How It's Made - Cardboard Boxes

www.interplas....
Cardboard boxes come in a wide variety of sizes shapes and colors but most share three basic structural components. One wavy sheet of paper called a flute, that is sandwiched between two flat sheets called liners. Together they form what's called a corrugated board. Production starts with a massive role of partially recycled paper. The width of the paper varies depending on the size of the boxes their making. Several feeds a machine called the corrugator. The machine presses the paper between two ridged rollers and is blasted with hot steam. This shapes the waves of the flute. Another roller applies glue to one side of the flute. The glues main ingredients are water and starch, which won't contaminate fresh produce the boxes may later contain. Next, the machine adheres one-liner sheet and then the other. The waves create an air cushion between the flute and the liners, strengthening the board. For added strength, some boxes have a double liner. www.interplas.c... Two flutes and three liners. The flutes may vary in thickness for more cushioning. The factory uses partially recycled paper for the flutes because it is more malleable than nonrecycled paper. A razor-thin circular saw trims each side. The corrugator machine then cuts the board up to nine times depending on the size of the box they are producing. The corrugator final function is to separate the boards into layers using flexible tongs called fingers. Workers do a quality control check before sending the boards off for printing. The next machine stacks the boards into piles of between twenty-five and eighty depending on their thickness. This machine also feeds one board at a time to the upcoming equipment. It does at lightning speed at a rate of up to eight thousand boards per hour.
First, the trimmer perforates the boards to create flaps and handles. Rubber sponges cushion the blades so that they only cut the parts they're supposed to. During the trimming, a press condenses the boxes overlapping panels to level out their thickness. Workers usually cut out the sponges by hand to make sure they fit snugly around the blades. The trimmer runs at a speed of eight kilometers per hour. Processing up to ninety boxes a minute. Workers send the cut-offs back to the paper mill to be recycled as many as six times over.
A folding machine now bends them along score lines that the corrugator made earlier. It then applies cold glue to the sections that will join together to form the box. Hot glue on the cardboard is wax coated. The next machine folds over the glued sections. They are invisible once the box is finished. Another machine stacks the boxes in piles. A separator arm moves the boxes to trays called skids, for shipping.
The printing of the boxes began in the factories ink kitchen. Computer-guided dispenser squirts out different shades of ink following a precise recipe to create a particular color one of five thousand in the pallet. One pail holds about twenty kilograms of printing ink. Enough for about two thousand boxes, depending on the coverage needed. The factory uses water-based ink because it dries instantly. The printing press applies the ink to the boards one color group at a time, through four consecutive stations. This factory uses a flexographic printing system. A process that can print drawings and illustrations. Some companies use a lithographic press which can also print photographs.
Back on the trimming line, more complicated types of box flaps and handles require what is called a flatbed trimmer. It holds the boards in place with suction while making intricate perforations. After removing the trimmed bits workers give the boxes one last quality check. Then they stack them and send them off to the warehouse

[@meters_and_madness]

Diecut flexo operator here.. sitting in the break room at the box plant watching how boxes are made. Trying to figure out where I went wrong in life.

[@InternationalPlastics]

Sorry to hear that Jack.

[@bored.in.california2111]

Could be worse. At least you still have your sense of humour

[@chikoritafan5830]

I wonder if you still work there or moved on to a different job?

[@frostyant7621]

Found this after thinking about if people order cardboard boxes online and if they come in boxes, or a box of the specific type they wanted. Then, I wondered, how are cardboard boxes made?

[@samstephens7688]

Sounds like you found the good stuff 😉

[@jessickalush3305]

The background music is a banger!

[@jadond.3913]

About to be working for Valley Packaging, thought about getting acquainted with the process. Very informative

[@FS28_]

Did any of your workers had there hands chopped off by the machinery and that hand started crawling around and strangle everybody?

[@Slai.]

furrysega7 Simspon refrence :D good.

[@InternationalPlastics]

Furrysega, thankfully this has not happened.

[@lukez9721]

lol but what if it did? That would be like scream but in real life

[@ahoorakia]

only when they change the blades ,they ask for volunteer employee, to check the sharpness!! LOL come on jack it's your turn today, put your hands here for second!!

[@jianniaponte9235]

This is the best video I have ever seen

[@UrlacherBears54]

DAMN YOU! A BOX!

[@InternationalPlastics]

Ummmm, okay?

[@barmbailey6934]

Are the boxes assembled in Flint Michigan?

[@corn_eel710]

Cool! never thought about this before, very educational

[@eddieinthebed]

Thank you algorithm for this informative video

[@InternationalPlastics]

You are welcome Jane.

[@stevekapschock6785]

Solid Snake thanks you! **thumbs up**

[@InternationalPlastics]

You are welcome Steve.

[@yaujj65]

This comment section is the best while the commentators made good jokes, the channel reply to the comments to make it funnier.

[@youssefwang2781]

yes! like this

[@jessickalush3305]

I found it nearly impossible to not hurt myself watching this.

[@irishnessie]

When can we see a finished box sir?

[@InternationalPlastics]

We have boxes ready to purchase immediately. www.interplas.com/corrugated-boxes

[@InternationalPlastics]

Killer Queen, boxes are available for order immediately and having them delivered depends on what one might be willing to pay for expedited shipping charges.

[@parkel69]

Oh we don't do that here. They're assembled in flint michigan

[@isaiahwolftail867]

Lol

[@richardbowers3647]

You have to purchase that machine separately & it's called a "box-forming" machine!!!

[@brandonnn7443]

*It is here that the boxes reach their final state of assembly.*

[@davidmiller9619]

I got here because of an old Simpsons episode...anyone else?

[@chincheek1]

LOL same

[@Slai.]

David Miller yeah.

[@jqckiscool]

OMFG no way you two

[@punnycomixcommentates2573]

David Miller i got here through extensive looking. first i tryed typing in how to make cardboard then i tryed doing alot of various kinds of that

[@youssefwang2781]

@@punnycomixcommentates2573 hhhh,yes ! The average person will not know what the corrugated carton refers to specifically, only the carton and the carton

[@Jgatti41]

1st off these are not cardboard boxes. Your cereal is packaged in a cardboard box. This is corrugated fiber board. There is a difference.

[@thibautmanchon4852]

Very interesting, thank you!

[@luisventura8506]

Very useful, thank you!!

[@Aqibengineerig]

Where can I get this machinery..as I am interesting in this business

[@InternationalPlastics]

Kashmir, we certainly wish we could help you out. Unfortunately, we do not sell the machinery, that makes boxes. Thank you for your question, we wish you good luck and all the best.

[@vinnymusewu3062]

did you figure out where to get it?

[@lsznlszn4073]

We are Die Cutting Machine factory. our videos for your reference: kzbin.info/door/VLdAtwDmw49bkdBPp9zWdg?view_as=subscriber. more details, Please contact: whatsapp: [phone]

[@BrianWASD]

Idk why im here i literally make boxes for work

[@rukhsanazeeshan2928]

How we can purchase this machine

[@beieber4life]

Those are corrugated boxes, cardboard is so different

[@InternationalPlastics]

For most people who are not in the industry or are not as educated about the difference cardboard and corrugated, there isn't much of a concern. This video is more for general education. Thanks for your input.

[@williams.w7281]

is it safe when people are around the working machine?

[@InternationalPlastics]

If the machine is used properly, yes.

[@leonabi-5]

yes it is totally safe.

[@sevgikadir8700]

So satisfying

[@InternationalPlastics]

We agree. Thanks.

[@andrewmueller8760]

Very interesting video

[@InternationalPlastics]

Thanks for visiting

[@undeadpharoah]

Do any of THESE boxes have candy in 'em?

[@youngmasterzhi]

No…

[@jedinite241]

[@MrArtVendelay]

40 years I am in this industry. This video is filled will inaccuracies.

[@InternationalPlastics]

Interesting. What might those be?

