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[   Carton Packaging
     World·Classic                                   ]
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Outline




          1.Carton Packaging Word
          2.Folding carton box template structure
          3.Terms
          4.Mathematics in the folding carton structure design

          5. Folding carton functional structure design

          6. Corrugated Carton
          7. Paper bag
          8.Cushion packaging

          9.Loading and transportation
          10.Carbon footprint




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1. Carton Packaging World




          Many people mistaked that carton packaging is the
          combination of the box template structural design and graphic
          design. In fact, the carton packaging is far more than that.
          In this chapter we will explain by two small examples : the
          carton packaging is a macrocosm, this industry is promising if
          you get involved.




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Sample 1 《 Carton Packaging World
1.1 The cost difference between two minor difference box templates
with specific cardboard size




                The client needs the packaging box structure
                    shown above, the carton box size is
                        80*45*100(mm) , cardboard



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Sample 1 《 Carton Packaging World

1.1 The cost difference between two minor difference box templates


Select carton box template A, draw the die line template according to the carton
box size :




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Sample 1 《 Carton Packaging World
1.1 The cost difference between two minor difference box templates
with specific cardboard size
 It can step and repeat 12 boxes in the standard-sized sheet(Note : This sample
 haven't take into account the loaded knife rationality factors )




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Sample 1 《 Carton Packaging World
1.1 The cost difference between two minor difference box templates
with specific cardboard size

 We can switch to carton box template B, its shape is exactly the same with
 box template A.




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Sample 1 《 Carton Packaging World
1.1 The cost difference between two minor difference box templates
with specific cardboard size




                                                save paper
                                                more than
                                                20%.



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Sample 2 《 Carton Packaging World

1.2 The carton packaging design impacts on transportation




          Because of the difference of the buffer design, cardboard
          material selection and structural design, the carton
          packaging design will have a significant impact on
          transportation.
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Sample 2 《 Carton Packaging World

1.2 The carton packaging design impacts on transportation


 Container size : 591cm*234cm



 Carton
 size :                                                           89 pieces
 50cm*30cm




 Carton
 size :
 50cm*31cm                                                        79 pieces

        The area increase
        2%, while cost
        increase 11%
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2. Folding carton structure


                                                Folding carton



                               Carton box



                                                Glued carton




            Carton packaging   Corrugated box




                               Paper bag


                                                                 11
Folding carton classification




                                    Tubes




  Folding carton                     Trays




                                Tubes and Trays




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Tubes 《   Folding carton structure analysis

2.1 The definition of tubes



   It originally refers to the smallest box lid area amang, such as toothpaste
   boxes, such as toothpaste box.

   Now, it is generally defined from the molding characteristics: it refers to the
   carton box that need both the lid and bottom closure panel fixed or sealed
   during the molding process.




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Tubes 《   Folding carton structure analysis

2.1.1 The structure of the tubes




    1 、 2 、 3 、 4-
    Panels
    5-Closure panel
    6-Dust flap
    7-Glue flap
    8-Closure panel
    9-Tuck flap




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Tubes 《   Folding carton structure analysis

2.1.2 The closure structure of Tubes



          Commonly closure structures :

                             1. Friction Tuck
                             2. Seal end
                             3. Locking tab
                             4. Push-in closure
                             5. Concave/Convex
                             6. Glued sealing
                             7. Snap lock bottom
                             8. Automatic lock bottom




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Closure 《 Tubes 《   Folding carton structure analysis

2.1.2.1 Friction Tuck

                                     The sealing structure uses the
                                     friction between the tongue, dust
                                     flap and the panels to achieve
                                     and maintain sealing, the
                                     sealing strength and reliability is
                                     poor, suitable for small,
                                     lightweight daily necessities and
                                     pharmaceutical packaging.




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Closure 《 Tubes 《   Folding carton structure analysis

2.1.2.4 Seal end




                      The locking strength and reliability of
                      the sealend structure is higher, but it is
                      less convenient.




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Closure 《 Tubes 《   Folding carton structure analysis

2.1.2.6 Push-in   closure




                       Each flap is part of the pattern, after
                       plug-in the flaps composite a
                       beautiful pattern.




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Closure 《 Tubes 《   Folding carton structure analysis

2.1.2.5 Locking tab




                      The locking tab structure combined the
                      friction and lock end sealing structure.
                      With high sealing strengt and
                      reliability, it is suitable for heavier
                      contents.




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Closure 《 Tubes 《   Folding carton structure analysis

2.1.2.7 Concave/Convex




               The Concave Convex structure with the own
               strength and stiffness of the cardboard,
               deformation of straight or curved creasing line on
               the box, depressed flaps to achieve sealing.


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Closure 《 Tubes 《   Folding carton structure analysis

2.1.2.8 Glued sealing




                    The glued sealing structure with the
                    panels attached to the flap stick
                    together.




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Closure 《 Tubes 《   Folding carton structure analysis

2.1.2.9 Snap lock bottom


Snap lock bottom
also called 1-2-3
closure, the
bottom structure
is simple,
aesthetic and
economic with
strength and
tightness, it is the
most commonly
used lock bottom
structure and
widely used in
cosmetics, alcohol
and food
packaging.




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Closure 《 Tubes 《   Folding carton structure analysis

2.1.2.9 Snap   lock bottom



When we drawing
the 1-2-3 bottom
structure, we usually
draw first part of the
closure, there is no
strict limit to the size
of A, generally
consistent with
proportions of the
box length. The
vertical distance of
the recessed portion
and the creasing line
of the length must
be 1/2 of the width.




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Closure 《 Tubes 《   Folding carton structure analysis

2.1.2.10 Automatic lock bottom


 The automatic
 lock bottom refers
 to the body and
 the bottom of the
 box can be folded
 into a flat plate
 shape, and the
 bottom of the box
 can be
 automatically
 restored to the
 sealing status
 when the box
 stretched.The
 structure is
 complex and the
 cost is higher than
 other boxes.

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Closure 《 Tubes 《   Folding carton structure analysis

2.1.2.10 Automatic    lock bottom



From the automatic lock bottom
structure, we can see both the
flap and width angle of the box
are 45 °, it is to avoid overlapp
when folding.
Part A is the locking tab which
is located the intersection of 1/2
length and 1/2 width of the box,
it is to enhance the lock
strength.




The shade area is the glued part, it is folded on the opposite direction. The larger size the
glued part, the more firmly.
The 2 ° slash on Part B is to facilitate waste remove from the slash after carton box die-
cutting.
The 3mm width in part C is to prevent the carton rupture after multilayer paper overlapped.
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Tubes 《   Folding carton structure analysis

2.1.3 Widely used tube folding carton box template




Widely used tube folding carton box template :

                                    1. Reverse tuck
                                    2. Straigt tuck
                                    3. Airplane style
                                    4. French reverse tuck
                                    5. Snap lock bottom
                                    6. Automatic lock bottom




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Widely used tube box templates 《 Tubes 《 Folding carton structure analysis


2.1.3.1 Reverse tuck




           The reverse tuck also abbreviated as RTE, it is the most primitive
           box template.
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Widely used tube box templates 《 Tubes 《 Folding carton structure analysis

2.1.3.2 Straight tuck




 The straight tuck also
 abbreviated as STE.

 Its drawback is that the
 two projections, when step
 and repeat it wastes paper
 material, but it is suitable
 used for the window style
 box.




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Widely used tube box templates 《 Tubes 《 Folding carton structure analysis


2.1.3.3 Airplane style




 As the name suggested,
 the airplane style box
 template shape looks
 likethe aircraft, its basic
 function and purpose is
 the same with straight
 tuck.




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Widely used tube box templates 《 Tubes 《 Folding carton structure analysis


2.1.3.4 French reverse tuck



 The French reverse tuck
 box template abbreviated
 as FRENCH STE.

 Its advantage is maintain
 the integrity of the display
 surface, the contents of
 the design can be
 extended to the lid of the
 box, it has became
 commonly used box
 template for cosmetics
 packaging.




