Production and industrial enterprises for the manufacture of corrugated packaging. Types of packaging made of corrugated cardboard. Types and brands of corrugated cardboard

In this article:

Packing products made of cardboard and corrugated cardboard are today one of the most sought-after containers in the world, domestic market. The share of containers made from pulp and paper materials accounts for about 50% of the total packaging consumed. This is because cardboard and corrugated cardboard are lightweight, characterized by high strength and low price. Therefore, paper packaging is used not only as a shipping container, but also as an individual wrapper.

Due to the constant increase in demand for paper packaging, many entrepreneurs are interested in how to organize the industrial production of paper packaging from corrugated cardboard and cardboard. In order to answer the question posed, it is necessary to familiarize yourself with the manufacturing technology of corrugated cardboard and cardboard, analyze the production of cardboard packaging and organizational details in the opening of an enterprise, as well as draw up a detailed business plan.

Corrugated board manufacturing technology

Before starting the production of corrugated cardboard, paper rolls, cardboard intended for corrugation, are placed in a room in which the air temperature should be more than 15 ° C. During the day should be the process of conditioning.

After this, the rolls are fixed on a roll (unwinding machine) and then the prepared paper, cardboard is fed to the heating cylinders, intermediate rollers. This equipment heats and moistens the paper. Thanks to this operation, the glue sticks deeper into the paper and provides reliable bonding with cardboard.

Further, the manufacture of corrugated cardboard is carried out on a corrugating press. On this equipment, paper passes between the corrugating shafts, the temperature of which is about 180 ° C. As a result of processing, a wavy layer of a certain profile is formed.

After that, the corrugated paper is placed in an applicator machine, where an adhesive film is applied using an adhesive shaft on one side. The amount of glue can be adjusted using a metering roller. Next, the corrugated layer is connected to a flat cardboard and processed by a clamping shaft, and as a result a two-layer corrugated cardboard is obtained. In this operation, corrugated board production may end.

If a three-layer corrugated cardboard is required for the production of containers, then a two-layer corrugated cardboard is transported to the storage bridge, and then to the size machine. On this equipment, glue is applied to the other side of the corrugated paper.

Finally, the corrugated board is transferred to a drying device, where it is glued and dried. The drying process can take place using electricity and steam or drying stoves. During this operation, moisture is removed from the corrugated board and the glue hardens.

After this operation, it is transported to the cooling part of the automated line. The cooling and drying process determines the characteristics of the corrugated board.

Then the corrugated cardboard sheets are fed into the department. slittingwhere it is cut and cut using circular knives. The cutting operation is often combined with a seal. As a result of these operations, groove lines are formed, due to which kink of sheets.

At the end, the corrugated cardboard is cut into sheets of specified parameters. From the sheets, a corrugated cardboard packaging is subsequently formed.

Equipment for the manufacture of corrugated cardboard and packaging

Corrugated cardboard manufacturing plant should have two lines available:

Corrugated board production line;
Corrugated packaging production line. A modern corrugated board production line should include a complex of high-performance automatic and semi-automatic equipment.

Lines for the production of corrugated cardboard and packaging of the company "TRANSPACK" (China) are in great demand on the Russian market.

Therefore, it will be advisable for a novice entrepreneur to purchase the “WJ-120–2200 D 1” line, the maximum speed of which is 120 m / min, and the maximum web width is 2200 mm.

To fully equip the plant, it is necessary to purchase a line for the production of packaging from corrugated cardboard of the YKM-SB 3 series of the TRANSPACK company, which includes a set of machines for processing sheets and manufacturing boxes of various sizes. The maximum productivity of automatic box production lines can be no more than 6000 packages per hour.

The TRANSPACK line includes the following list of main and auxiliary equipment:

Serving table;
3 pcs. printing sections;
Slotting and grooving section;
Rotary die cutting section;
Automated Stacker;
Automated folding and gluing machine;
Logging and cutting machine;
Mini-slotter;
Packing table;
Waste press;
Dissolver for the production of glue;
Measuring instruments.

Given the level of prices for equipment for the production of corrugated cardboard and packaging in 2013, capital investments for the purchase of lines will be at least 98 million rubles.

Cardboard Production Technology

Cardboard manufacturing is carried out as a result of a technological process, which includes the following steps:

1. Raw material preparation includes a number of operations:

the dissolution of waste paper is carried out in a pulper.
purification of waste material from large ingredients, which is performed on a high concentration vortex cleaner.
the release of the cleaned mass is carried out in a pulsating mill.
fine cleaning.

