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Sizing New Corrugated Box Designs
June 1, 2007 By: Al Grant Paperboard PackagingThe ocean we swim in is mostly secondary packaging, when new projects arise or a firm has a problem that needs correcting. Regarding the latter, an oddly shaped steel filter weighing approximately 75 pounds that was shipped with excessive movement and damage recently crossed our path.
Ordinarily, after design, the worst is said to be over. Yet other traps await the unsuspecting. When dealing with suppliers nationally as we do, we must first ascertain whether they use U.S. or metric as the basis of measurement. The allowance a designer uses in allowing fit between the product and the corrugated members will vary with the weight, density and size relationship.
 Al Grant |
My company had to recently develop a 275 doublewall square RSC, with an extra score approximately 3 plus inches from the top flap scores to enable accepting the same size product in two different heights. After assembling the carton and sealing the bottom, we inserted a multi-wall diecut corrugated member thick enough to grasp the bottom of the products. After product insertion, we placed another, different size multi-wall diecut to do the same to the top of the product, then sealed the top.
When using the lower height, the four corners at the top would be cut down to the next score line and the flaps overlapped and sealed. This created a bump at the top, which was not objectionable since the cartons were single-tiered on a pallet and either racked or stood alone by the end user. The packaging components were corrugated fiberboard, thereby satisfying sustainable packaging issues that the customer had.
Because the predominant graphics were printed on two panels, we opted for individual panel mounts. With a square box, this enabled us to use the same mounts on two equal length and width cartons having different heights. On the other panels, we located one hinged hand hold on each for manual transporting.
Regarding the former, a new hearing aid testing device journeyed our way. It was fragile and needed protection in the parcel environment. For openers, we devised a reverse tuck folding carton with pye locks and allowed a 1/16-in. fit on all three dimensions. It fit like a glove, but the two-color graphics art needed some tweaking from registration issues.
The problem now became how to float this product in a shipper. We used a revised creased and slotted tray in 32 ECT. When formed, it elevates inside about ½ in. from the bottom. Because there is an additional wall thickness on all four sides, if forms a cushion. The product recesses itself ½ in. below the top of the tray, so we added a cut scored double wall sheet folded in half and placed it above the product. This also adds a snug effect.
This now goes into a 200 test C-flute regular slotted carton. We opted for a Mullen test over edge crush test because of its superior penetration resistant qualities when shipping parcels.
Because all sides are cushioned by ½ in., this package will even stand the postal environment, which subjects parcels to a transportation mugging.
The allowance a designer uses in allowing fit will change depending on weight, density and size. In our project above, it was necessary for us to maintain a ¼ in. fit throughout, since both the product and corrugated members are fairly heavy. With only ⅛ in. allowance on the height, this gave us a tight, snug fit after the carton was sealed.
Proprietary obligation limits us in our examples. Whether it be folding carton, plastic bag or pail, or corrugated carton, the minefields are always there. Take the time to evaluate actual samples before committing to an order. Trust what you see and feel — not what you think. Remember that assumption is the mother of all screw-ups.
Al Grant is president of The Catenate Group, Inc., a packaging firm dedicated to the solution of problems in secondary packaging that exist in today's production, warehousing and transportation environments. Entering its 20th year, the company continues to service clients in the chemical, cosmetic and pharmaceutical industries as well as those in construction and swimming pools.