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Tubes 《   Folding carton structure analysis

2.1.4 10 principles of the folding carton structural design




                 10 principles of the folding
                 carton structure design




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10 principles 《 Tubes 《   Folding carton structure analysis

2.1.4.1 10 principles 1-2




 ( 1 ) Whether the product has individual packaging
       •   plain tuck flap : Individual packaging, do not need to consider pollution,
           scattered factors
       •   slit-lock tuck flap : The tuck structure is more conducive to the
           production and operation compare to the glued structure


 ( 2 ) One time open or multiple times open during usage
       •   slit-lock tuck flap:It offers more secure closure design than the one time
           open, mainly used on heavier content packaging.
       •   plain tuck flap : It keeps the integrity of the folding carton with multiple
           times open.




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10 principles 《 Tubes 《   Folding carton structure analysis
2.1.4.1 10 principles 3~5




 ( 3 ) Heavy weight products
     • tuck and tongue lock : It provide a very secure cover design




 ( 4 ) Whether consumers expect to be able to see the product before buying?
     • Aperture or window : The product can be see clearly
     • Plain tuck flap : The customer could even touch the product.

 ( 5 ) Whether the products need to be leak-proof structure ?
     • double-glued end seals : The non-independent packaging product
       coated with glue on two dust flaps and the back cover, which is more
       effective to prevent leakage.



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10 principles 《 Tubes 《   Folding carton structure analysis

2.1.4.1 10 principles ~6




 ( 6 ) Which process included in the carton packaging production?
     • Each process in carton packaging production can be completed by
       equipment or by hand, it should be equipped with a different design on
       manual, semi-automatic or automatic production.




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10 Principles 《 Tubes 《 Folding carton structure analysis

2.1.4.1 10 Principles 7~8



 ( 7 ) Whether the carton box need to prevent unexpected opening ?
     • double-glued end seals:The glued operation can prevent the folding
       carton with unexpected open, such as toothpaste box.

 ( 8 ) Which loading way the folding carton applied?
     • Vertical loading : Commonly loading way, it is easy for mechanized
       production; such as grain and powder.
     • Horizontal loading : The basic design is the same with vertical loading,
       only changes the open direction. Automation equipment is more complex.
     • Top loading : Some products require bigger diameter loading. This type
       of folding carton is often designed with KDF( knocked-down-flat) or flat
       sheets delivered. Dimensionally unstable products (such as clothing) tend
       to use the top loading design, as well as toys.




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《 Folding carton structure analysis

2.2 Trays


                              The definition of Trays

  The tray is folded by a cardboard
  with right angles or diagonally
  angles. The tray folding carton is
  suitable for packing shoes, hats,
  clothing, food and gifts. The
  commonly tray structure and the
  name of each part listed in the
  photo.




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10 Principles 《 Tubes 《 Folding carton structure analysis

2.1.4.1 10 Principles 9~10




 ( 9 ) How to use the folding carton ?
     • The folding carton design need to consider how it could be storaged. On
       the dresser or drawers? Medicine cabinet or refrigerator?
     • Easy to open, accessible and tear lines and other auxiliary design should
       considered in the carton box design.

 ( 10 ) How to sale the product ?
    • Excellent folding carton design is helpful for the sales display
    • It need to provide a stable and attractive display way.




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Trays 《 Folding carton structure analysis

2.2.1 Molding method



 Each panel of the tray folding carton
 need to be connected with certain
 structure, the concrete molding method
 include:
 ( 1 ) Fold assembly
 ( 2 ) Lock connection




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Trays 《 Folding carton structure analysis

2.2.3 Top and Base




                       a ) top lid    b ) cap lid      c)Buckle lid



   The lid, body of the box are mutually independent with open structure, the inner
   dimension of the lid is slightly larger than the outer size of the tray to ensure that the
   lid can be smoothly cover on the body. The top and base structure used for shoes,
   clothing and assembled goods.
   a) Top lid : The height of the lid equal to the height of the box so that it almost
      cover up all the box body.
   b) Cap lid : The height of the lid is less than the height of the body, generally only
      covering the upper opening portion of the body.
   c) Buckle lid : The body with matching edge to seam with the lid, the height of the
      box equal to the height of the lid and the height of the matching edge of the box
      body.
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Trays 《 Folding carton structure analysis

2.2.2 Lock connection type




 Straight lock structure               Bend lock structure




   Slant lock structure


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Trays 《 Folding carton structure analysis

2.2.4 Typical lid structure




                    a ) Body                          b ) Lid




    It also known as drawer lid. Lid is an independent piece, box body can be
    drawn within the lid forward.




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Trays 《 Folding carton structure analysis

2.2.5 Commonly tray structure




          Commonly tray structure :

                                1. Double side wall
                                2. Foot lock
                                3. 4-spot glued
                                4. 6-spot guled




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Commonly tray structure 《 Trays 《 Folding carton structure analysis

2.2.5.1 Double side wall




As the name suggested, the wall
structure of the tray has doubled, it
is easy of production, various parts
folded completely, normally can be
made of top and base box.


Since the glued part need to be
folded to form the double side wall,
 its maximum value can not
exceed the depth of the box
subtracting the thickness of the
paper.




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Commonly tray structure 《 Trays 《 Folding carton structure analysis

2.2.5. 2 Foot lock




The foot lock plays both
the foot and lock rule of
the box.
The size of the male lock
is smaller than the size of
the female lock in the box
lock structure, the male
lock is drawn to the inside
with 15 ° angle, and the
female lock is 15 ° angle
to the outside. The four
fixed flaps folded can not
affect the lock, it is the
relationship between C
and C-2B in the tray
structure.



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Commonly tray structure 《 Trays 《 Folding carton structure analysis

2.2.5.3 Four-spot glued tray




 Four-spot glued tray is one of the
 most simple and valuable box
 template, it also named Beers tray,
 mainly for packing shirts, sweaters,
 food and toys etc.


 The biggest characteristics of Four-
 spot glued box is the lid and the
 bottom of the tray can be completely
 the same size to match perfectly,
 unlike other trays, the lid must be
 bigger than the bottom.




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Commonly tray structure 《 Trays 《 Folding carton structure analysis

2.2.5.4 Six-spot glued tray




The change and design of the six-
spot glued tray is on the basis of
four-spot glued tray.It is widely used
in frozen food, fish, seafood,
vegetables packaging fields.


The width of the lid is 2 times bigger
than the width of the bottom.




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3.The characteristics of folding carton




           Outline :

                          1. The bearing characteristics
                          2. The influence of the two sides of the
                              paper on structure design
                          3. The Offset
                          4. The texture direction
                          5. The texture direction design of Tubes
                          6. The texture direction design of Tubes with
                              curved surface
                          7. The texture direction design of Trays
                          8. The texture direction design of regular
                              polygon trays


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《   The characteristics of folding carton

3.1 The bearing characteristics




          As we all know but may not pay special attention to the
          phenomenon: the bearing force of flat sheet cardboard is
          small, once creasing and properly folded, it could bear great
          pressure.



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《   The characteristics of folding carton

3.2 The influence of the two sides of the paper on structure design


    No matter ordinary cardboard or corrugated board has two sides, ordinary
    cardboard has a surface layer and a bottom layer, corrugated cardboard
    has out layer paper and inner layer paper.

    It influences the molding when folding, which need to be taken into account
    in the structure design.




         ( a ) Inner fold 90° ( b ) Outer fold 90° ( c ) Inner fold ( d ) Outer fold
              1-bottom layer   2-surface layer   3-bottom layer   4-surface layer




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《   The characteristics of folding carton

3.3 The influence of the two sides of the paper on structure design




    There is an example :




         Caliper 2mm, Length 40mm.The creasing line is on the
         middle of the cardboard. Then we start to fold.




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《   The characteristics of folding carton
3.4 The influence of the two sides of the paper on structure design




                                 There're two concerns:
                                 1. the length of the cardboard is 40 mm
                                 before folding, after folding the inner size
                                 isn't 40/2=20mm,it is 19mm because of the
                                 caliper.


