What is a Cardboard?
Cardboard is a type of paper stock known for its versatile nature and is commonly used in the packaging industry to make boxes of different shapes and styles. Initially, it is made of paper pulp pressed and glued together to form sturdy sheets. Its thickness also depends on its layers and manufacturing process, ranging from lightweight to heavy-duty rigid sheets. The most affordable and sustainable packaging material is also a popular choice for shipping and storing purposes.
This recycled material is said to be made with 70-80% recycled paper, which is then mixed with other materials and fibers to strengthen it. You can even mix shredded pieces of cardboard with treated chemicals to recycle them into another type of paper stock.
How Cardboard Material is Made?
Most people need clarification on this term and a search to see if cardboard material is made of paper. Yes, it is made of paper but not the same as normal paper. It is a type of paper product that is thicker and more rigid than standard paper. This flexible material is versatile enough to be cut and folded into different shapes and sizes to suit the needs of the product. Its manufacturing process includes many steps, beginning with the fibers’ pulping and then through multiple stages of pressing and molding.
The process begins with the most crucial step, where paperboard manufacturing involves dispersing raw materials into single fibers known as paper pulp. Its primary objective is to dissolve the lignin fiber present in the wood while preserving the fiber itself. Various methods include chemical, mechanical, and bioforms, which manufacturers commonly employ to complete the pulping process. Despite the process, water plays an essential role, with approximately 26.4 gallons (100 L) required to produce one kilogram of paper. Mechanical pulping is a time-consuming and hefty method of separating fibers without chemicals. The wood chips are ground by stones and soaked in water to create pulp. Due to its heavy and aggressive process, it boasts high yields and minimal pollution, which results in low-strength pulp.
On the other hand, chemical pulping involves mechanical methods and the use of chemicals. It undergoes cooking, followed by grinding wood chips to produce cellulose fibers. This method yields high-quality paper and is considered more efficient.
Both virgin pulp and recycled cardboard pulp naturally contain lignin, which gives them a dark brown color. To prepare them for paperboard production, bleaching is necessary to purify the pulp and change its color. Various bleaching methods, including delignification, oxidation, and reduction, are employed depending on factors such as pulp color, chemical composition, and treatment processes.
Paperboard is constructed by layering pulp and spraying water onto a mesh screen to create a mat. This process builds up the pulp fibers, strengthening the paperboard. Each grade of paperboard is carefully blended to meet specific standards.
Once the mat is formed, excess water must be removed. Initially, 20% of the water drips through gravity as the mat passes over a foundation screen. The mat then moves through sponge rollers to press and squeeze out water further. The mat is stretched and heated to complete the drying process, reducing the moisture content to 5%.
The dried paperboard is then cut into various widths and rolled into large rolls for transportation to box manufacturers. These widths enable the production of boxes in multiple sizes, shapes, and configurations to meet customer requirements.
After the layers of cardboard are assembled, they undergo a crucial step known as bonding and drying. This process is essential for ensuring that the layers firmly adhere to each other and that any excess moisture is eliminated.
First, the assembled cardboard passes through a series of heated rollers or drying chambers. These rollers or chambers provide controlled heat, which activates the adhesive properties of the materials used in the cardboard layers. As a result, the layers bond securely, forming a unified and sturdy structure.
Additionally, the heat applied during this process evaporates any remaining moisture in the cardboard. Excess humidity can weaken the cardboard and compromise its structural integrity. Removing this moisture makes the cardboard stronger, more rigid, and better suited for its intended purpose.
Overall, the bonding and drying stages are crucial for ensuring that the cardboard is of high quality and ready for further processing or packaging. It plays a vital role in creating cardboard products that are durable, reliable, and able to withstand the rigors of transportation and handling.
The end of this process is to assemble the sheets of cardboard paperboard into the desired shapes and sizes of boxes for the intended use. It may include cutting, scoring, creasing to make folds easy, and printing to make the boxes attractive.
