In addition to the structural design discussed in this article, printed bar codes, labels, and graphic . boxes with higher basis weight, using wet strength resin additives or adhesives or application of surface barrier coatings. How can we arrive at the optimal packaging solutions that strike the right balance between cost, environmental impact, and safety, while allocating costs appropriately? <>>> | In 2018, approximately 32.1 million tons of corrugated boxes were recycled out of 33.9 million tons of total paper and paperboard recycling. Leave the strapping, bundling or other unitizing device in place until boxes are ready for use. High-humidity conditions can weaken the adhesive that bonds the fluted medium to the liners, enough, in fact, that the corrugated can delaminate. For more comprehensive information on this category of MSW, see the 2018 Data Tables on the Advancing Sustainable Materials Management: Facts and Figures Report page. Recycling of aluminum beverage cans was 670,000 tons, or 50.4 percent of generation in 2018. If your boxes are crushing while stacked in your facility, or if you are planning to send product to areas where high humidity is prevalent, please contact us and allow FlexPAC to help you find the right solutions to your problems. In fact, when boxes are stacked on a pallet with as little as inch hanging-over, as much as 30% of their strength is lost! EPA used statistics from the American Forest & Paper Association (AF&PA) to estimate post-consumer paper and paperboard generation in 2018. This web page provides an overview of data on containers and packaging in municipal solid waste (MSW). EPA based its generation estimates on data supplied by the Steel Recycling Institute (SRI). | Its important to monitor whether the recommended pre-stretchage is being adhered to in the process. Check out our self-paced learning resources and tools including books, accreditation manuals and newsletters. Other paper packaging, such as cartons and sacks, is mostly recycled as mixed papers. You may also want to look at reconfiguring the box dimensions to fit the pallet. Some of these include polyethylene terephthalate (PET) soft drink and water bottles, high-density polyethylene (HDPE) milk and water jugs, film products (including bags and sacks) made of low-density polyethylene (LDPE) and other containers and packaging (including clamshells, trays, caps, lids, egg cartons, loose fill, produce baskets, coatings and closures) made up of polyvinyl chloride (PVC), polystyrene (PS), polypropylene (PP) and other resins. Wood packaging includes mostly wood pallets, as well as wood crates. Evidence of damage is heavy creasing to the corrugate, a punctured case or other tell-tale signs, such as tears and rips. Containers and packaging products in MSW are made of several materials: paper and paperboard, glass, steel, aluminum, plastics, wood, and small amounts of other materials. Although it would be difficult to calculate the reduction of strength under fluctuating conditions over time, the chart below (Protective Packaging for Distribution, 2010) is used to determine the compression strength loss over time under various environmental conditions. Even stretching the limits of extreme accountability, its virtually impossible for an inanimate objectsay, a case of twenty-four 18oz cans of cornto heed a common warning: Travel at your own risk., Or even the caution Items may shift during loading.. 3 0 obj Container and packaging products, especially corrugated boxes, are among frequently recycled products. Avoid stacking boxes too high, whether loose or banded, because of slight instability. Additionally, about 14.3 percent of the wood containers and packaging waste generated was combusted with energy recovery, while the remainder (58.8 percent) was landfilled. The corrugated board is considered as the second most used packaging material and the world's environmentally acceptable solution for packaging, with wide range of applications. <>/XObject<>/Font<>/ProcSet[/PDF/Text/ImageB/ImageC/ImageI] >>/MediaBox[ 0 0 612 792] /Contents 4 0 R/Group<>/Tabs/S/StructParents 0>> After recycling, the combustion of corrugated boxes was 230,000 tons, and landfills received 940,000 tons in 2018. For example, at 50% relative humidity (RH) a corrugated box is at 80% of its potential stacking strength. Colder temperatures hold less moisture. However, once the . We have the experience to ask the right questions to ensure the boxes we provide you will meet your products needs and will remain structurally sound. Ideally, there should be no gaps between cases that are stacked on top of each other. An excel testing template is available as a tool to support the statistical evaluation of the test results and communication with suppliers/customers. Corrugate is 71% weaker