CORRUGATED FIBERBOARD BOX

CORRUGATED FIBERBOARD BOX

Box Basis

1. Flutes

Four standard flute sizes are in common use, designated A, B, C and E. The sizes were given their letter names in the sequence of their introduction. A is the largest. B, which is smaller was the next size introduced. C came next, but it is between A and B in size. E is both the most recent and the smallest.

Flute measurements are given with a plus-or-minus allowance. Although the meshed steel rollers that form them are hard, the abrasive nature of the corrugating material and the high speeds of the machines causes wear. Minor variations in size have little effect on performance.

The selection of flute size is determined by the basis weight of the linerboard and corrugating material and the performanace characteristics desired in the finished container. For double-wall and triple-wall board, the flute sizes for each sheet of corrugated material are usually different. This technique combines their advantages, and prevents any weakness that might result if the flutes were perfectly aligned.

2. Manufacturer's Joint

It is inefficient to ship setup, empty boxes. At the same time, the box manufacturer tries to complete as many as the steps as possible. One step he can complete involves brining the side and end panels of a slotted box blank together and joining them.

Three methods are used to seal this manufacturer's joint. They are glue, wire stitches or staples, and tape.

Glue and stitches require an extra short tab on one send or side panel. When the boz is partially folded, the tab overlaps and is fastened to the adjacent side or end panel. The overlap, in more cases, is at least 1¼ inches, and it can be on the inside or outside of the box. On the outside, the inner panels remain smooth; on the inside, there is less opportunity for the exposed tab to snag.

Glue is the most common method of sealing the manufacturer's joint. Various formulas, including hot melts, can be used. The adhesive is usually applied to the tab with a roller.

Metal fasteners provide a stronger joint. When they are unwound from a spool of wire as they are formed, they are wire stitches. Preformed fasteners are staples. They may be applied diagonally, horizionally, or vertically along the tab, at set intervals. A "tie-stitch" joint has an extra stitch at the top and bottom. A "double stitch" joint has two stitches at each point.

An extra tab is not needed for a taped joint. The side and end panels are simply butted together and taped.

3. Solid Fiberboard

Solid fibre sheets are constructed by gluing two or more flat plies of paperboard together. Usually, the outer ply is linerboard, and the other piles are corrugating material for filler paperboards. The inner ply also may be linerboard.

Modified corrugators can be used to make solid fibreboard. Usually, however, it is made on less complex machines called pasters, which apply adhesive to the entire surface of each layer.

The board can be scored in the machine direction, cut to diestired widths and cut off to desired lengths, just as corrugated board is on a corrugator.

My using layers with different basis weights, the thickness of the finished material can be changed. Solid fibreboard is ually produced in thickness ranging from 0.045 inches (45 points, or about 3/64ths of an inch) to 0.135 inches (135 points, or a little more than 1/8 inch. For special applications, it can be made as much as ¼ inch thick.

4. Box Dimensions

The inside dimensions of a box are critical for proper fit around the product. Box manufacturing is base on this fit. At the same time, outside dimensions must be considered for proper palletization and distribution.

Dimensions can be stated in metric units or in inches and fractions.

Dimensions are alwayss given in the sequence of length, width and depth. International organizations use the words length, breadth and height.

Length is always the larger of the two dimensions of the open face of a box as it is set up for filling. Width is the smaller dimension of the open face. Depth is the distance perpendicular to the length and width.

End-opening boxes are measured as though they were top-opening. Boxes with multiple parts, such as telescope styles, may have different dimensions for each part. Box styles that do not have a manufacturer's joint such as wrap-arounds, are measured as they will be after the user's joint (the first closure) has been sealed.

Tubes and folders with three dimensions are measured in the same way as boxes, with length being the larger of the two dimensions of the open face, and width the smaller.

The first of the two dimensions of pads, partition pieces and sheets has the greater stacking strength, that is, parallel to the flute direction of corrugated board, or perpendicular to the grain of soild fiberboard.

5. Box Specifications

Manimum Size and Weight - Minimum Requirements

Boxes must comply with the burst, puncture or edge crush test and other requirements shown below.

Test Procedures

a. Burst Test

Tests to determine compliance with the bursting test requirements must be conducted in accordance with Technical Assoication of Pulp and Paper Industry (TAPPI), Offical Test Method T-810.

A minimum of six bursts must be made, three from each side of the board, and only one burst test will be permitted to fall below the specified minimum value. Board failing to pass the foregoing test will be accepted if the retest consisting of 24 bursts, 12 from each side of the board, not more than four burst tests fall below the specided minimum value.

b. Puncture Test

Tests to determine compliance with the puncture test requirements must be conducted in accordance with Technical Assocation of Pulp and Paper Industry (TAPPI), Offical Test Method T-803.

A minimum of four puncture tests must be made and only one puncture test will be permitted to fall below the specified minimum value.

c.Edge Crush Test

Tests to determine compliance with the edge crush requirements must be conducted in accordance with Technical Association of Pulp and Paper Industry (TAPPI), Offical Test Method T-811, A or B.

A minimum of six tests must be made and only one test is permitted to fall below the specification minimum value, and that one test cannont fall below the specified minimum value by more than 10%.

Board failing to pass the foregoing will be accepted if in a retest consisting of 24 tests, not more than four tests fall below the specified minimum value, and none of those tests fall below the specified value by more than 10%.

Weight Facings

The minimum combined weight of facings specified in this table do not apply in connection with board complying with the minimum edge crush test. Any combination of facings in combination with corrugated medium(s) is sufficient to provide corrugated fibreboard that will comply with applicable minimum edge crush requirements.

Size Extension Formula

If weight of box and contents is less than the maximum weight shown, the manimum outisde dimensions for the box may be increased half the percentage that the actual weight is less than the maximum weight specified.

Alternate Requirements

Where rules, commodity descriptions and Numbered Packages specify boxes, containers, trays and component parts thereof to be made of corrugated fibreboard having a minimum bursting or puncture test as shown in Column A below, boxes, containers, trays and component parts thereof may be made of corrugated fibreboard having a minimum edge crush test as shown in Column B below. These alternate provisions will exempt basis weight requirements.

Box Styles

Box Styles1: Slotted

Slotted-Type Boxes

Slotted box styles are generally made from one piece of corrugated or solid fibreboard. The blank is scored and slotted to permit folding. A joint is formed by the box manufacturer at the point where one side panel and one end panel are brought together. Boxes are then shipped flat to the user. Flaps, extending from the side and end panels to form the top and bottom, are closed by the user when the box is needed.

The International Box Code refers to these styles as Slotted-Type Boxes, while the carrier Classifications call them Conventional Slotted Boxes.

1. Regular Slotted Container - RSC

All flaps are the same depth, and the two outer flaps (normally the lengthwise flaps) are one-half the container's width, so they they meet at the center of the box when folded.

This is a highly effcient design. The only overlaps are the flap for a glued or stitched manufacturer's joint and the inner (or minor) flaps. There is very little manufacturing waste.

The RSC can be used for most products, and is the most common box style.

If the product requires a flat, even bottom surface, or the protection of two full layers, a fill-in pad can be placed between the two inner flaps.

2. Overlap Slotted Container - OSC

All flaps are the same depth, and the outer flaps overlap by an inch of more.

The box is easily closed, usually with staples driven through the overlap area.

This style is used when the length of the box is considerably greater than the width, resulting in a long gap between the inner flaps. The sealed overlap helps to keep the outer flaps from pulling apart.

3. Full-Overlap Slotted Container - FOL

All flaps are the same depth, and their depth equals the width of the box. When closed, the outer flaps come within one inch of complete overlap. The style is especially resistant to rough handling. Stacked on it's bottom panel, the overlapping flaps provide added cushioning. Stacked on it's side, the extra thickness provide added stacking strength.

4. Center Special Slotted Container - CSSC

Inner and outer flaps are cut to different depths, with the depth of the inner flaps equal to half the length, and the depth of the outer flaps meet at the center of the box.