[@MrArtVendelay]

The product is called corrugated, not cardboard. The wavy sheet is called corrugated medium, or just medium. It is not called flute, however it is fluted. The width of the roll of linerboard doesn't vary based on the boxes it varies based on the width of the narrowest part of the Corrugator. The fingers on the downstacker doesn't separate the sheets, that is done by the knife. The fingers just keep the sheets from buckling upwards as they move thru the downstacker. The rubber sponges, or ejection rubber insure the sheet does not get stuck to the die. At the same time, the narrator talks about leveling their thickness, but that is not done on the machine shown which is a rotary die cutter. Crushing of the glue flap or it's opposite panel is not done on an RDC but on a Flexo folder gluer where the crushing take place. The folding machine or Folder Gluer does not fold the sheet with the scores made on the corrugutator. To the contrary it folds the along the scores perpendicular to the corrugator scores which were either die cut into the sheet with scoring knife put in on another machine like a slitter/scorer or put in by the scores on a Flexo Folder Gluer or Printer slotter but definately not by the corrugator. The same machine Glues, folds and stacks the boxes. It normally will count the boxes and kick them out when they reach the required count, normally 25, Then a pile of 25 is ejected from the machine and heads automatically to a bundling machine. Nothing of great consequence wrong here. Just a series of inaccuracies. The flat bed and rotary die cutters are not called trimmers.

[@InternationalPlastics]

MrArtVendelay, You are quite correct on all accounts. Suppose this video is more educational to those individuals who may not know the difference and that don't get caught up in the semantics. It was really great of you to give such a detailed explanation of corrections and where the video is a bit misleading. However it does a pretty nice job of keeping something that could be rather boring, a bit more on the interesting side.

[@shawngrubb9287]

@@MrArtVendelay a rotary could crush the glue lap/trim panel if you're using cork on the die board. Some of our customers require extra crush for unit stabilization that the pull collars in a flexo or the crush rolls in a folder gluer usually can't crush as well as desired. Agreed about all of the inaccuracies though, and although it's "meant to be an educational video" and supposedly using more general terms etc doesn't mean it needs to be flat out wrong about so many things. My guess would be someone in marketing made this video and has very limited knowledge of actual corrugated or how boxes are made. I see it a lot when dealing with office staff vs floor employees.

[@aday1481]

thanks !

[@InternationalPlastics]

+Yada Discharoen Thanks

[@richardbowers3647]

Card board is not corrugated!!! Also The box forming is not shown here!!! Check it out???

[@InternationalPlastics]

Richard you make a very good point. Suppose the video is aimed at more educating the general public and to drum up more interest. Only us in the industry know that it is referred to as corrugated, but we don't really need a video like this, do we? Well, hopefully not. Ha ha.

[@1sniper1wolf1]

Solid Snake wants to know your location.

[@InternationalPlastics]

www.interplas.com/

[@luckyzhao9157]

so good

[@robee2461]

ben i holi

[@InternationalPlastics]

Thank you.

[@sunildiver1988]

how much this machine will cost

[@InternationalPlastics]

Unfortunately, we are not a seller of corrugated container converters, and therefor unable to answer your question. Thank you for asking.

[@leonabi-5]

hello sir ,we are professional carton box machine manufacturer from China, including 3ly/5ly/7ly TSH corrugated cardboard production line and high speed FLEXO printing slotting die-cutting machine, the TS-Automatic folder gluer machine and the BZJ-S Automatic /semi automatic flute laminator，and all kinds of accessories. if you are interested please contact me (Whatapp :15731668108, E-mail: andybi157959252163.com) or give me your e-mail dress or cell-phone number i will send you more details.

[@gauravkumarsharma9526]

@@leonabi-5 how much does the machine cost

[@leonabi-5]

@@gauravkumarsharma9526 hi, thanks for your inquiry, friend, can I know which machine you are interested? or do you use whatsapp or wechat? my number is 0086-15731668108 thank you.

[@vinnymusewu3062]

@@leonabi-5 I need more information as I am interested in machinery. email [e-mail]

[@ankitgarg6163]

What will be the price of the plant?

[@InternationalPlastics]

to what plant are you referring?

[@termsofuniverse7251]

I'm here because UPS tried to charge me $25 for a cardboard box...

[@RD-wx3zg]

Box fort.

[@InternationalPlastics]

SSSSSSSSWWWWWWWWWWEEEEEEEEEEEEEEETTTTTTTTTTTTTT

[@annapotat0987]

why do i kinda wanna eat it now

[@Ssouth18]

When I see a cardboard I just want take a bite dont know why

[@Chris-rg6nm]

I came here after throwing away some Amazon boxes, thinking why don't they buy boxes back. Think about all the wasted energy creating a box, someone using it for 1 day, then breaking it down and it getting turned into pulp, just to have made into a box again.