at 95% humidity vs. 50% humidity. )3$q:z]==V/_WwOw~cogf8{<>E5ep8\3^G}`*Y Extreme cold also affects moisture content, making the boxes more fragile. Additionally, the combustion of containers and packaging was 7.4 million tons (21.5 percent of total combustion with energy recovery) and landfills received 30 . Packaging products are comprised of different plastic resins. Moisture Content Takes a Leading Role. The data below are from 1960 to 2018, relating to the total number of tons of wood packaging generated, recycled, composted, combusted with energy recovery and landfilled. First, its important to ensure compatibility between the film used and the stretch-wrap machinery. This article will use the word corrugated to refer to boxes in the KD (knocked-down) position, in contrast to the erected box. If corrugated cardboard becomes wet, it becomes a source for bacterial growth. Packaging engineers work to meet the performance requirements of a box while controlling total costs throughout the system.. MoistTech is very experienced with the requirements in the corrugated board moisture control process. 2023 PMMI Media Group. 1 0 obj Extreme cold also affects moisture content, making the boxes more fragile. Additionally, about 13 percent of the aluminum containers and packaging waste generated was combusted with energy recovery, while the remainder (52.1 percent) was landfilled. You need to be laser focused on specific targets, so you know exactly where to make improvements. Gaposis that originates at the palletizer dramatically increases the potential for damage. Take a look at the products and at the other materials we studied. Checkout our packaging and processing solutions finder, ProSource. Experience has demonstrated that a target moisture from 5.8 to 7.5% total combined board moisture works well throughout the year. Store boxes off the floor, on pallets or other flat dunnage. Find out about the current National Patient Safety Goals (NPSGs) for specific programs. Tell us what you're looking for and we'll do our best to make it work! The corrugated industry produces the N1 transport packaging in the world. At FlexPAC, we have tools and experience to help determine the right corrugated board grade for a given situation. endobj The Joint Commission is a registered trademark of the Joint Commission enterprise. Approximately 20.6 percent of the other miscellaneous packaging was combusted with energy recovery, while the majority was landfilled (79.4 percent). Fax: 317-872-7872. 2)XxN=.26^k )B7/-:vb aZ-NQ@4M Aesthetically, corrugated takes on a faded, dried-out appearance, even through kraft-brown liners. Regardless of the percent of recycled content, the resulting corrugated is not as strong as its counterpart comprised of virgin material. Pallets should be of quality construction; otherwise, splinters, protruding nails, and other defects can inflict damage. The net import of unfilled aluminum cans is estimated from data collected by the Department of Commerce. Official websites use .gov Typical analog range is 0-10% moisture and up to as much as 40%, subject to . We also collaborate with our supply chain partners to develop the optimal packaging materials for your specific needs. Corrugated should be stored on pallets, ideally, which avoids direct contact with the floor and retains the means for mechanical handling (caution: forklifts, if operated carelessly, can damage corrugated). Through leading practices, unmatched knowledge and expertise, we help organizations across the continuum of care lead the way to zero harm. 4 0 obj And unfortunately, humidity is one factor that cannot always be controlled. In fact, its possible that damage waste has a greater adverse impact on the environment than the extra packaging itself. FEFCO members can download the document here OR please contact FEFCO at Houriet.lefebvre@fefco.org One way to avoid this is to use air-ride suspension trailers, which are uniquely adapted with air hoses that span from the truck to the trailer. Another option would be to use corrugated pallet liners to cover the bottom of the pallet (pallet deck) to make it a solid surface. Corrugated boxes were the largest single product category of MSW in 2018 at 33.3 million tons generated, or 11.4 percent of total generation. There are three main causes of compression-loss when palletizing boxes: Pallet Overhang, Wooden Pallets, and Interlocked Stacking Patterns. All rights reserved. it means that all the well known requirements of other standards are met (e.g. So, although eliminating damages completely from supply chains is unrealistic, companies can approach the issue pragmatically and establish a system to measure and monitor the process so improvements can be made more efficiently. Corrugated boxes also represent the largest single product of