The style is especially strong because both the top and bottom have full double thicknesses of corrugated board. The inner flaps, with no gap, provide a level base for the product.

A variation of the Center Special Slotted Container is the Side Special Slotted Container - SSS. All pairs of flaps meet, but not at the center of the box.

5. Bag-in-Box

A number of design concepts are combined in this packaging innovation. A liquid, semi-liquid, granular or powdered product is placed in a plastic bag to prevent sifting of leakage, and the bag is placed in a box for protection, ease of handling and stacking strength.

Bag-in-Box is used for many products, including wine, milk, paint, wallboard compound, detergent powders and pet food. The plastic and its seal must be the proper type for the product.

Many bags incorporate dispensing devices, and the box can have die-cut holes or perforations to provide access and to position the dispenser for use.

Advantages of bag-in-box include its light weight in comparison to other forms of packaging, the rectangular shape that allows full use of shipping and storage space, the fact that it can be stored flat until it is used, and the relative simplicity of setup, filling and closure.

As shown, the corrugated structure combines a Center Special Slotted Container with a full-depth sleeve or liner for added protection and stacking strength, plus top and bottom pads for extra product protection. The International Box Codes are 0204 for the box, 0904 for the sleeve, and 0901 for the pads. The sleeve and pads might be omitted, depending on the gross weight of the filled package.

The Department of Transportation has authorized bag-in-box styles for certain acids and other corrosives.

6. Center Special Overlap Slotted Container - CSO or CSOSC

All flaps are the same depth, and their depth equals one-half the length of the box. The length can be no more than twice the width.When closed, the inner flaps meet at the center of the box, providing a level base and full top protection. Depending on the ratio of length to width, the outer flaps overlap at random, up to full overlap.

7. Center Special Full-Overlap Slotted Container - SFF

Inner and outer flaps are cut to different depths, with the depth of the inner flaps equal to half the length, and the depth of the outer flaps equal to the width. When closed, the inner flaps meet at the center of the box, and outer flaps fully overlap.

With three full thicknesses of corrugated board over the entire top and bottom, this style provides extra cushioning when stacked on it's bottom, or extra stacking strength when stacked on it's side.

8. Snap-Bottom Box

The top of the box is the same as a regular slotted container. The four flaps that form the bottom panel are die cut. To set up, the user folds the largest bottom panel first, then the two end panels. When the remaining bottom panel is folded and pressure applied near the center, the flap "snaps" into the slot created by the other panels.

The style is convenient for small-volume shippers who do not have automatic set-up equipment.

Because the bottom is not fully sealed, it may not be suitable for heavy products.

Box Styles2: Telescope

Telescope-Style Boxes

Telescope boxes usually consist of more than one piece, such as a separate top, or top and bottom, that fit over and slide onto a body.

The International Box Code calls these boxes Telescope-Style. The truck and rail Classifications call them Telescope Boxes if the cover extends over at least two-thirds of the depth, and Boxes with Covers if the cover extends over less than two-thirds of the depth.

1. Full-Telescope Design-Style Box - FTD

The two-piece box is made from two scored and slotted retangular blanks, with minimal manufacturing waste.The full-depth cover slides completely over the body, providing extra thicknesses of board on all side and end panels. This provides compression strength suitable for high stacking of fragile articles."Design style" refers to the joining of flaps on the side or end panels, rather than on top or bottom of the box. The advantage is a flat bottom (and top) suitable for paper, books and similar products.

2. Full-Telescope Half-Slotted Box - FTHS

Each of the two box blanks resembles a regular slotted container, but with only one set of flaps. They are both slotted on one edge rather than two, accounting for the term "half slotted". The depth of the cover piece is slightly more than the depth of the body, so that the cover will slide over the body to its full depth.

Two thicknesses of corrugated board on all four sides provide product protection and stacking strength.

The style is used extensively for fresh fruits and vegetables, frequently with ventilation holes for the circulation of cool air. At destination, the cover is easily removed so that the contents can be examined.

A single half-slotted box (International Box Code: 0200) is sometimes used as a cover for the palletized products, such as refridgerators or washing machines.

