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Outline
6. Corrugated Carton
7. Paper bag 8.Cushion packaging
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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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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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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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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(NoteThis sample haven't take into account the loaded knife rationality factors
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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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1.1 The cost difference between two minor difference box templates with specific cardboard size
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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. http://www.packmage.com 9 / 93
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Folding carton
Carton box
Glued carton
Carton packaging
Corrugated box
Paper bag
11
Tubes
Folding carton
Trays
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Tubes Folding
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
1234-Panels
5-Closure panel
6-Dust flap 7-Glue flap 8-Closure panel 9-Tuck flap
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Tubes Folding
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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The locking strength and reliability of the sealend structure is higher, but it is less convenient.
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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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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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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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The glued sealing structure with the panels attached to the flap stick together.
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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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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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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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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 diecutting. The 3mm width in part C is to prevent the carton rupture after multilayer paper overlapped.
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Tubes Folding
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Widely used tube box templates Tubes Folding carton structure analysis
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
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Widely used tube box templates Tubes Folding carton structure analysis
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
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
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2One 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 flapIt keeps the integrity of the folding carton with multiple
times open.
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3Heavy weight products tuck and tongue lockIt provide a very secure cover design
4Whether consumers expect to be able to see the product before buying? Aperture or windowThe product can be see clearly Plain tuck flapThe customer could even touch the product. 5Whether the products need to be leak-proof structure double-glued end sealsThe 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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2.1.4.1 10 principles ~6
6Which 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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7Whether 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. 8Which loading way the folding carton applied? Vertical loadingCommonly loading way, it is easy for mechanized production; such as grain and powder. Horizontal loadingThe basic design is the same with vertical loading, only changes the open direction. Automation equipment is more complex. Top loadingSome 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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2.2 Trays
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9How 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. 10How 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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Each panel of the tray folding carton need to be connected with certain structure, the concrete molding method include: 1Fold assembly 2Lock connection
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atop lid
bcap 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 lidThe height of the lid equal to the height of the box so that it almost cover up all the box body. b) Cap lidThe height of the lid is less than the height of the body, generally only covering the upper opening portion of the body. c) Buckle lidThe 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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aBody
bLid
It also known as drawer lid. Lid is an independent piece, box body can be drawn within the lid forward.
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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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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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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 Fourspot 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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The change and design of the sixspot 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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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
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The
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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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.
aInner fold 90 bOuter fold 90 cInner fold dOuter fold 1-bottom layer 2-surface layer 3-bottom layer 4-surface layer
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The
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
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
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
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The
Generally, the longitudinal texture should be vertical with the main creasing line
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The
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
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
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
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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Mainly because of the mechanical and physical properties, the folding carton structure exist many mathematical relationships.
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Mathematics
We often see some carton packaging rupture, deformation during transportation,this kind of 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.
For example, if the product size is 10*10*15 cm, caliper is 1mm, the inner size of the carton box should be 10.1*10.1*15.2cm.
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Mathematics
4.2 The size relationship of the small middle reverse tuck folding carton
The glue flap size 10~16mm
Width(mm) 1620 2024 2438 3857 57108 Length(mm) 2030 3060 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.
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Tuck(mm) 10 13 16 20 22 Tuck(mm) 3 5 7
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Mathematics
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Mathematics
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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
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Folding
5.1 Handle
The handle structure is designed to facilitate consumers. 1Requirements
3Size 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
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Folding
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.
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Folding
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Folding
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
5.6 Partition
The partition structure used to protect of the fragile commodity such as ceramics, glass packaging to prevent breakage. It can be divided into integral partition structure and split partition structure. The Integral partition structure takes advantages of the carton body panels or flaps extended the lining design.It saves the process, easy for processing and it is environment friendly.
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Folding
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.
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Folding
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.
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6. Corrugated box
The corrugated box can be divided into slot, set-up and folding carton three basic types according to the processing methods. 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. 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.
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Corrugated box
6.1 Slot
Slot cartonIt is the most commonly carton structure.It is mainly used for food
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Corrugated box
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Corrugated box
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.
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Corrugated box
The carton box is compact and save the paperboard the most.
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Corrugated box
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Corrugated box
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Corrugated box
1 Corrugated box design should firstly consider the relationship between the strength of the corrugated paperboard and the contents.
2The 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
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
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Paper bag
After the sealing end bag filling with goods, the opening sealing
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Paper bag
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Paper bag
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Paper bag
The bottom and the top of the bag with glued sealing, the valve used for filling.
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Paper bag
The the material on bottom end glued layer by layer, after filling the bag top sealed with glue.
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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
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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.
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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.
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10 Carbon footprint
Subsequent versions of this document will go into the details of this chapter.
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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
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