Then the mass enters the composite pool, where rosin glue, starch and alumina are added to its composition. Finally, the paper pulp is re-fine-cleaned on knotters and vortex cleaners.

2. Cardboard dressing. The paper pulp is fed to special machines, where the substance is subjected to dehydration, pressing, and drying. As a result of these operations, the formation of a cardboard sheet. Finally, the waste paper cardboard passes through the shafts of the machine calender, where the sheets are smoothed out under high pressure.

Ready-made cardboard is wound on a tambour shaft, and sent to a slitting machine. On this equipment, cardboard is cut into sheets. The cardboard manufacturing process is nearing completion.

Cardboard manufacturing equipment

The cardboard factory must have an automated line. Such a line should include a list of equipment for the preparation of waste paper and paper pulp:

Pulper;
Swirl cleaner that eliminates heavy inclusions;
Turbo separator;
Pulsating mill;
Disc mill;
Vibrating screen;
Knotter;
Vortex cleaners to eliminate light inclusions;
Mixer for waste paper.

The cardboard production line should also include a specialized machine that forms a cardboard sheet, dehydrates it and dries it. A modern machine for the production of cardboard can produce 20-300 tons of products per day, the maximum width of the canvas can be 6000 mm.

For the manufacture of cardboard, you need the raw materials:

cellulose,
waste paper
or their composition.

It is known that for the manufacture of 1 ton of cardboard it is necessary:

2 tons of steam;
1.1 tons of waste paper;
600-800 kW of electricity;
15-20 cc m 2 of water.

The technology of manufacturing paper packaging from cardboard and corrugated cardboard

The manufacturing technology of cardboard and corrugated cardboard containers depends on the equipment available at the enterprise. Equipment for cardboard packaging is selected based on the planned production volumes, nomenclature and construction of the box.

The manufacturing process for the manufacture of containers of cardboard and corrugated cardboard includes the following steps:

Sheet cutting. For cutting corrugated cardboard at enterprises using a cutting and leveling machine.
Printing. A flexographic station prints a single-color or multi-color print.
Forming blanks for boxes. Depending on the design of the boxes, various equipment can be used at this production stage.
Bonding boxes. At this stage, the packaging from the corrugated cardboard is fed to a folding-gluing machine.

The machine for the production of boxes works in automatic mode.

At the end of the production process, cardboard products are formed into bundled bundles that are placed on a pallet. For further convenience of transportation, bundles are tied into pallets. In this operation, the production of cardboard boxes is completed.

Organizational subtleties in opening an enterprise

To organize an enterprise for the production of corrugated cardboard and corrugated packaging, it is recommended to set up a business as an LLC on a common taxation system.

OKVED codes:

21.21 - “Production of corrugated cardboard, paper and cardboard packaging”;
21.11 - “Production of pulp and wood pulp”;
21.12 - “Production of paper and cardboard.”

In the manufacture of corrugated cardboard and packaging, it is necessary to adhere to the standards GOST 7376-89, GOST 7420–89, GOST 7691–81.

Business plan for the organization of an enterprise for the production of corrugated cardboard and packaging from it

The planned enterprise should include two production sites:

Corrugated board production;
For the production of containers.

For the production of corrugated cardboard, the company plans to order all the raw materials - paper and sheets of cardboard at OJSC Mari PPM. Raw materials will be delivered by rail and road.

Requirements for Production Facilities

The production facilities in which the manufacture of corrugated cardboard and boxes are carried out must have the following parameters:

For the production of corrugated cardboard, a room with an area of \u200b\u200babout 1400 m 2 is necessary;
For the production of packaging, it is necessary to allocate 1000 m 2. In the production room, ventilation should be designed accordingly SNIP 2.04.05–91, the fire safety system - SNIP 21-01-0197. The temperature in production rooms should be more than 18 ° C, and relative humidity - not more than 80%. Warehouse requirements for finished products and raw materials

Warehouses for storage of packaging and raw materials must comply with the following parameters:

The area of \u200b\u200bthe warehouse for corrugated cardboard should be at least 500 m 2;
The area of \u200b\u200bthe warehouse for raw materials should be 500 m 2;
Warehouses should be protected from groundwater and moisture sources;
The air temperature in the rooms should be more than +5 ° С.

The need for staff by category:

Director
Chief Accountant;
24 workers involved in the production process.

Total: 26 people.

Work of employees of the enterprise should be organized in 3 shifts. The duration of one shift is 8 hours, 5 days a working week.