                                 2. The first statement is not entirely
                                 accurate,because of the two sides of the
                                 paper, when folding on the middle, the
                                 internal loss is different with different
                                 specifications of the cardboards, it need to
                                 be taken into account.


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《   The characteristics of folding carton

3.6 The Offset

                                       Because of the dust
                                       flap under the
                                       cover, to be strictly
                                       the panel connect
                                       with the cover
                                       should add a
                                       caliper, else the
                                       cover will be
                                       hindered by the
                                       dust flap when
                                       folding.

                                       The additional
                                       caliper is offset.




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《   The characteristics of folding carton

3.7 The texture direction

      During the folding carton manufacturing process, the creasing line can effectively
      control the cardboard deformation, its role can not be ignored.As the fiber
      orientation, so that the cardboard folding onthe creasing line, the force on the
      transverse indentation line (the line parallel to the creasing line) is bigger than
      the longitudinal creasing line (the line parallel to longitudinal creasing line), so
      the bounce of transverse creasing line is bigger, thus increasing tension of the
      cardboard surface and enhance the strength of the carton.

      As the fiber alignment, and the stiffness and binding force for the same kind of
      cardboard longitudinal fiber were greater than the transverse, which leads to the
      longitudinal stiffness greater than the transverse board; in addition, because
      most of the carton stacking flat folded for transportation and storage, so the
      carton need resistance to repeated folding to avoid the creasing line crack which
      might affect the appearance and strength of carton.

      Thus when design the texture direction of the folding cartion, it needs to consider
      the different of vertically and horizontally physical properties of the cardboard
      and the creasing line position.

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《   The characteristics of folding carton

3.8 The texture direction design of Tubes



Generally, the longitudinal texture should
be vertical with the main creasing line
(longer creasing line).
Advantages :
• It makes the 4 surfaces of the box body
    smooth, avoid ballooning phenomenon.
•   It is helpful to high speed gluer machine.
•   The creasing line is not easy to burst and
    break(especially on thick paper ).

When the carton size is smaller and
accuracy requirement is not too high, it
could apply mixed step and repeat ignore
the texuture direction, thereby saving cost.



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《   The characteristics of folding carton

3.9 The texture direction design of Tubes with curved surface




            The bending resistance of the sheet transverse(parallel to the
            texture direction) is smaller than longitudinal,which means the
            cardboard transverse bending easier, with the curved surface, the
            texture direction of the folding carton should be perpendicular to
            the curved creasing line.

            We can clearly the horizontal of box a is easy to bend so that the
            box body is formed into a very smooth arch.While box b on the
            contrary, because the creasing line design of paperboard is
            unreasonable caused the box body distortion.
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《   The characteristics of folding carton

3.10 The texture direction design of Trays




                 The length direction of the tray folding carton
                 should be perpendicular to the longitudinal
                 direction of the cardboard.In this case it provides
                 higher stiffness in a short span, facilitates the
                 cartons strong and straight, and the transverse
                 creasing line on the length direction gives the
                 carton more strength.


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《   The characteristics of folding carton

3.11 The texture direction design of regular polygon trays




     The texture direction design of the regular polygon tray, one plan is the longitudinal
     cardboard parallel to one of the box bottom corner angle bisector, another is
     longitudinal cardboard vertical to one of the box bottom corner angle bisector.Both
     two kinds of texture design have deficiencies, both affected the carton folding.

     The hexagonal box also has the problem. With the increase of the number of
     polygon box bottom, gradually tend to circle,the circle has no direction, so the more
     sides the polygon tray has, the smaller difference of the two kinds of plans, but the
     best choice is texture direction design which the board longitudinal vertical to the
     bisector lines of the bottom angle.




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《   The characteristics of folding carton

3.12 The texture direction design




      For irregular folding cartons, the texture direction design should obey the basic
      cardboard texture direction design rules, but the irregular box has uncertainty, we
      suggest make samples to test first then choose which one texture direction
      design is more reasonable.




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4. Mathematics in the folding carton structure design




                Mainly because of the mechanical and physical properties,
                the folding carton structure exist many mathematical
                relationships.




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《 Mathematics   in the folding carton structure design

4.1 How to decide the inner size of the carton box




   We often see some carton              For example, if the product size is 10*10*15
   packaging rupture, deformation        cm, caliper is 1mm, the inner size of the carton
   during transportation,this kind of    box should be 10.1*10.1*15.2cm.
   circumstance except the paper
   strength is not enough, collision,
   one big issue is packaging size
   relatively big than the product.

   Generally, the length and width of
   the inner size of the carton box
   should be one caliper larger than
   the product, the depth should be 2
   times caliper larger than the
   product.




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《   Mathematics in the folding carton structure design

4.2 The size relationship of the small middle reverse tuck folding carton


                                                                 The glue flap size 10~16mm
                                                                                    
                                                                   Width(mm)          Tuck(mm)
                                                                    16 ~ 20               10
                                                                    20 ~ 24               13
                                                                    24 ~ 38               16
                                                                    38 ~ 57               20
                                                                   57 ~ 108               22
                                                                                    
                                                                 Length(mm)           Tuck(mm)
                                                                    20 ~ 30                3
                                                                    30 ~ 60                5
                                                                   60 ~ 120                7
   The dust flap size could be bigger or smaller than
   the value in the formula, but can not be more than                               
   1/2 Length, else they will be overlapped.                    Female lock=Male lock+2mm


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《   Mathematics in the folding carton structure design

4.3 Tube folding carton structure design
                                                         1. The straight line on the inserted
                                                            cover for friction locking function,
                                                            the size of the cover changed based
                                                            on the carton size, generally it is
                                                            20mm, with two R angles;
                                                         2. Glue flaps 10-16mm ;
                                                         3. Compare to outter layer the inner
                                                            layer sealing face should be smaller;
                                                         4. The angle of the dust flap should be
                                                            less or equal than 15 °;
                                                         5. The dust flap size should be smaller
                                                            than the width of the box;
                                                         6. The outter layer sealing face size
                                                            less or equal to the width of the box;
                                                         7. The right side face size is slightly
                                                            less than the width of the box
                                                            0.8mm; even for heavy cartons,
                                                            should reduce the cardboard caliper
                                                            because the glue flap and right side
                                                            face are jointed together, there will
                                                            be one more caliper on the right
                                                            side face.

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《   Mathematics in the folding carton structure design

  4.4 Tube folding carton structure design

1. The tuck lock
   0.8mm(generally 0.8mm or
   cardboard caliper);
2. The tuck lock sealing
   design;
3. Dust flap design ;
4. The second angle of the
   dust flap is 15 °;
5. The first angle of the dust
   flap is 45°;
6. The top closure panel
   shoulder is 6mm ;
7. The dust flap shoulder is
   6mm ;
8. The tuck lock on the small
   carton box generally is
   10mm.



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5. Folding carton functional structure design




           Outline:

                              1. Handle design
                              2. Hanging hole design
                              3. Window design
                              4. Displays design
                              5. Easy to open design
                              6. Dispenser design
                              7. Lining design
                              8. Partition wall design




                                        64 / 93          http://www.packmage.com
《   Folding carton functional structure design

5.1 Handle

The handle structure is designed to facilitate consumers.
1 ) Requirements
•   enough strength, safe and reliable;
•   the box body or local strength can not be weakened;
•   proper size and do not harm the hand;
•   decoration
2 ) split structure and overall structure
•   The split structure is the handle and box body independent of
    each other
•   The overall structure is the handle or handle hole designed
    directly on the box body
                                                                                             30mm
3 ) Size
•   The palm wide generally between 70-100mm, thickness
    around 20-40mm.The width of the handle is generally above
    20mm, heavier goods the width should take larger values to
    ensure the strength.                                                           100mm


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《   Folding carton functional structure design

5.2 Hanging hole




  Design the hanging holes on the
  carton box so that the goods can
  be displayed on the shelves.

  The hanging hole and the content
  gravity should on the same
  vertical line.Hanging hole is
  mainly in the form of round,
  rectangle, rounded triangle etc.




