Manufacturing and industrial enterprises for the production of corrugated packaging. Types of corrugated cardboard packaging. Types and brands of corrugated board

In this article:

Packaging products made of cardboard and corrugated board are today one of the most demanded containers in the world, domestic market. The share of containers made from pulp and paper materials accounts for about 50% of the total volume of consumed packaging. This is due to the fact that 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 the demand for paper packaging, many entrepreneurs are interested in how to organize industrial production paper packaging from corrugated board and cardboard? In order to answer the question posed, you need to familiarize yourself with the technology of manufacturing corrugated board and cardboard, analyze the production carton packaging and organizational subtleties in starting a company, as well as drawing up a detailed business plan.

Corrugated cardboard manufacturing technology

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

After that, the rolls are fixed on a roll (unwinding machine) and then the prepared paper, cardboard are fed to the heating cylinders, intermediate rollers. This equipment is used to heat and moisten the paper. Thanks to this operation, the glue penetrates better into the paper and ensures reliable adhesion to the cardboard.

Further, the production of corrugated cardboard is carried out on a corrugated press. With this equipment, the paper passes between corrugating rollers, 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 a glue applicator, where a glue film is applied using a glue roller on one of the sides. The amount of glue can be adjusted using the metering roller. Next, the corrugated layer is connected to the flat cardboard and processed by the pressure roller, and the result is a two-layer corrugated cardboard. In this operation, the production of corrugated board can be completed.

If a three-layer corrugated board is required for the production of containers, then the two-layer corrugated board is transported to the storage bridge, and then to the gluing machine. This equipment applies glue to the other side of the corrugated paper.

Finally, the corrugated board is transferred to the dryer, where it is glued and dried. The drying process can be carried out using electricity and steam or drying ovens. During this operation, moisture is removed from the corrugated board and the glue is hardened.

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

Then the sheets of corrugated board are fed to the department slitting, where it is cut and cut using circular knives. The cutting operation is very often combined with compaction. As a result of these operations, scoring lines are formed, thanks to which fold of sheets.

Finally, the corrugated board is cut into sheets of specified parameters. In the future, corrugated cardboard packaging is formed from the sheets.

Equipment for the manufacture of corrugated board and packaging

A corrugated board plant should have two lines available:

• Corrugated board production line;
• A line for the production of corrugated cardboard packaging. Modern line for the production of corrugated cardboard should include a complex of high-performance automatic and semi-automatic equipment.

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

Therefore, for a novice entrepreneur, it will be advisable to purchase the line "WJ-120-2200 D 1", maximum speed 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 corrugated cardboard packaging of the YKM-SB 3 series of the TRANSPACK company, which includes a set of machines for processing sheets and producing boxes of various dimensions. Maximum productivity automatic lines for the production of boxes can be no more than 6000 packs per hour.

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

• Feed table;
• 3 pcs. printed sections;
• Screening and scoring section;
• Rotary die cutting section;
• Automated stacker;
• Automated folder-gluer machine;
• Slitting and cutting machine;
• Mini Slotter;
• Packing table;
• Waste press;
• Dissolver for the production of glue;
• Measuring instruments.

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

Cardboard production technology

The production of cardboard is carried out as a result of a technological process that includes the following stages:

1. Preparation of raw materials includes a number of operations:

• recycling of waste paper is carried out in a pulper.
• cleaning waste paper from large ingredients, which is carried out on a high-concentration vortex cleaner.
• additional release of the cleaned mass is carried out in a pulsating mill.
• fine cleaning.

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

2.Processing of cardboard... The pulp is fed to special machines, where the substance is dehydrated and pressed, dried. As a result of these operations, the formation of a cardboard sheet is carried out. Finally, the recycled paperboard passes through the rolls of the machine calender, where the sheets are flattened under high pressure.

The finished cardboard is wound on a tambour shaft and sent to a slitting machine. This equipment is used to cut the cardboard into sheets. The technological process of cardboard production is coming to an end.