Cost of corrugated board and packaging

To calculate the cost of 1000 m 2 corrugated cardboard, we take into account the cost of raw materials for the manufacture of 1000 m 2 of finished products. The cost of raw materials for the production of 1000 m 2 corrugated cardboard is: 3 rubles / m 2 * 1000 m 2 \u003d 3000 rubles.

Total SS \u003d 3000 rubles.

Electricity Costs:

For the production of 1000 m 2 of corrugated cardboard, 1500 kW / h are consumed.

Total electricity costs (Se) will be: 1500 kW / h * 4 rubles. \u003d 6000 rubles;

Steam costs for technological operations:

The cost of 1 Gcal of steam is C \u003d 161.32 rubles;

The specific rate of steam consumption for the production of corrugated board is 4 Gcal;

Total costs for steam (St) will be: 161.32 rubles / Gcal * 4 Gcal \u003d 645, 28 rubles.

Costs of wages paid to workers: 328,000 rubles per month, for the year - 3,936,000 rubles.

Co (costs of basic and additional wages for workers for the manufacture of 1000 m 2 corrugated cardboard) \u003d 400 rubles.

Payroll taxes - 140 rubles.

The costs of the maintenance and operation of equipment (SMS): 4000 rubles per year;

Calculation of the workshop cost of 1000 m 2 corrugated cardboard: SSC \u003d Ss + Ce + St + Co + SsmSSts \u003d 3000 rubles + 6000 rubles + 645.28 rubles + 400 rubles + 4000 rubles \u003d 14045.28 rubles

Workshop cost for the entire volume of corrugated cardboard manufactured for the year: SStsg \u003d 12,6406800 rubles.

Corrugated cardboard packaging costs

We assume that they make up 2.5% of the workshop cost:

As a result of the calculations, it was found that the annual cost of packaging from corrugated cardboard will be: 3110406 \u200b\u200brubles, per unit. production (1000 m 2 corrugated cardboard) costs will amount to 352.3 rubles.

General factory expenses: 6,220,500 rubles per year, per 1 unit. production - 706.5 rubles.

Costs of rental premises: 1300525 rubles per year, per 1 unit. products - 152.1 rubles.

Total total cost will be: JV (per 1000 m 2 corrugated cardboard) \u003d 15396, 18 rubles, for the annual production volume the cost will be 862186, 08 thousand rubles.

Revenue

The total volume of corrugated cardboard per month - 5821200 m 2;

The volume of corrugated packaging per month is 250,000 pcs. The average market value of 1 m 2 of corrugated cardboard is 15 rubles.

Total revenue for the sale of corrugated board will be: 5821200 m 2 * 15 rubles / m 2 \u003d 87,318,000 rubles. The company plans to sell part of the corrugated packaging (50%) at a price of 20 rubles per unit, and the remaining part - 25 rubles per unit.

Total revenue for the implementation of corrugated packaging will be: 125,000 pcs. * 20 rub. + 125000 pcs. * 25 rubles \u003d 25000000 + 31250000 \u003d 5625000 rubles.

Total revenue for the month: 92,943 thousand rubles.

Revenues for the year will amount to 1,115,316 thousand rubles.

Net profit for the year will be: 1115316 thousand rubles - 862186, 08 thousand rubles \u003d 253129.92 thousand rubles, net profit per month - 21094160 rubles.

Capital investments for the purchase of equipment amount to 98 million rubles.

With such a monthly level of income from production activities, the payback period will be 5 months. Calculations showed that the organization of the industrial production of corrugated cardboard and packaging is a cost-effective and profitable type of business.

Corrugated cardboard remains one of the most popular packaging materials. It is an environmental product that is easy to recycle and has a low cost and sufficient durability.

Corrugated cardboard is 2, 3, 5 or 7-layer. Depending on the density of raw materials and the height of the corrugations, the following brands of corrugated board are distinguished: E (1.1 - 1.6 mm), B (2.2 - 3.2 mm), C (3.2 - 4.4 mm) and A (4.4 - 5.5 mm).

For the production of corrugated cardboard, corrugating paper having a density of 100 to 140 g / m², cardboard for flat layers with a density of 150 to 235 g / m² of brown or white color, as well as starch or silicate glue, are used.

The manufacture of corrugated board is a simple process. However, this process must meet a number of requirements.

Condition Requirements

Corrugated cardboard production is carried out in a special room, the area of \u200b\u200bwhich should leave about 800 m². A lifting mechanism (hoist or electric lift truck) is required.

The temperature in the production room should not be lower than 18 ° C, humidity - not more than 80%.