3. Partial Telescope Design Style Box - PTD

4. Partial-Telescope Half-Slotted Box - PTHS

The only difference between the full telescope and the partial telescope is the depth of the cover. For a partial telescope, it must be less than, but at least two-thirds of, the depth of the body.

With two layers of corrugated board over a majority of the side and end panels, the style has great resistance to buldging when subjected to overhead weight.

The style is suitable for products that settle or that may be safely compressed. The box is sometimes overfilled, and the style's flexibility allows it to remain intact as the settling or compression take place.

5. Design-Style Box with Cover - DSC

6.Half-Slotted Box With Cover - HSC

The covers of both of these styles extend over less than two-thirds the depth of the body, distinguishing them from the partial-telescope styles.

The half-slotted box frequently uses a design-style cover, beacuase it is easier to close the smaller side flaps.

These boxes are frequently used for both shipping and shelf storage, or other applications where the cover must be removed and replaced frequently.

7. Double-Cover Box - DC

A shell or tube forms the body. The two interchangeable covers are usually design-style.

The pieces are shipped flat to the user, who opens the tube and sets up the covers.

The style is frequently used for tall or heavy products that would be difficult to lower into a box. The item is placed on the bottom cover, and the shell is lowered over the product.

The style is also used for granular and other free-flowing products. When the number of articles or quanity of products varies the tube can be cut down to the level of contents.

8. Interlocking Double-Cover Box - IC

Flanges on the body, folded together (interlocked) with flanges on the covers, are held in place with strapping.

The style offers the same ease of packing provided by the double-cover box, with the assurance that the covers will not separate from the body. This feature offers advantages for the movement of large or heavy products such as washers, dryers, refrigerators, water heaters, vending machines, and some hazardous materials.

9. Bulk Bin

The bulk bin is a large corrugated fibreboad tube or half slotted body, with one or two covers frequently of the interlocking type.

The distinction between a box and a bulk bin is not defined, but usually refers to the quantity of contents. The container for 40 pounds of a granular product, or a single refridgerator, is a box; the container for 3,000 pounds of a granular product ("in bulk"), or 500 towels ("loose" products) or small packages, is a bulk bin.

Some carriers encourage the use of a bulk bin to consolidate smaller packages and reduce handling time. However, the customer at destination must be capable of handling the bulk bin.

Because of their filled weight, bulk bins are usually placed on a pallet, providing easy access for the tines of a fork-lift truck. Lift trucks with fingers are sometimes used; the fingers slip under the flanges of the interlocking covers, and pallets are not needed.

Bulk bins are used for everything from automobile parts to marshmallows. Boxes with more than four sides, such as a octagonal style (International Box Code: 0350) may be used as bulk bins for watermelons and other products that won't fill corners.

10. Double-Thickness Score-Line Box - DTSLB

These boxes are combinations of other styles, with one telescoping over the other so that there are at least two thicknesses of board over all score lines.

The box is particularly resistant to rough handling.

The style may be used for bulk bins, but is generally use for small, heavy products weighing up to 300 pounds such as motors or bulk nails.

In the International Box Code, each part or set of parts of the box would have its own number. The truck Classification provides a seperate description.

Box Styles3: Folders

Folder-Type Boxes

One or more pieces of board provide an unbroken bottom surface, and are scored to fold around a product. The International Box Code describes thm as Folder-Type Boxes. The carrier Classifications us the term Folders or Five-Panel Folders.

1. One-Piece Folder - 1PF

One piece of board is cut so that it provides a flat bottom, with flaps forming the sides and ends, and extentions of the side flaps meeting to form the top.

One-, two- and three-piece folders are used for books and other items shipped as single units.

2. Two-Piece Folder - 2PF

Two rectangular scored pieces provide a double unbroken layer for the bottom, and a double layer for the top. Flaps of one piece form the slides, and flaps of the second piece form the ends.

3. Three-Piece Folder - 3PF

One rectangular scored pieces provide a double unbroken layer for the bottom. Flaps form two sides and meet to cover the top. Two other scored rectangles form the ends; folded flaps tuck into the body.