Equipment for the production of cardboard

A paperboard plant must have an automated line. Such a line should include a list of equipment for the preparation of waste paper and paper pulp:

• Pulper;
• Vortex cleaner, which allows you to eliminate heavy inclusions;
• Turbo separator;
• Pulse mill;
• Disc mill;
• Vibrating sieve;
• Knot catcher;
• Vortex cleaners to eliminate light inclusions;
• Stirrer for waste paper.

The line for the production of cardboard should also include a specialized machine that forms the 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 web width can be 6000 mm.

For the manufacture of cardboard, raw materials are needed:

• cellulose,
• waste paper
• or their composition.

It is known that for the production 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 cubic meters m 2 of water.

Manufacturing technology of paper packaging from cardboard and corrugated board

The technology for manufacturing containers from cardboard and corrugated board depends on the equipment available at the enterprise. Equipment for carton packaging is selected based on the planned production volume, nomenclature and box design.

The production process for the manufacture of containers from cardboard and corrugated board includes the following stages:

• Cutting sheets... For cutting corrugated cardboard at the enterprises use a cutting and creasing machine.
• Printing... One-color or multi-color printing is applied at the flexographic station.
• Formation of blanks for boxes. Depending on the design of the boxes, different equipment can be used at this production stage.
• Bonding boxes. At this stage, the corrugated cardboard packaging goes to the folder-gluer.

The box making machine works in automatic mode.

At the end of the production process, cardboard products are formed into tied bundles, which are placed on a pallet. For further convenience of transportation, bundles are tied into pallets. This operation ends the production of cardboard boxes.

Organizational subtleties in starting an enterprise

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

OKVED codes:

• 21.21 - "Production of corrugated cardboard, paper and cardboard packaging";
• 21.11 - "Production of cellulose 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 organizing 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 board all raw materials - paper and cardboard sheets, the company plans to order from JSC "Mariyskiy PPM". Delivery of raw materials will be carried out by rail and road.

Requirements for production facilities

The production facilities in which the production of corrugated board and boxes is carried out must have the following parameters:

• For the production of corrugated board, a room with an area of ​​about 1400 m 2 is required;
• It is necessary to allocate 1000 m 2 for the production of packaging. V production area ventilation should be designed according to SNIP 2.04.05–91, fire safety system - SNIP 21–01–97. The temperature in industrial premises should be more than 18 ° С, and the relative humidity should not exceed 80%. Warehouse requirements for finished products and raw materials

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

• The warehouse area for corrugated board must be at least 500 m 2;
• The area of ​​the warehouse for raw materials should be 500 m 2;
• Warehouses must be protected from groundwater and moisture sources;
• The air temperature in the premises must be more than +5 ° С.

Personnel requirements by category:

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

Total: 26 people.

The work of the company's employees should be organized in 3 shifts. The duration of one shift is 8 hours, 5 days work week.

Cost of corrugated board and packaging

To calculate the cost of 1000 m 2 of 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 manufacturing 1000 m 2 of corrugated cardboard is: 3 rubles / m 2 * 1000 m 2 = 3000 rubles.

Total Сс = 3000 rubles.

Electricity costs:

The production of 1000 m 2 of corrugated cardboard requires 1500 kW / h.

Total electricity costs (E) will be: 1500 kW / h * 4 rubles. = 6,000 rubles;

Steam costs for technological operations:

The cost of 1 Gcal of steam is C = 161.32 rubles;

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

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

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

Co (expenses for the main and additional wages for workers for the manufacture of 1000 m 2 of corrugated cardboard) = 400 rubles.

Payroll taxes - 140 rubles.

Equipment maintenance and operating costs (Ccm): 4000 rubles per year;

Calculation of the workshop cost of 1000 m 2 of corrugated board: SSts = Cs + Se + St + Co + SsmSSts = 3000 rubles + 6000 rubles + 645.28 rubles + 400 rubles + 4000 rubles = 14,045.28 rubles

Workshop cost for the entire volume of corrugated board, manufactured per year: SStsg = 126406800 rubles.

The cost of manufacturing corrugated cardboard packaging

Let's assume that they make up 2.5% of the workshop cost:

As a result of the calculations, it was found that the annual costs for corrugated cardboard packaging will be: 3110406 ​​rubles, per unit. production (1000 m 2 of corrugated board) costs will be 352.3 rubles.

