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  1. Carton Packaging World·Classic [ ] Shared by Packmage CAD Team

  2. Outline 1.Carton Packaging Word 2.Folding carton box template structure 3.Terms 4.Mathematics in the folding carton structure design 5. Folding carton functional structure design 6. Corrugated Carton 7. Paper bag 8.Cushion packaging 9.Loading and transportation 10.Carbon footprint

  3. 1. Carton Packaging World Many people mistaked thatcarton packaging is the combination of the box template structural design and graphic design. In fact, the carton packaging is far more than that. In this chapter we will explain by two small examples : the carton packaging is a macrocosm, this industry is promising if you get involved.

  4. Sample 1《 Carton Packaging World 1.1 The cost difference between two minor difference box templates with specific cardboard size The client needs the packaging box structure shown above, the carton box size is 80*45*100(mm),cardboard

  5. Sample 1《 Carton Packaging World 1.1 The cost difference between two minor difference box templates Select carton box template A, draw the die line template according to the carton box size:

  6. Sample 1《 Carton Packaging World 1.1 The cost difference between two minor difference box templates with specific cardboard size It can step and repeat 12 boxes in the standard-sized sheet(Note:This sample haven't take into account the loaded knife rationality factors)

  7. Sample 1《 Carton Packaging World 1.1 The cost difference between two minor difference box templates with specific cardboard size We can switch to carton box template B, its shape is exactly the same with box template A.

  8. Sample 1《 Carton Packaging World save paper more than 20%. 1.1 The cost difference between two minor difference box templates with specific cardboard size

  9. Sample 2《 Carton Packaging World 1.2 The carton packaging design impacts on transportation Because of the difference of the buffer design, cardboard material selection and structural design, the carton packaging design will have a significant impact on transportation.

  10. Sample 2《 Carton Packaging World The area increase 2%, while cost increase 11% 1.2 The carton packaging design impacts on transportation Container size:591cm*234cm Carton size:50cm*30cm 89 pieces Carton size:50cm*31cm 79 pieces

  11. 2. Folding carton structure Folding carton Carton box Glued carton Carton packaging Corrugated box Paper bag

  12. Tubes Folding carton Trays Tubes and Trays Folding carton classification

  13. Tubes《 Folding carton structure analysis 2.1 The definition of tubes It originally refers to the smallest box lid area amang, such as toothpaste boxes, such as toothpaste box. Now, it is generally defined from the molding characteristics: it refers to the carton box that need both the lid and bottom closure panel fixed or sealed during the molding process.

  14. Tubes《 Folding carton structure analysis 2.1.1 The structure of the tubes 1、2、3、4-Panels 5-Closure panel 6-Dust flap 7-Glue flap 8-Closure panel 9-Tuck flap

  15. Tubes《 Folding carton structure analysis 2.1.2 The closure structure of Tubes Commonly closure structures: • Friction Tuck • Seal end • Locking tab • Push-in closure • Concave/Convex • Glued sealing • Snap lock bottom • Automatic lock bottom

  16. Closure《 Tubes《 Folding carton structure analysis 2.1.2.1 Friction Tuck The sealing structure uses the friction between the tongue, dust flap and the panels to achieve and maintain sealing, the sealing strength and reliability is poor, suitable for small, lightweight daily necessities and pharmaceutical packaging.

  17. Closure《 Tubes《 Folding carton structure analysis 2.1.2.4 Seal end The locking strength and reliability of the sealend structure is higher, but it is less convenient.

  18. Closure《 Tubes《 Folding carton structure analysis 2.1.2.6 Push-in closure Each flap is part of the pattern, after plug-in the flaps composite a beautiful pattern.

  19. Closure《 Tubes《 Folding carton structure analysis 2.1.2.5 Locking tab The locking tab structure combined the friction and lock end sealing structure. With high sealing strengt and reliability, it is suitable for heavier contents.

  20. Closure《 Tubes《 Folding carton structure analysis 2.1.2.7 Concave/Convex The Concave Convex structure with the own strength and stiffness of the cardboard, deformation of straight or curved creasing lineon the box, depressed flaps to achieve sealing.

  21. Closure《 Tubes《 Folding carton structure analysis 2.1.2.8 Glued sealing The glued sealing structure with the panels attached to the flap stick together.

  22. Closure《 Tubes《 Folding carton structure analysis 2.1.2.9 Snap lock bottom Snap lock bottom also called 1-2-3 closure, the bottom structure is simple, aesthetic and economic with strength and tightness, it is the most commonly used lock bottom structure and widely used in cosmetics, alcohol and food packaging.

