Cardboard box is one of the most used packaging materials. It is an essential product in packaging production. Not only does it fill the shelves, it can also be seen in the entire supply chain. Looking at a cardboard box typically printed and branded with inviting colors and expressions, it's hard to imagine it starting life as a tree. Let's examine the steps in the box production process together.

Generally, consumers often forget to think about how products came about, but we think the packaging should be celebrated. So how does a tree turn into a box?

In order to learn how to produce box, the steps of box production are as follows;

Tree

While searching for recycled cardboard as ideal for box production, at some point a cardboard box started life as a tree. Typically, the trees used in box manufacture are softwoods such as pine and fir wood. The reason they were chosen is because they have long fibers that can help create tension that increases strength as well as creating a smooth surface for the board. Many growers will choose wood from sustainable and managed woodlands; This means that all trees felled are modified to help preserve the forest's ecosystem. The paper and cardboard created will have a different color depending on the tree used. For example, silver birch trees will produce a dark color, while a spruce will create a light brown color. These processes are also very important factors in box production.

Paper Pulp

After the wood is cut, sawdust is made. These wood chips are then pulped. This can be done by grinding wood against a stone or chemically cooking wood chunks. However, you can add chemicals like sodium sulfate to increase the strength of the dough. For most cartons, the pulp is left in the same color. However, it can be bleached to create a white look.

Corrugated

After the pulp dries, you can start creating cardboard. For corrugated cardboard, it requires two pieces of paper or cardboard, called lining, and one piece of corrugated cardboard that fits between the liners. Grooving helps give the cardboard more strength and a higher level of protection against damage.

Paper rolls made from dried pulp are fed from a corrugated roller that grooves or crushes the paper. Depending on the quality of the box made, it will depend on the level of thread required. This is used for high quality boxes, as increasing the groove leads to higher material usage and hence increased strength. For cheaper boxes, fewer grooves can be used, which can help save space, help use less material and lower carbon emissions.

Corrugating machine uses hot steam to create the troughs. At the same time, the glue is rolled down both sides of the groove so that it adheres to the liners. After the corrugated board is formed, it is cut to provide straight edges.

Cutting

Now that you have a complete corrugated board, it's time to cut the card to size depending on the box requirements. There is a comprehensive guide and most of the machines are programmed to cut the carton to automatically scale based on production demand. After the base frame is cut, the board is sent to a trimmer.

The trimmer is designed to tackle complex situations that the cutting machine cannot handle. A trimmer can add handles to the boxes and cut the required wings to form the box. The trimmer also scores the cardboard, making it easier to fold when the box is ready for assembly.

Assembly

The assembly will depend on the requirements of the box. The use of lids and slots may be best for businesses looking to build their boxes on demand. Besides these, boxes made with tape are often effective to build as and when required. Usually, for more sturdy boxes, glue and stitching are used to fold the sections together and keep the box secure.

Specific innovative machines can create boxes for you on request. It is possible to produce perfectly sized boxes depending on your needs to reduce waste and ensure the best fit. The box can also be made in a way that can significantly reduce the packaging production time.

After assembly, the cuts can be recycled to continue in the box-making chain. After cans are branded, printed and used, they can be recycled and create a continuous cycle of recycled can production.

We also contribute to making your customers feel special by offering solutions to your box needs in our Istanbul-based production facility. We are just a phone call or mail away for your box production requests with the size and different production modules you want.