General plant expenses: 6,220,500 rubles per year, for 1 unit. products - 706.5 rubles.

Premises rental expenses: 1,300,525 rubles per year, for 1 unit. products - 152.1 rubles.

Total total cost will be: Cn (for 1000 m 2 of corrugated board) = 15396, 18 rubles, for the annual production the cost will be - 862186, 08 thousand rubles.

Revenue

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

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

The total proceeds for the sale of corrugated board will be: 5821200 m 2 * 15 rubles / m 2 = 87 318 000 rubles. The company plans to sell part of the corrugated packaging (50%) at a price of 20 rubles per piece, and the rest - 25 rubles per piece.

Total proceeds from the sale of corrugated packaging will be: 125,000 pcs. * 20 rub. + 125000 pcs. * RUB 25 = 25,000,000 + 31,250,000 = 5,625,000 rubles.

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

The revenue for the year will be 1,115,316 thousand rubles.

Net profit for the year will be: 1115316 thousand rubles - 862186, 08 thousand rubles = 253129.92 thousand rubles, net profit for the 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 industrial production corrugated board and packaging is a profitable and profitable type of business.

Corrugated board remains one of the most popular materials for packaging production. It is an ecological product that is easily recyclable and has a low cost and sufficient durability.

Corrugated cardboard can be 2, 3, 5 or 7 layers. Depending on the density of raw materials and the height of the corrugations, the following grades 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, corrugated paper with 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 production of corrugated board is a simple process. However, this process must meet a number of requirements.

Requirements for conditions

The production of corrugated board is carried out in a special room, the area of ​​which should be about 800 m². A lifting mechanism (telpher or electric forklift) is required.

The temperature in the production area should be at least 18 ° C, humidity - no more than 80%.

Description of the technological process

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

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

Next, the paper for corrugating goes into a corrugating machine (corrugating press). Here it passes between toothed corrugating shafts heated to 150-180 ° C, 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 shaft teeth.

After that, the corrugated paper is fed into the glue applicator. With the help of a glue roller, an adhesive film is applied to the tops of the corrugations of one of the sides (the amount of glue applied is regulated by changing the position of the metering roller). Then the corrugated layer is combined with flat cardboard, which is tightly glued to the tops of the corrugations under the action of the pressure roller. This stage completes the two-layer corrugated board production process.

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

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

During the drying process, excess moisture is removed from the corrugated cardboard layers, and the glue is finally hardened. Then the products go to the cooling part of the line.

The drying process followed by cooling largely determines the quality of the resulting corrugated board.

After that, the corrugated board is fed into the slitting section, where it is cut and cut using a system of circular knives. The cutting process is often combined with creasing or compaction of corrugated board in a straight section of a certain width. As a result, scoring lines are formed along which the sheets are folded. The creasing is done using so-called creasing couplings.

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

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

• Press;
• roll;
• thermal equipment (heaters, cooling devices);
• sheet stacker;
• bridge;
• equipment for vacuum stretching, cutting, drying.

The total cost depends on the manufacturing company. With a small start-up capital, it makes sense to buy used equipment - it will cost 1.5-2 times cheaper, how new technique for the manufacture of corrugated board.

Reliable and quality production lines:

• Chinese-made WJ120-1800-A (it costs about $ 140,000 used and $ 180,000 new);
• LGK-125E, produced by the domestic company Gofromash LLC (about $ 50,000 used, $ 70,000 new).

They differ in productivity: this indicator for the first line is 100 m / min, the second - 30 m / min. You can purchase a second line to start. LGK-125E - a good option for a novice entrepreneur - with uninterrupted work, you can reach one hundred percent 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 the products, then you will have to separately purchase a flexographic machine (price about $ 20 thousand).

Raw materials for the production of corrugated board

The quality of the materials used will directly depend on appearance, characteristics and environmental friendliness of finished corrugated cardboard sheets. The choice of raw materials should be based on the scope of the finished product. If its purpose is to make boxes, then ordinary waste paper (secondary raw materials) will do.