  23. Closure《 Tubes《 Folding carton structure analysis 2.1.2.9 Snap lock bottom When we drawing the 1-2-3 bottom structure, we usually draw first part of the closure, there is no strict limit to the size of A, generally consistent with proportions of the box length. The vertical distance of the recessed portion and the creasing line of the length must be 1/2 of the width.

  24. Closure《 Tubes《 Folding carton structure analysis 2.1.2.10 Automatic lock bottom The automatic lock bottom refers to the body and the bottom of the box can be folded into a flat plate shape, and the bottom of the box can be automatically restored to the sealing status when the box stretched.The structure is complex and the cost is higher than other boxes.

  25. Closure《 Tubes《 Folding carton structure analysis 2.1.2.10 Automatic lock bottom From the automatic lock bottom structure, we can see both the flap and width angle of the box are 45 °, it is to avoid overlapp when folding. Part A is the locking tab which is located the intersection of 1/2 length and 1/2 width of the box, it is to enhance the lock strength. The shade area is the glued part, it is folded on the opposite direction. The larger size the glued part, the more firmly. The 2 ° slash on Part B is to facilitate waste remove from the slash after carton box die-cutting. The 3mm width in part C is to prevent the carton rupture after multilayer paper overlapped.

  26. Tubes《 Folding carton structure analysis 2.1.3 Widely used tube folding carton box template Widely used tube folding carton box template: • Reverse tuck • Straigt tuck • Airplane style • French reverse tuck • Snap lock bottom • Automatic lock bottom

  27. Widely used tube box templates《 Tubes《 Folding carton structure analysis 2.1.3.1 Reverse tuck The reverse tuck also abbreviated as RTE, it is the most primitive box template.

  28. Widely used tube box templates《 Tubes《 Folding carton structure analysis 2.1.3.2 Straight tuck The straight tuck also abbreviated as STE. Its drawback is that the two projections, when step and repeat it wastes paper material, but it is suitable used for the window style box.

  29. Widely used tube box templates《 Tubes《 Folding carton structure analysis 2.1.3.3 Airplane style As the name suggested, the airplane style box template shape looks likethe aircraft, its basic function and purpose is the same with straight tuck.

  30. Widely used tube box templates《 Tubes《 Folding carton structure analysis 2.1.3.4 French reverse tuck The French reverse tuck box template abbreviated as FRENCH STE. Its advantage is maintain the integrity of the display surface, the contents of the design can be extended to the lid of the box, it has became commonly used box template for cosmetics packaging.

  31. Tubes《 Folding carton structure analysis 2.1.4 10 principles of the folding carton structural design 10 principles of the folding carton structure design

  32. 10 principles《 Tubes《 Folding carton structure analysis 2.1.4.1 10 principles 1-2 • (1)Whether the product has individual packaging • plain tuck flap:Individual packaging, do not need to consider pollution, scattered factors • slit-lock tuck flap:The tuck structure is more conducive to the production and operation compare to the glued structure • (2)One time open or multiple times open during usage • slit-lock tuck flap:It offers more secure closure design than the one time open, mainly used on heavier content packaging. • plain tuck flap:It keeps the integrity of the folding carton with multiple times open.

  33. 10 principles《 Tubes《 Folding carton structure analysis 2.1.4.1 10 principles 3~5 • (3)Heavy weight products • tuck and tongue lock:It provide a very secure cover design • (4)Whether consumers expect to be able to see the product before buying? • Aperture or window:The product can be see clearly • Plain tuck flap:The customer could even touch the product. • (5)Whether the products need to be leak-proof structure? • double-glued end seals:The non-independent packaging product coated with glue on two dust flaps and the back cover, which is more effective to prevent leakage.

  34. 10 principles《 Tubes《 Folding carton structure analysis 2.1.4.1 10 principles ~6 • (6)Which process included in the carton packaging production? • Each process in carton packaging production can be completed by equipment or by hand, it should be equipped with a different design on manual, semi-automatic or automatic production.

  35. 10 Principles《 Tubes《 Folding carton structure analysis 2.1.4.1 10 Principles 7~8 • (7)Whether the carton box need to prevent unexpected opening? • double-glued end seals:The glued operation can prevent the folding carton with unexpected open, such as toothpaste box. • (8)Which loading way the folding carton applied? • Vertical loading:Commonly loading way, it is easy for mechanized production; such as grain and powder. • Horizontal loading:The basic design is the same with vertical loading, only changes the open direction. Automation equipment is more complex. • Top loading:Some products require bigger diameter loading. This type of folding carton is often designed with KDF( knocked-down-flat) or flat sheets delivered. Dimensionally unstable products (such as clothing) tend to use the top loading design, as well as toys.

