Introduction to Corrugated Cardboard
The United States hit a record high in 2020 for yearly use of cardboard, with around 80% of products sold being packaged in it, resulting in over 120 billion pieces used and over 13,000 separate pieces of consumer cardboard packaging thrown away by American households. Despite this, corrugated cardboard remains one of the most successful and sustainable packaging materials due to its high recycling rate, with nearly 97% recovered for recycling as of 2020.
History of Corrugated Cardboard
Corrugated packaging originated in the 1850s with an English patent issued in 1856 to Edward Charles Healey and Edward Ellis Allen for making ruffled collars and cushioning for hats. Later, in 1871, American Albert L. Jones patented the first corrugated paper packaging material for cushioning glass bottles. The production of corrugated fiberboard boxes began with a process involving brushes and cutting sheets, later improved by piling dozens of sheets under pressure.
- 1856: English patent issued for making ruffled collars and cushioning for hats
- 1871: American Albert L. Jones patented the first corrugated paper packaging material
- 1870: Robert Gair discovered a method to make prefabricated cartons by cutting cardboard in one operation
Production Process
Corrugation machines can produce up to 1,000 feet of product per minute using three constituent elements: paper, steam, and adhesive. The process involves mounting paper stock onto unwinding stands, heating it to 176-190°C with pressurized steam, and shaping it into a fluted pattern at the corrugating rolls. An adhesive is then applied to the flue tips, and the first liner is added to form the corrugated product.
- Mounting paper stock onto unwinding stands
- Heating the paper stock to 176-190°C with pressurized steam
- Shaping the paper stock into a fluted pattern at the corrugating rolls
- Applying an adhesive to the flue tips and adding the first liner
Recycling and Sustainability
Corrugated fiberboard is made from fast-growing pine, with some companies owning their own sustainable forests. The production process involves debarking, chipping, and pulping the trees, with modern methods relying on mechanical pulping for its lower cost and higher yield. Recycling paper-based packaging is highly effective, requiring only 75% of the energy used for virgin paper production, and reduces electricity and water usage by 50% and 90%, respectively.
The recycling process involves shredding, pulping, and screening to remove contaminants, followed by treatment with chemicals and magnets to decolorize and purify the material, making it cost-effective and straightforward. Eco-friendly coatings are gaining popularity in packaging manufacturing, driven by consumer demand for sustainability.
Conclusion
The development of cardboard boxes required decades of experimentation and engineering refinement. Packaging engineers must balance cost, manufacturability, effectiveness, and marketability to produce innovative packaging solutions, applying scientific thinking and critical thinking skills to design challenges. By understanding the history, production process, and sustainability of corrugated cardboard, we can appreciate the importance of this versatile and eco-friendly packaging material.
Key Vocabulary
| Term | Definition | Example Usage |
|---|---|---|
| Corrugated Cardboard | A type of packaging material made from paperboard with a wavy, fluted layer for added strength and cushioning. | The company uses corrugated cardboard to package their products for shipping. |
| Recycling Rate | The percentage of materials that are recovered and reused, reducing waste and the need for new raw materials. | The recycling rate for corrugated cardboard is nearly 97%, making it a highly sustainable material. |
| Corrugation Machine | A machine used to produce corrugated cardboard by shaping paperboard into a fluted pattern. | The factory uses a corrugation machine to produce up to 1,000 feet of corrugated cardboard per minute. |
| Fluted Pattern | A wavy, layered pattern created in the corrugation process to add strength and cushioning to the cardboard. | The fluted pattern in corrugated cardboard helps to absorb shocks and protect products during shipping. |
| Sustainable Forest | A forest managed to maintain its ecological integrity and productivity, ensuring a continuous supply of timber and other forest products. | Some companies own their own sustainable forests to ensure a responsible and renewable source of materials for corrugated cardboard production. |
| Debarking | The process of removing the bark from trees, typically as a first step in the production of paper or cardboard. | Debarking is an essential step in the production of corrugated cardboard, as it helps to improve the quality and consistency of the final product. |
| Mechanical Pulping | A process used to break down wood into pulp for paper production, using mechanical forces rather than chemicals. | Mechanical pulping is a cost-effective and efficient method for producing corrugated cardboard, with a higher yield than chemical pulping methods. |
| Eco-Friendly Coatings | Coatings used in packaging production that are designed to be environmentally friendly, biodegradable, and non-toxic. | Eco-friendly coatings are gaining popularity in corrugated cardboard production, driven by consumer demand for sustainable and responsible packaging solutions. |
| Virgin Paper Production | The production of paper from raw materials, such as wood pulp, rather than from recycled materials. | Recycling corrugated cardboard requires only 75% of the energy used for virgin paper production, making it a more sustainable option. |
| Pulping | The process of breaking down wood or other plant material into a pulp, typically for paper production. | Pulping is a critical step in the production of corrugated cardboard, as it helps to create a consistent and high-quality material. |
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Vocabulary Quiz
1. What percentage of products sold in the United States are packaged in cardboard?
A) 50%
B) 70%
C) 80%
D) 90%
2. In what year did American Albert L. Jones patent the first corrugated paper packaging material for cushioning glass bottles?
A) 1856
B) 1860
C) 1871
D) 1880
3. What is the temperature range to which the paper stock is heated during the corrugation process?
A) 150-170°C
B) 160-180°C
C) 176-190°C
D) 180-200°C
4. How much energy is required for recycling paper-based packaging compared to virgin paper production?
A) 50%
B) 60%
C) 75%
D) 90%
5. By what percentage is water usage reduced through recycling paper-based packaging?
A) 50%
B) 70%
C) 80%
D) 90%
Answer Key:
1. C
2. C
3. C
4. C
5. D
Grammar Focus
Grammar Focus: Use of the Passive Voice
Grammar Quiz:
1. The new employee ____________________ by the HR department yesterday.
was interviewed
interviews
is interviewing
to interview
2. The company’s profits ____________________ by 20% last year due to effective marketing strategies.
were increased
have increased
are increasing
increase
3. The researcher’s findings ____________________ in a prestigious scientific journal.
are publishing
have been published
publish
were published
4. The new policy ____________________ by the management team and will be implemented next month.
has been approved
approves
is approving
to approve
5. The ancient city ____________________ by archaeologists using advanced technology and excavation techniques.
is being excavated
has been excavated
excavate
were excavating
Answer Key:
1. was interviewed
2. were increased
3. have been published
4. has been approved
5. has been excavated