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

Corrugated board production technology

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

For the organization of work, a small production line for the production of corrugated cardboard, the following minimum staff will be required: a driver, an assembly specialist and product quality control. It is not necessary to hire a cleaning lady and an accountant on the staff - you can use the services of third-party organizations.

Since the line is fully automated, there is no need to hire additional personnel.

Premises for the workshop

For renting a workshop, you will need a room that meets a number of requirements. The area should be from 750 sq. meters (assuming a small line is used). It is necessary to maintain the temperature in it at least 18 degrees and humidity - no more than 80%.

Electricity, sewerage and water supply must be available.

As a workshop, such a room will be enough, if there are other employees on the staff (accountant, manager), then additional offices will be required. It is necessary that there is a convenient parking near the rented premises for trucks, ideally a railway line.

Income and expenses

How much revenue will the corrugated packaging production line generate? First, let's calculate the opening costs this business... The purchase of equipment will require at least $ 70 thousand (subject to the purchase of an inexpensive used line and a flexographic machine).

The first batch of materials will cost about $ 4.5 thousand. Premises rental and renovation: it all depends on the location, city or area. On average, it will take about $ 3 thousand. Staff salary: about $ 2 thousand. Company registration and other expenses will amount to $ 2,000.

With full sales, the total income per month will be about $ 18,000. Net profit - on average 17%, that is, $ 3 thousand... The payback period for the business is 2-3 years.

- This is an option for more experienced entrepreneurs with an initial investment. At correct organization the operation of the line and the full implementation of the product can achieve significant success.

Ministry of Science and Education of the Russian Federation

Northwest Institute of Printing

St. Petersburg State University technology and design

Faculty of Printing Technologies and Equipment

Specialty 261202 "Technology of printing production"

Form of study: part-time

Department "Technologies of Printing Production"

Course work

By discipline: "Materials Science"

R&D: "Corrugated cardboard and features of its production"

Student Yurtaev S.V.

Group TZ-4

Head Gruzdeva I.G.

Saint Petersburg, 2010

Introduction

1 Types of corrugated board

1.1 Corrugation shape

2 Features of the production of corrugated board

2.1 History of the development of corrugated board

2.2 Production of corrugated board

2.3 Cardboard

2.4 Adhesive for corrugated board production

3 Application and processing

3.1 Technology of production of corrugated packaging

Conclusion

List of sources used

In this course work, a material such as corrugated cardboard is investigated, technical information on manufacturing is collected, different types, stamps, corrugated board. The technology for the preparation of glue, some components that are used for the manufacture of special types of corrugated cardboard are described. Within this term paper the wide possibilities of using corrugated board in various spheres of life were studied. The properties of various grades of corrugated board and their purpose are characterized. For some purposes, corrugated cardboard with a high corrugated layer is used, for others, on the contrary, with a low one, a different corrugation pitch 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, used paper and cardboard raw materials, adhesives, and manufacturing technology. From the same raw materials, you can get completely different corrugated board. Much depends on the observance of technological instructions in the production process, from the right choice composition of three layers, and the glue used.

1 Types of corrugated board

Corrugated cardboard is the most commonly used packaging material in the 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 corrugated board production is the ability to use paper and board obtained from waste paper, which is positive from the point of view of saving resources and protecting the environment.

Corrugated cardboard consists, as a rule, 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 layers makes corrugated cardboard, despite the characteristics of its components, especially rigid, having resistance both in the direction perpendicular to the plane of the cardboard and in directions along the planes. To further improve the physical properties of corrugated cardboard packaging, five- and seven-layer corrugated cardboard is 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 own requirements on the production process.

History of corrugated board

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

In 2005, the following quantities of corrugated board (in kilograms) were produced per capita:

Spain 55

Belgium 54

Austria 52

Germany 49

France 48

Netherlands 43

Ireland 39

United Kingdom 38

Corrugated board brands

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

Corrugated cardboard is distinguished by the type of profile - the geometric dimensions of internal waves, which determine the geometric and physical characteristics of corrugated cardboard. The ranges of sizes of heights and widths of waves are grouped into classes denoted by the Latin letters A, B, C, etc. Below is a table of corrugated board profiles

Table 1

The grades of cardboard differ from each other in absolute resistance to punching (MPa), resistivity of rupture with application of a destructive force along the corrugations (kN / m), resistance of the end compression of corrugations (kN / m).

