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Paperboard is a thick
paper Paper is a thin sheet material produced by mechanically or chemically processing cellulose fibres derived from wood, Textile, rags, poaceae, grasses, Feces#Other uses, herbivore dung, or other vegetable sources in water. Once the water is dra ...
-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 A point is a small dot or the sharp tip of something. Point or points may refer to: Mathematics * Point (geometry), an entity that has a location in space or on a plane, but has no extent; more generally, an element of some abstract topologica ...
) than
paper Paper is a thin sheet material produced by mechanically or chemically processing cellulose fibres derived from wood, Textile, rags, poaceae, grasses, Feces#Other uses, herbivore dung, or other vegetable sources in water. Once the water is dra ...
and has certain superior attributes such as foldability and rigidity. According to
ISO The International Organization for Standardization (ISO ; ; ) is an independent, non-governmental, international standard development organization composed of representatives from the national standards organizations of member countries. Me ...
standards, paperboard is a paper with a
grammage Grammage and basis weight, in the pulp and paper industry, are the area density of a paper product, that is, its mass per unit of area. Two ways of expressing the area density of a paper product are commonly used: * Expressed in grams (g) per s ...
above 250 g/m2, but there are exceptions. Paperboard can be single- or multi-ply. Paperboard can be easily cut and formed, is lightweight, and because it is strong, is used in
packaging Packaging is the science, art and technology of enclosing or protecting products for distribution, storage, sale, and use. Packaging also refers to the process of designing, evaluating, and producing packages. Packaging can be described as a coo ...
. Another end-use is high quality graphic printing, such as book and magazine covers or postcards. Paperboard is also used in
fine art In European academic traditions, fine art (or, fine arts) is made primarily for aesthetics or creative expression, distinguishing it from popular art, decorative art or applied art, which also either serve some practical function (such as ...
s 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.


History

In 1817, the first paperboard carton was produced in
England England is a Countries of the United Kingdom, country that is part of the United Kingdom. It is located on the island of Great Britain, of which it covers about 62%, and List of islands of England, more than 100 smaller adjacent islands. It ...
.
Folding carton The folding carton created the packaging industry as it is known today, beginning in the late 19th century. The process involves folding carton made of paperboard that is printed, laminated, cut, then folded and glued. The cartons are shipped f ...
s first emerged around the 1860s and were shipped flat to save space, ready to be set up by customers when they were required. The mechanical die cutting and creasing of blanks was developed in 1879. In 1911 the first kraft sulphate mill was built in
Florida Florida ( ; ) is a U.S. state, state in the Southeastern United States, Southeastern region of the United States. It borders the Gulf of Mexico to the west, Alabama to the northwest, Georgia (U.S. state), Georgia to the north, the Atlantic ...
. 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.


Terminology and classification

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: * Boxboard or cartonboard: paperboard for
folding carton The folding carton created the packaging industry as it is known today, beginning in the late 19th century. The process involves folding carton made of paperboard that is printed, laminated, cut, then folded and glued. The cartons are shipped f ...
s and rigid set-up boxes ** Folding boxboard (FBB): a bending grade capable of being scored and bending without fracture ** Chipboard: a recycled, low quality board *** White lined chipboard (WLC): a white, often clay-coated chipboard **
Kraft Kraft Foods Group, Inc. was an American food manufacturing and processing conglomerate (company), conglomerate, split from Kraft Foods Inc. on October 1, 2012, and was headquartered in Chicago, Illinois. It became part of Kraft Heinz on July ...
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 Liquid packaging board is a multi-ply paperboard with high stiffness, strong wet sizing and a high barrier coating, e.g. plastic. Only virgin paper fibers are used. The barrier coating must hold the liquid and prevent migration of air and flavo ...
** Solid bleached board (SBB) or solid bleached sulphate (SBS): clean white board used for foods etc. Sulphate refers to the
kraft process The kraft process (also known as kraft pulping or sulfate process) is a process for conversion of wood into wood pulp, which consists of almost pure cellulose fibres, the main component of paper. The kraft process involves treatment of wood chip ...
** Solid unbleached board (SUB): board made from unbleached chemical pulp * Containerboard: a type of paperboard manufactured for the production of
corrugated fiberboard Corrugated fiberboard, corrugated cardboard, or corrugated is a type of packaging material consisting of a fluted corrugated sheet and one or two flat linerboards. It is made on "flute lamination machines" or "corrugators" and is used for maki ...
** 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 Bookbinding is the process of building a book, usually in codex format, from an ordered stack of paper sheets with one's hands and tools, or in modern publishing, by a series of automated processes. Firstly, one binds the sheets of papers alon ...
for making hardcovers.


