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WHAT IS A CARTON?A carton is a multi-layer material, typically with three or more layers of cellulose fibers obtained from wood. The top layer of the carton is usually smooth with a pigmented coating, typically based on Chinese clay, calcium carbonate, or titanium dioxide, usually a combination of two. The outer layers are glued or bound with a styrene-butadiene emulsion or a mixture of starch and water. The back side may also be coated in white, brown, cream, or gray, depending on the type of fibers used. Additional components of the carton may include OBA (Optical Brightening Agents).HOW IS A CARTON CLASSIFIED OR CATEGORIZED?Papers and cartons are classified based on their fiber composition, manufacturing, processing, refining, grammage, and thickness. Grammage is the weight of the material per square meter in grams (g/m²), while thickness is measured in microns (µ) (1000 µ = 1mm). The boundary between paper and carton is typically around 160 - 170 g/m². Most packaging cartons range in grammage from 200 - 600 g/m² and thickness between 350 - 800µ (0.35 – 0.8 mm).KEY FEATURES OF CARTONCarton is a mechanically strong material. Its rigidity and toughness ensure durability under pressure, providing protection for products during distribution and use. It can be cut, folded, stacked, and glued. These properties give packaging designers the ability to create functional, creative packaging. The surface is usually white and smooth, making it suitable for printing. Printing on packaging ensures an attractive graphic appearance and allows for the application of important product information. Carton can be printed or enhanced using classical heat printing techniques, 3D partial varnish coatings, or laminated onto other materials like aluminum foil or plastic film, improving both the appearance and properties of the carton.WHAT IS FBB?Folding Box Board consists of a middle layer of mechanical pulp, sandwiched between two layers of bleached chemical pulp. The top layer or liner is typically coated with pigment in two or three layers. The inner side of the bleached chemical pulp is cream-colored (manila), while the outer side is translucent, allowing the color of the middle mechanical pulp to show through. Some manufacturers of FBB add a slight amount of bleaching to achieve a higher whiteness of the mechanical pulp. FBB with either medium white or bleached mechanical pulp is described as GC2. When the inner side of the chemical pulp is thicker or coated with white pigment so that both sides are white, it is referred to as White Back Folding Box Board or GC1. FBB can be coated with plastic extrusion, laminated with other materials, or processed in ways that improve the appearance and functional properties of the board. FBB has a wide range of uses. It is used for packaging cosmetics, chocolates, sugar, confectionery (cakes, pastries), medical and health products, toilet items (cotton swabs, cotton balls, etc.), frozen and chilled food, dry food, coffee, tea, bakery goods, clothing, toys, games, and photographic products.MEANING OF PAPER LABELS - GRADESFirst letter (surface treatment):A = cast coatedG = pigment coatedU = uncoatedSecond letter (composition of the carton):Z = bleached virgin chemical pulpC = virgin mechanical pulpN = virgin chemical pulpT = recycled, secondary fibers with white, cream, or brown reverse sideD = recycled, secondary fibers with gray backNumbers (except D):1. white reverse side2. cream reverse side3. brown reverse sideNumbers (D grade):1. bulk ≥ 1.45 cm³/g2. 1.3 cm³/g < bulk < 1.45 cm³/g3. bulk ≤ 1.3 cm³/gHARD BLEACHED BOARD SBB, GZMultiply construction SBB is made exclusively from bleached chemical pulp. The top surface is usually coated with pigment, and the back side may also be coated with pigment.FOLDING BOX BOARD FBB, GC1Multiply construction FBB has a white reverse side and is made from a layer of mechanical pulp sandwiched between layers of bleached chemical pulp. The top surface is coated with pigment, and the back side is thinner and may also be coated with pigment.FOLDING BOX BOARD FBB, GC3Multiply construction FBB has a cream reverse side and is made from a layer of mechanical pulp sandwiched between layers of bleached chemical pulp.GC1G = pigment coatedC = virgin mechanical pulp1 = white reverse sideGC2G = pigment coatedC = virgin mechanical pulp2 = cream reverse sideGZG = pigment coatedZ = bleached virgin chemical pulpGD2G = pigment coatedD = recycled/secondary fiber with gray back2 = 1.3 cm³/g < bulk < 1.45 cm³/gGT3G = pigment coatedT = recycled/secondary fiber with white, cream, or brown reverse3 = brown reverse sideTwo main methods of obtaining fibers from their sourcesChemical pulp - the use of chemicals to convert wood into pulp results in 30% less than mechanical pulp, but pulp produced by the KRAFT process has superior strength.Thermo-mechanical pulp - a two-step process of pulp production that results in a high yield of wood fibers at the cost of strength.Which boards are also used for packaging?A small number of cartons are made from 100% recycled, non-bonded fiberboards. These cartons are gray on both sides. Cartons are also made from microflute - corrugated board. These are used to provide extra protection for fragile products such as glass, porcelain, and sensitive electronic items, providing a high standard of print and varnish finish.Why are cardboard sheets multi-layered?The multi-layer structure that forms the carton ensures important technical properties and allows for the customization of fiber selection (pulp) for each layer, processing, and forming separate layers that achieve the highest possible quality. The multi-layer structure gives rigidity to the carton, allows for good folding, stacking, and has excellent gluing properties. It also helps with grammage and controlling the thickness of the carton. When making outer surface layers, the use of high-quality fibers is crucial, as these fibers are most exposed to use and finishing (printing, pressing, folding).TerminologySBB - Solid Bleached Board - Food Board, premium carton, the most expensive (allows direct food contact)SUB - Solid Unbleached BoardFBB - Folding Box BoardWLC - White Lined ChipboardKraftboard - kraft board, commonly used for drink holdersLaminated board - cardboard laminated with another material used for liquid packagingContainer board - container board, used to produce corrugated cardboardCorrugated medium - the inner layer of corrugated boardLinerboard - the strong, rigid board used on one or both sides of corrugated boardBinder's board - bookbinding board used to make hardcover book coversABBREVIATIONS ACCORDING TO DIN 19303GZ - Coated SBBAZ - Cast coated SBBGC1 - Coated FBB, white reverse sideGC2 - Coated FBB, cream reverse sideGN - Coated SUB, white or brown reverseGT - Coated WLC, cream or white reverseGD1 - Coated WC, gray reverse (bulk specification < 1.45 cm³/g)GD2 - Coated WC, gray reverse (bulk specification 1.3 - 1.45 cm³/g)GD3 - Coated WC, gray reverse (bulk specification < 1.3 cm³/g)UZ - Uncoated SBBUC1 - Uncoated FBB, white reverseUC2 - Uncoated FBB, cream reverseUT - Uncoated WLC, cream or white reverseUD - Uncoated WLC, gray reverseSBB - Solid Bleached BoardFBB - Folding Box BoardSUB - Solid Unbleached BoardWLC - White Lined ChipboardG - CoatedU - UncoatedA - Coated with glossZ - Bleached virgin fresh pulpC - Virgin mechanical fresh pulpN - Unbleached chemical fresh pulpT - Recycled pulp with white or cream reverseD - Recycled pulp with gray reverseBarbara V.