Micro corrugated board

Microcorrugated cardboard - three-layer corrugated cardboard with a thickness of 1.5 to 1.8 mm. Unlike corrugated cardboard, microcorrugated cardboard, due to its smaller thickness, has slightly lower strength characteristics, it is used for lighter structures that require a presentation. Microcorrugated cardboard has lower shock-absorbing qualities compared to corrugated cardboard and therefore when choosing a material for fragile packaging this disadvantage worth considering.

Micro-corrugated board is marked with the letter "E" and has its history from the original name of the brand of micro-corrugated board "Elite", the production of which was established in the USA. The low 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.

Micro-corrugated cardboard is used for individual, presentable cardboard packaging, usually with offset and flexo printing.

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

Double-layer corrugated board

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 and can be reeled up, although it can also be produced in sheets.

Five-layer corrugated board

"P" - 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 board such as "B + B", "B + C", "B + E", etc.

Rarely used types of corrugated board

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

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

1.1 Corrugation shape

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

Advantages of corrugated board over other packaging materials.

Everyone knows the main advantages of cardboard. It is lightweight (a box made of corrugated cardboard is three to four times lighter than a similar plastic box, three times lighter than a box made of wood). Accordingly, when transporting goods packed in cardboard boxes, they save money, the fuel boxes themselves can be delivered to the customer in a folded form. Cardboard is multifunctional - it can be used for packaging various goods.

The cardboard is recyclable. With proper organization, a multiple return to the economic cycle of the primary cellulose used in the production of cardboard is achieved, which significantly saves the material resources of manufacturers. In addition to recycled cardboard, various fibrous plates, lumpy gaskets and others are also made from recycled materials, as a rule, Construction Materials... Waste paper is a substitute for cellulose, wood and paper pulp, which has a beneficial effect on the environmental situation.

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

Corrugated cardboard box

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

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

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

Production technology

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

However, in order to decide on the start of this business, it is necessary to research the technology of production of cardboard and corrugated cardboard, to analyze the production of cardboard containers and coordination issues in opening an organization.

The manufacturing methodology for corrugated board and board packaging lines depends on the manufacturing line that is already in place in the enterprise. The installation for cardboard and corrugated cardboard packaging is selected based on the planned production volume, design and nomenclature of the box.

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

• Stage 1: cutting sheets.

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

• Stage 2: print.

The flexographic station is used to apply one-color or multi-color printing.

• Stage 3: form blanks for boxes.

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

This stage ensures the delivery of containers to the folder-gluer.

The equipment for the production of packaging lines works in automatic mode.

• Stage 5.

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

Equipment

An enterprise for the production of cardboard packaging must have an automated line for the production of corrugated cardboard in the first list. Such a plant should have a list of techniques for specializing pulp and waste paper.

• Hydro-breaker.
• A vortex cleaner that eliminates heavy start-up problems.
• Knot catcher;
• Turbo separator.
• Pulse mill;
• Disc mill;
• Vibrating sieve;
• A vortex cleaner that allows you to eliminate light problems in switching on.
• Stirrer for waste paper.

Lines for the production of corrugated board must also have a special machine that forms the board sheet. This machine should dry and dehydrate it. A modern cardboard production plant can produce 25-310 tons of products per day. The maximum sheet length can be 6 m.

Required material for the manufacture of cardboard:

• Cellulose.
• Waste paper.
• Their confusion.

For the production of 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 range of prices for equipment for the production of corrugated cardboard, the investment for the purchase of the line will be at least 100 million rubles.

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

A characteristic feature of corrugated board is the existence of corrugated (corrugated) layers. Corrugated board contains alternating flat and corrugated layers, which are glued together with different adhesives along the line of contact. Bonding takes place between the flat cardboard layer and the bottom with the upper surface of the corrugation waves.

