Dispersion Barrier Performance under Crease Compression in Folding Boxboard
Wide matrix channels and shallow penetration depth prevent polymer micro-fractures in dispersion-coated folding boxboard during creasing.
Kaolin Clay Base Coat
Mineral Underlay
Hydrated aluminum silicate particles applied directly to the raw fiber surface create a smooth and uniform foundation for subsequent finishing layers. A kaolin clay base coat fills the deep valleys between cellulose fibers to reduce the overall roughness of the paperboard. This application is the first step in producing high quality folding carton grades.
Platelet Arrangement
The hexagonal shape of the clay particles allows them to overlap like shingles on a roof. This orientation creates a tortuous path for liquids, which helps hold the top coat pigments on the surface rather than letting them sink into the base. It also provides a bright, neutral starting point for the final color of the board.
Coating Efficiency
Using a relatively inexpensive mineral for the thickest part of the coating stack reduces the total cost of the material. Because the base coat does the heavy work of leveling, the top coat can be thinner and more focused on print fidelity. This dual layer approach optimizes both the cost and the performance of the packaging.
By using a coarser clay in this layer, the mill can achieve a level surface without the high cost of premium pigments. Successful application results in a high performance board with a reduced total cost.