Corrugated 201Design and testing to create the perfect packaging solution

Presented ByKurt Buche – Design Lab ManagerKurt has 11 years of packaging experience and several roles within the Advance Packaging design lab including: designer, customer liaison engineer, testing supervisor, and design lab manager.

Kurt is a graduate of Michigan State University with a BS in Packaging, he is also a certified ISTA CPLP test technician

Catherine Cole – Sales and Marketing AnalystCatherine has been with Advance Packaging for the past 7 years in a variety of roles throughout the Customer Service and Sales Departments.

Catherine holds an MBA from Grand Valley State University

With Special GuestsBryan Rybiski – Customer Service ManagerBryan has 12 years of experience at Advance Packaging, and is a graduate of the School of Packaging at Michigan State University with a Bachelor of Science in Packaging Engineering

Kevin Smeenge – Customer Liaison EngineerKevin has 13 years of experience with Advance Packaging in several roles including factory ticket coordinator, designer, and customer liaison engineer.

Kevin is a graduate of Western Michigan University with a BS in industrial design

Part 1: Basics of Package Design

Reading CADs (why those weird numbers?)The computer-aided designs (CADs) you see are meant to represent an unfolded drawing of the final product including allowances which we will discuss shortly. All measurements are from the inside unless otherwise noted.

25`0

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1 4 `0 3

1 1 `0 2

9 2 `0 62 3 `0 1 2 2 `0 3 2 3 `0 3 2 2 `0 3 1 `1 2

Many corrugated companies use sixteenths rather than decimals to note measurements. This makes verification in the box plant quick and easy, but it takes some getting used to for everyone else. The numbers following the “ ` “ symbol represent sixteenths of an inch. For instance: 22`03 is really 22 3/16 inches

Measuring your packaging ALWAYS measure and give measurements from the inside (after all, it’s meant to house your product, and the product goes in the box)

Measurements are given as length x width x depth This will mean taking your box or tray apart and laying it out flat Measure from the center of the score to the center of the next score

Remember: The measurement from Score to score will match the CAD drawing, and will not be the exact dimension. Because of the thickness of the board, there are allowances for folding that depend on the flute size. These allowances are subtracted from the measurement to get the dimensionScoring Allowances for Glued Slotted ContainersFirst Panel All Other Panels DepthB Flute none 1/8 inch 5/16 inchC Flute 1/16 inch 3/16 inch 3/8 inchE Flute None 1/16 inch 1/8 inchBC Doublewall3/16 inch 3/8 inch 3/4 inch

Scoring Allowances The inside measurement from score to score of a flattened box will not be the carton’s exact dimension. Similarly, the outside measurements of a carton will be different from the inside. We have to account for the caliper –thickness- of the board so that the inside dimension will be accurate once the box is folded The example below is for a box with an 18” length and 12” width. As you can see, the outside measurements are larger than the inside due to the board thickness

Scoring Allowances Continued The CAD drawings will include the allowances in the dimensions This example is for a 23 x 22 x 14 HSC in 32 ECT C. For C flute, the caliper is 3/16”

L e n g th+ b o a rd c a lip e r

- 1 /8 "

W id th+ b o a r d c a lip e r

L e n g th+ b o a rd c a lip e r

W id th+ b o a rd c a lip e r

1 34

9 2 38

2 23162 33

162 23162 31

16

1 118

1 4316

255

16 C

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n D e p th + b o a rd c a lip e r

Why Work With Packaging Engineers?Engineers can help you design the most efficient, cost effective protective and aesthetic packaging for your product. Expert designers understand your needs whether it’s structural integrity for shipping, optimal product showcasing for point of purchase displays, or the requirements of automated equipment like case erectors and sealers. Corrugated designers have multiple tools at their disposal to take your packaging from concept to production

Why Work With Packaging Engineers? ContinuedHere’s an example of how engineers can help maximize efficiency. Say we’re looking at an RSC with dimensions of 24 x 18 x 3 (44 ECT C)

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3 `0 6

9 `0 2

8 6

2 4 ` 0 3 1 `0 61 8 ` 0 32 4 ` 0 31 8 ` 0 1

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• Makes folding/gluing very difficult• Difficult to keep straight once its glued• Hard for filler to assemble, fill, and seal without popping the glue joints loose or the body scores ripping• Makes ripping corners very easy when loading• A lot of waste in the flaps (9+ inch flaps and only a 3 inch body)