The indicator that determines the characterizing types of corrugation are - h (corrugation height) and t (corrugation pitch). The height of the corrugation is the gap between its top and bottom points. The corrugation pitch is the distance between one and the second upper adjacent corrugation points. The conditioned combination of the step and height of the corrugation is called the profile.

The main tasks of 3-layer corrugated board profiles:

• Corrugated board of profile C:

used in the production of boxes and packaging for the transportation and storage of products, while having high stacking strength.

• Profile B corrugated board:

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

• Corrugated board with profile E:

is intended for the production of small package sizes, while having a low stacking strength and a very good printable surface.

The main tasks of 5-layer corrugated board profiles:

• Corrugated board with CB profile:

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

• Corrugated board with CE profile:

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 printable surface.

Corrugated board production line

Brands and types of corrugated board

The type of corrugated board is designed to comply with the parameters of a corrugated board GOST.

This product belongs to multilayer raw materials. Its thickness is determined by the amount of flat layer, or as it is called liner, as well as fluting (paper for corrugation).

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

Three-layer corrugated board

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

The task of the sheet three-layer corrugated board is to produce containers and additional packages. They are intended for packaging products that cannot withstand static loads.

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

Steam line

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

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

• Cassette type corrugators.
• Vacuum roller B, C, format 1500 (working speed 125m / min).
• Imported corrugated board.
• Accumulative bridge (presence of vacuum tension of the web).
• Frequency splicing synchronization (with drying table).
• Cutting-scoring, longitudinal, thin-knife installation with an electronic control system and five types of scoring.
• Cross two-level cutting.
• Stacker.

Additional equipment available:

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

BHS line

Corrugated five-layer cardboard is used for the production of particularly strong and rigid packaging. For example, packaging of meat processing plant products, vegetables, fruits. Also for the production of large containers: packaging for a refrigerator, washing machine. Depending on the task of the container, the corrugation of the "BC" profile is used, the combination "BB" is rarely used.

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

BHS lines for the production of 5-layer corrugated board for the output of a quality product, perform the following operations:

• installation of a cardboard roll on a rolling device;
• preliminary strengthening of the heating of the cardboard;
• glue cladding at a specialized gluing machine;
• gluing a 2-layer corrugated board with a heated liner, forming a five-layer corrugated board;
• drying of corrugated board.

After unwinding the batting, the paper goes into a corrugating press, in which the paper is corrugated using two rollers and heating steam. Starch glue is applied to the top of the corrugation from the upper side. Further, the cardboard material is transferred to another corrugated press where the corrugated sheet is connected to the cardboard. As a result of this process, a 2-layer corrugated board is obtained.

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

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

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

And also to change the size of the workpiece. The finished fabric is transferred to a special scoring and cutting unit, in which strips of the required width are cut and at the same time the edges are cut. The line of the next fold of the canvas is also applied there in order to correctly form the box.

After that, the material is cut into a sheet of the required length, thus forming a workpiece completely ready for further processing. Subsequent sheet manipulations are carried out on the processing line.

Corrugated boxes

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

Stage I: material procurement.

The first stage of production includes a number of operations:

• dissolve waste paper (dissolving takes place in a pulper);
• to clean the waste mass from large-scale ingredients (the process is carried out on a vortex cleaner with a high concentration);
• dissolution of finished, cleaned accumulations (carried out on 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: dressing 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);
• at the end of this operation, the process of forming a cardboard box takes place. Finally, the boxes of waste pass through the rolls of machine calenders and there, under the pressure of high pressure, the sheet of the product is smoothed;
• the finished product is wound on tambour shafts and sent to a slitting machine;
• On the machine, the cardboard is cut into several sheets of the required parameters, and this becomes the final technological process making a cardboard box.

Equipment for the line for the production of corrugated boxes:

An enterprise for the production of cardboard containers must have, in the required order, an automated line for the production of corrugated boxes. Such a plant should have a list of techniques for specializing pulp and waste paper.

The box, which is made of corrugated cardboard, has a complex structure and is produced by rotary or flat die cutting. This ensures high quality and precision. The most common boxes in this category are American (four-valve) packing boxes for a wide range of product use and various tray-type products.

Video: Production of corrugated packaging

 

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