues which together give it a grey colour. Products made of recycled board usually have a less predictable composition and poorer functional properties than virgin fibre-based boards.[6] Health risks have been associated with using recycled material in direct food contact. Swiss studies have shown that recycled material can contain significant portions of mineral oil, which may migrate into packed foods.[7] Mineral oil levels of up to 19.4 mg/kg were found in rice packed in recycled board.[8]

Others: It is also possible to use the fibres of Sugarcane Bagasse, Straw, Hemp, Cotton, Flax, Kenaf, Abaca
Abaca and other plant products

Pulping[edit] Main article: Pulp (paper) Two principal methods for extracting fibres from their sources are:

Chemical pulping uses chemical solutions to convert wood into pulp, yielding around 30% less than mechanical pulping; however, pulp made by the kraft process has superior strength Thermo mechanical pulp
Thermo mechanical pulp is a two-stage process which results in a very high yield of wood fibres at the expense of strength.

Bleaching[edit] Main article: Bleaching of wood pulp Pulp used in the manufacture of paperboard can be bleached to decrease colour and increase purity. Virgin fibre pulp is naturally brown in colour, because of the presence of lignin. Recycled paperboard may contain traces of inks, bonding agents and other residue which colors it grey. Although bleaching is not necessary for all end-uses, it is vital for many graphical and packaging purposes. There are various methods of bleaching, which are used according to a number of factors for example, the degree of colour change required, chemicals chosen and method of treatment. There are three categories of bleaching methods:

Bleaching by delignification using chlorine gas, which is a method that has been largely replaced by procedures which are gentler to the environment such as the use of oxygen as a replacement for the chlorine gas. Bleaching by oxidation using chemicals such as chlorine dioxide, hydrogen peroxide or sodium hypochlorite. Bleaching by reduction using chemicals such as sodium bisulphite.[6]

Plies[edit]

(1) single-ply vs. (2) multi-ply

Multi-ply paperboard generally has higher creasing and folding performance than single-ply as a result of layering different types of pulp into a single product. In cases where the same kind of pulp is being used in several layers, each separate layer is treated and shaped individually in order to create the highest possible quality.[6] Coating[edit] In order to improve whiteness, smoothness and gloss of paperboard, one or more layers of coating is applied. Coated paper is usually made up of:

a pigment, which could be china clay, calcium carbonate or titanium dioxide, usually a combination of two an adhesive or binder as styrene-butadiene emulsions or starches and water.

Additional components could be OBA (optical brightening agents).[9] Grades[edit] The DIN Standard 19303 " Paperboard
Paperboard - Terms and grades" (Publication date : 2005-09) defines different grades of paperboard based on the surface treatment (first letter), the main furnish (second letter) and the colour (non-D grade) or bulk (D grade only) (numbering).

First letter (surface treatment) Second letter (main furnish) Number

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

Z = bleached virgin chemical pulp C = virgin mechanical pulp N = unbleached virgin chemical pulp T = recycled/secondary fibre with white, cream or brown reverse D = recycled/secondary fibre with grey back

All except D grades:

white reverse side cream reverse side brown reverse side

D grades only:

bulk ≥ 1.45 cm2/g 1.3 cm2/g < bulk < 1.45 cm2/g bulk ≤ 1.3 cm2/g

Example: GC1 would be a "pigment coated", "virgin mechanical pulp" board with a "white reverse side". Often the used paperboard type would be FBB, which was coated on both sides. Common terms[edit] Basis Weight (US): Is the weight in 1,000 square feet (93 m2) of paperboard. Brightness: Brightness is a technical term that is defined as the amount of blue-white light that a paper reflects.[10] This property is very subjective and individual to each buyer and end use, as skin colour and food are better reproduced on ‘warm’ (yellow) whites and not blue whites. Grammage: The grammage of the paperboard is assessed in accordance ISO 536.[11] Grammage expresses mass per unit area and is measured in g/m2.[10] PH: Surface pH is measured on a water extract and is on a scale of 0–14. 0 is acidic, 7 is neutral and 14 is alkaline.[12] Stiffness: Stiffness is one of the most important properties of paperboard as it affects the ability of cartons to run smoothly through the machine that erects, fills and closes them. Stiffness also gives strength and reduces the propensity of a carton to bulge under the weight of settling flowable contents such as cereals. Although most paper strength properties increase with increasing sheet density, stiffness does not. A rule of thumb is that stiffness is proportional to the 1.6 power of sheet caliper. The species of fiber used has an effect on stiffness, other things being equal. Northern softwood species impart superior stiffness compared to southern softwoods. Other factors which affect board stiffness include coatings and moisture content.[10] Smoothness: Smoothness is particularly important when being used for printing, the smoother the paperboard, the better the image quality, because of better ink coverage. Smoothness is measured using air leak methods – the greater the rate of air leakage, at a specific air pressure, from under a cylindrical knife placed on the surface, the rougher the surface.[10] Caliper/Thickness: In the United States
United States caliper is usually expressed in thousandths of an inch (0.001”) or points, where a sheet of paperboard with a thickness of 0.024” would be 24 points. In Europe it is often sold in g/m2, however the thickness of the board is measured in micron (μm). Paperboard
Paperboard also tends to be referred to with thickness rather than weight.[9] Whiteness: It refers ideally to the equal presence of all colours, because a truly white sheet will reflect all wavelengths of visible light equally.[10] Paperboard
Paperboard industry[edit] The paperboard sector is mainly looked at in conjunction with the paper industry. The Paper
Paper & Paperboard
Paperboard market size (2007) had a value of 630.9 billion USD and a volume of 320.3 million metric tons.[5] Of that market 40.1% is European. About 50% of all produced paper is used for packaging, followed by printing and writing.[5] According to ProCarton, the consumption of paper and paperboard seem to correlate with economic trends (GDP).[13][14] Sales of carton in Europe
Europe sum up to around 8 billion Euros worth. Over 1,100 printers produce 5.4 million tonnes of cartonboard yearly. Cartons make up one third of paper and board packaging and 15% of all packaging. A bit more than half (54%) of the European carton is produced using recovered fibre or waste paper. The paper and paperboard industry is quite energy and capital intensive. Just a coated board machine itself can cost around 90 - 120 million Euros[15] (about 125 - 166 million USD in 11/2011). Economies of scale apply, because of which a few large players often dominate the market place. E.g. in North America the top 5 producers have a market share of 85%. See also[edit]

Coated paper Papermaking Slip sheet

References[edit]

^ Robertson, Gordon L. (2005). Food Packaging
Packaging - Principle and Practice (2nd Ed.). p. 111. ISBN 978-0-8493-3775-8. ^ Paperboard
Paperboard Packaging
Packaging Alliance. " Paperboard
Paperboard Packaging" (PDF). Archived from the original (PDF) on November 21, 2008. Retrieved 2009-07-18. ^ ASTM
ASTM D996 ^ Soroka, W. Illustrated Glossary of Packaging
Packaging Terminology (Second ed.). Institute of Packaging
Packaging Professionals. ^ a b c Datamonitor (June 2008). "Global Paper
Paper and Paperboard
Paperboard - Industry Profile". access-date= requires url= (help) ^ a b c Iggesund Paperboard
Paperboard AB (2008). " Paperboard
Paperboard the Iggesund Way": 10. ^ Federal Institute for Risk Assessment (Germany). "Migration of mineral oil from packaging materials to foodstuffs (BfR Opinion No. 008/2010 of 2009-12-09)" (PDF). Retrieved 2010-04-21. ^ Bundesinstitut für Risikobewertung. "Übergänge von Mineralöl aus Verpackungsmaterialien auf Lebensmittel" (PDF). Retrieved 2010-04-21. ^ a b Kirwan, Mark J. (1998). Paper
Paper and paperboard packaging technology. London: Blackwell Publishing. ISBN 978-1-4051-6845-8. ^ a b c d e Twede, Diana; Selke, Susan E. M. (2004). "Cartons, Crates and Corrugated Board: Handbook of Paper
Paper and Wood
Wood Packaging Technology". Lancaster, PA: DasTech Publications. ^ ISO: International Organisation for Standardisation (1995). "Paper and board -- Determination of grammage". Retrieved 2009-07-18. ^ Iggesund Paperboard
Paperboard (2008). "Product Catalogue: General Technical Information". Archived from the original on July 13, 2011. Retrieved 2009-07-18. ^ Dr. Peter Ince (1999–2000). "Paper, Paperboard
Paperboard and Woodpulp – Production, Consumption and Trade ECE/FAO Forest Products Annual Market Review" (PDF). Archived from the original (PDF) on June 5, 2011. Retrieved 2009-07-18. ^ Pro Carton
Carton (2009). "The Carton
Carton Packaging
Packaging Fact File: Cartons, Industry and the Environment" (PDF). Retrieved 2009-07-20. ^ Metso Corporation’s press release (2011). "Metso to supply coated board line to International Paper
Paper & Sun Cartonboard in China". Archived from the original on 2011-10-13. Retrieved 2011-11-04.