Production

Fibrous material is turned into pulp and bleached to create one or more layers of board, which can be optionally coated for a better surface and/or improved appearance. Pulp board is produced on pulping machines that can handle higher grammage and several plies.


Raw materials

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 Wood is a structural tissue/material found as xylem in the stems and roots of trees and other woody plants. It is an organic materiala natural composite of cellulosic fibers that are strong in tension and embedded in a matrix of lignin t ...
pulp. Today paperboard packaging in general, and especially products from
certified Certification is part of testing, inspection and certification and the provision by an independent body of written assurance (a certificate) that the product, service or system in question meets specific requirements. It is the formal attestatio ...
sustainable Sustainability is a social goal for people to co-exist on Earth over a long period of time. Definitions of this term are disputed and have varied with literature, context, and time. Sustainability usually has three dimensions (or pillars): env ...
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 Recycling is the process of converting waste materials into new materials and objects. This concept often includes the recovery of energy from waste materials. The recyclability of a material depends on its ability to reacquire the propert ...
material. Raw materials include: *
Hardwood Hardwood is wood from Flowering plant, angiosperm trees. These are usually found in broad-leaved temperate and tropical forests. In temperate and boreal ecosystem, boreal latitudes they are mostly deciduous, but in tropics and subtropics mostl ...
: C. in length e.g.
Birch A birch is a thin-leaved deciduous hardwood tree of the genus ''Betula'' (), in the family Betulaceae, which also includes alders, hazels, and hornbeams. It is closely related to the beech- oak family Fagaceae. The genus ''Betula'' contains 3 ...
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 stiffness tests. Hardwood fibres fill the sheet better and therefore make a smoother paper that is more opaque and better for printing. Hardwood makes an excellent corrugating medium. *
Softwood Scots pine, a typical and well-known softwood Softwood is wood from gymnosperm trees such as conifers. The term is opposed to hardwood, which is the wood from angiosperm trees. The main differences between hardwoods and softwoods is that the sof ...
: C. in length e.g.
Pine A pine is any conifer tree or shrub in the genus ''Pinus'' () of the family Pinaceae. ''Pinus'' is the sole genus in the subfamily Pinoideae. ''World Flora Online'' accepts 134 species-rank taxa (119 species and 15 nothospecies) of pines as cu ...
and
spruce A spruce is a tree of the genus ''Picea'' ( ), a genus of about 40 species of coniferous evergreen trees in the family Pinaceae, found in the northern temperate and boreal ecosystem, boreal (taiga) regions of the Northern hemisphere. ''Picea'' ...
which have typically long fibres and make superior paperboard in services where strength is important. Softwood makes excellent linerboard. *
Recycled Recycling is the process of converting waste materials into new materials and objects. This concept often includes the recovery of energy from waste materials. The recyclability of a material depends on its ability to reacquire the propert ...
: 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. 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. Mineral oil levels of up to 19.4 mg/kg were found in rice packed in recycled board. * Others: It is also possible to use the fibres of Sugarcane Bagasse,
Straw Straw is an agricultural byproduct consisting of the dry wikt:stalk, stalks of cereal plants after the grain and chaff have been removed. It makes up about half of the crop yield, yield by weight of cereal crops such as barley, oats, rice, ry ...
,
Hemp Hemp, or industrial hemp, is a plant in the botanical class of ''Cannabis sativa'' cultivars grown specifically for industrial and consumable use. It can be used to make a wide range of products. Along with bamboo, hemp is among the fastest ...
,
Cotton Cotton (), first recorded in ancient India, is a soft, fluffy staple fiber that grows in a boll, or protective case, around the seeds of the cotton plants of the genus '' Gossypium'' in the mallow family Malvaceae. The fiber is almost pure ...
,
Flax Flax, also known as common flax or linseed, is a flowering plant, ''Linum usitatissimum'', in the family Linaceae. It is cultivated as a food and fiber crop in regions of the world with temperate climates. In 2022, France produced 75% of t ...
,
Kenaf Kenaf tymology: Persian ''Hibiscus cannabinus'', is a plant in the family Malvaceae also called Deccan hemp and Java jute. ''Hibiscus cannabinus'' is in the genus ''Hibiscus'' and is native to Africa, though its exact origin is unknown. The n ...
, Abaca and other plant products


Pulping

Two principal methods for extracting fibres from their sources are: *
Chemical pulp Pulp is a fibrous lignocellulosic material prepared by chemically, semi-chemically, or mechanically isolating the cellulosic fibers of wood, fiber crops, waste paper, or rags. Mixed with water and other chemicals or plant-based additives, pu ...
ing 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 is a two-stage process which results in a very high yield of wood fibres at the expense of strength.