4. Five-Panel Folder - FPF

A single cut and scored piece features a fifth panel used as a closing flap, completely covering a side panel.

The closed box has several thicknesses in each end, providing stacking strength and proection for long articles of small diameter which might be damaged, or damage the box, if pushed through the ends.

5. Wrap-Around Blank

The wrap-around blank differs slightly from a five-panel folder. The joint flap is not as deep as the full side panel, and the end flaps do not overlap. In addition, the dimensions are less elongated.

The finished box is essentially an RSC, turned on its side so that the bottom and top are unbroken. The joint, however, is not formed until the final closure.

A wrap-around blank is formed into a box by folding it tightly around a rigid product. The positioning of the product, folding and sealing are performed by automatic equipment.

6. Self-Locking Tray

Formed from a single piece of board, te design features an unbroken bottom, and several thicknesses in the end panels.

Trays are not shipping containers, but they are frequently used as inner containers for parts, delicate produce, letter mail and other products, or as elements of display stands.

7. Tuck Folder

Formed from a single piece of board and set up manually or by machine, the tuck folder can be easily opened and reclosed.

8. One-Piece Telescope - 1PT

Formed from a single rectangle piece of scored and slotted board, the style combines the features of telescope styles and folders. At least two layers of board on one side and both ends provide stacking strength, and the bottom and top are unbroken.

The bos is usually set up on automatic equipment. It is frquently used for the shipment of processed and forzen meats.

Box Styles4: Slide Type

Slide-Type Boxes

Two or more rectangular, scored pieces of board are folded so that each forms a tube or shell. The pieces then slide into or onto each other to complete the box.

Slide-type boxes are easily opened and closed. They are usually made in small sizes, and used for products shipped via Parcel Post and small shipment services.

The carrier Classifications refer to these styles as Slide Style Boxes.

1. Double-Slide Box

Formed from two pieces of board, the style provides two thinknesses on the side panels for stacking strength, and one thickness on all other panels. The bottom and top surfaces are unbroken.

2. Triple-Slide Box

Formed from three pieces of board, the style provides two thicknesses of board on all six panels.

The extra strength and cushioning ability make the boz well suited for fragile items, including pharmaceuticals.

The International Box Codes for the parts of a Tirple-Slide Box are 0906 for the outer shell, 0904 for the middle piece, and 0907 for the inner piece.

Box Styles5: Rigid

Rigid-Type Boxes

The three pieces of a rigid box style include two identical end panels, and a body that folds to form the two side panels, and unbroken bottom, and the top. Flaps used to form the joints can be on either the end pieces or the body.

The end panels are attached to the body with special equipment, usually at the user's plant. Six joints must be sealed to set up the box before it is filled.

The name comes from the fact that, once the six joints are sealed, the box is rigid.

The International Box Code indentifies these styles as Rigid-Type Boses. In the carrier Classifications rigid boxes are classified as Conventional Slotted Boxes or Recessed End Boxes.

1. No. 2 Bliss Box

The body is a rectangular scored sheet, and each end piece has four flaps. Seams are formed on the body panels.

The four corner flaps give the Bliss style good stacking strength.

Bliss boxes are used for bulk packs such as meats, and for explosives, fresh fruits and vegetables, and other articles requiring a strong construction.

2. No. 4 Bliss Box

Corner flaps are included in the body blank. End pieces have one flap that supports the top panel when the box is closed. Seams are formed on the end panels.

Advantages and use of the style are similar to those for the No. 2 Bliss Box.

If the body blank from a No. 4 box is combined with the end pieces of a No. 2 box, double protection and strength are obtained on the four vertical edges. The combination is known as a No.4-2 Bliss box.

3.Recessed-End Box - REB

The piece of the box are indentical to those for a No. 2 Bliss Box, but the end panels are slightly smaller and are reversed when they are attached to the body.

The cress provides a shock-absorbing feature that cushions the product on the ends and corners. The recess can also serve as a hand grip for light boxes.

