Causes and countermeasures of carton bulging and damage
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In the process of using corrugated boxes, two major issues often arise: bulging or deformation and damage to the carton. These problems can significantly impact product protection and overall efficiency. Below is an analysis of the causes and solutions to these challenges.
**1. Causes of the Problems**
**(1) Bulging or Deformation**
1. **Incorrect Flute Type Selection**
The A-flute has the highest flute height, offering good vertical resistance but less horizontal strength compared to B or C flutes. 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 Stacked Shelves**
In warehouses, products are often stacked very high—typically two shelves high. This long-term static load on the bottom cartons can lead to gradual deformation, especially in the center of the box where the most pressure is applied. If the shelves are too wide, the corners of the carton may fall into the gaps, causing bulges or deformations.
3. **Improper Box Height Design**
For carbonated drinks or water containers, the box height is usually set slightly above the bottle height (e.g., 2mm higher). However, due to long-term stacking and transportation vibrations, the box wall can become thinner, increasing the overall height and making the bulging more noticeable.
**(2) Carton Damage**
1. **Unreasonable Box Size Design**
The dimensions of a box directly affect its structural integrity. Larger boxes with a greater perimeter require higher compressive strength. For example, 596mL × 24 bottles of bottled water boxes are commonly damaged due to their large weight and single-flute construction.
2. **Insufficient Corrugated Cardboard Thickness**
Over time, corrugated rollers wear down, reducing the thickness of the cardboard. This leads to lower compressive strength and increased risk of damage.
3. **Corrugated Deformation**
Different flute types have varying strengths. U-shaped flutes offer good elasticity but lower flat compression strength, while V-shaped flutes provide better rigidity but are prone to permanent damage under excessive pressure. UV-shaped flutes combine the best features of both, offering high strength and recovery.
4. **Inappropriate Layer Design**
The number of layers in the cardboard affects the box’s durability. Too few layers can result in higher damage rates, especially for heavier or fragile items.
5. **Poor Adhesive Bonding**
Weak adhesion between layers reduces the box's strength. Poor bonding can be identified by tearing the surface; if fibers are pulled out, it indicates strong adhesion. Otherwise, weak bonding can lead to structural failure.
6. **Unsuitable Printing Design**
Excessive printing pressure or full-page printing can crush the corrugation, reducing the box’s compressive strength. It’s recommended to avoid printing at fold lines and limit color registration to reduce damage.
7. **Incorrect Paper Specifications**
Using low-quality or improperly selected paper can compromise the box’s strength. The paper must meet standards for moisture content, tightness, and ring compression strength.
8. **Transportation Issues**
Rough handling, improper loading, and excessive vibration during transit can cause significant damage. Improper packaging methods or lack of protective measures can also contribute to this problem.
9. **Warehouse Management Problems**
Poor storage conditions, such as high humidity or excessive stacking, can weaken the box over time. High stacks increase the risk of collapse, even if the box meets standard strength requirements.
**2. Solutions to the Problems**
**(1) Addressing Bulging or Deformation**
1. **Choose the Right Flute Type**
B-flute is ideal for many applications due to its balance of strength and flexibility. While it offers less vertical resistance than A-flute, it provides better planar strength and supports stacking effectively.
2. **Improve Warehouse Stacking Conditions**
Avoid stacking two shelves high if possible. If necessary, use additional layers or flat boards to distribute the load evenly and prevent concentrated pressure.
3. **Set Accurate Box Dimensions**
Ensure the box height matches the product height to minimize bulging. This is particularly important for tall boxes like those used for carbonated drinks or water tanks.
**(2) Reducing Carton Damage**
1. **Design Boxes with Practical Dimensions**
Consider not only material efficiency but also market standards, ease of handling, and ergonomic principles. Keep the weight of each box within 20kg to reduce damage risk.
2. **Ensure Proper Corrugated Thickness**
Monitor the thickness of the corrugated cardboard throughout production. Worn rollers can reduce thickness, so regular maintenance is essential.
3. **Minimize Corrugated Deformation**
Control the quality of base paper and improve manufacturing techniques to reduce deformation. Use flexographic printing instead of traditional methods to avoid crushing the flutes.
4. **Use Appropriate Cardboard Layers**
Choose the right number of layers based on the product’s weight and environmental conditions. More layers mean higher strength and durability.
5. **Strengthen Adhesive Quality**
Test and control the peel strength of the adhesive. Ensure suppliers meet national standards for paper tightness and moisture content.
6. **Optimize Printing Layout**
Avoid full-page printing and minimize color registration. Excessive printing can reduce compressive strength by up to 20%.
7. **Select Suitable Paper Specifications**
High-quality base paper is critical for box strength. Focus on improving the core paper rather than just increasing the face paper’s grade for better cost-effectiveness.
8. **Improve Transportation Practices**
Reduce unnecessary handling, use proper loading methods, and train workers to handle goods carefully. Avoid over-tight bundling and protect against moisture.
9. **Enhance Warehouse Management**
Follow the first-in-first-out principle, avoid over-stacking, and maintain dry, well-ventilated storage conditions. Proper management can significantly extend the life of the boxes.
By addressing these issues systematically, companies can enhance the performance and longevity of their corrugated packaging, ensuring better product protection and customer satisfaction.