Process description

Before the production process begins, rolls of corrugating paper and cardboard for flat layers should be in the room with an air temperature of at least 15 ° C for 24 hours, where they are conditioned.

Then the rolls are fixed on the unwinding machine (peal), after which the paper and cardboard are fed to special heating cylinders and intermediate rollers, where they are moistened and uniformly heated. This contributes to a deeper penetration of the adhesive into the thickness of the paper and better bonding with cardboard.

Next, the corrugating paper enters the corrugating machine (corrugating press). Here it passes between gear corrugated shafts heated to 150-180 ° С, as a result of which a wavy layer of a given profile is formed. The dimensions of the corrugations depend on the configuration of the teeth of the shafts.

After this, the corrugated paper enters the applicator machine. Using an adhesive shaft, an adhesive film is applied to the tops of the corrugations of one of the sides (the amount of adhesive applied is controlled by changing the position of the metering shaft). Then the corrugated layer is combined with a flat cardboard, which, under the action of the pressure roll, adheres tightly to the corrugation tops. This stage completes the production process of a two-layer corrugated cardboard.

The resulting two-layer corrugated cardboard is fed through an inclined conveyor belt to the storage bridge, and then to the size machine, where glue is applied to the free side of the corrugated paper.

After that, corrugated cardboard is fed into a drying device, where it is glued and dried. The drying process is carried out using drying ovens and a drying machine. Heating can be done with steam or electricity.

During drying, excess moisture is removed from the layers of corrugated cardboard, and the glue finally hardens. Further, the product enters the cooling part of the line.

The drying process with subsequent cooling largely determines the quality of the resulting corrugated board.

After that, the corrugated board is fed into the section of longitudinal-transverse cutting, where it is cut and cut using a system of circular knives. The cutting process is often combined with corrugation, or compaction of the corrugated board in a straight section of a certain width. As a result, groove lines are formed along which the sheets are bent. Steering is performed using the so-called groove couplings.

Then the corrugated cardboard is cut into sheets of the required length, from which the container is subsequently made.

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A small plant will require an automated line. Its acquisition is the main category of financial investments in this business. Standard line includes:

press;
peal;
thermal equipment (heaters, devices for cooling);
stacker;
bridge;
equipment for vacuum stretching, cutting, drying.

The total cost depends on the manufacturer. With a small starting capital, it makes sense to buy used equipment - it will cost 1.5-2 times cheaperthan a new technique for making corrugated board.

Reliable and high-quality production lines:

WJ120-1800-A of Chinese production (costs about $ 140 thousand second-hand and $ 180 thousand new);
LGK-125E, manufactured by the domestic company GofroMash LLC (about $ 50,000 second-hand, $ 70,000 new).

They differ in productivity: this indicator for the first line is 100m / min, the second - 30 m / min. To start, you can purchase a second line. LGK-125E is a good option for a novice entrepreneur - with trouble-free operation, you can reach a 100% sale of finished products, which is what we need.

Nuance: if, in addition to the production of corrugated cardboard sheets, it is necessary to mark products, then you will have to purchase a flexographic machine separately (price about $ 20 thousand).

Raw materials for the production of corrugated board

The appearance, characteristics and environmental friendliness of the finished corrugated board sheets will directly depend on the quality of the materials used. Raw materials should be selected based on the scope of the finished product. If its purpose is the manufacture of boxes, then ordinary waste paper (recycled materials) is suitable.

When organizing a small business, it is optimal to produce double-layer corrugated cardboard. This will require the following consumables: paper (from 100 to 150 - density), cardboard (with a density of 150-250), silicate glue. The average paper consumption is 1 kg. to get 1m. corrugated cardboard.

Corrugated board manufacturing technology

The production process consists of three stages. First, the paper is corrugated, then silicate glue is applied to one side, then it is glued to cardboard. This technology is used to create two-layer cardboard. To create three or more layers, gluing additional structures of corrugated paper with cardboard is required.

To organize the work of a small corrugated board production line, the following minimum staff will be required: a driver, a specialist in assembly and quality control of products. It is not necessary to hire a cleaner and accountants - you can use the services of third-party organizations.

Since the line is fully automated, it is not necessary to hire additional personnel.

Workshop room

To rent a workshop, you need a room that meets a number of requirements. The area should be from 750 square meters. meters (provided that a small line is used). It is necessary to maintain a temperature of at least 18 degrees and a humidity of not more than 80%.

Electricity, sewage and water supply must be.