recycled paper and paperboard containers and packaging. of strength/force applied to hold the product together. We develop and implement measures for accountability and quality improvement. The amount of wood pallet recycling (usually by chipping for uses such as mulch or bedding material, but excluding wood combusted as fuel) in 2018 was 3.1 million tons. View them by specific areas by clicking here. EPA estimated the amount of generation of aluminum cans using Aluminum Association data on the number of cans consumed domestically and on average can weight. corrugated boxes. Moisture and temperature are important considerations when discussing the strength and longevity of corrugated boxes. Use good materials handling procedures; dont drop or throw bundles or pallet. Once a box is formed, both before and after it is filled with product, maintaining its moisture content is critical to maintaining the boxs compression strength. The main purpose of packaging is to provide protection for products. Corrugate is 71% weaker at 95% humidity vs. 50% humidity. Before putting together a plan, lets examine how product damage occurs and some questions to ponder. Another set of problems relate to unitizing. Beginning in 2009, the Glass Packaging Institute provided production data. In cool and dry areas, consider using lamination as a finish. Less-than-ideal or fluctuating conditions reduce their effectiveness and shorten their useful life. Incidentally, superimposed weight should be like-on-like, meaning, weights other than corrugated should not be superimposed on unit loads of corrugated. Its not easy loading a 53-ft.-trailer. Storage and transportation can expose corrugated boxes to fluctuations in temperature and humidity. Carton box moisture control. Avoid temperature and humidity extremes and fluctuations in storage areas. Those unit loads can be unstable and therefore hazardous, since they can collapse on their own and more probably under a superimposed load. Acceptance Conditions and Procedure for Certifying Bodies, World standards - Comparison testing methods FEFCO / EN / ISO / TAPPI, FEFCO Technical Specifications for Converting Equipment_V1.2, The updated document is now available here, this plant can guarantee that the product delivered to the customer fulfils all. Pallets should be of quality construction; otherwise, splinters, protruding nails, and other defects can inflict damage. Touch points can become flash points for product damage. Because corrugated is hygroscopic, the relative humidity of the storage area should be maintained within favorable tolerances. Simply stated, unusable boxes can result in unsold products. With the landscape of product damage defined, the path toward improvement must start with a robust system that helps pinpoint where efforts need to be focused. Heat can also reduce the moisture content of corrugated boxes, making them brittle. This means that the cases are doing their job to protect whats inside. EPA estimated the generation of aluminum packaging at 1.9 million tons in 2018, or 0.7 percent of MSW generation. Heat and humidity are the two biggest enemies of packaging strength. The type of dunnage selected depends on the type of shipment and the other packaging materials being used, as well as convenience and price. Is this practical? In honour of #EarthDay, our amazing team shared 'One Thing I Do For Earth Day'. The more in-depth information you uncover and the more precisely you can identify the sources of the issues, the better youll be able to develop and execute a corrective action plan. EPA included estimates for some other miscellaneous packaging, such as bags made of textiles and small amounts of leather. Still have a question about the data? The aim of this study was to develop a model to predict spatio-temporal moisture content distribution in corrugated fibreboard cartons under standard RFC shipping conditions. Packaging Digest is part of the Informa Markets Division of Informa PLC. The boxes they need for shipping represent, on average, less than 1% of the value of their contents. Source: American Forest and Paper Association. In very humid environments, such as a warehouse with an uncontrolled climate in the summertime, stacking strength is greatly reduced. (Plastic packaging as a category in this analysis does not include single-service plates and cups, and trash bags, both of which are classified as nondurable goods). Additionally, about 13.4 percent of the glass containers and packaging waste generated was combusted with energy recovery, while the remainder (55.4 percent) was landfilled. All rights reserved. Secure .gov websites use HTTPS The data below are from 1960 to 2018, relating to the total number of tons of glass containers generated, recycled, composted, combusted with energy recovery and landfilled. Find the exact resources you need to succeed in your accreditation journey. All of these cause problems as the corrugated is erected into boxes, whether the operation is manual or automated. Alternate bundle direction, or alternate loose boxes at intervals for greater stability. EPA estimated 14.5 million tons of plastic containers and packaging were generated in 2018, approximately 5.0 percent of MSW generation. <> What is The Joint Commission's position on managing cardboard or corrugated boxes and shipping containers? A dash in the table means that data is not available. OW8lF0Bd9n?DL0C S\E vmi]L'E`f ur4Z{.