Further reading[edit]

Brody, A. L., and Marsh, K, S., Encyclopedia of Packaging
Packaging Technology, John Wiley & Sons, 1997, ISBN 0-471-06397-5 Soroka, W., Fundamentals of Packaging
Packaging Technology, IoPP, 2002, ISBN 1-930268-25-4

External links[edit]

TAPPI—Technical Association of the Pulp and Paper
Paper Industry ' Paper
Paper thickness cross reference guide

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Packaging

General topics

Active packaging Child-resistant packaging Contract packager Disposable food packaging Food packaging Luxury packaging Modified atmosphere/modified humidity packaging Package pilferage Package testing Packaging
Packaging engineering Pharmaceutical packaging Reusable packaging Shelf life Sustainable packaging Tamper-evident Tamper resistance Wrap rage

Containers

Aerosol Container Aluminium bottle Aluminum can Ampoule Antistatic bag Bag-in-box Bags and flexible containers Barrel Beer bottle Biodegradable bag Blister pack Boil-in-Bag Bottle Box Bulk box Cage Case Carboy Carton Chub Clamshell Corrugated box design Crate Disposable cup Drum Envelope Flexible intermediate bulk container Foam food container Folding carton Glass
Glass bottle Growler Insulated shipping container Intermediate bulk container Jar Jerrycan Jug Juicebox Keg Multi-pack Oyster pail Packet (container) Padded mailer Pail Paper
Paper bag Paper
Paper sack Plastic bag Plastic bottle Popcorn bag Retort pouch Sachet Security bag Self-heating can Self-heating food packaging Shipping container Skin pack Spray bottle Tetra Brik Tin can Tub (container) Tube Unit load Vial Wooden box

Materials and components

Adhesive Aluminium foil Bail handle Bioplastic Biodegradable plastic BoPET Bubble wrap Bung Cellophane Closure Coated paper Coating Coextrusion Corrugated fiberboard Corrugated plastic Cushioning Desiccant Double seam Foam peanut Glass Hot-melt adhesive Kraft paper Label Lid Linear low-density polyethylene Liquid packaging board Low-density polyethylene Metallised film Modified atmosphere Molded pulp Nonwoven fabric Overwrap Oxygen scavenger Package handle Packaging
Packaging gas Pallet Paper Paper
Paper pallet Paperboard Plastic film Plastic pallet Plastic wrap Polyester Polyethylene Polypropylene Pressure-sensitive tape Screw cap Screw cap
Screw cap (wine) Security printing Security tape Shock detector Shock and vibration data logger Shrink wrap Slip sheet Staple (fastener) Strapping Stretch wrap Susceptor Tamper-evident
Tamper-evident band Tear tape Temperature data logger Time temperature indicator Tinplate Velostat