Such a room will be sufficient as a workshop, if the staff has other employees (accountant, manager), then additional offices will be required. It is necessary that near the rented premises there should be convenient parking for trucks, ideally a railway line.

Income and expenses

What income will the corrugated packaging production line bring? First, we calculate the costs of opening this business. A minimum of $ 70,000 will be required to purchase equipment (subject to the purchase of an inexpensive used line and flexographic apparatus).

The first batch of materials will cost about $ 4.5 thousand. Room rental and repair: it all depends on location, city or district. On average, it will take about $ 3 thousand. Salary to staff: about $ 2 thousand. Registration of the company and other expenses amount to $ 2 thousand.

With a full sale, the amount of total revenue per month will be about $ 18 thousand. Net profit - an average of 17%, that is, 3 thousand. $. The payback period of a business is 2-3 years.

- This is an option for more experienced entrepreneurs with initial investments. With the proper organization of the line and the full sale of goods, significant success can be achieved.

Ministry of Science and Education of the Russian Federation

Northwest Press Institute

Saint Petersburg State University of Technology and Design

Faculty of Printing Technologies and Equipment

Specialty 261202 "Technology of printing production"

Form of study: correspondence

Department of Printing Technologies

Course work

Discipline: "Materials"

R&D: “Corrugated cardboard and features of its production”

Student Yurtaev S.V.

Group TZ-4

Head Gruzdeva I.G.

St. Petersburg, 2010

Introduction

1 Types of corrugated cardboard

1.1 The shape of the corrugation

2 Features of corrugated board production

2.1 History of the development of corrugated board

2.2 Corrugated board production

2.3 Cardboard

2.4 Glue for the production of corrugated cardboard

3 Application and processing

3.1 Corrugated packaging technology

Conclusion

List of sources used

In this course work investigated such material as corrugated cardboard, collected technical information on the manufacture of various types, brands, corrugated board. The technology for the preparation of glue, some components that are used for the manufacture of special types of corrugated board are described. As part of this course work, the broad possibilities of using corrugated cardboard in various fields of life were studied. Characterized by the properties of various grades of corrugated board and their purpose. For some purposes, use a corrugated cardboard with a high corrugated layer, for others, on the contrary, with a low, a different step of the corrugation is also used to give the required characteristics. Corrugated cardboard, as a packaging material, can have the broadest properties and characteristics that depend on the production method, the raw materials used for paper and cardboard, glues, and manufacturing technology. From the same starting materials, you can get completely different corrugated cardboards. Here, a lot depends on the observance of the technological instructions in the production process, on the correct choice of the composition with three layers, and the adhesive used.

1 Types of corrugated cardboard

Corrugated cardboard is the most frequently used packaging material in industry, characterized by low weight, cost, but high physical parameters. It is one of the most common materials in the world for use as packaging. A feature of the production of corrugated cardboard is the ability to use paper and cardboard obtained from waste paper, which is positive from the point of view of saving resources and protecting the environment.

Corrugated cardboard, as a rule, consists of three layers: two flat layers of cardboard (topliners) and one layer of paper between them, which has a wavy (corrugated) shape (fluting). Such a composition of the layers makes the corrugated board, despite the characteristics of its components, particularly rigid, having resistance both in the direction perpendicular to the plane of the cardboard and in the directions along the planes. To further improve the physical properties of corrugated cardboard packaging, five- and seven-layer corrugated cardboard are used - a material in which layers of cardboard and paper alternate one after another. The dimensions, quality and other parameters of corrugated cardboard packaging are established by industry standards, which also impose their requirements on the production process.

History of corrugated board

Corrugated paper was patented in 1856 in the UK and was used as a lining for hats. Corrugated cardboard in the current sense of the word was patented twenty-five years later, on December 20, 1871, by an American Albert Jones from New York. It was a two-layer corrugated cardboard: cardboard, which lacked one of the flat layers. The first corrugated board machine was built in 1874 - from that moment mass production began, gradually spreading to the whole world. In the same year, a three-layer corrugated cardboard was first produced. Currently, more than three hundred thousand people are employed in the production of corrugated packaging all over the world, in the world there are more than one and a half thousand manufactures.

In 2005, the following amount of corrugated cardboard (in kilograms) was produced per capita:

Spain 55

Belgium 54

Austria 52

Germany 49

France 48

Netherlands 43

Ireland 39

Great Britain 38

Corrugated board brands

According to their physical properties and structure, corrugated cardboard is divided into classes marked with a letter denoting the number of layers and the class number. The most used in industry is a three-layer corrugated cardboard of classes T-21, T-22, T-23, T-24. The five-layer corrugated cardboard is designated by the letter P, the two-layer corrugated cardboard is indicated by the letter D.