+};pf K@i%LEwpX9hH 1. While having a certain amount of moisture in the air (around 6% 7%) will ensure proper creasing, avoid cracks, maintain good bending and impact resistance, as well as cushioning and shock absorption, higher humidity levels can actually have a negative impact on those characteristics of corrugated board that we value most. When building pallet loads of flat boxes, use deck boards to distribute weight evenly. Indianapolis, IN 46278 Sources: USDA Forest Service Southern Research Station and Virginia Polytechnic Institute. Forty% of the strength of corrugate is lost within the first 30 days of storage. According to industry numbers, corrugated is utilized for 95% of packaged goods, with boxes (i.e. But, did you know that merely changing the way you stack and palletize your boxes could significantly affect their performance? Ensure that pallets are free of nails, large splinters, and other sharp objects that can damage corrugated boxes. Learn about the development and implementation of standardized performance measures. Approximately 46million tons of paper and paperboard were recycled in 2018for a recycling rate of 68.2percent, which was the highest compared to other materials in MSW. After the manufacturing process, the corrugated board is cut into sheets and stored in a stack until optimum moisture content has been reached in order to The recycling rate of PET bottles and jars was 29.1 percent in 2018 (910,000 tons). We should do our best to keep boxes relatively dry because humidity can have a huge impact on their performance. endobj Overall, paper and paperboard containers and packaging totaled 41.9 million tons of MSW generation in 2018, or 14.3 percent of total generation. Fluctuations in humidity can impact it even further. On the surface this number might seem small, but the ramifications can be quite large. Drive performance improvement using our new business intelligence tools. Please click here to see any active alerts. EPA also estimated the recycling of plastic products based on data published annually by the American Chemistry Council, as well as additional industry data. During the day, the warmer air picks up moisture, and as the air cools in the evening, it releases it as dew. Is the product appropriately stabilized? Looking for other information? Learn how working with the Joint Commission benefits your organization and community. The moisture content of corrugated materials prefers a state of equilibrium with atmospheric humidity. Humidity varies by region and season, a fact intuitively grasped by all. A solution for avoiding direct contact with the floor and for avoiding superimposed weights is storage racks, especially if the facility already is so equipped. Because products must be brought securely to market, some form of packaging will always be needed. Corrugated boxes stored under ideal conditions will remain usable for a long period of time. The typical adhesive used for corrugated is of a starch composition, not known for being moisture-resistant (there are moisture-resistant formulations but they are more expensive). This was 11.8percent of MSW landfilled in 2018. But is there an optimal balance between overpackaging and underpackaging? 4dn2PE;o%jM ]oPk3x H7,9F;* F#u ghEIk*aMx\EV)lDPf!>%{ m sHq*XJmNl3p#N3)}X6uUWZWmH[7V{!+)HD?^M@=L`dTm.tVm$Ex7D`9X$W;$_4H+W+Qoj%H The multipliers can be used to calculate compression loss for specific situations. Using an interlocked pattern, which rotates each layer on the load, can destroy up to 50% of the compression strength. If no, please comment on how we could improve this response. If you work in the seafood industry, you know exactly how delicate the process of transporting the latest catch to its point of sale can On April 28, we join the rest of Canada in observing the Day of Mourning. How to ensure your best conveying project yet. Box users make major investments in the development, production and promotion of their products. Store boxes flat from the time they are received until they are ready for use. The data below are from 1960 to 2018, relating to the total number of tons of steel containers and packaging generated, recycled, composted, combusted