Tuesday 26 August 2014

OUGD601 - Context of Practice 3: Research (Packaging terms)

Common Terms in the Corrugated and Solid Board Industry

0201Standard Regular Case with outer flaps meeting both top and bottom for sealing, see FEFCO case codes
BoardPapers of 220 gsm and above are often referred to as board.
Box compression TestStrength test, the maximum loading before collapse.
Break PackTransit Container (e.g. large corrugated case), may also be known as tertiary packaging
Carton BoardA paper product made from one or more layers of fibrous cellulose material.
Corrugated BoardConsists of one or more sheets of fluted paper between outer and inner liners.
CoreA central card tube that is used to wind paper on, allowing reels of paper to be positioned on to the corrugator before being made into board.
CorrugatorA machine that makes corrugated board from fluting and liners.
Crash Lock (glued)A style that enables the base of the case to be locked together without the use of tape, and can also be adapted by incorporating a glued section that will allow for speedy assembly.
Cutter GuideA detailed line drawing showing a plan view of design / style of case before erection.
DeckleThe width of the paper or board being run on a Corrugator.
Die-CutterMachine for stamping complicated designs from corrugated board.
Double wall boardA combination of two layers of board, made for extra strength. Board therefore comprises liner-fluting-liner-fluting-liner, see Fig. 1
FEFCOThe European Trade Association for Corrugated Board manufacture, www.fefco.org
FEFCO case codes (styles)A standard set of patterns used within the corrugated industry, usually identified with a four-digit number (e.g. 0201). Details at http://www.fefco.org/index.php?id=65&no_cache=1
FibreboardAlternative name for papers used in corrugated board.
Fluting MediumPaper that can be corrugated with heat and pressure to provide the central layer in corrugated board. It separates the liners and provides the strength and rigidity. There are five common configurations, see Fig. 1
FormeA cutting / creasing tool used on a die-cutter for complicated designs.
Gluer / ErectorAn automated machine for gluing and sealing cases.
Grammage (gsm)Mass per unit area of a paper, given as grammes per square metre (gsm or g/m2).
Hand ErectA pack / carton erected / assembled by hand, most commonly used for complex design or small runs. See also machine erect
Inner LinerPaper material used for the inside of corrugated board. It is less important, in terms of appearance, than the outer liner but will have to conform to regulatory requirements if it is designed for food contact.
KraftOriginally 100% pure wood pulp now may contain some recycled fibre. It may be white or brown depending on the treatment.
Locking TabsA device that is incorporated into the design of a pack to hold it together during construction.
LinerOne of the paper materials from which corrugated board is made, see outer liner and inner liner; kraft & test.
Machine ErectA pack / carton erected by a fully / partially mechanical machine. See also hand erect
OCCOld corrugated containers, an important grade of recycled fibre
Outer LinerPaper material used for the outside of corrugated board, generally high quality as it is printed with graphics
PerforationsUsed to help either the folding of a case or the removal of panels for display purposes.
Primary PackThat which the consumer takes home, consumer unit (e.g. bottle, carton but could be a multi-pack)
PulpPulp is the most common material used to make paper. The timber resources used to make wood pulp are referred to as pulpwood. Wood pulp generally comes from softwood trees such as spruce, pine, fir, larch and hemlock, but also some hardwoods such as eucalyptus and birch.
RRPRetail Ready Packaging
Secondary PackSecond level of packaging designed to contain primary pack (e.g. shrink wrapped corrugated tray)
Single faceIn the manufacture of Corrugated board, one piece of fluting glued to one liner only, see Fig. 2  (Not to be confused with the same term in relation to presentation of an on-shelf pack)
Single wallConventional method of making corrugated board, fluting medium is sandwiched between two liners (liner-fluting-liner).
SRPShelf Ready Packaging
Tertiary PackTransit Container (e.g. large corrugated case), may also be known as break-pack
Tear StripA device that is either made up of plastic tape applied to the inside of the case during manufacture, which enables the finished pack to be opened quickly. The same effect can be achieved using perforations.
Test LinerPaper made either from a combination of wood pulp and recycled fibre or entirely recycled fibre

Common Fluting Grades

The five configurations of flute in most general use are: 
F FluteA very fine flute, (also known as microflute) which is used for 'corrugated cartons', it gives excellent crush resistance and rigidity image of F-flute grade 
E FluteA fine flute used for 'corrugated cartons'. it gives excellent crush resistance. image of E-flute grade 
B FluteBy far the most widely specified flute profile in Europe thanks to its superb robustness (difficult to crush), good compression strength and compactness which minimises storage space. image of B-flute grade 
C FluteA larger flute than 'B', offering greater compression strength, but it may be crushed more easily. It also takes up more storage strength than 'B' flute. image of C-flute grade 
Double WallA Combination of two flute sizes, usually 'B' and 'C', is specified when compression strength is more important than storage and robustness. image of Double Wall grade 

The Structure of Corrugated Board

Corrugated board is created by gluing fluting and liner papers together.
 image of single-faced corrugated boardSingle-faced corrugated board (corrugated rolls) consists of liner paper and fluting
 image of single-wall corrugated boardSingle-wall corrugated board is made of an outer liner, the fluting and an inner liner
 image of double-wall corrugated boardDouble-wall corrugated board is created by gluing two single-faced corrugated webs together and laminating them to a liner web.
 image of triple-wall corrugated boardTriple-wall corrugated board consists of three single-faced corrugated boards with different types of fluting and an inner liner.

The ‘Closed Loop’ of Corrugated Board Manufacture

Continuous cycle of manufacture for corrugated board

Common Terms for Printing

Flexographic printingOften abbreviated to flexo, is a method of printing most commonly used for packaging.A flexo print is achieved by creating a mirrored master of the required image as a 3D relief in a rubber or polymer material. A measured amount of ink is deposited upon the surface of the printing plate (or printing cylinder) using an anilox roll. The print surface then rotates, contacting the print material which transfers the ink.
Litho PrintHigh Quality Print ideally suited to full process work on medium / large sized production scale manufacturing runs
Silk ScreenHigh Quality Print ideally suited for large format packaging (Dump Bins) ideally suited smaller production runs
PantonePMS (pantone matching system) allows for a standard range of colour formulations, to ensure consistency of colour matching.
Post-PrintA method of printing after the papers have been made into board, and usually occurs during the conversion process.
Pre-PrintHigh Quality Print ideally suited for large production runs. Paper is printed before being manufactured into board.
Process Set (CMYK)(short for Cyan, Magenta, Yellow, and Key) is a subtractive colour model used in colour printing.  This colour model is based on mixing pigments of the following colours in order to make other colours: C = Cyan M = Magenta Y = Yellow K = Key (Black).
UV VarnishA liquid application applied over a print, which results in a high gloss finish.
Machine VarnishA liquid application applied over print, which produces a matt finish and helps prevent ink rub.

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