Causes and countermeasures of carton bulging and damage
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In the process of using cartons, two main issues often arise: bulging or fatness, and damage to the carton itself. Let's explore the causes behind these problems:
**1. Causes of Bulging or Fatness**
(1) **Improper Flute Type Selection**
The A-flute has the highest flute height, which provides good vertical pressure resistance but is less effective in horizontal stability. When A-flute boxes are loaded with products and subjected to vibrations during transport, repeated impacts can cause the walls to thin out, leading to bulging.
(2) **Impact from Stacking on Shelves**
When products are stacked high in warehouses—often two shelves high—the weight exerts a "creep" effect on the carton, especially at the bottom. Prolonged static load can cause bending deformation. If the pressure is sustained, the carton may collapse. The middle of the box surface experiences the most deformation, creating a parabolic bulge. Testing shows that corners have the strongest resistance, while the center is weakest. Therefore, placing heavy loads directly in the center can lead to permanent damage.
(3) **Incorrect Box Height Design**
For carbonated beverages and water tanks, the box height is typically set to the bottle height plus 2mm. However, due to long-term stacking and transportation vibrations, the box wall may thin out, increasing the overall height and making the packaging appear bulged.
**2. Causes of Carton Damage**
(1) **Unreasonable Carton Size Design**
The dimensions of the carton (length, width, height) significantly affect its strength. Larger perimeters mean higher compressive strength, but not proportionally. For example, large water tank boxes (596mL × 24 bottles) are more prone to damage due to their high weight and single-flute structure. Additionally, when the height increases, the compressive strength decreases by about 20% if the perimeter remains constant.
(2) **Insufficient Corrugated Cardboard Thickness**
Worn corrugating rollers can reduce the thickness of the cardboard, lowering its compressive strength and making it more susceptible to damage.
(3) **Corrugation Deformation**
Different corrugation shapes (U, V, UV) influence strength and elasticity. U-shaped corrugations offer good elasticity but lower flat compression strength. V-shaped provide better stiffness but are prone to permanent damage under excessive force. UV-type combines the best of both, offering higher strength and durability.
(4) **Poor Layer Design**
The number of layers in the cardboard affects the carton’s durability. More layers increase strength, but they must be chosen based on product weight, storage conditions, and handling requirements.
(5) **Weak Adhesion**
If the bond between layers is weak, the carton’s strength is compromised. Poor adhesion can result from low-quality paper, improper glue, or faulty manufacturing processes.
(6) **Unfavorable Printing Design**
Printing can damage the corrugation, especially if the pressure is too high. Full-page printing or printing near fold lines can crush the flutes, reducing compressive strength by up to 40%.
(7) **Inappropriate Paper Usage**
Using incorrect paper grades or insufficient quantities can lead to weak cartons. Compressive strength should be a key consideration in paper selection, not just burst resistance.
(8) **Transportation Issues**
Improper loading, rough handling, and long-distance transport can all contribute to carton damage. Vibrations, shocks, and moisture exposure during transit also weaken the structure.
(9) **Poor Warehouse Management**
High stacking, humidity, and lack of ventilation can degrade carton strength over time. Stacking too high can cause collapse within days, even if the carton meets standard compressive strength requirements.
**2. Solutions to Address These Issues**
(1) **Choose the Right Flute Type**
Opt for B-flute, which offers better planar strength and is suitable for stacked goods. While it slightly reduces compressive strength, it supports the contents effectively.
(2) **Improve Stacking Conditions**
Avoid stacking two shelves high if possible. Use intermediate corrugated layers or flat boards to distribute weight evenly and prevent concentrated pressure.
(3) **Set Accurate Carton Dimensions**
Ensure the box height matches the product height to avoid bulging, especially for tall items like water tanks or carbonated drinks.
(4) **Design Optimal Carton Sizes**
Balance material efficiency with practicality. Consider market trends, ergonomic factors, and ease of handling. Limit package weight to 20kg as per international standards.
(5) **Ensure Proper Corrugated Thickness**
Regularly check the thickness of corrugated cardboard and replace worn rollers to maintain structural integrity.
(6) **Minimize Corrugation Damage**
Control base paper quality, adjust production settings, and use flexographic printing to reduce deformation. Avoid rough handling during transport.
(7) **Use Appropriate Cardboard Layers**
Select the right number of layers based on product weight and environmental conditions. More layers mean higher strength.
(8) **Strengthen Adhesion Quality**
Test peel strength regularly and ensure adhesives and materials meet national standards. Improve equipment and adhesive quality for better bonding.
(9) **Avoid Excessive Printing**
Reduce full-page or complex printing to prevent crushing of flutes. Monochrome printing has a smaller impact on strength than multi-color designs.
(10) **Select Suitable Base Paper**
Choose high-quality base paper with proper moisture content, tightness, and ring compression strength. Focus on improving the core paper rather than just increasing the grade of the face paper.
(11) **Improve Transportation Practices**
Train handlers to avoid rough treatment. Use box trucks instead of open vehicles to protect against moisture and physical damage.
(12) **Enhance Warehouse Management**
Follow first-in, first-out principles. Keep stacks low, and maintain dry, well-ventilated storage conditions to preserve carton strength.