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《   Folding carton functional structure design

5.3 Window




  Open window on the carton box, glue
  transparent sheets of thin plastic or
  glass paper, so that the product inside
  could show in front of consumers.

  There has one window, double or three
  window structure, the location of
  window is to fully display the inner
  product. The window profile need to
  enhance the decoration, such as plum,
  heart shaped etc.The window position,
  size and shape should coordinate with
  the carton decoration patterns, text and
  box liner.



                                             67 / 93              http://www.packmage.com
《 Folding   carton functional structure design

5.4 Easy to open structure
                                                                                    ①
  Easy open structure is the local structure to facilitate consumer
     open the carton packaging more conveniently.
  a.   Tear port : Open a gap near the cover or sealing location,
       tear the port when need to open the packaging.
  b.   Half cutting line : Cutting line on the carton opening
       position, depth is half of the cardboard caliper, when the
       need to open the packaging, tear the half cutting line when
       need to open the packaging.
                                                                                            ②
  c.   Dentate line : On the carton opening port, with 1.5 ×
       1.5mm, 1.5 × 0.75mm, with corrugated dentate knife and
       other different types of dentate knife presse the dentate line,
       tear the dentate line when need to open the packaging.
  d.   Zipper line : Add the cutting line on the carton opening
       port like a zipper, tear it when in use.



                      ④


                                                                                            ③


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《   Folding carton functional structure design

5.5 Dispenser




                The dispenser carton box can conveniently pour out the
                contents, reducing it scattered, it is suitable for powder,
                particle and liquid goods 。




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《   Folding carton functional structure design

5.6 Partition

The partition structure      The Integral partition
used to protect of the       structure takes
fragile commodity such       advantages of the
as ceramics, glass           carton body panels or
packaging to prevent         flaps extended the
breakage. It can be          lining design.It saves
divided into integral        the process, easy for
partition structure and      processing and it is
split partition structure.   environment friendly.




                                          70 / 93                http://www.packmage.com
《   Folding carton functional structure design

5.6 Partition




The split partition structure is mutually
independent with the box body, it is the
accessory for the carton. It is relatively
easy.

when it inserted into the box, the
contents being partitioned and located
in the holes.




                                             71 / 93              http://www.packmage.com
《   Folding carton functional structure design

5.7 Displays




  The Displays shown the goods
  under certain support.The cover
  of the carton can be folded to the
  lower box body so that the box
  body display tiltly, it is very
  suitable for attracting consumers.




                                       72 / 93              http://www.packmage.com
6. Corrugated box


    The corrugated box can be divided into slot, set-up and folding carton three basic types
     according to the processing methods.
      a. Slot    The slot box template with a cardboard through cutting, creasing and
         folding, The side flap need to be stapled or glued. It can be folded into a flat
         shape for storage and transportation.
      b. Set up Generally composed by two parts, the box body, cover and bottom
         seperated independently, when using they can be set up together.
      •   Folding carton The box template through processing, folding and does not require
          any nails or glue.Such as 04 type box template.




                                          73 / 93               http://www.packmage.com
《 Corrugated box

6.1 Slot



     ① Slot carton , It is the most commonly
     carton structure.It is mainly used for food
     packaging.Based on this box template
     there   are   many      changes   for   special
     structure protection.




                                              74 / 93   http://www.packmage.com
《 Corrugated box

6.2 Half slot carton


        ② Half slot carton , typical sample is the step up transport container and shelf
        packaging for fruit, vegetables. The
         structure include top and base box template and shallow box structure.




                                               75 / 93                   http://www.packmage.com
《 Corrugated box

6.4 FEFCO standard box template



  The international commonly box template and code: the box template code consists of
  four digits, top two on behalf of box template, last two on behalf of the different style.
   It ranges from 02 to 07 totally 6 types, 09 type is the accessory.

  •   02 type——Including 0201 、 0202 、 0203 、 0204 、 0205 6 styles.Each style
      the top and bottom with clousure panel size.
  •   03 type——Including 0310 and 0325 two styles,all are cover, bottom and open
      box set up structure.
  •   04 type——Only 0402 style , processing and folding with a cardbaord without
      any stamples and glue.
  •   09 type——Accessories, including partition, pad etc., totally 45 types, they are
      used for dividing, fixing,location and cushioning.




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《 Corrugated box

6.3 Folding carton




    The   carton    box  is
    compact and save the
    paperboard the most.




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《 Corrugated box

6.5 FEFCO box template




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《 Corrugated box

6.6 FEFCO box template




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《 Corrugated box

6.7 Corrugated box design




   1 ) Corrugated box design should firstly consider
   the relationship between the strength of the
   corrugated paperboard and the contents.
   The basic framework for the transport packaging :
   First class……Used for export product or expensive
   product transportation packaging;
   Second     calss……domestic      goods      transport
   packaging;
   Third class……Cheap goods or short-distance
   transport packaging.


   2 ) The ergonomics principle must take into
   account in the carton structure design.
   The unreasonable box size design might cause
   fatigue and injury.


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《 Corrugated box

6.8 Various carton icons




      The icons should be put in the specified location to facilitate all the work in the
                             whole transportation process.




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7. Paper bag




     The paper bag is the bag container with one end or two end sealing, generally
     made by kraft paper, coated paper, aluminized paper etc.

     The most common paper bag is the bag with flat bottom, it can be placed vertically
     and can be folded into a flat shape. The paper bag used for scattered goods
     packaging, also used for outer packaging, it has the direct effect on sales
     promotion.




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《 Paper bag

7.1 Paper bag structure




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《 Paper bag

7.2.1 Sealing end bag




  After the sealing end bag filling
  with goods, the opening sealing
  with adhesive or U nail.This bag
  mainly used for packing granular
  product.




                                      84 / 93   http://www.packmage.com
《 Paper bag

7.2.2 Sealing valve bag




The bottom and the top of
the bag sealing, there's a
valve on the top bag
corner, it usually used for
small particles product
packaging.




                              85 / 93   http://www.packmage.com
《 Paper bag

7.2.3 Glued bag




   The bottom of the
   bag sealed by
   folding and glue
   method, its structure
   similar to the sealing
   end bag.




                            86 / 93   http://www.packmage.com
《 Paper bag

7.2.4 Glued valve bag




   The bottom and the top
   of the bag with glued
   sealing, the valve used
   for filling.




                             87 / 93   http://www.packmage.com
《 Paper bag

7.2.5 Flat bottom open bag




  The the material on bottom end
  glued layer by layer, after filling the
  bag top sealed with glue.




                                            88 / 93   http://www.packmage.com
《 Paper bag

7.2.6 Handle bag

             The paper bag used more and more frequently in the
             real life, especially the market competition is
             becoming increasingly intensified, the paper bag as
             advertising tool with rich and varied forms.




                                       89 / 93              http://www.packmage.com
8. Cushioning packaging




                          It is estimated that billions of dollars lost on the
                          packaging products destructive test, not to mention the
                          lost because of the unreasonable cushioning
                          packaging. At the same time the unreasonable design
                          and large amount waste of resources phenomenon
                          widely exists.
                          So the cushioning packaging is a very important topic,
                          and at present lack of theoretical research and
                          professional talent.



                          Subsequent versions of this document will go into
                          the details of this chapter.




                                     90 / 93                http://www.packmage.com
9. Loading issue



         Many people may not realize transportation belongs to packaging category,
         as the example of cushioning packaging we mentioned before, a little
         change may bring a few percentage points even ten percent change on the
         container utilization.

         Subsequent versions of this document will go into the details of
         this chapter.




                                         91 / 93               http://www.packmage.com
10 Carbon footprint




         Subsequent versions of this document will go into the details of
         this chapter.




