Production Process
Mechanical transformation of flat paperboard sheets or rolls into functional packaging structures defines the final stage of the manufacturing chain. In a modern packaging plant, boxboard converting involves several distinct operations including printing, die cutting, creasing, and gluing. This stage turns raw material into finished cartons that meet specific dimensional tolerances.
The process must preserve the integrity of the board layers while achieving sharp folds and clean edges.
Technical Precision
Accuracy in registration determines the success of the secondary packaging. Boxboard converting requires precise alignment between the printed graphics and the physical cuts or creases. Fluctuations in moisture content within the board can lead to dimensional instability, which causes issues during folding and gluing.
Proper tension control prevents the substrate from stretching before it enters the die station.
Structural Integrity
Crease depth and width are critical variables in the folding operation. Boxboard converting relies on the controlled delamination of the inner plies of the board to allow for a 90 or 180 degree bend without cracking the top liner. When the scoring tool strikes the board, it creates a hinge that directs the stresses of folding away from the delicate outer surface.
If the pressure is too low, the fold will be irregular or cause the carton to spring back. Conversely, excessive pressure can rupture the surface fibres and compromise the visual quality of the pack.