Processes

Aseptic processing Authentication Automatic identification and data capture Blow fill seal Blow molding Calendering Canning Coating Containerization Curtain Coating Die cutting Die forming (plastics) Electronic article surveillance Extrusion Extrusion
Extrusion coating Glass
Glass production Graphic design HACCP Hermetic seal Induction sealing Injection molding Laminating Laser cutting Molding Papermaking Plastic welding Plastics extrusion Printing Quality assurance Radio-frequency identification Roll slitting Shearing (manufacturing) Thermoforming Track and trace Vacuum forming Ultrasonic welding Vacuum packaging Verification and validation

Machinery

Barcode printer Barcode reader Bottling line Calender Can seamer Cartoning machine Case sealer Check weigher Conveyor system Extended core stretch wrapper Filler Heat gun Heat sealer Industrial robot Injection molding
Injection molding machine Label
Label printer applicator Lineshaft roller conveyor Logistics automation Material handling equipment Mechanical brake stretch wrapper Multihead weigher Orbital stretch wrapper Palletizer Rotary wheel blow molding systems Shrink tunnel Staple gun Tape dispenser Turntable stretch wrapper Vertical form fill sealing machine

Environment, post-use

Biodegradation Environmental engineering Glass
Glass recycling Industrial ecology Life-cycle assessment Litter Paper
Paper recycling Plastic recycling Recycling Reusable packaging Reverse logistics Source reduction Sustainable packaging Waste management

v t e

Paper

History Manufacture/Papermaking

Types

Bible Blotting Bond Cardboard Cartridge Coated paper Construction Cotton
Cotton (rag) Crêpe Display Dó Asphalt Glassine India Korean Kraft Laid Manila Newsprint Oatmeal Onionskin Origami Baking Building Rice Rolling Scritta Paperboard Security Seed Copy Stone Tar Thermal Tissue Tracing Transfer Tree-free Wallpaper Washi Waterproof Wax Wood-free Wove Writing Xuan

Materials

China clay Fiber crop Paper
Paper chemicals Papyrus Wood
Wood pulp

Specifications

Grammage Density Paper
Paper sizes Units of paper quantity Surface chemistry of paper Wet strength

Manufacture and process

Bleaching of wood pulp Calender Conical refiner Deinking Paper
Paper pollution Environmental impact of paper Handmade paper Hollander beater Kraft process Organosolv Paper
Paper machine Paper
Paper recycling Papermaking Soda pulping Sulfite process

Industry

Paper
Paper industry In Europe In Canada In India In Japan In the United States Paper
Paper mill List of paper mills

Category:Paper Commons

v t e

Wood
Wood products

Lumber/ timber

Batten Beam Bressummer Cruck Flitch beam Flooring Joist Lath Molding Panelling Plank Plate Post Purlin Rafter Railroad ties Reclaimed Shingle Siding Sill Stud Timber
Timber truss Treenail Truss Utility pole

Engineered wood

Glued laminated timber

veneer LVL parallel strand

I-joist Fiberboard

hardboard Masonite MDF

Oriented strand board Oriented structural straw board Particle board Plywood Structural insulated panel Wood-plastic composite

lumber

Fuelwood

Charcoal

biochar

Firelog Firewood Pellet fuel Wood
Wood fuel

Fibers

Cardboard Corrugated fiberboard Paper Paperboard Pulp Pulpwood Rayon

Derivatives

Birch-tar Cellulose

nano

Hemicellulose Cellulosic ethanol Dyes Lignin Liquid smoke Lye Methanol Pyroligneous acid Pine
Pine tar Pitch Sandalwood oil Tannin Wood
Wood gas

By-products

Barkdust Black liquor Ramial chipped wood Sawdust Tall oil Wood
Wood flour Wood
Wood wool Woodchips

Historical

Axe ties Clapboard Dugout canoe Potash Sawdust
Sawdust brandy Split-rail fence Tanbark Timber
Timber framing Wooden masts