                                      92 / 93              http://www.packmage.com
Information Update




          We will update the file irregularly and more valuble
          information will be updated in the future, please keep an
          eye on our twitter.
          http://www.twitter.com/packmage


          Packmage CAD team




                                  93 / 93           http://www.packmage.com

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Carton packaging wikipedia

  • 1. [ Carton Packaging World·Classic ] Shared by Packmage CAD Team 1 / 93 http://www.packmage.com
  • 2. Outline 1.Carton Packaging Word 2.Folding carton box template structure 3.Terms 4.Mathematics in the folding carton structure design 5. Folding carton functional structure design 6. Corrugated Carton 7. Paper bag 8.Cushion packaging 9.Loading and transportation 10.Carbon footprint 2 / 93 http://www.packmage.com
  • 3. 1. Carton Packaging World Many people mistaked that carton packaging is the combination of the box template structural design and graphic design. In fact, the carton packaging is far more than that. In this chapter we will explain by two small examples : the carton packaging is a macrocosm, this industry is promising if you get involved. 3 / 93 http://www.packmage.com
  • 4. Sample 1 《 Carton Packaging World 1.1 The cost difference between two minor difference box templates with specific cardboard size The client needs the packaging box structure shown above, the carton box size is 80*45*100(mm) , cardboard 4 / 93 http://www.packmage.com
  • 5. Sample 1 《 Carton Packaging World 1.1 The cost difference between two minor difference box templates Select carton box template A, draw the die line template according to the carton box size : 5 / 93 http://www.packmage.com
  • 6. Sample 1 《 Carton Packaging World 1.1 The cost difference between two minor difference box templates with specific cardboard size It can step and repeat 12 boxes in the standard-sized sheet(Note : This sample haven't take into account the loaded knife rationality factors ) 6 / 93 http://www.packmage.com
  • 7. Sample 1 《 Carton Packaging World 1.1 The cost difference between two minor difference box templates with specific cardboard size We can switch to carton box template B, its shape is exactly the same with box template A. 7 / 93 http://www.packmage.com
  • 8. Sample 1 《 Carton Packaging World 1.1 The cost difference between two minor difference box templates with specific cardboard size save paper more than 20%. 8 / 93 http://www.packmage.com
  • 9. Sample 2 《 Carton Packaging World 1.2 The carton packaging design impacts on transportation Because of the difference of the buffer design, cardboard material selection and structural design, the carton packaging design will have a significant impact on transportation. 9 / 93 http://www.packmage.com
  • 10. Sample 2 《 Carton Packaging World 1.2 The carton packaging design impacts on transportation Container size : 591cm*234cm Carton size : 89 pieces 50cm*30cm Carton size : 50cm*31cm 79 pieces The area increase 2%, while cost increase 11% 10 / 93 http://www.packmage.com
  • 11. 2. Folding carton structure Folding carton Carton box Glued carton Carton packaging Corrugated box Paper bag 11
  • 12. Folding carton classification Tubes Folding carton Trays Tubes and Trays 12 / 93 http://www.packmage.com
  • 13. Tubes 《 Folding carton structure analysis 2.1 The definition of tubes It originally refers to the smallest box lid area amang, such as toothpaste boxes, such as toothpaste box. Now, it is generally defined from the molding characteristics: it refers to the carton box that need both the lid and bottom closure panel fixed or sealed during the molding process. 13 / 93 http://www.packmage.com
  • 14. Tubes 《 Folding carton structure analysis 2.1.1 The structure of the tubes 1 、 2 、 3 、 4- Panels 5-Closure panel 6-Dust flap 7-Glue flap 8-Closure panel 9-Tuck flap 14 / 93 http://www.packmage.com
  • 15. Tubes 《 Folding carton structure analysis 2.1.2 The closure structure of Tubes Commonly closure structures : 1. Friction Tuck 2. Seal end 3. Locking tab 4. Push-in closure 5. Concave/Convex 6. Glued sealing 7. Snap lock bottom 8. Automatic lock bottom 15 / 93 http://www.packmage.com
  • 16. Closure 《 Tubes 《 Folding carton structure analysis 2.1.2.1 Friction Tuck The sealing structure uses the friction between the tongue, dust flap and the panels to achieve and maintain sealing, the sealing strength and reliability is poor, suitable for small, lightweight daily necessities and pharmaceutical packaging. 16 / 93 http://www.packmage.com
  • 17. Closure 《 Tubes 《 Folding carton structure analysis 2.1.2.4 Seal end The locking strength and reliability of the sealend structure is higher, but it is less convenient. 17 / 93 http://www.packmage.com
  • 18. Closure 《 Tubes 《 Folding carton structure analysis 2.1.2.6 Push-in closure Each flap is part of the pattern, after plug-in the flaps composite a beautiful pattern. 18 / 93 http://www.packmage.com
  • 19. Closure 《 Tubes 《 Folding carton structure analysis 2.1.2.5 Locking tab The locking tab structure combined the friction and lock end sealing structure. With high sealing strengt and reliability, it is suitable for heavier contents. 19 / 93 http://www.packmage.com
  • 20. Closure 《 Tubes 《 Folding carton structure analysis 2.1.2.7 Concave/Convex The Concave Convex structure with the own strength and stiffness of the cardboard, deformation of straight or curved creasing line on the box, depressed flaps to achieve sealing. 20 / 93 http://www.packmage.com
  • 21. Closure 《 Tubes 《 Folding carton structure analysis 2.1.2.8 Glued sealing The glued sealing structure with the panels attached to the flap stick together. 21 / 93 http://www.packmage.com
  • 22. Closure 《 Tubes 《 Folding carton structure analysis 2.1.2.9 Snap lock bottom Snap lock bottom also called 1-2-3 closure, the bottom structure is simple, aesthetic and economic with strength and tightness, it is the most commonly used lock bottom structure and widely used in cosmetics, alcohol and food packaging. 22 / 93 http://www.packmage.com
  • 23. Closure 《 Tubes 《 Folding carton structure analysis 2.1.2.9 Snap lock bottom When we drawing the 1-2-3 bottom structure, we usually draw first part of the closure, there is no strict limit to the size of A, generally consistent with proportions of the box length. The vertical distance of the recessed portion and the creasing line of the length must be 1/2 of the width. 23 / 93 http://www.packmage.com
  • 24. Closure 《 Tubes 《 Folding carton structure analysis 2.1.2.10 Automatic lock bottom The automatic lock bottom refers to the body and the bottom of the box can be folded into a flat plate shape, and the bottom of the box can be automatically restored to the sealing status when the box stretched.The structure is complex and the cost is higher than other boxes. 24 / 93 http://www.packmage.com
  • 25. Closure 《 Tubes 《 Folding carton structure analysis 2.1.2.10 Automatic lock bottom From the automatic lock bottom structure, we can see both the flap and width angle of the box are 45 °, it is to avoid overlapp when folding. Part A is the locking tab which is located the intersection of 1/2 length and 1/2 width of the box, it is to enhance the lock strength. The shade area is the glued part, it is folded on the opposite direction. The larger size the glued part, the more firmly. The 2 ° slash on Part B is to facilitate waste remove from the slash after carton box die- cutting. The 3mm width in part C is to prevent the carton rupture after multilayer paper overlapped. 25 / 93 http://www.packmage.com
  • 26. Tubes 《 Folding carton structure analysis 2.1.3 Widely used tube folding carton box template Widely used tube folding carton box template : 1. Reverse tuck 2. Straigt tuck 3. Airplane style 4. French reverse tuck 5. Snap lock bottom 6. Automatic lock bottom 26 / 93 http://www.packmage.com
  • 27. Widely used tube box templates 《 Tubes 《 Folding carton structure analysis 2.1.3.1 Reverse tuck The reverse tuck also abbreviated as RTE, it is the most primitive box template. 27 / 93 http://www.packmage.com
  • 28. Widely used tube box templates 《 Tubes 《 Folding carton structure analysis 2.1.3.2 Straight tuck The straight tuck also abbreviated as STE. Its drawback is that the two projections, when step and repeat it wastes paper material, but it is suitable used for the window style box. 28 / 93 http://www.packmage.com
  • 29. Widely used tube box templates 《 Tubes 《 Folding carton structure analysis 2.1.3.3 Airplane style As the name suggested, the airplane style box template shape looks likethe aircraft, its basic function and purpose is the same with straight tuck. 29 / 93 http://www.packmage.com
