Cardboard is a versatile, thick paper material widely used for making all kinds of boxes for packaging, shipping, and storage. It’s created by pressing and gluing paper pulp into strong sheets, with thickness varying from light to heavy-duty based on its layers and production process. Affordable and eco-friendly, it’s a top choice for sustainable packaging.
This cardboard is made from 70-80% recycled paper, blended with other fibers and materials to make it stronger. You can also shred used cardboard and treat it with chemicals to recycle it into new paper.
Many people wonder if cardboard is made of paper. Yes, it is a paper-based product, but it’s thicker and stiffer than regular paper. This versatile material can be easily cut and folded into various shapes and sizes to fit different products. Its manufacturing process starts with pulping fibers, followed by several stages of pressing and molding to create its sturdy structure.
Cardboard production starts with pulping, where raw materials like wood are broken down into individual fibers to create paper pulp. The goal is to remove lignin from the wood while keeping the fibers intact. This can be done using chemical, mechanical, or bio-pulping methods. Water is key, with about 26.4 gallons (100 liters) needed per kilogram of paper. Mechanical pulping, which grinds wood chips with stones and soaks them in water, is a time-intensive process that avoids chemicals. It produces high yields with less pollution but results in lower-strength pulp.
Chemical pulping combines mechanical grinding with chemicals to break down wood chips into cellulose fibers, producing high-quality paper more efficiently than mechanical pulping alone. Both virgin and recycled cardboard pulp contain lignin, giving them a dark brown color. To prepare the pulp for paperboard, bleaching is used to purify it and lighten its color. Different bleaching methods, like delignification, oxidation, or reduction, are chosen based on the pulp’s color, chemical makeup, and treatment needs.
Paperboard is crafted by carefully layering pulp, a mixture of fibers typically derived from wood or recycled paper, and spraying it with water onto a fine mesh screen to form a wet mat. This process interlocks the pulp fibers, creating a strong, cohesive structure that forms the basis of paperboard. Each grade of paperboard—whether designed for lightweight packaging or heavy-duty applications—is meticulously blended with specific fiber compositions and additives to meet precise industry standards for strength, thickness, and durability.
Once the wet mat is formed, the next critical step is removing excess water to solidify the material. Initially, about 20% of the water drains naturally through gravity as the mat passes over a foundation screen, allowing the fibers to settle and bond. The mat then moves through a series of sponge rollers that apply pressure to squeeze out additional water, further compacting the fibers. To complete the drying process, the mat is stretched and passed through heated rollers or drying chambers, which evaporate remaining moisture until the paperboard reaches a final moisture content of about 5%. This thorough drying ensures the paperboard is rigid, stable, and ready for further processing into packaging materials like boxes or cartons.
The dried paperboard is cut into various widths and rolled into large rolls for transport to box manufacturers. These widths allow for the creation of boxes in diverse sizes, shapes, and configurations to meet customer needs.
Many people wonder if cardboard is made of paper. Yes, it is a paper-based product, but it’s thicker and stiffer than regular paper. This versatile material can be easily cut and folded into various shapes and sizes to fit different products. Its manufacturing process starts with pulping fibers, followed by several stages of pressing and molding to create its sturdy structure.
After the layers are assembled, the next step they undergo is crucial which is known as bonding & drying. This process is done to make sure if the layers firmly adhere to each other and to check if any excess moisture is eliminated.
The assembled cardboard passes through heated rollers or drying chambers, where controlled heat activates the adhesive in the layers, securely bonding them into a strong, unified structure.
The applied heat also evaporates residual moisture in the cardboard, which could otherwise weaken its structure. This drying process enhances the cardboard’s strength, rigidity, and suitability for its intended use.
The bonding and drying stages are critical for producing high-quality cardboard, ensuring durability and reliability for further processing, packaging, transportation, and handling.
The end of this process is to assemble the sheets of cardboard paperboard into the desired shapes and sizes of boxes for the intended use. It may include cutting, scoring, creasing to make folds easy, and printing to make the boxes attractive.