Bleaching

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 Lignin is a class of complex organic polymers that form key structural materials in the support tissues of most plants. Lignins are particularly important in the formation of cell walls, especially in wood and bark, because they lend rigidit ...
. Recycled paperboard may contain traces of inks, bonding agents and other residue which colors it grey. Although
bleaching Bleach is the generic name for any chemical product that is used industrially or domestically to remove color from (i.e. to whiten) fabric or fiber (in a process called bleaching) or to disinfect after cleaning. It often refers specifically t ...
is not necessary for all end-uses, it is vital for many graphical and packaging purposes. There are various methods of
bleaching Bleach is the generic name for any chemical product that is used industrially or domestically to remove color from (i.e. to whiten) fabric or fiber (in a process called bleaching) or to disinfect after cleaning. It often refers specifically t ...
, 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 Redox ( , , reduction–oxidation or oxidation–reduction) is a type of chemical reaction in which the oxidation states of the reactants change. Oxidation is the loss of electrons or an increase in the oxidation state, while reduction is ...
using chemicals such as
chlorine dioxide Chlorine dioxide is a chemical compound with the formula ClO2 that exists as yellowish-green gas above 11 °C, a reddish-brown liquid between 11 °C and −59 °C, and as bright orange crystals below −59 °C. It is usually ...
,
hydrogen peroxide Hydrogen peroxide is a chemical compound with the formula . In its pure form, it is a very pale blue liquid that is slightly more viscosity, viscous than Properties of water, water. It is used as an oxidizer, bleaching agent, and antiseptic, usua ...
or
sodium hypochlorite Sodium hypochlorite is an alkaline inorganic chemical compound with the formula (also written as NaClO). It is commonly known in a dilute aqueous solution as bleach or chlorine bleach. It is the sodium salt of hypochlorous acid, consisting of ...
. * Bleaching by reduction using chemicals such as sodium bisulphite.


Plies

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.


Coating

In order to improve whiteness, smoothness and gloss of paperboard, one or more layers of
coating A coating is a covering that is applied to the surface of an object, or substrate. The purpose of applying the coating may be decorative, functional, or both. Coatings may be applied as liquids, gases or solids e.g. powder coatings. Paints ...
is applied.
Coated paper Coated paper (also known as enamel paper, gloss paper, and thin paper) is paper that has been coated with a mixture of materials or a polymer to impart certain qualities to the paper, including weight, surface gloss, smoothness, or reduced ink ab ...
is usually made up of: * a
pigment A pigment is a powder used to add or alter color or change visual appearance. Pigments are completely or nearly solubility, insoluble and reactivity (chemistry), chemically unreactive in water or another medium; in contrast, dyes are colored sub ...
, which could be
china clay Kaolinite ( ; also called kaolin) is a clay mineral, with the chemical composition aluminium, Al2Silicon, Si2Oxygen, O5(hydroxide, OH)4. It is a layered silicate mineral, with one tetrahedron, tetrahedral sheet of silica () linked through oxygen ...
,
calcium carbonate Calcium carbonate is a chemical compound with the chemical formula . It is a common substance found in Rock (geology), rocks as the minerals calcite and aragonite, most notably in chalk and limestone, eggshells, gastropod shells, shellfish skel ...
or
titanium dioxide Titanium dioxide, also known as titanium(IV) oxide or titania , is the inorganic compound derived from titanium with the chemical formula . When used as a pigment, it is called titanium white, Pigment White 6 (PW6), or Colour Index Internationa ...
, usually a combination of two * an adhesive or binder as
styrene-butadiene Styrene-butadiene or styrene-butadiene rubber (SBR) describe families of synthetic rubbers derived from styrene and butadiene (the version developed by Goodyear is called Neolite). These materials have good abrasion resistance and good aging ...
emulsions or
starch Starch or amylum is a polymeric carbohydrate consisting of numerous glucose units joined by glycosidic bonds. This polysaccharide is produced by most green plants for energy storage. Worldwide, it is the most common carbohydrate in human diet ...
es and
water Water is an inorganic compound with the chemical formula . It is a transparent, tasteless, odorless, and Color of water, nearly colorless chemical substance. It is the main constituent of Earth's hydrosphere and the fluids of all known liv ...
. Additional components could be OBA ( optical brightening agents).


