What is Paperboard Packaging?

1. Paperboard: An overview

History

The folding carton box marks a significant point in history, as it was one of the first popular forms of packaging.

It has been in use since the 19th century and gradually became popular due to the ease of sourcing raw materials and the speed of manufacture.

Initially, paperboard was glued with strings and tacks to create packaging.

Initially, folding carton manufacturing was done manually, but it has developed significantly since then.

Now, we are going to talk about how folding carton boxes are made in a bit more detail!

Process

In most cases, folding cartons are made of paperboard (i.e. recycled paper pulp) to form the packaging.

The paperboard is cut, folded and laminated, then delivered flat for construction and packaging.

Specifically, folding carton manufacturing companies process the paperboard and create dielines for artwork designs, which are then printed on large pieces of paperboard that are cut and scored.

This process involves reducing the rolls of paperboard to flat sheets, which are then fed into a printing press. Any pictures or artwork are then printed on the sheets.

Once printed and any other post-pressing activities have been completed, the sheets are cut, folded and glued to create your ideal packaging.

Depending on the packaged products, the folding cartons will undergo additional structural engineering and quality control procedures to ensure the product is securely contained.

2. Advantages of Folding Carton

Folding carton boxes have numerous advantages, which is why they have been used for packaging for so long.

Retail-friendly

The primary benefit of folding cartons is that they are ideal for retail shelves.

You can design high-quality packaging using custom folding cartons to attract consumers' attention.

Folding carton boxes are durable and thus less prone to damage during transportation than other forms of packaging.

Also, thanks to their flexibility in printing and finishing processes, folding cartons are attractive to display and offer an upmarket feel and effective brand differentiation.

Environmentally friendly

Folding cartons like Kraft are a great choice because of the materials used in their production. This makes them an excellent option if you are looking for an eco-friendly, affordable and attractive packaging material.

Kraft is a sustainable packaging option because of the way it is made and the fact that folding carton boxes can be recycled.

Sustainable inks and coatings, such as aqueous coating, can be used to create completely sustainable product packaging that will appeal to your eco-conscious shoppers!

Flexibility in printing and finishing

Folding carton boxes can make your product stand out without compromising its quality.

They are relatively light and offer a wide range of high-quality printing and finishing options.

Custom packaging companies can help you identify and select the ideal design and finish to make your folding carton box stand out and provide a premium customer experience.

Cost efficiency

Folding cartons are popular because they are cost-effective yet still give a high-end feel.

They are an inexpensive packaging solution, particularly given the advantages they offer.

Folding cartons are a cost-effective solution if you are looking for high-quality, sustainable packaging.

These advantages (and many others) explain why folding carton boxes are used for packaging in various industries.

3. Folding Carton Paper Grades

Various grades of paper are used in folding carton boxes, each with their own capabilities.

You might be asking yourself: 'It's just paper; how hard can it be?'

Well, each paper grade has different printing and finishing capabilities, and undergoes various processes to suit your product and brand.

It is worth knowing what you need from your paperboard box to create the perfect packaging.

Solid Bleached Sulphate (SBS)

SBS is a high-grade paperboard that is highly tear-resistant.

It is made from a mixture of 20 percent recycled material and 80 percent freshly cut wood chips, which are chemically processed and bleached.

SBS paperboard is available in brilliant white and has a thin coat of naturally occurring clay to provide a smooth printing surface with a special finish.

These grades of paperboard provide an ideal surface for:

• Design elements

• High-quality printing

• Finishes
• Coatings

Solid Unbleached Sulfate (SUS) Paperboard

The process for producing solid unbleached sulfate (SUS) paperboard is similar to that for SBS, except that it is not bleached and therefore has a different colour.

SUS paperboard is brown and coated to produce a smoother printing surface.

The brown colour of the material may cause the printed output to appear duller or faded.

However, the colour and recyclability of the material make this paper grade exceptionally successful in communicating sustainable brand initiatives.

4. Paperboard printing and coating alternatives

This is where branding comes in.

As mentioned briefly, the paper grade and coating significantly impact the printing of your packaging design.

White paper grades provide the best surface for producing accurate colours because they can easily be matched in the Pantone colour matching system during the design process.

However, natural brown kraft paper is more difficult to print on because the colour of the paper grade can change the printing output entirely.

Colours may appear dull and pale. Thus, the final product may be difficult to read or view if there is any text.

To achieve the best colour output when printing on kraft folding cartons, it is best to lay your design in white ink and then print your final design.

Paperboard has the advantage of being suitable for both offset and digital printing due to its versatility.

Offset printing is recommended for the best quality output. This is particularly important for very complex designs that require sharp lines.

Simple designs that do not require much definition to be memorable are better suited to digital printing.

Folding cartons can also be coated to suit particular industries.

For example, the food and restaurant sector usually requires wax coatings to prevent leaks and grease stains on the final packaging.

Moreover, aqueous coating can be used to create environmentally friendly initiatives and can be applied to the inside of food packaging without the incorporation of any harmful or toxic substances.

Due to the flexibility of folding cartons, they can also withstand special and unique finishes that contribute to your branding, such as:

• Embossing/debossing

• Spot UV printing

• Foil stamping

5. Design elements to consider

The best thing about paperboard is that it is cost-effective. This means you can invest in design features that will take your brand identity to new heights.

Although this packaging material's printing possibilities are extremely versatile, it is also worth noting that paperboard can take on unlimited design possibilities.

Embossing & Debossing

Embossing and debossing is a technique that stamps images, designs and text onto materials to create raised or indented images.

This is very effective for things such as:

• Logos

• Certifications

• Artwork

Spot UV printing

UV printing is a process in which a coating is applied to the material and then cured with ultraviolet (UV) light.

This coating is applied to certain parts of the printed product to fix the colour, create a nice sheen, and protect the surface against water and wear and tear.

A spot finish can also be used to create a variety of textures on a printed surface, making it more dramatic and eye-catching.

Spot UV is one of the many speciality printing methods used to create effective packaging and distinguish between brands/products.

Similar to lamination, it improves the quality of printed products. It should be noted that 'spot UV printing' is a misnomer, since it is a coating process rather than a printing process.

6. Paperboard in industries

Paperboard packaging is used in almost every industry.

Industries that use paperboard packaging include:

The cosmetics industry, including makeup and skincare products.

The food and beverage industry, e.g. cereal boxes and other containers.

The cannabis industry, for example, uses paperboard packaging for CBD oils.

Secondary packaging for pharmaceuticals.

Ultimately, your packaging is the spokesperson for your brand and products.

Folding cartons are an effective method of achieving this, no matter what industry your business operates in!

Call our product specialists today for help and advice on your first project!