Body blanksof different lengths, or end panels with flaps of different depths, permit adjustment of the inside length of the box for different products or quanitities.

The style is frequently used for long, light and fragile articles, such as flourescent light fixtures.

When te flaps on the end pieces are extended and doubled back over the outside of the box, a triple thickness, with add protection is achieved.

Box Styles6: Self Erecting

Self Erecting Boxes

Usually made in one piece, self-erecting styles have die-cut and slit-scored bottom flaps. Two pairs of adjacent bottom flaps are folded inward and fastened to each other when the joint is formed.

The box is shipped flat to the user. When it is opened, the two portions of the bottom slide together, and the box is ready to fill.

The style is a time-saver for small volume shippers who do not have automatic set-up equipment. Since the bottom is not fully sealed, however, the style may not be appropriate for heavy products.

The International Box Code indentifies these styles as Rigid-Type Boses. In the carrier Classifications rigid boxes are classified as Conventional Slotted Boxes or Recessed End Boxes.

Box Styles7: Interior Forms

Interior Form Boxes

Liners, shells or tubes, pads, build-ups, dividers, partitions and other inner packing pieces can be made in an infinite variety of ways to separate or cushion products, to strengthen the box, or to prvent product movement by filling voids. They may be simple rectangles, or scored, slotted, scored and slotted, or die-cut shapes.

Many of the types in common use have been given International Box Code numbers. The railroad Classification provides sepcifications for some pieces used in the packing of glassware and other fragile articles.

Pads are plain rectangles of corrugated or soild fibreboard. They can be used to fill the space between the inner flaps of RSC, to completely cover the bottom or top of a box, or to separate layers of product. Vertically, they can be used to separate products or add stacking strength.

Tubes or shells are scored rectangles, folded and sometimes joined with tape to forum a multi-sided structure open at both ends. When used as sleeves for individiual items such as glassware, adjacent shells provide double protection.

Triangular shells are frequently used for stacking strength in the corners of boxes. Rectangular shells that are the same size and depth as the box (minus the thickness of the box) are called liners.

Partitions or dividers provide a seperate cell for each item in a box. They are used primarily for glass-ware and other fragile articles.

Scored and folded inner packing pieces can take many shapes. Included in this group are built-up pads consisting of multiple pieces glued together.

Inner packing pieces are used for cushioning, suspension and separation, and to fill voids. The suspension function holds the product away from the walls of the box to lessen the impact of drops or bumps. Complete filling of voids created by irregularly shapped products adds stacking strength to the box.

Innter packing forms are usually die cut to poisition and support irregular products from below, or lock them into position from above. Altenatively, forms can be placed on two sides or ends of a product. Some inner paking forms are extentions of the box flaps.

In many cases, the box itself is rather common, but ingenious inner packing makes an irregular product easy to pack and safe to ship.

Box Styles8: Display

Display-Type Boxes

Retail displays are being formed in non-traditional ways. Warehouse-type retailers have had an impact on this developement.

Filled, sealed boxes of product may be grouped as a display. The effect can be striking when full-color pictures of the product appear on the face panels.

A mass grouping of boxes of product, with the top few boxes open, may be used. These top boxes may be cut down to trays, or have cut-outs providing access to the product. When this display forat is known in advance, the box manufuacturer can develope a shippiping container with access panels or other display features.

Counter displays are designed to stimulate impluse sales, usually at the service or check-out counter. The unit may consist of a tray of product and a colorful header card, packaged together in an outer shipping countainer.

Floor display/shippers are pre-packaged units that contain everything needed to erect a full floor-stand display, including the product. A large try may be used, perhaps with dividers or partitions. A large header card, and a folded shell that will become the floor base, are included in the shipping container.

Floor displays are free-standing units packaged unassembled, and without product, in a shipping container. They may be designed to hold several cases of separately shipped product, or a few samples, or to call attention to a product on a nearby shelf. Designs range from simple dumps bins to elaborate houses, trees, and treasure chests. They must be easy to assemble, and have the structural strength to hold the product and take the abuse of shoppers for the period of time they will be in use.

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