Grades

The DIN Standard 19303 "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). 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

Basis weight: in the US, it is the weight of of the same paperboard; the traditional British definition is the weight, in pound, of 100 of the same board Brightness: Brightness is a technical term that is defined as the amount of blue-white light that a paper reflects. 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 Grammage and basis weight, in the pulp and paper industry, are the area density of a paper product, that is, its mass per unit of area. Two ways of expressing the area density of a paper product are commonly used: * Expressed in grams (g) per s ...
of the paperboard is assessed in accordance ISO 536. Grammage expresses mass per unit area and is measured in g/m2. PH: Surface pH is measured on a water extract and is on a scale of 0–14. 0 is
acidic An acid is a molecule or ion capable of either donating a proton (i.e. hydrogen cation, H+), known as a Brønsted–Lowry acid, or forming a covalent bond with an electron pair, known as a Lewis acid. The first category of acids are the ...
, 7 is neutral and 14 is
alkaline In chemistry, an alkali (; from the Arabic word , ) is a basic salt of an alkali metal or an alkaline earth metal. An alkali can also be defined as a base that dissolves in water. A solution of a soluble base has a pH greater than 7.0. The ...
. 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. 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. Caliper/thickness: In the
United States The United States of America (USA), also known as the United States (U.S.) or America, is a country primarily located in North America. It is a federal republic of 50 U.S. state, states and a federal capital district, Washington, D.C. The 48 ...
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 Europe is a continent located entirely in the Northern Hemisphere and mostly in the Eastern Hemisphere. It is bordered by the Arctic Ocean to the north, the Atlantic Ocean to the west, the Mediterranean Sea to the south, and Asia to the east ...
it is often sold in g/m2, however the thickness of the board is measured in
micron The micrometre (English in the Commonwealth of Nations, Commonwealth English as used by the International Bureau of Weights and Measures; SI symbol: μm) or micrometer (American English), also commonly known by the non-SI term micron, is a uni ...
(μm). Paperboard also tends to be referred to with thickness rather than weight. Whiteness: It refers ideally to the equal presence of all colours, because a truly white sheet will reflect all wavelengths of visible light equally.


Paperboard industry

The paperboard sector is mainly looked at in conjunction with the paper industry. The Paper & Paperboard market size (2007) had a value of US$630.9 billion and a volume of 320.3 million metric tons. Of that market 40.1% is European. About 50% of all produced paper is used for packaging, followed by printing and writing. According to ProCarton, the consumption of paper and paperboard seem to correlate with economic trends (GDP). Sales of carton in 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 (about 125 - US$166 million in 11/2011).
Economies of scale In microeconomics, economies of scale are the cost advantages that enterprises obtain due to their scale of operation, and are typically measured by the amount of Productivity, output produced per unit of cost (production cost). A decrease in ...
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

*
Card stock Card stock, also called cover stock and pasteboard, is paper that is thicker and more durable than normal writing and printing paper, but thinner and more flexible than other forms of paperboard. Card stock is often used for business cards, ...
*
Coated paper Coated paper (also known as enamel paper, gloss paper, and thin paper) is paper that has been coated with a mixture of materials or a polymer to impart certain qualities to the paper, including weight, surface gloss, smoothness, or reduced ink ab ...
*
Fiberboard Fiberboard (American English) or fibreboard (Commonwealth English) is a type of engineered wood product that is made out of wood fibers. Types of fiberboard (in order of increasing density) include particle board or low-density fiberboard (LDF ...
*
Papermaking Papermaking is the manufacture of paper and cardboard, which are used widely for printing, writing, and packaging, among many other purposes. Today almost all paper is Pulp and paper industry, made using industrial machinery, while handmade pape ...
* Slip sheet * Homasote


References


Further reading

* Brody, A. L., and Marsh, K, S., ''Encyclopedia of Packaging Technology'', John Wiley & Sons, 1997, * Soroka, W., ''Fundamentals of Packaging Technology'', IoPP, 2002,


External links


TAPPI
��Technical Association of the Pulp and Paper Industry {{Authority control Products introduced in 1817 Visual arts materials Coated paper English inventions Packaging materials Paper Pulp and paper industry es:Cartón fr:Papier cartonné it:Cartoncino ja:板紙 no:Massivpapp fi:Kartonki sv:Kartong