with energy recovery and landfilled. Can retailers really afford to do this? FEFCO has updated the GMP (Good Manufacturing Practice) document in March 2020. Additionally, about five percent of the steel containers and packaging waste generated was combusted with energy recovery, while the remainder (21.2 percent) was landfilled. FEFCO 1952 - 2022. For this analysis, EPA classified products made of paper and paperboard materials as either nondurable goods or as containers and packaging. Containers and packaging include products such as corrugated boxes, milk cartons, and bags and sacks (See the definitions of nondurable goods and containers and packaging for more information). Corrugated packaging Custom solutions made from renewable resources that protect and promote your goods. The logical question one would ask, then, Is all the packaging thats being used necessary? In many cases, the answer is no. Corrugated cardboard boxes are no exception. The porosity of wood fibers, which is what corrugated boxes are made of, allows it to absorb and release moisture, a phenomenon that isknown as hygroscopy. Share sensitive information only on official, secure websites. JavaScript appears to be disabled on this computer. . Corrugated boxes can protect even the most fragile items, including glass and chemical liquids. Mechanical measuring device: Bobst,BW PapersystemsandTechnology Coaching Manual operations are slowed and automated case erectors are jammed. Is there a viable solution? Improper and fluctuations in relative humidity can be seen in: These can result in the box structure breaking down, leading to a reduction in strength and, eventually, failure. The data below are from 1960 to 2018, relating to the total number of tons of paper and paperboard containers and packaging generated, recycled, composted, combusted with energy recovery and landfilled. EPA defines containers and packaging as products that are assumed to be discarded the same year the products they contain are purchased. That way, the oldest inventory is used rather than remaining around and becoming more compromised. Water is used in the corrugated board production and aids in creating the liner board, forming the flute structure, and as part of the starch adhesive that combines them. Cardboard in storage quantities (recommend consultation with your Fire Marshal) should be placed in hazardous areas protected per LS.02.01.30 and cannot obstruct the means of egress in accordance with standard LS.02.01.20. Its fair to say that billions of productsall types, all sizes, all purposesmake the trip from the manufacturing plant to a distribution center to a retail store. EPA measures the generation, recycling, composting, combustion with energy recovery and landfilling of paper and paperboard products. Our team has worked with countless companies whose boxes have faced just about every environmental condition imaginable. At 85% RH, a box has 50% of its potential stacking strength. Please be aware that cardboard boxes and or cardboard shelving units should not be allowed or found in areas such as: OR storerooms Central Supply Clinical areas Also, do not use cardboard boxes to store items in a dirty utility room. That worker should be trained to never toss, drag, or drop that bundle. Registered in England and Wales. And just where do you start? rAbuZrVI4*S~BA/9xd)0u %PDF-1.5 Stretch film, also known as stretch wrap or pallet wrap, is one of the most popular unitization materials on the market. endobj Stiffer trailers combined with rough roads can magnify the compressive stress on boxes by a factor of 10. The total generation of paper and paperboard in MSW was 67.4 million tons in 2018, which was 23.1percent of total MSW generation that year. Functionally, corrugated becomes brittle and crinkly. it can produce a certificate at the customer's request, it can offer better product quality through better control and. In addition to accreditation, certification, and verification, we provide tools and resources for health care professionals that can help make a difference in the delivery of care. Most plants are now checking their combined board's total moisture content, measuring it off of the dry end of the corrugator with an automatic weighing and drying oven (see Special Note). How appropriately stretch-wrap is applied can be a big factor in whether a product sustains damage. Easy Way to Analyze Moisture Content of Corrugated Boxes During production of corrugated boards, manufacturers often face a unique problem caused by inaccurate control of moisture; if the moisture content of the corrugated box is higher, it may leads to collapsing of the box. x[oH |EX,NC$NCw?R' -%k(;=! Corrugated is an engineered material, specified by paper grade, flute, style, manufacturers joint, and adhesivemainly. Consider: Is there overhang or underhang? Keep learning with our Hospital Breakfast Briefings Webinar Series. An official website of the United States government. Pepsi and Fantas respective new visual identities are optimized for both analog, physical spaceslike packagingand for the online and digital worlds. Our sensor calibrations, measurement wavelengths, algorithms and sensor optical requirements are pre-set at the factory. Gain an understanding of the development of electronic clinical quality measures to improve quality of care. Another area to examine is the force-to-load measurement, or the amount (in lbs.) In fact, up to 15% of compression strength may be destroyed. Shock and vibration can affect stiff trailers with no cushion load. Pallets made with green wood can have a moisture content (MC) ranging from 50-100% and can easily contain more than ten pounds of water. And if there has to be an investment in storage racks, a favorable tradeoff is that the specified heights of unit loads can be increased, leading to increased storage densities, and later, increased handling efficiencies. Seas the day with our quick guide to corrugated seafood shippers! Informa Markets, a trading division of Informa PLC. Despite its repetitive nature, this exercise presupposes a certain level of risk for product damage. Sustainability has increased the popularity of corrugated comprising recycled content. Check out our Frequent Questions page. The new national standard "corrugated board" GB/T6544-2008 stipulates that the moisture content of paperboard should be no more than 14%, that is, an upper limit for the moisture content of cardboard. The stacking of unit loads saves space; however, some type of flat cover should be placed on the top of a unit load in order to evenly distribute the superimposed weight. Corrugated box design is the process of matching design factors for corrugated fiberboard boxes with the functional physical, processing and end-use requirements. In this table below published in the Handbook of Package Engineering (c.1992), you can see that the greater the humidity the less stacking strength a box has. The boxes are usable, and dont end up ready for recycling before they can fulfill their purpose; The boxes will run smoothly on automatic setup, filling and closing equipment, avoiding costly jam-ups, repacking and lost time; The boxes will stack squarely, avoiding costly accidents during palletization, storage and shipment; and. The corrugated medium is often 0.026 pounds per square foot (0.13 kg/m) basis weight in the U.S.; in the UK, a 90 grams per square metre (0.018 lb/sq ft) fluting paper is common. <>>> 2 0 obj It is useful and instructive for box design considerations to quantify the expected strength loss as a function of the equilibrated moisture content of corrugated board and so minimize box failure in high humidity . A .gov website belongs to an official government organization in the United States. Easy Way to Analyze Moisture Content of Corrugated Boxes During production of corrugated boards, manufacturers often face a unique problem caused by inaccurate control of moisture; if the moisture content of the corrugated box is higher, it may leads to collapsing of the box. The total amount of paper and paperboard combusted in 2018was 4.2million tons. Therefore, any discussion about improving the sustainability of production and consumption must always address packaging as an essential part of the supply chain. Returning to the 95% statistic that opened this article, its division among the versions of corrugated might vary; however, corrugated, as an overall category, will retain its dominance. endobj Excessive moisture or water can soften or dissolve the corrugating adhesive, causing delamination; a box that literally falls apart won't offer much protection. Wandering around hoping to find treasuresor in this case, problemsisnt a strategy when so much money is on the line. Stack boxes only on smooth, clean surfaces. Containers and packaging make up a major portion ofmunicipal solid waste (MSW), amounting to 82.2 million tons of generation in 2018 (28.1 percent of total generation). For example, at 50% relative humidity (RH) a corrugated box is at 80% of its potential stacking strength. SRI also provided recycling data for steel containers and packaging. Number 8860726. EPA estimated that the generation of these glass containers was 9.8 million tons in 2018, or 3.3percent of MSW generation. How the unit load is designed and interacts with material handling, packaging and transportation go a long way to determining the extent, if any, of damage. Implementing this GMP means having a total control system in place in each manufacturing plant. First, learn whether the damage occurred in manufacturing, distribution or in transit.