Cardboard is a universally common material found in packaging, printing, and construction. With various types available, each serving specific purposes, cardboard offers versatility and functionality across industries.
Corrugated cardboard, valued for its strength and durability, consists of a fluted layer—available in types like B-flute, C-flute, E-flute, and F-flute—sandwiched between two flat layers. The fluted layer provides cushioning and rigidity, making corrugated cardboard ideal for packaging and shipping boxes. E-flute, with its thinner profile, is the most commonly used in packaging for its balance of strength and flexibility. This construction enables corrugated cardboard to withstand rough handling and stacking during transit, ensuring reliable protection for goods.
Solid Bleached Sulfate (SBS) cardboard, made from bleached virgin wood pulp, has a smooth, bright surface perfect for high-quality printing. It’s flexible for folding, creasing, and special finishes like embossing or debossing, while staying strong and looking clean. SBS comes in two types: Coated One-Sided (C1S), with a coated surface on one side for printing, and Coated Two-Sided (C2S), coated on both sides for even better print quality. It’s widely used for luxury packaging, cosmetic boxes, greeting cards, and premium retail products.
Solid Unbleached Sulfate (SUS) or Solid Unbleached Kraft (SUK) cardboard has a natural brown color, as it skips the chemical bleaching process, giving it an eco-friendly look and cost benefits. Made from unbleached virgin fibers, it features a clay coating on one side for a smooth, consistent surface ideal for printing and writing.
Chipboard, a unique cardboard type, is ideal for packaging due to its eco-friendly nature, being made from compressed recycled paper and wood waste. Its sturdy construction makes it perfect for strong boxes, cartons, and padding, offering an affordable, sustainable alternative. By repurposing materials, chipboard reduces waste while providing strength and environmental benefits for various packaging needs.
Highly Versatile: Cardboard comes in multiple types (corrugated, SBS, SUS, chipboard), excelling in packaging, printing, and construction applications.
Exceptionally Strong: Corrugated cardboard’s fluted layer ensures durability, handling rough transit and stacking with ease.
Eco-Friendly Choice: Chipboard, made from recycled paper and wood waste, and unbleached SUS minimize environmental impact.
Cost-Effective Solution: SUS and chipboard deliver affordability through minimal processing and recycled materials.
Superior Print Quality: SBS (C1S and C2S) and SUS offer smooth, coated surfaces for vibrant printing and specialty finishes.
Lightweight Strength: Cardboard provides robust support without adding unnecessary weight, perfect for shipping.
Fully Customizable: Supports precise creasing, folding, embossing, and debossing for tailored packaging designs.
Completely Recyclable: Most cardboard types are recyclable, driving sustainable waste management.
Protective Power: Corrugated cardboard’s cushioning safeguards goods during transportation.
Industry Standard: Dominates luxury packaging, cosmetic boxes, greeting cards, cartons, and padding with unmatched reliability.
Cardboard thickness, measured in microns, inches, or millimeters, is key for industries like packaging, printing, and manufacturing. It affects the cardboard’s strength, durability, and fit for specific uses. Understanding thickness helps you choose the right cardboard for packaging design, product development, or manufacturing, ensuring better efficiency and results. Let’s explore why cardboard thickness matters across these industries.
| Basestock Properties (Units) | Nominal Basis Weight (GSM) | Caliper (Inches) | Thickness (Microns) | Commonly Used For |
|---|---|---|---|---|
| 12 pt | 210 gsm | 0.012″ | 220 μ | Bags |
| 14 pt | 250 gsm | 0.014″ | 250 μ | Takeout Boxes, Cups |
| 16 pt | 300 gsm | 0.016″ | 320 μ | Heavy Duty Bags, Takeout Box |
| 18 pt | 350 gsm | 0.018″ | 360 μ | All Box Packaging |
| 24 pt | 420 gsm | 0.024″ | 440 μ | Heavy Duty Boxes |
| 28 pt | 500 gsm | 0.028″ | 500 μ | Very Heavy Duty Boxes |
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