How It's Made Cardboards

Summary

This video provides an in-depth look at the production of cardboard boxes, from start to finish. It begins with large rolls of partially recycled paper fed into a corrugator, where the paper is shaped into fluted layers and glued to liners, creating strong, cushioned boards. The process includes precise cutting, perforating, folding, and gluing, with quality control checks at various stages. Recyclable cut-offs are sent back to the paper mill, emphasizing sustainability. Finally, the boxes are stacked, pressed, and secured for shipping. The video offers viewers a detailed and engaging behind-the-scenes glimpse of modern cardboard manufacturing.

Takeaways

• 📦 Cardboard production begins with large rolls of partially recycled paper, with width depending on the box size.
• ⚙️ The paper is fed into a corrugator, where it is squeezed between rollers and exposed to hot steam to form flutes.
• 💧 An adhesive made of water and starch is applied to one side of the flute, making it safe for food packaging.
• 🌀 Liner sheets are applied on both sides of the flute, creating an air cushion that enhances the board's strength.
• 🛠️ Some boxes have multiple flutes and liners for extra durability, and flute thickness varies for cushioning needs.
• ♻️ Partially recycled paper is used for flexibility, and trimmings are sent back to the paper mill for recycling.
• 🔪 Precision tools like circular saws and aluminum 'fingers' trim and separate boards into layers according to size.
• ✂️ Trimmers create perforations for flaps and handles, while presses even out overlapping panels of the box.
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• 🤖 Folding machines shape boxes along score lines, and cold glue is applied to join sections securely.
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• 📦 Completed boxes are stacked, pressed, and secured with a white wire, ready for shipping after quality checks.

Q & A

What is the starting material for producing cardboard?

The production of cardboard begins with a large roll of partially recycled paper, with the width of the paper varying according to the size of the boxes being created.

What is the purpose of the corrugator machine in cardboard production?

The corrugator machine squeezes the paper between two rigid rollers and exposes it to hot steam to form the waves in the flute, which provide strength and cushioning to the cardboard.

What type of adhesive is used on the cardboard flutes, and why?

The adhesive is mainly composed of water and starch, making it safe for use with fresh produce that the boxes might eventually hold.

How do the flutes and liners contribute to the cardboard's strength?

The waves in the flutes create an air cushion between the liners, enhancing the board’s strength and providing cushioning. Some boxes have multiple flutes and liners for added durability.

Why does the factory use partially recycled paper for the flutes?

Partially recycled paper is more flexible than non-recycled paper, which helps in forming the flutes and maintaining the cardboard’s structural integrity.

What role does the precision circular saw play in the production process?

The precision circular saw trims each side of the board to the required dimensions before the corrugator cuts the board into sections based on the size of the box.

How are the boards separated into layers after cutting?

The boards are separated into layers using flexible aluminum tools called 'fingers,' which organize the boards before quality control inspection.

What is the function of the trimmer and press in shaping the cardboard?

The trimmer creates perforations to form flaps and handles, while rubber sponges cushion the blades to cut only intended areas. The press compresses overlapping panels to even out thickness.

How are the boxes folded and glued into their final shape?

A folding machine shapes the cardboard along pre-scored lines, cold glue is applied to areas that will be joined, and another machine folds the glued sections, which remain hidden once the box is completed.

What is the final step before the cardboard boxes are ready for shipping?

The boxes are stacked, pressed, and secured with a sturdy white wire to prepare them for shipping.