Types of Cardboard
Cardboard is a universally common material found in packaging, printing, and construction. With various types available, each serving specific purposes, cardboard offers versatility and functionality across industries.
1: Corrugated Cardboard
Corrugated cardboard is known for its strength and durability, thanks to its unique construction of a fluted layer sandwiched between two flat layers. The fluted layer provides cushioning and rigidity, making corrugated cardboard ideal for packaging and shipping boxes. It can withstand rough handling and stacking during transportation, making it a popular choice for protecting goods in transit.
2: Solid Bleached Sulfate (SBS)
SBS is widely used where high-end printing is required. Due to its smooth and bright surface, it is a popular choice in the packaging industry and is flexible enough to provide creasing, folding, and other special finishes like embossing and debossing. Made from bleached virgin wood pulp, it also offers a bright, clean appearance with maximum strength. SBS is commonly used for luxury products, cosmetic boxes, greeting cards, and premium retail packaging.
3: Solid Unbleached Surface (SUS)
SUS or solid unbleached kraft (SUK), has a natural brown colour due to the exclusion of the chemical bleaching process. This material not only possesses an environmentally friendly appearance but also economic advantages. Made from unbleached virgin fibers, this type of cardboard has a clay coating on one side that offers a consistent surface for printing and writing.
4: Chipboard
Chipboard is a special type of cardboard that’s great for packaging. It’s made from recycled paper and wood waste, which makes it eco-friendly. Because it’s compressed and sturdy, it’s perfect for making strong boxes and cartons. Plus, it’s affordable and helps reduce waste by repurposing materials that would otherwise be thrown away. It is also use as an ideal alternative for various packaging needs, including padding, providing strength and environmental consciousness in one.
Benefits of Cardboard Material
- Cardboard can be easily customized and adapted to suit various packaging needs, from shipping boxes to retail packaging and displays.
- Despite being lightweight, it is remarkably strong and durable, providing excellent protection for packaged goods during transit and handling.
- Cardboard packaging is generally more affordable compared to alternative materials, making it a cost-effective choice for businesses looking to minimize packaging expenses.
- It is recyclable, biodegradable, and made from renewable resources, making it an environmentally sustainable packaging option that aligns with green initiatives and consumer preferences.
- It offers excellent printability, allowing for vibrant and high-quality graphics, branding, and product information to be displayed on packaging, enhancing visual appeal and brand recognition.
- Its lightweight nature helps reduce shipping costs and carbon emissions associated with transportation, making it an eco-friendly choice for packaging materials.
- It can be easily cut, folded, and shaped into various sizes, shapes, and configurations to accommodate different products and packaging requirements, offering flexibility and customization options for businesses.
Cardboard Thickness Guide
Understanding the thickness of cardboard is essential for various industries, including packaging, printing, and manufacturing. The thickness of cardboard, often measured in microns, inches, or millimeters, plays a crucial role in determining its strength, durability, and suitability for specific applications.
Whether you’re involved in packaging design, product development, or manufacturing, knowing the thickness of cardboard can help you make informed decisions and optimize your processes for efficiency and effectiveness. Join us as we delve into the nuances of cardboard thickness and its significance in various industries.
Basestock Properties (Units) | Nominal Basis Weight (GSM) | Caliper (Inches) | Thickness (Microns) | Commonly Used For |
|---|---|---|---|---|
| 12pt | 250gsm | 0.012" | 305μ | Bags |
| 14pt | 275gsm | 0.014" | 356μ
| Takeout Boxes, Cups |
| 16pt | 300gsm | 0.016” | 406μ | Heavy duty bags and takeout box |
| 18pt | 350gsm | 0.018” | 456μ | All box packaging |
| 24pt | 400gsm | 0.024” | 610μ | Heavy duty boxes |
| 28pt | 527gsm | 0.028” | 710μ | Very heavy duty boxes |