Corrugated cardboard is distinguished by the type of profile - the geometric dimensions of the internal waves, which determine the geometric and physical characteristics of the corrugated cardboard. Ranges of sizes of height and width of waves are grouped according to classes denoted by Latin letters A, B, C, etc. Below is a table of corrugated board profiles

Table 1

Cardboard grades differ from each other in absolute burst resistance (MPa), specific burst resistance with the application of a breaking force along the corrugations (kN / m), and end-compression resistance of the corrugations (kN / m).

Microcorrugated board

Microcorrugated cardboard - three-layer corrugated cardboard with a thickness of 1.5 to 1.8 mm. Unlike corrugated board, microcorrugated board due to its smaller thickness has slightly lower strength characteristics, it is used for lighter structures requiring presentation. Microcorrugated cardboard has lower shock-absorbing qualities compared to corrugated cardboard and therefore this choice should be taken into account when choosing a material for fragile packaging.

The microcorrugated cardboard is marked with the letter “E” and has its own history from the original name of the microcorrugated cardboard brand “Elite”, the production of which was established in the USA. The small height of the corrugation and the smaller width of the corrugations of this brand allows you to get a flat surface and high planar rigidity.

Microcorrugated cardboard is used for individual, presentable cardboard packaging, usually with offset and flexo printing.

Advantages of using microcorrugated cardboard: Lightweight and durable construction, which better protects the goods inside; Suitable for packaging large and small-sized goods in any industry and for food products. This type of corrugation allows you to create even very small boxes that have a fairly attractive appearance.

Double Layer Corrugated Cardboard

It is marked with the letter “D” - (the so-called “two-layer”), (Figure 1), consists of one flat and one corrugated layers. This type of corrugated cardboard is flexible, wound into a roll, although it can also be made in sheets.

Five-layer corrugated cardboard

“P” is a five-layer corrugated cardboard, consisting of three flat (two outer and one inner) and two corrugated layers. It is possible to manufacture a five-layer corrugated cardboard of the type "B + B", "B + C", "B + E", etc.

Rarely used types of corrugated cardboard

Four-layer corrugated cardboard is a combination of one outer and one inner liner and two corrugated media. This type of corrugated cardboard is made in sheets and is used, as a rule, for laminating. In Russia, the most popular four-layer corrugated cardboard with a profile of "C + E".

Seven-layer corrugated cardboard consists of three corrugated, two flat outer and two flat inner layers

1.1 The shape of the corrugation

More than 90% of the corrugated cardboard produced in the world has a sinus-shaped corrugation shape (Figure 2). Sometimes for special purposes a V-shaped corrugation is made.

Advantages of corrugated cardboard in comparison with other packaging materials.

The main advantages of cardboard are known to all. It is light (a box of corrugated cardboard is three to four times lighter than a similar plastic, three times as a box of wood). Accordingly, when transporting goods packaged in cardboard boxes it is saved, the fuel boxes themselves can be delivered to the customer in a folded form. The cardboard is multifunctional - it can be used for packaging various goods.

Cardboard is recyclable. With proper organization, a multiple return to the economic cycle of the primary pulp used in the production of cardboard is achieved, which significantly saves manufacturers' material resources. In addition to chipboard, various fibrous plates, tuberous pads and other, as a rule, building materials are also made from recycled materials. Waste paper is a substitute for pulp, wood and paper pulp, which favorably affects the environmental situation.

An important advantage of cardboard is its familiarity to consumers who trust packaging made from cellulose raw materials. The image of cardboard as an environmentally friendly material is often an important factor in the choice of packaging.

Corrugated box

Packaging products, which are made of corrugated cardboard, are today one of the most needed packages in the domestic and world markets. Its manufacture is entirely provided by the corrugated board production line.

The share of packaging, which is made from paper and cellulose raw materials, accounts for about 67% of the total volume of consumed packaging. This can be explained by the fact that the corrugated board has a light weight, which is characterized by high quality and low cost.

Most often, corrugated board production lines pay off within 3-4 months after the start of their operation.

Production technology

In view of the constant increase in demand for paper containers, many enterprises are interested in organizing the industrial production of paper packaging from cardboard and corrugated cardboard.

However, in order to decide on the beginning of this business, it is necessary to study the technology for the production of cardboard and corrugated cardboard, to analyze the manufacture of cardboard containers and coordination issues in the opening of the organization.