  • 30. Widely used tube box templates 《 Tubes 《 Folding carton structure analysis 2.1.3.4 French reverse tuck The French reverse tuck box template abbreviated as FRENCH STE. Its advantage is maintain the integrity of the display surface, the contents of the design can be extended to the lid of the box, it has became commonly used box template for cosmetics packaging. 30 / 93 http://www.packmage.com
  • 31. Tubes 《 Folding carton structure analysis 2.1.4 10 principles of the folding carton structural design 10 principles of the folding carton structure design 31 / 93 http://www.packmage.com
  • 32. 10 principles 《 Tubes 《 Folding carton structure analysis 2.1.4.1 10 principles 1-2 ( 1 ) Whether the product has individual packaging • plain tuck flap : Individual packaging, do not need to consider pollution, scattered factors • slit-lock tuck flap : The tuck structure is more conducive to the production and operation compare to the glued structure ( 2 ) One time open or multiple times open during usage • slit-lock tuck flap:It offers more secure closure design than the one time open, mainly used on heavier content packaging. • plain tuck flap : It keeps the integrity of the folding carton with multiple times open. 32 / 93 http://www.packmage.com
  • 33. 10 principles 《 Tubes 《 Folding carton structure analysis 2.1.4.1 10 principles 3~5 ( 3 ) Heavy weight products • tuck and tongue lock : It provide a very secure cover design ( 4 ) Whether consumers expect to be able to see the product before buying? • Aperture or window : The product can be see clearly • Plain tuck flap : The customer could even touch the product. ( 5 ) Whether the products need to be leak-proof structure ? • double-glued end seals : The non-independent packaging product coated with glue on two dust flaps and the back cover, which is more effective to prevent leakage. 33 / 93 http://www.packmage.com
  • 34. 10 principles 《 Tubes 《 Folding carton structure analysis 2.1.4.1 10 principles ~6 ( 6 ) Which process included in the carton packaging production? • Each process in carton packaging production can be completed by equipment or by hand, it should be equipped with a different design on manual, semi-automatic or automatic production. 34 / 93 http://www.packmage.com
  • 35. 10 Principles 《 Tubes 《 Folding carton structure analysis 2.1.4.1 10 Principles 7~8 ( 7 ) Whether the carton box need to prevent unexpected opening ? • double-glued end seals:The glued operation can prevent the folding carton with unexpected open, such as toothpaste box. ( 8 ) Which loading way the folding carton applied? • Vertical loading : Commonly loading way, it is easy for mechanized production; such as grain and powder. • Horizontal loading : The basic design is the same with vertical loading, only changes the open direction. Automation equipment is more complex. • Top loading : Some products require bigger diameter loading. This type of folding carton is often designed with KDF( knocked-down-flat) or flat sheets delivered. Dimensionally unstable products (such as clothing) tend to use the top loading design, as well as toys. 35 / 93 http://www.packmage.com
  • 36. 《 Folding carton structure analysis 2.2 Trays The definition of Trays The tray is folded by a cardboard with right angles or diagonally angles. The tray folding carton is suitable for packing shoes, hats, clothing, food and gifts. The commonly tray structure and the name of each part listed in the photo. 36 / 93 http://www.packmage.com
  • 37. 10 Principles 《 Tubes 《 Folding carton structure analysis 2.1.4.1 10 Principles 9~10 ( 9 ) How to use the folding carton ? • The folding carton design need to consider how it could be storaged. On the dresser or drawers? Medicine cabinet or refrigerator? • Easy to open, accessible and tear lines and other auxiliary design should considered in the carton box design. ( 10 ) How to sale the product ? • Excellent folding carton design is helpful for the sales display • It need to provide a stable and attractive display way. 37 / 93 http://www.packmage.com
  • 38. Trays 《 Folding carton structure analysis 2.2.1 Molding method Each panel of the tray folding carton need to be connected with certain structure, the concrete molding method include: ( 1 ) Fold assembly ( 2 ) Lock connection 38 / 93 http://www.packmage.com
  • 39. Trays 《 Folding carton structure analysis 2.2.3 Top and Base a ) top lid b ) cap lid c)Buckle lid The lid, body of the box are mutually independent with open structure, the inner dimension of the lid is slightly larger than the outer size of the tray to ensure that the lid can be smoothly cover on the body. The top and base structure used for shoes, clothing and assembled goods. a) Top lid : The height of the lid equal to the height of the box so that it almost cover up all the box body. b) Cap lid : The height of the lid is less than the height of the body, generally only covering the upper opening portion of the body. c) Buckle lid : The body with matching edge to seam with the lid, the height of the box equal to the height of the lid and the height of the matching edge of the box body. 39 / 93 http://www.packmage.com
  • 40. Trays 《 Folding carton structure analysis 2.2.2 Lock connection type Straight lock structure Bend lock structure Slant lock structure 40 / 93 http://www.packmage.com
  • 41. Trays 《 Folding carton structure analysis 2.2.4 Typical lid structure a ) Body b ) Lid It also known as drawer lid. Lid is an independent piece, box body can be drawn within the lid forward. 41 / 93 http://www.packmage.com
  • 42. Trays 《 Folding carton structure analysis 2.2.5 Commonly tray structure Commonly tray structure : 1. Double side wall 2. Foot lock 3. 4-spot glued 4. 6-spot guled 42 / 93 http://www.packmage.com
  • 43. Commonly tray structure 《 Trays 《 Folding carton structure analysis 2.2.5.1 Double side wall As the name suggested, the wall structure of the tray has doubled, it is easy of production, various parts folded completely, normally can be made of top and base box. Since the glued part need to be folded to form the double side wall, its maximum value can not exceed the depth of the box subtracting the thickness of the paper. 43 / 93 http://www.packmage.com
  • 44. Commonly tray structure 《 Trays 《 Folding carton structure analysis 2.2.5. 2 Foot lock The foot lock plays both the foot and lock rule of the box. The size of the male lock is smaller than the size of the female lock in the box lock structure, the male lock is drawn to the inside with 15 ° angle, and the female lock is 15 ° angle to the outside. The four fixed flaps folded can not affect the lock, it is the relationship between C and C-2B in the tray structure. 44 / 93 http://www.packmage.com
  • 45. Commonly tray structure 《 Trays 《 Folding carton structure analysis 2.2.5.3 Four-spot glued tray Four-spot glued tray is one of the most simple and valuable box template, it also named Beers tray, mainly for packing shirts, sweaters, food and toys etc. The biggest characteristics of Four- spot glued box is the lid and the bottom of the tray can be completely the same size to match perfectly, unlike other trays, the lid must be bigger than the bottom. 45 / 93 http://www.packmage.com
  • 46. Commonly tray structure 《 Trays 《 Folding carton structure analysis 2.2.5.4 Six-spot glued tray The change and design of the six- spot glued tray is on the basis of four-spot glued tray.It is widely used in frozen food, fish, seafood, vegetables packaging fields. The width of the lid is 2 times bigger than the width of the bottom. 46 / 93 http://www.packmage.com
  • 47. 3.The characteristics of folding carton Outline : 1. The bearing characteristics 2. The influence of the two sides of the paper on structure design 3. The Offset 4. The texture direction 5. The texture direction design of Tubes 6. The texture direction design of Tubes with curved surface 7. The texture direction design of Trays 8. The texture direction design of regular polygon trays 47 / 93 http://www.packmage.com
  • 48. The characteristics of folding carton 3.1 The bearing characteristics As we all know but may not pay special attention to the phenomenon: the bearing force of flat sheet cardboard is small, once creasing and properly folded, it could bear great pressure. 48 / 93 http://www.packmage.com
  • 49. The characteristics of folding carton 3.2 The influence of the two sides of the paper on structure design No matter ordinary cardboard or corrugated board has two sides, ordinary cardboard has a surface layer and a bottom layer, corrugated cardboard has out layer paper and inner layer paper. It influences the molding when folding, which need to be taken into account in the structure design. ( a ) Inner fold 90° ( b ) Outer fold 90° ( c ) Inner fold ( d ) Outer fold 1-bottom layer 2-surface layer 3-bottom layer 4-surface layer 49 / 93 http://www.packmage.com
  • 50. The characteristics of folding carton 3.3 The influence of the two sides of the paper on structure design There is an example : Caliper 2mm, Length 40mm.The creasing line is on the middle of the cardboard. Then we start to fold. 50 / 93 http://www.packmage.com