5 6 ` 0 4

1 ` 1 03 ` 0 32 4 ` 0 33 ` 0 32 4 ` 0 1

24`1

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3

1 8 ` 1 0

3

Better Designs with the same dimensions1385.16 in of ²board

49`12 CORRUGATION3`01

20`0

5

3`03

20`0

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30`

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30`1

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1523.6 in of ²board Five Panel Folder FOL

Computer Aided Design and Sampling• Designers use CAD programs to create designs for customers• Designs are scored and cut using CAD tables to make samples• Note: A sample from the CAD table will not be a perfect representation of a production sample. The CAD table does not simulate any crushing or production tolerances

• For instance: A carton cut on the table will not fold as easily as a carton run on production machines

Conceptual Design – 3D renderings3D Rendering and conceptual design allows corrugated users to see their designs in action before a sample is even cut!• Efficient product development• Design without product samples, build from 2D drawings• Import 3D models (SolidWorks, AutoCAD)• Rapid concepts with graphics• Visualize product quantities and size requirements • Illustrator compatibility• P.O.P., Retail, and consumer product• Assembly instructions

Production TolerancesST-003 Box Plant Tolerances Tolerances Print Location

•As specified ± 1/4" •Centered in specified panel ± 1/2" if location not given •(for "graphics" items see WI 12.17) Board Caliper •As specified in ST-005 Finished Dimensions (unfolded items) •Length, as specified ± 1/8" •Width, as specified ± 1/16" Warp •Maximum 1/4" per lineal foot •Maximum 1/8" per lineal foot where specified with the 1/8" max warp adder. Rotary Die Cut•Individual panel scores as specified ± 1/16" •Maximum deviation from cumulative score measurements ± 1/8" •Blank dimensions as specified ± 1/8" inch in the machine direction. Access Holes •As specified ± 1/2" on either axis—in all cases, hole should be visually square to panel edges

Because production equipment can not produce a “perfect” item the way a CAD table can, all box plants have tolerances. The standard box plant tolerances are listed below

Part 2: ISTA Package/Product Testing Why is testing important?• Product needs to arrive in good condition• Eliminate over-packing, optimizing materials (especially important with UPS and FedEx dimensional weight changes)• Eliminate multiple revisions to the package design• Increase confidence

ISTA Tests – What do the numbers mean?1-Series (most common 1A, 1E, 1G)• Do NOT simulate actual transport hazards• Not based on real life shipping data• Simply stated, 1-Series tests are quick tests to see if the pack is “in the ballpark”• 3 components to 1-series

1. Environmental conditioning2. Vibration (random or sin)3. Shock – drop tests or impacts

3-Series (most common 3A, 3E)• Tests simulate a particular shipping environment (parcel, LTL, etc.)• Based on actual data of real life transport hazards• Multiple components, varies between tests1. Environmental conditioning (min 12 hours)2. Random vibration (with and without top load)3. Shock/drops (multiple sequences)4. Fork lift handling (where applicable)5. Compression

Random Vibration vs. Sin WaveISTA 1A and 1G are the same test except the 1A specifies sin wave vibration and the 1G specifies random vibration

Sin Wave (ISTA 1A)• Does not mimic any real world shipping environment, it is based on 14,200 impacts on the table• Unrepresentative damage• People still use this method because it has been carried over from old test methods or a random vibration table is not available• Only use if you have a very specific vibration wave you are looking to recreate, such as a product being attached to a motor

Random Vibration (ISTA 1G)• All modes of transportation produce random vibration• Always choose random vibration over a sin wave for standard shipping tests if random vibration is available• Much more realistic of real world shipping conditions

Impact and vibration tests simulate transport while compression testing simulates storage Drop testing also simulates transportation and material handlingTesting Equipment

APC Design Lab Resources

• 7 full time designers/engineers with an experience range from 1 year to 44+ years

• 2 high speed sample cutters• 40+ stock board grades

available for sample making• ISTA Certified Test Lab

Contact us at 616.949.6610 or visit our website: www.advancepkg.com for more information