The methodology for the production of packaging lines for the production of corrugated cardboard and cardboard depends on the production line, which is already available at the enterprise. The installation for cardboard and corrugated cardboard packaging is selected based on the planned production volume, structure and nomenclature of the box.

The industrial process for the production of packaging from corrugated cardboard and cardboard reads several stages:

Stage 1: cutting sheets.

To carry out the cutting of containers at enterprises, it is necessary to use a shedding and cutting machine.

Stage 2: print.

The flexographic station is printed in one color or multi color.

Stage 3: form blanks for boxes.

Given the design of the boxes at this industrial stage, various techniques can be applied.

This stage ensures the receipt of containers on the folding-gluing machine.

Equipment for the production of packaging lines operates in automatic mode.

5 stage.

At the end of industrial processes, cardboard products are formed into a tied bundle, which is placed on a pallet. For subsequent comfort, the transportation of bundles is tied into pallets. This stage in the corrugated board production line is final.

Equipment

The cardboard packaging company needs to have an automated line for the production of corrugated cardboard in the first list. Such an installation should have a list of techniques for the specialization of paper pulp and waste paper.

Hydraulic breaker.
A swirl cleaner that eliminates severe switching problems.
Knotter;
Turboseparator.
Pulsation mill;
Disc mill;
Vibrating screen;
A vortex cleaner that eliminates minor malfunctions in the inclusion.
The mixer for waste mass.

Corrugated board production lines should also have a special machine forming a cardboard web. This machine must dry and dehydrate it. A modern installation for the manufacture of cardboard can produce 25-310 tons of products per day. The maximum sheet length can be 6 m.

Necessary material for the manufacture of cardboard:

Cellulose.
Waste paper.
Their confusion.

To produce 1 ton of cardboard, you need:

2.5 tons of steam;
1.2 tons of waste paper;
650-850 kW of electricity;
17-23 cubic meters m 2 of water.

Analyzing the price range of equipment for the manufacture of corrugated cardboard, capital investments for the purchase of the line will be at least 100 million rubles.

The corrugated cardboard production line, the price of which is 2.6 million rubles from different manufacturers, also has all the equipment, but costs several times less. However, the acquisition of used models is fraught with all sorts of marriages and malfunctions.

A characteristic feature of corrugated cardboard is the existence of undulating (corrugated) layers. Corrugated cardboard contains alternating flat and corrugated layers that are glued with different adhesives along the contact line. Gluing occurs between a flat layer of cardboard and the bottom with the upper surfaces of the corrugation waves.

An indicator that determines the characterizing types of corrugations are - h (corrugation height) and t (corrugation pitch). The height of the corrugation is the gap between its upper and lower points. Corrugation pitch is the distance between one and the second upper adjacent corrugation points. A conditional combination of step and corrugation heights is called a profile.

The main tasks of the profiles of a 3-layer corrugated cardboard:

Corrugated cardboard profile C:

it is used in the manufacture of boxes and packaging for transportation and storage of products, while it has high stacking strength.

Corrugated cardboard profile B:

it is intended for the production of boxes, trays and containers for transportation and storage of products, while it has low stacking strength but a good printing surface.

Corrugated cardboard with profile E:

intended for the production of small packaging, while having low strength in stacking and a very good surface in print.

The main tasks of the profiles of 5-layer corrugated cardboard:

Corrugated cardboard with a profile SV:

it is intended for the production of boxes and trays for heavy products that require high protection, while having very high stacking strength, as well as high impact resistance.

Corrugated board with CE profile:

it is intended for the production of boxes and trays for heavy products that require high protection, while having very high stacking strength, high impact resistance, and a good print surface.

Corrugated Cardboard Production Line

Marks and types of corrugated cardboard

The type of corrugated cardboard is intended to meet the parameters of the corrugated cardboard sheet according to GOST.

This product is a multi-layer raw material. Its thickness determines the amount of a flat layer, or as it is called a liner, as well as fluting (corrugated paper).

T is a three-layer corrugated cardboard. It contains two flat layers and one corrugated.

Three-layer corrugated cardboard

P is a five-layer corrugated cardboard that contains three flat (two outer and one inner) and two corrugated layers.

The task of sheet three-layer corrugated cardboard is to produce containers and additional packaging. They are intended for packaging products that do not tolerate static load.

The task of sheet, five-layer corrugated cardboard is to produce packaging products for transportation. Products for them need maximum protection against involuntary damage or shock. Also, a five-layer corrugated cardboard is necessary for the manufacture of large-sized corrugated packaging.

Steam line

Steam lines for the production of corrugated cardboard are designed for the manufacture of three- and two-layer corrugated cardboard.

The steam line for the production of corrugated board includes the following installations:

Corrugated presses of cassette types.
Vacuum shaft B, C, format 1500 (working speed 125m / min).
Imported corrugated.
Accumulative bridge (the presence of vacuum tension of the canvas).
Frequency gluing (with drying table).
Cutting and grooving, longitudinal, thin-cut installation with electronic control system and five types of grooves.
Cross two-level cutting.
Stacker.

Additional equipment available:

comb corrugated press;
gluing together;
longitudinal cutting;
transverse cutting.

BHS line

Five-layer corrugated cardboard is used to produce particularly strong and rigid packaging. For example, packaging of meat products, vegetables, fruits. Also for the production of large containers: packaging for a refrigerator, washing machine. Depending on the task of the container, the “BC” profile corrugation is used, and the “BB” combination is rarely used.

bhs 5-layer corrugated cardboard production line installed at the new Ilim corrugated plant is designed for the output of a 5-layer corrugated cardboard with profiles B, C and E. It is also possible to use corrugated cardboard of profile A, K, F.

BHS line for the production of 5-layer corrugated cardboard for the release of a quality product, perform the following operations:

installation of a cardboard roll on a rolling device;
pre-heating cardboard heating;
glue cladding on a specializing gluing plant;
gluing a 2-layer corrugated cardboard with a heated liner, forming a five-layer corrugated cardboard;
corrugated board drying.

After unwinding, batting of paper passes into a corrugator, in which the paper is corrugated with the help of two shafts and heated steam. Starch glue is applied to the top of the corrugation from the upper side. Further, the cardboard material goes into another corrugator where the corrugated sheet is connected to the cardboard. As a result of this process, a 2-layer corrugated cardboard is obtained.

Further, the material from the two-layer corrugated cardboard is laid in the form of a loop to create some margin and uninterrupted operation of the corrugator. After that, the material is transferred to the heater and fed to the size installation.

Starch glue is applied there. 2-ply corrugated board is combined with other cardboard material.So, a three-layer corrugated cardboard is formed. To make a five-layer corrugated cardboard in a corrugated installation, there is one more corrugated press.

The glued corrugated cardboard layers enter the dryer, in which excess moisture is released and the material adheres firmly to the layers. At the final, rotary scissors are fixed. They are needed to eliminate substandard procurement and ensure the transition to the next stage.

And also to change the size of the workpiece. The finished web goes into a special cutting and cutting unit, in which strips of the required width are cut and the edges are cut at the same time. There, the line of the next fold of the canvas is applied in order to properly form the box.

After that, the material is cut into a sheet of the required length, while this forms a blank ready for further processing. Subsequent manipulations of the sheets are carried out on the processing line.

Corrugated boxes

The corrugated box production line carries out the production of products during technological processes, which include several stages.

Stage I: material procurement.

The first stage of production includes a number of operations:

dissolve waste paper (dissolution occurs in the pulper);
clean the waste paper from large-scale ingredients (the process is carried out on a vortex cleaner with a high concentration);
dissolution of finished, cleaned clusters (produced in a pulsating mill);
fine cleaning;
mass flow into the composite pool;
the composition of the clusters is the addition of rosin glue, alumina and starch;
the resulting paper pulp undergoes additional, fine cleaning, which is carried out on vortex cleaners and knotters.

Stage II: the manufacture of a cardboard box.

The paper conglomerate begins to enter a special machine (the substance in it is pressed and dehydrated, as well as dried);
upon completion of this operation, the process of forming a cardboard box. In conclusion, waste boxes pass through the shafts of machine calendars and there, under the emphasis of high pressure, the product sheet is smoothed out;
the finished product is wound on tambour shafts and sent to a cutting-longitudinal machine;
On the machine, cardboard is cut into several sheets of the necessary parameters, and this becomes the final process of manufacturing a cardboard box.

Equipment for the production of corrugated boxes:

The company for the production of cardboard containers should have, in the necessary order, an automated line for the production of corrugated boxes. Such an installation should have a list of techniques for the specialization of paper pulp and waste paper.

The box, which is made of corrugated cardboard, has a complex structure and is produced by rotational or flat die cutting. This ensures high quality and accuracy. The most common boxes in this category are American (four-valve) packaging boxes for widespread use of the product and various tray-shaped products.

Video: Corrugated packaging production

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