The Intricate Journey of Crafting Corrugated Boxes: An Inside Look

What Makes Corrugated Boxes a Preferred Choice?

Corrugated boxes are more than just containers; they’re a blend of innovation, precision, and reliability. Lauded for their durability and adaptability, these boxes have found their way into diverse industries, safeguarding products of varying natures. But have you ever wondered how these dependable boxes are birthed?

?? What’s the Fabric of a Corrugated Box?

It might be surprising, but not all paper is made equal. Corrugated boxes owe their strength to a specialized type of paper, distinct from your everyday cardboard. This paper, combined with a meticulous manufacturing process, crafts a box that’s both robust and versatile.

Corrugated boxes are mostly made of kraft paper. The properties of the paper vary depending upon the strength and other requirements of the client. Kraft paper is categorised into 2 basic mediums- fluting and liner.

? Why Choose Corrugated Over Cardboard?

Simply put, the fluted layers! A box's resilience stems from its corrugated paper, offering an added layer of protection compared to flat cardboard. But how do we ensure every box's unmatched sturdiness?

?? Step 1: Selecting the Perfect Paperboard

The heart of the box lies in its material. A harmonious blend of linerboard and the iconic corrugated, or fluted, layer determines its rigidity. But how do we ascertain the paper grade's thickness?

? How is the Paper Grade Determined?

The answer rests with the box's destined purpose. If the box needs to be tough, we may opt for a 3-ply or even a 5-ply box, ensuring it withstands the tests of transportation and time.

The paper grade is determined as per the requirement of the box. There are different criteria to decide the paper- on the basis of GSM (grammage per sq metre), BF (burst factor), RCT (crush test) etc.

?? Step 2: Crafting the Corrugated Board

The magic happens on the corrugating line. Here, up to seven sheets of paper converge, undergoing a transformation under the corrugating machine. The outcome? A multi-layered corrugated board, its strength dictated by the number of incorporated layers.

? Ever Noticed the Wavy Middle Layer? How’s That Made?

It’s the result of meticulous craftsmanship. As paper travels between corrugating rolls, it assumes that signature zig-zag pattern, known as the flute. This is no random design – it's strategic, boosting the box's overall strength.

?? Step 3: Personalizing the Box

Branding is pivotal in today’s market. That’s why, post the formation of the corrugated board, it undergoes printing, if necessary. Be it intricate graphics, brand logos, or vital product information, techniques like lithography bring the box's persona to life.

?? Step 4: Giving the Box Its Shape

Die-cutting equipment meticulously sculpts the corrugated board, fashioning panels, flaps, and folds. These are then folded, glued, and structured to craft the familiar box shape. But how do we guarantee precision?

?? Step 5: The Crucial Quality Checks

At KIG Kraft Tech, quality isn’t an afterthought. Post-production, every box is scrutinized for its dimensions, print accuracy, and structural robustness. Only those that meet our stringent standards embark on their journey to package, protect, and please.

?? Conclusion: More than Just a Box

Every corrugated box from KIG Kraft Tech is a testament to commitment, innovation, and precision. The next time you spot one, know there's a meticulous journey behind its creation. Curious about our boxes or the crafting process? Let's connect and embark on a journey together!