Cardboard Box Making

How cardboard boxes are made?

Cardboard boxes are one of the most commonly used forms of packaging in today’s world. From shipping goods to moving houses, they have become an essential part of our lives. But have you ever wondered about the process behind the making of these sturdy boxes?

Manufacturing of cardboard boxes involves a complex process of shaping layers of paper pulp into various shapes and sizes, which are then skillfully transformed into the boxes we use every day.

In this article, we will delve into the fascinating world of cardboard box production, exploring the intricate steps involved in the manufacturing process.

So let’s venture into the world of cardboard box making and discover how this everyday product is created!

Process Of Making Cardboard Boxes

Raw materials

The primary raw material used in the production of cardboard boxes is paper pulp, derived from wood chips. These wood chips come from both softwood trees like pine and hardwood trees like birch or gum.

Other materials used include water, to aid in the processing of pulp and chemicals such as sodium hydroxide and sodium sulfide, which help in separating the wood into fibers. Recycled cardboard and paper are also used extensively in the process, promoting sustainability and reducing the demand for fresh wood pulp.

Manufacturing process of cardboard boxes

  1. Pulping: First step in the manufacturing process is pulping. Wood chips are mixed with water and chemicals in a large vat known as a pulper. The mixture is then heated, which breaks down the wood into fibrous pulp. If recycled materials are being used, they are also added to the pulper at this stage and broken down into pulp.
  2. Cleaning and screening: Pulp is then cleaned and screened to remove any unwanted particles or impurities. The clean pulp is then passed through a series of screens to separate the fibers and get a uniform pulp consistency.
  3. Floatation tank: Next, the pulp is put into a flotation tank, where ink and other contaminants are removed. This process is mainly used when recycled materials are involved.
  4. Drying and pressing: The clean pulp is then pressed and dried to form sheets of paper. The sheets are passed through heated rollers, which remove the moisture and result in a flat, smooth piece of paper.
  5. Corrugating and gluing: This paper is then passed through a machine known as a corrugator, which crimps and heats the paper to create ridges, known as flutes. This gives the paper its strength and rigidity. Another layer of paper is then glued on top to create the corrugated cardboard.
  6. Cutting and printing: The final stage is cutting and printing. The corrugated cardboard is cut into the desired shape and size using a die cutter. If the boxes need printing, this is done at this stage using large, industrial printers.
  7. Gluing and folding: Finally, the cut and printed pieces are folded and glued together to form the final cardboard box. The boxes are then ready for use or for shipment to the customer. 

Manufacturing Process for Each Box type

Different types of boxes necessitate alterations in the manufacturing process. The key differences typically lie in the type of cardboard used, the production techniques applied and the finish on the box.

1) Rigid boxes

Rigid boxes (also known as gift boxes) are made from highly condensed paperboard that is four times thicker than the paperboard used in standard folding cartons.

They are not folded or collapsed and are usually hand-wrapped with the desired finish, such as specialty paper or fabric, contributing to their high-end appeal.

2) Folding cartons

These boxes are made from a single piece of cut and scored paperboard, then shipped flat and folded into shape when needed. They are highly versatile and can be customized with various finishes and printing techniques.

3) Corrugated boxes

These are the most common type of boxes and the process has been detailed above. However, variations exist within this category, like single-wall, double-wall or triple-wall corrugated boxes. These variations depend on the number of corrugated medium or fluting layers used and this determines the strength and rigidity of the box.

Paying attention to these differences ensures the production of boxes that are fit for purpose, whether for shipping, retail or gift giving. Each box type requires different materials, machinery and techniques, further emphasizing the complexity and versatility of the box manufacturing industry.

Common misconceptions about cardboard box manufacturing

Despite its importance, there are several misconceptions about the manufacturing process of cardboard boxes.

Let’s take a look at some common misconceptions and the truth behind them:

I) Cardboard boxes are made from trees

While it is true that wood pulp derived from trees is a primary raw material in cardboard box production, the industry has made significant strides toward sustainability. Recycled materials like old cardboard and paper are extensively used in the process, reducing the demand for fresh wood pulp.

II) Cardboard boxes are made entirely by machines

While machines play a significant role in box production, human labor is equally vital. Skilled workers operate and maintain the machinery, conduct quality control checks and perform various tasks such as gluing and folding by hand.

III) All boxes are created equal

As discussed earlier, different types of boxes require varying production techniques and materials. The one size fits all principle does not apply in the box manufacturing industry, with specific processes tailored to meet specific needs.

Environmental impact of cardboard box manufacturing

The cardboard box industry has been criticized for its environmental impact, particularly regarding deforestation and waste.

However, efforts have been made to reduce the industry’s carbon footprint and promote sustainability.

  1. Use of recycled materials: As mentioned earlier, the use of recycled materials in cardboard box production has significantly increased. This reduces the demand for raw materials like wood pulp and lessens the strain on natural resources.
  2. Efficient use of energy: Manufacturers are constantly investing in new technology and machinery to increase efficiency and reduce energy consumption. This includes using renewable energy sources like solar panels, implementing energy-saving measures and optimizing production processes to minimize waste.
  3. Recyclability: Cardboard boxes are highly recyclable and can be reused multiple times before reaching the end of their life cycle. This further reduces the need for raw materials and minimizes waste.

Frequently Asked Questions (FAQs)

Are all cardboard boxes created equal? 

No. Different types of boxes require varying production techniques and materials. The type of box, be it rigid, folding cartons or corrugated, determines the production process.

Are cardboard boxes produced entirely by machines? 

While machines play a significant role in the production process, human labor is integral as well. Skilled workers operate and maintain the machinery, conduct quality control checks and perform tasks such as gluing and folding by hand.

What measures are taken to reduce the environmental impact of cardboard box manufacturing? 

The industry has made efforts to reduce its carbon footprint by increasing the use of recycled materials, investing in new technology and machinery to reduce energy consumption and promoting the recyclability of cardboard boxes.

How does the number of fluting layers affect the corrugated box? 

Number of fluting layers determines the strength and rigidity of the corrugated box. The more the fluting layers (single-wall, double-wall, triple-wall), the stronger and more rigid the box.

What types of paper are used in the production of cardboard boxes?

Typically, manufacturers use Kraft paper for the outer layers and recycled paper for the fluted inner layer. Kraft paper is known for its strength and durability.

Final Words

The production of cardboard boxes is a fascinating process that involves the use of various raw materials and intricate steps to create the end product. From paper pulp to corrugated cardboard to final printing, each step requires skill and precision to ensure high quality custom boxes are produced.

So next time you receive a package or move houses, take a moment to appreciate the effort and craftsmanship that goes into making these versatile boxes. So, this is how cardboard boxes are made!