  • 51. The characteristics of folding carton 3.4 The influence of the two sides of the paper on structure design There're two concerns: 1. the length of the cardboard is 40 mm before folding, after folding the inner size isn't 40/2=20mm,it is 19mm because of the caliper. 2. The first statement is not entirely accurate,because of the two sides of the paper, when folding on the middle, the internal loss is different with different specifications of the cardboards, it need to be taken into account. 51 / 93 http://www.packmage.com
  • 52. The characteristics of folding carton 3.6 The Offset Because of the dust flap under the cover, to be strictly the panel connect with the cover should add a caliper, else the cover will be hindered by the dust flap when folding. The additional caliper is offset. 52 / 93 http://www.packmage.com
  • 53. The characteristics of folding carton 3.7 The texture direction During the folding carton manufacturing process, the creasing line can effectively control the cardboard deformation, its role can not be ignored.As the fiber orientation, so that the cardboard folding onthe creasing line, the force on the transverse indentation line (the line parallel to the creasing line) is bigger than the longitudinal creasing line (the line parallel to longitudinal creasing line), so the bounce of transverse creasing line is bigger, thus increasing tension of the cardboard surface and enhance the strength of the carton. As the fiber alignment, and the stiffness and binding force for the same kind of cardboard longitudinal fiber were greater than the transverse, which leads to the longitudinal stiffness greater than the transverse board; in addition, because most of the carton stacking flat folded for transportation and storage, so the carton need resistance to repeated folding to avoid the creasing line crack which might affect the appearance and strength of carton. Thus when design the texture direction of the folding cartion, it needs to consider the different of vertically and horizontally physical properties of the cardboard and the creasing line position. 53 / 93 http://www.packmage.com
  • 54. The characteristics of folding carton 3.8 The texture direction design of Tubes Generally, the longitudinal texture should be vertical with the main creasing line (longer creasing line). Advantages : • It makes the 4 surfaces of the box body smooth, avoid ballooning phenomenon. • It is helpful to high speed gluer machine. • The creasing line is not easy to burst and break(especially on thick paper ). When the carton size is smaller and accuracy requirement is not too high, it could apply mixed step and repeat ignore the texuture direction, thereby saving cost. 54 / 93 http://www.packmage.com
  • 55. The characteristics of folding carton 3.9 The texture direction design of Tubes with curved surface The bending resistance of the sheet transverse(parallel to the texture direction) is smaller than longitudinal,which means the cardboard transverse bending easier, with the curved surface, the texture direction of the folding carton should be perpendicular to the curved creasing line. We can clearly the horizontal of box a is easy to bend so that the box body is formed into a very smooth arch.While box b on the contrary, because the creasing line design of paperboard is unreasonable caused the box body distortion. 55 / 93 http://www.packmage.com
  • 56. The characteristics of folding carton 3.10 The texture direction design of Trays The length direction of the tray folding carton should be perpendicular to the longitudinal direction of the cardboard.In this case it provides higher stiffness in a short span, facilitates the cartons strong and straight, and the transverse creasing line on the length direction gives the carton more strength. 56 / 93 http://www.packmage.com
  • 57. The characteristics of folding carton 3.11 The texture direction design of regular polygon trays The texture direction design of the regular polygon tray, one plan is the longitudinal cardboard parallel to one of the box bottom corner angle bisector, another is longitudinal cardboard vertical to one of the box bottom corner angle bisector.Both two kinds of texture design have deficiencies, both affected the carton folding. The hexagonal box also has the problem. With the increase of the number of polygon box bottom, gradually tend to circle,the circle has no direction, so the more sides the polygon tray has, the smaller difference of the two kinds of plans, but the best choice is texture direction design which the board longitudinal vertical to the bisector lines of the bottom angle. 57 / 93 http://www.packmage.com
  • 58. The characteristics of folding carton 3.12 The texture direction design For irregular folding cartons, the texture direction design should obey the basic cardboard texture direction design rules, but the irregular box has uncertainty, we suggest make samples to test first then choose which one texture direction design is more reasonable. 58 / 93 http://www.packmage.com
  • 59. 4. Mathematics in the folding carton structure design Mainly because of the mechanical and physical properties, the folding carton structure exist many mathematical relationships. 59 / 93 http://www.packmage.com
  • 60. 《 Mathematics in the folding carton structure design 4.1 How to decide the inner size of the carton box We often see some carton For example, if the product size is 10*10*15 packaging rupture, deformation cm, caliper is 1mm, the inner size of the carton during transportation,this kind of box should be 10.1*10.1*15.2cm. circumstance except the paper strength is not enough, collision, one big issue is packaging size relatively big than the product. Generally, the length and width of the inner size of the carton box should be one caliper larger than the product, the depth should be 2 times caliper larger than the product. 60 / 93 http://www.packmage.com
  • 61. Mathematics in the folding carton structure design 4.2 The size relationship of the small middle reverse tuck folding carton The glue flap size 10~16mm     Width(mm) Tuck(mm) 16 ~ 20 10 20 ~ 24 13 24 ~ 38 16 38 ~ 57 20 57 ~ 108 22     Length(mm) Tuck(mm) 20 ~ 30 3 30 ~ 60 5 60 ~ 120 7 The dust flap size could be bigger or smaller than the value in the formula, but can not be more than     1/2 Length, else they will be overlapped. Female lock=Male lock+2mm 61 / 93 http://www.packmage.com
  • 62. Mathematics in the folding carton structure design 4.3 Tube folding carton structure design 1. The straight line on the inserted cover for friction locking function, the size of the cover changed based on the carton size, generally it is 20mm, with two R angles; 2. Glue flaps 10-16mm ; 3. Compare to outter layer the inner layer sealing face should be smaller; 4. The angle of the dust flap should be less or equal than 15 °; 5. The dust flap size should be smaller than the width of the box; 6. The outter layer sealing face size less or equal to the width of the box; 7. The right side face size is slightly less than the width of the box 0.8mm; even for heavy cartons, should reduce the cardboard caliper because the glue flap and right side face are jointed together, there will be one more caliper on the right side face. 62 / 93 http://www.packmage.com
  • 63. Mathematics in the folding carton structure design 4.4 Tube folding carton structure design 1. The tuck lock 0.8mm(generally 0.8mm or cardboard caliper); 2. The tuck lock sealing design; 3. Dust flap design ; 4. The second angle of the dust flap is 15 °; 5. The first angle of the dust flap is 45°; 6. The top closure panel shoulder is 6mm ; 7. The dust flap shoulder is 6mm ; 8. The tuck lock on the small carton box generally is 10mm. 63 / 93 http://www.packmage.com
  • 64. 5. Folding carton functional structure design Outline: 1. Handle design 2. Hanging hole design 3. Window design 4. Displays design 5. Easy to open design 6. Dispenser design 7. Lining design 8. Partition wall design 64 / 93 http://www.packmage.com
  • 65. Folding carton functional structure design 5.1 Handle The handle structure is designed to facilitate consumers. 1 ) Requirements • enough strength, safe and reliable; • the box body or local strength can not be weakened; • proper size and do not harm the hand; • decoration 2 ) split structure and overall structure • The split structure is the handle and box body independent of each other • The overall structure is the handle or handle hole designed directly on the box body 30mm 3 ) Size • The palm wide generally between 70-100mm, thickness around 20-40mm.The width of the handle is generally above 20mm, heavier goods the width should take larger values to ensure the strength. 100mm 65 / 93 http://www.packmage.com
