Folding Carton from one or more flat cutting, are space providing media and commonly used in daily life. The ease with which they can be manipulated, stacked, stored, and transported makes them be the most popular and widely used container both for trade and industry as well as for personal use.
The folding carton manufacturing consists of 5 basic processes: structual design, printing and finishing, die-cutting, gluing, warehousing, and distribution.
The main point to be aimed at is to provide customers with a variety of samples that affords them the opportunity to determine the prototype of their packaging solution. In this phase, the designer should decide the type of paperboard to be used, carton style and dimensions, such as length, width and depth.
Printing and Finishing
At this stage, image either for decorative or functional purpose, such as trademark, texts for guide of handling or opening, or basic ingredients of the content, are printed on sheets of paper. And offset printing is the most widely used method for folding carton. After that, paper might undergo a series of finishing treatment to satisfy diverse needs of different customers. For example, paper is sometimes coated or varnished to get a clear surface which is more resistant to moisture and scuff, or laminated to prevented rapid wear and destruction of the paper itself. In general, this phase is sophisticated and integrated, during which a total and delicate management is needed to produce attractive and demontrative cartons.
This function should be viewed as the stage where the paperboard sheet is further converted by cutting, scoring(creasing), debossing, embossing, stripping, etc., to change the printed sheet into a carton blank or other types of paperboard product. Creating dies is meticulous work. The die must be designed so that it efficiently cuts the desired material with minimal waste. Most factories which use die cutting as part of their manufacturing process have techniques for recycling material left over from die cutting, but they want to avoid excess if possible. Often, multiple dies are fitted together on one mount and nestled with each other for maximum efficiency. Materail left over from the die cutting process may be melted down and reused, or reworked into other components.
After die-cutting, according to the design, paper is glued at the predetermined position.
Warehousing and distribution
The last department usually delivers glued, folded and collapsed cartons which are case-packed and or palletized before proceeding to warehousing prior to the customer’s packaging operation. Recently, a relatively variation on this theme is to pack cartons or blanks into cartridges or forms that are compatible with the high speed packaging line in the customer’s plant. This high speed automated handling of blanks or cartons is a necessary element for many of today’s packaging lines.