Packaging Substrate
Paperboard manufactured primarily from recovered paper and board fibres is the standard material for a wide range of secondary retail packaging. Mills produce recycled boxboard by repulping sorted recovered paper, cleaning the stock, and forming it into a multi-ply sheet on a continuous machine. This board provides a cost-effective and circular packaging option for dry goods, household products, and consumer electronics.
Fibre Structure
The multi-ply construction of this material allows mills to place different grades of recovered fibre in different layers of the board. The top layer is often made from higher-quality printed waste or bleached fibres to provide a smooth surface for clay coating and printing. In contrast, the middle and bottom layers use mixed packaging waste and newsprint to build thickness and stiffness at a lower cost.
Because the recovered fibres have been dried and repulped multiple times, they are shorter than virgin fibres, which reduces the overall tensile strength but increases the bulk of the board.
Contamination Barrier
The presence of residues from printing inks, adhesives, and solvents in the recovered pulp requires careful management for food-contact applications. Recycled board often contains mineral oils that can migrate into food unless a functional barrier is applied to the inner surface of the package. This safety requirement drives the development of specialized barrier coatings that block the passage of these volatile compounds while maintaining the recyclability of the carton.