  36. 《 Folding carton structure analysis 2.2 Trays The definition of Trays The tray is folded by a cardboard with right angles or diagonally angles. The tray folding carton is suitable for packing shoes, hats, clothing, food and gifts. The commonly tray structure and the name of each part listed in the photo.

  37. 10 Principles《 Tubes《 Folding carton structure analysis 2.1.4.1 10 Principles 9~10 • (9)How to use the folding carton? • The folding carton design need to consider how it could be storaged. On the dresser or drawers? Medicine cabinet or refrigerator? • Easy to open, accessible and tear lines and other auxiliary design should considered in the carton box design. • (10)How to sale the product? • Excellent folding carton design is helpful for the sales display • It need to provide a stable and attractive display way.

  38. Trays《 Folding carton structure analysis 2.2.1 Molding method Each panel of the tray folding carton need to be connected with certain structure, the concrete molding method include: (1)Fold assembly (2)Lock connection

  39. Trays《 Folding carton structure analysis 2.2.3 Top and Base a)top lidb)cap lidc)Buckle lid The lid, body of the box are mutually independent with open structure, the inner dimension of the lid is slightly larger than the outer size of the tray to ensure that the lid can be smoothly cover on the body. The top and base structure used for shoes, clothing and assembled goods. • Top lid:The height of the lid equal to the height of the box so that it almost cover up all the box body. • Cap lid:The height of the lid is less than the height of the body, generally only covering the upper opening portion of the body. • Buckle lid:The body with matching edge to seam with the lid, the height of the box equal to the height of the lid and the height of the matching edge of the box body.

  40. Trays《 Folding carton structure analysis 2.2.2 Lock connection type Bend lock structure Straight lock structure Slant lock structure

  41. Trays《 Folding carton structure analysis 2.2.4 Typical lid structure a)Bodyb)Lid It also known as drawer lid. Lid is an independent piece, box body can be drawn within the lid forward.

  42. Trays《 Folding carton structure analysis 2.2.5 Commonly tray structure Commonly tray structure: • Double side wall • Foot lock • 4-spot glued • 6-spot guled

  43. Commonly tray structure《Trays《 Folding carton structure analysis 2.2.5.1 Double side wall As the name suggested, the wall structure of the tray has doubled, it is easy of production, various parts folded completely, normally can be made of top and base box. Since the glued part need to be folded to form the double side wall, its maximum value can not exceed the depth of the box subtracting the thickness of the paper.

  44. Commonly tray structure《Trays《 Folding carton structure analysis 2.2.5. 2 Foot lock The foot lock plays both the foot and lock rule of the box. The size of the male lock is smaller than the size of the female lock in the box lock structure, the male lock is drawn to the inside with 15 ° angle, and the female lock is 15 ° angle to the outside. The four fixed flaps folded can not affect the lock, it is the relationship between C and C-2B in the tray structure.

  45. Commonly tray structure《Trays《 Folding carton structure analysis 2.2.5.3 Four-spot glued tray Four-spot glued tray is one of the most simple and valuable box template,it also named Beerstray, mainly for packing shirts, sweaters, food and toys etc. The biggest characteristics of Four-spot glued boxis the lid and the bottom of the tray can be completely the same size to match perfectly, unlike other trays, the lid must be bigger than the bottom.

  46. Commonly tray structure《Trays《 Folding carton structure analysis 2.2.5.4 Six-spot glued tray The change and design of the six-spot glued trayis on the basis of four-spot glued tray.It is widely used in frozen food, fish, seafood, vegetables packaging fields. The width of the lid is 2 times bigger than the width of the bottom.

  47. 3.The characteristics of folding carton Outline: • The bearing characteristics • The influence of the two sides of the paper on structure design • The Offset • The texture direction • The texture direction design of Tubes • The texture direction design of Tubes with curved surface • The texture direction design of Trays • The texture direction design of regular polygon trays

  48. 《 The characteristics of folding carton 3.1 The bearing characteristics As we all knowbut may not pay special attention to the phenomenon: the bearing force of flat sheetcardboard is small, once creasing and properly folded, it could bear great pressure.

  49. 《 The characteristics of folding carton 3.2 The influence of the two sides of the paper on structure design No matter ordinary cardboard or corrugated board has two sides, ordinary cardboard has a surface layer and a bottom layer, corrugated cardboard has out layer paper and inner layer paper. It influences the molding when folding, which need to be taken into account in the structure design. (a)Inner fold 90° (b)Outer fold 90° (c)Inner fold (d)Outer fold 1-bottom layer 2-surface layer 3-bottom layer 4-surface layer

  50. 《 The characteristics of folding carton 3.3 The influence of the two sides of the paper on structure design There is an example: Caliper 2mm, Length 40mm.The creasing line is on the middle of the cardboard. Then we start to fold.