The aim of the pulping process is to break down the structure of the fibre source into the fibres ready to be made into market pulp.
To achieve this the fibres are put through either of the two processes that are used to develop the pulp. The two process are mechanical pulping or chemical pulping (otherwise known as kraft).
The chemical process, as you may have previously read involves cooking the wood shavings in a sulphate solution to digest the wood. Both sulphate and sulphite can be used to separate the fibres from the lignin which, is a natural glue like substance that bonds the fibres.
Chemical pulping degrades the lignin into small water soluble molecules which can be washed away without weakening the fibres. The result of the chemical process is either a dark brown in colour or, it can be bleached during the procedure resulting in a white kraft.
Mechanical pulping however involves grinding debarked logs against a revolving stone or disk grinders in order to break down the fibres to make a pulp.
The stone gets sprayed with water to remove the fibres, this however results in very little removal of lignin meaning paper quality is reduced, which therefore also indicates that the strength of the fibres may have been impaired from the process.
Mechanical pulping however is a low cost solution which generates a higher output.
For more than 100 years, corrugated boxes have reigned as the go-to method of packaging for product transportation. In today’s market, corrugated materials are used to display, promote, and package just about every product on earth. Whether it’s food, toys, office supplies, computers, clothes, furniture, or electronics, everything we buy has traveled some distance to reach us and will typically have been protected by a corrugated container from its original point of manufacture.
Benefits of Corrugated
The origins of the corrugated paper manufacturing process can be traced back to shipping and packaging operations in the 19th century. Today, it is used throughout most of the world during transit from the manufacturer all the way to the point of sale, or direct to the consumer’s home. Some of the extensive benefits of corrugated include its:
Minimal weight
Practicality
Usefulness
Sustainability
Recyclability
Design and merchandising appeal
In addition to these practical and environmental benefits, corrugated also offers limitless design possibilities and merchandising appeal to consumers. Even when the destination has been reached, corrugated can be recycled and used for the same purpose all over again.
Innovation in the Corrugated Industry
Corrugated manufacturers continue to improve their corrugated paper manufacturing process and products to adapt to changes in distribution systems, the needs of retailers, and consumer demands. This includes finding ways to build stronger paper that’s lightweight and water-resistant.
To remain versatile in the face of these ever-changing demands, corrugated facilities have equipped themselves with machine-automated technology that enables them to make an astounding $23 billion annually in the United States alone. As populations increase and the demand for products continues to grow, corrugated is likely to remain the best option for transporting products and materials safely all around the world.
The Corrugated Paper Manufacturing Process
The process for making corrugated boxes involves six steps that begin with sustainable timber harvesting and finish up in a specialty carton plant like the one used by FGS. To understand this process with a simple illustration, you can take a piece of paper and add waves in it (known as flutes). Glue the fluted paper to layers of strong linerboard and hey presto — you’ve got a tough piece of combined board that can take a beating while protecting even the most fragile of contents on the inside.
The production of commercial corrugated is a little more involved than the example above, involving specialized machines and customization. Find the details of each step of the corrugated manufacturing process below: