Cardboard Box: How is it Made? Inside the Factory

Starting from kraft paper to the cardboard box. Find out how they are produced inside this incredible factory
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The cardboard box has many uses, but the main one is the transport of objects.
To learn about the production stages, we will visit the Georgia Pacific factory located in the United States. It is one of the leading companies in its sector.
Let's find out how the box is made from corrugated cardboard.
Corrugated cardboard is produced from reels of kraft paper. The equipment that does this transformation is known as a corrugator. Each part of the cardboard is made with different grades of fibers.
The cardboard cover uses long fibers, which are found in softwoods.
In the core, papers with short fibers coming from harder wood are used.
The first step of corrugated cardboard is to join its cover with the corrugated core.
For this, the paper sheet with short fibers passes through a system of gears through which this corrugation is made. The whole process is done with high temperature and pressure. This way the cardboard is firm and resistant.
The cardboard cover is passed through a pressure roller, which presses it onto the corrugated paper. With the correct temperature and pressure, the parts are joined together perfectly through the glue.
The result is known as plain corrugated cardboard.
Looking in more detail at the manufacture of the core, the kraft cardboard passes through a bridge, for the application of the cover.
The bridge allows production to not stop, even if one of the coils runs out. This equipment is known as a splicer.
Its function is precisely to change a coil with another in the process, avoiding losses and stops for its exchange.
The paper also passes through a system of preheated rollers before joining it to the cover.
The simple corrugated cardboard is taken by conveyors to the machine that will apply the second layer.
In this diagram we see that one of the units transfers the plain corrugated cardboard together with the liner in another unit to form the final corrugated cardboard.
If the cardboard to be manufactured is double-walled, then the unit provides another layer of single corrugated cardboard.
Looking at the equipment, the simple corrugated cardboard passes through other preheated rollers.
Where the glue is applied where the other wall will go.
This wall is usually the outside of the cardboard. This is where you define whether the color will be brown or white.
The cardboard also passes through a system of heated mats so that the glue dries properly.
The cardboard passes through a cutter, which cuts it to the specified width.
Finishing the manufacture of corrugated cardboard, it is cut into sheets.
The dimensions of the cardboard sheet correspond exactly to the order placed.
It is on the conveyor belt itself that the sheets are prepared for stacking.
The stacks are formed in a lifting compartment.
Another set of mats take them out for quality control. From here they are prepared for storage and transport.
At the cardboard box factory, the sheets are prepared for their final purpose.
These machines prepare the artwork and dimensions of the boxes.
There are two types of cardboard box production: rotary cutting and flexo cutting.
In the flexo equipment, the boxes are glued and printed. As for the rotary ones, they remain open and are manually closed at the customer's location. They are usually pizza boxes for example.
In flexo machines, it is possible to print more than one box on the same cardboard sheet, optimizing the process. Meanwhile, in rotary cutting, only one box per sheet is made.
Each set of machines receives the cardboard sheets through the infeed conveyor.
Robotic carts feed the machines' stock with the defined plates.
The sheets are loaded onto the machines by presses and belts.
The rollers that feed the machines are made of a material that does not damage the cardboard.
A vacuum system forces the cardboard through. While the art print is done.
#cardboard box #manufacture
00:00 Cardboard box factory
01:20 Cardboard making
05:30 Cut into sheets
06:38 Boarding of plates
07:17 Making the cardboard boxes
11:51 Packing the boxes
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