Cartons are increasingly used in the packing of edible products including liquid food items such as ...

1. Carton Manufacturing - Steps in the Process
Cartons are increasingly used in the packing of edible products including liquid food items such as
juices and milk. The heavier version of the carton boxes are used to pack more heavier and solid
products. Cartons that are usually used in packing food products are traditionally made out of
paperboards. In carton manufacturing, a series of sequential process is being carried out. This
includes
Paper board making
The first step in the carton manufacturing process is the making of the paperboards. In this process,
wooden chips are first softened by adding chemicals. The softened wooden chips are then made in to
a pulp form. The mixture of pulp and water is then allowed to go through a machine. The pulp that is
obtained is then sent through several layers of filtration to remove the unwanted material from the
pulp. Water and chlorine are added during this screening process. The pulp is then made to attain a
form of a mat of wooden fibre by removing the liquid content from the wooden pulp. This fibre is
then dried to get the required solid paper board.
Coating with waterproof materials
The dried paper board is then subjected to a process of adding water proof coating by passing it
between rollers that coats the molten polyethylene on to the paper board. This process is repeated
for a number of times until a thick film of polyethylene gets created on top of the paperboard. This
film will act as the waterproofing layer.
Printing and cutting
In this process, the coated paperboard is then allowed to pass through a machine that contains a
combination of printing rollers and die cutting tool. First the paperboard passes through the printing
rollers, where the required images and letters are printed on top of the paper board. The printed
board is then passed through a die cutting tool, where the stamping of the carton along the edges
will occur.

2. Sealing
The cut carton boxes are then fed in to a sealing machine, where the carton boxes are folded along
the seams. The seams are then heated so that the polyethylene coating gets bonded in a stronger
fashion. This is actually the final step in the carton manufacturing process.
All along the carton manufacturing process, Quality of the product is checked by inspecting the
different attributes. During the pulp creation stage, the pulp mixture should be inspected for its
correct color and fiber density. Some of the measures such as the width, thickness and the fiber
density of the paperboard are continuously inspected. The measurement tool is attached as part of
the processing machine and will not allow the paperboard to go to the next process, if there is any
deviation in measurements from the set standards. Due to the efficient manufacturing process, there
is very little scrap that comes out of this process. The carton manufacturing process has not
undergone any major changes over the last several years as the different processes are standardized
and have been calibrated to produce quality cartons.
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