  • 66. Folding carton functional structure design 5.2 Hanging hole Design the hanging holes on the carton box so that the goods can be displayed on the shelves. The hanging hole and the content gravity should on the same vertical line.Hanging hole is mainly in the form of round, rectangle, rounded triangle etc. 66 / 93 http://www.packmage.com
  • 67. Folding carton functional structure design 5.3 Window Open window on the carton box, glue transparent sheets of thin plastic or glass paper, so that the product inside could show in front of consumers. There has one window, double or three window structure, the location of window is to fully display the inner product. The window profile need to enhance the decoration, such as plum, heart shaped etc.The window position, size and shape should coordinate with the carton decoration patterns, text and box liner. 67 / 93 http://www.packmage.com
  • 68. 《 Folding carton functional structure design 5.4 Easy to open structure ① Easy open structure is the local structure to facilitate consumer open the carton packaging more conveniently. a. Tear port : Open a gap near the cover or sealing location, tear the port when need to open the packaging. b. Half cutting line : Cutting line on the carton opening position, depth is half of the cardboard caliper, when the need to open the packaging, tear the half cutting line when need to open the packaging. ② c. Dentate line : On the carton opening port, with 1.5 × 1.5mm, 1.5 × 0.75mm, with corrugated dentate knife and other different types of dentate knife presse the dentate line, tear the dentate line when need to open the packaging. d. Zipper line : Add the cutting line on the carton opening port like a zipper, tear it when in use. ④ ③ 68 / 93 http://www.packmage.com
  • 69. Folding carton functional structure design 5.5 Dispenser The dispenser carton box can conveniently pour out the contents, reducing it scattered, it is suitable for powder, particle and liquid goods 。 69 / 93 http://www.packmage.com
  • 70. Folding carton functional structure design 5.6 Partition The partition structure The Integral partition used to protect of the structure takes fragile commodity such advantages of the as ceramics, glass carton body panels or packaging to prevent flaps extended the breakage. It can be lining design.It saves divided into integral the process, easy for partition structure and processing and it is split partition structure. environment friendly. 70 / 93 http://www.packmage.com
  • 71. Folding carton functional structure design 5.6 Partition The split partition structure is mutually independent with the box body, it is the accessory for the carton. It is relatively easy. when it inserted into the box, the contents being partitioned and located in the holes. 71 / 93 http://www.packmage.com
  • 72. Folding carton functional structure design 5.7 Displays The Displays shown the goods under certain support.The cover of the carton can be folded to the lower box body so that the box body display tiltly, it is very suitable for attracting consumers. 72 / 93 http://www.packmage.com
  • 73. 6. Corrugated box The corrugated box can be divided into slot, set-up and folding carton three basic types according to the processing methods. a. Slot The slot box template with a cardboard through cutting, creasing and folding, The side flap need to be stapled or glued. It can be folded into a flat shape for storage and transportation. b. Set up Generally composed by two parts, the box body, cover and bottom seperated independently, when using they can be set up together. • Folding carton The box template through processing, folding and does not require any nails or glue.Such as 04 type box template. 73 / 93 http://www.packmage.com
  • 74. 《 Corrugated box 6.1 Slot ① Slot carton , It is the most commonly carton structure.It is mainly used for food packaging.Based on this box template there are many changes for special structure protection. 74 / 93 http://www.packmage.com
  • 75. 《 Corrugated box 6.2 Half slot carton ② Half slot carton , typical sample is the step up transport container and shelf packaging for fruit, vegetables. The structure include top and base box template and shallow box structure. 75 / 93 http://www.packmage.com
  • 76. 《 Corrugated box 6.4 FEFCO standard box template The international commonly box template and code: the box template code consists of four digits, top two on behalf of box template, last two on behalf of the different style. It ranges from 02 to 07 totally 6 types, 09 type is the accessory. • 02 type——Including 0201 、 0202 、 0203 、 0204 、 0205 6 styles.Each style the top and bottom with clousure panel size. • 03 type——Including 0310 and 0325 two styles,all are cover, bottom and open box set up structure. • 04 type——Only 0402 style , processing and folding with a cardbaord without any stamples and glue. • 09 type——Accessories, including partition, pad etc., totally 45 types, they are used for dividing, fixing,location and cushioning. 76 / 93 http://www.packmage.com
  • 77. 《 Corrugated box 6.3 Folding carton The carton box is compact and save the paperboard the most. 77 / 93 http://www.packmage.com
  • 78. 《 Corrugated box 6.5 FEFCO box template 78 / 93 http://www.packmage.com
  • 79. 《 Corrugated box 6.6 FEFCO box template 79 / 93 http://www.packmage.com
  • 80. 《 Corrugated box 6.7 Corrugated box design 1 ) Corrugated box design should firstly consider the relationship between the strength of the corrugated paperboard and the contents. The basic framework for the transport packaging : First class……Used for export product or expensive product transportation packaging; Second calss……domestic goods transport packaging; Third class……Cheap goods or short-distance transport packaging. 2 ) The ergonomics principle must take into account in the carton structure design. The unreasonable box size design might cause fatigue and injury. 80 / 93 http://www.packmage.com
  • 81. 《 Corrugated box 6.8 Various carton icons The icons should be put in the specified location to facilitate all the work in the whole transportation process. 81 / 93 http://www.packmage.com
  • 82. 7. Paper bag The paper bag is the bag container with one end or two end sealing, generally made by kraft paper, coated paper, aluminized paper etc. The most common paper bag is the bag with flat bottom, it can be placed vertically and can be folded into a flat shape. The paper bag used for scattered goods packaging, also used for outer packaging, it has the direct effect on sales promotion. 82 / 93 http://www.packmage.com
  • 83. 《 Paper bag 7.1 Paper bag structure 83 / 93 http://www.packmage.com
  • 84. 《 Paper bag 7.2.1 Sealing end bag After the sealing end bag filling with goods, the opening sealing with adhesive or U nail.This bag mainly used for packing granular product. 84 / 93 http://www.packmage.com
  • 85. 《 Paper bag 7.2.2 Sealing valve bag The bottom and the top of the bag sealing, there's a valve on the top bag corner, it usually used for small particles product packaging. 85 / 93 http://www.packmage.com
  • 86. 《 Paper bag 7.2.3 Glued bag The bottom of the bag sealed by folding and glue method, its structure similar to the sealing end bag. 86 / 93 http://www.packmage.com
  • 87. 《 Paper bag 7.2.4 Glued valve bag The bottom and the top of the bag with glued sealing, the valve used for filling. 87 / 93 http://www.packmage.com
  • 88. 《 Paper bag 7.2.5 Flat bottom open bag The the material on bottom end glued layer by layer, after filling the bag top sealed with glue. 88 / 93 http://www.packmage.com
  • 89. 《 Paper bag 7.2.6 Handle bag The paper bag used more and more frequently in the real life, especially the market competition is becoming increasingly intensified, the paper bag as advertising tool with rich and varied forms. 89 / 93 http://www.packmage.com
  • 90. 8. Cushioning packaging It is estimated that billions of dollars lost on the packaging products destructive test, not to mention the lost because of the unreasonable cushioning packaging. At the same time the unreasonable design and large amount waste of resources phenomenon widely exists. So the cushioning packaging is a very important topic, and at present lack of theoretical research and professional talent. Subsequent versions of this document will go into the details of this chapter. 90 / 93 http://www.packmage.com
  • 91. 9. Loading issue Many people may not realize transportation belongs to packaging category, as the example of cushioning packaging we mentioned before, a little change may bring a few percentage points even ten percent change on the container utilization. Subsequent versions of this document will go into the details of this chapter. 91 / 93 http://www.packmage.com
  • 92. 10 Carbon footprint Subsequent versions of this document will go into the details of this chapter. 92 / 93 http://www.packmage.com
  • 93. Information Update We will update the file irregularly and more valuble information will be updated in the future, please keep an eye on our twitter. http://www.twitter.com/packmage Packmage CAD team 93 / 93 http://www.packmage.com