[@NK-fx1qs]

im here because amazon won't disclose the amount of waste caused by 2 day shipping - are boxes expensive to make by the millions (amazon doesn't reuse boxes)

[@tsg7official]

*Bridgett wants to know your location*

[@InternationalPlastics]

185 Commerce Center Greenville SC 29615

[@Jack-ox7lv]

:o

[@yawbus690]

This video is accurate but at the same time its not

[@imchangingaccountnoreason1103]

looks like a roof

[@InternationalPlastics]

Interesting! Didn't see that until you mentioned it. Nice observation.

[@mywa8314]

I work at a cardboard factory...It fucking suks!

[@irmasanchez5274]

Partially recycled paper is extremely toxic. It includes all the glossy boxes, color dyes, etc.

[@shawngrubb9287]

Actually, it's not. The majority of recycled paper is made to be food grade and contains no toxins. The ink used is also food grade and is regulated so that there are no toxic additives. The kemi liner("glossy boxes") is also not toxic and follows the same guidelines. All of that is pretty highly regulated by the FDA and other regulatory agencies to ensure no toxic chemicals can be introduced into any food these are used to ship in. The only actual issue with recycled liner generally is its smaller fiber size which results from the recycling process, which can cause poor printing and generally is weaker than virgin paper so it tends not to fold or cut as well. However the upsides are faster adhesion bond to glue, lower porosity(which is a big deal with a lot of newer case erectors that use suction to pick up the cartons to feed through) and some others.

[@bitchdontkillmyvibe5964]

i was high so i looked this up but imm still high 🔆

[@lucindathefaithful7599]

“ISN’T THERE ANYTHING ON THAT ISN’T ABOUT BOXES?!”

[@andrewmueller8760]

Very interesting video

[@InternationalPlastics]

Glad you think so!

[@messijaffa2693]

"Class, instead of going to the box factory today, we'll be going to the...box factory!"

[@InternationalPlastics]

Ha ha. We will see you there.

[@youngmasterzhi]

Damn Tv ruining my imagination like a--ummm-uhhhh…uhhh

[@kimfrankwatson4688]

I work in a box making factory now! There are some things that are wrong here, lol - when the boxes are being folded, it's along score lines that the machine they're going through made. The corrugator made score lines going through the length of the box, not the width.

[@InternationalPlastics]

Kim Frank Watson, Those are some great points you've mentioned. Thanks.

[@BrickTamlandOfficial]

what i dont get is how the boxes I have dont show a part where the sides come together. like in the video there is a tab that is glued down to make the 4 sides of the box connect but the boxes i get dont have any tab on it anywhere so its like all one square piece. how do they do that?

[@starstruckt]

so how did u come across this video ??

[@sublimeade]

Do any of these boxes have candy?

[@Yotsukaido]

The story of how two brothers and five other men parlayed a small business loan into a thriving paper goods concern is a long and interesting one.

[@ellycehill3904]

I’m here bc I was drinking a milk carton and I was wondering how it was made and then I realized it was cardboard and I started thinking “how was coardboard made"

[@Jgatti41]

Should find a video that shows how cardboard is made. This video does not show that process of how cardboard is made.

[@RavenwolfFoxtrack]

I'm the truck driver that brings the used cardboard bails to the recycling plant that turns the old cardboard into new roll stock, that I then take to the plant that turns the role stock into new cardboard boxes.

[@CesareVesdani]

Cardboard boxes are amazing.

[@InternationalPlastics]

We agree. For as "simple" as they are, they are an amazing product!

[@mn_mt0964]

Corrugated fiber board..... if you know you know so funny

[@box.cardboard]

thank you

[@CerebralAilment]

SPOTTED THE CAT

[@fxmz8396]

@@CerebralAilmentlmao 😂

[@cyberen]

This room is the most popular one in our factory.

[@InternationalPlastics]

Cyberen, that is an interesting fact that you have let us know. Thank you.

[@isaiahwolftail867]

Lol

[@pearlsoyster7845]

This industry is on my interest !!!

[@yawbus690]

I work in the industry

[@christiansalmeron8424]

I ended up here because I’m High

[@shawngrubb9287]

While I appreciate the video, as someone who's ran various flexos and die cutters amongst other machines, some of this video just hurt to watch. As soon as I got to the point where they said about why companies use recycled liner I wanted to throw things because of how incorrect the reasoning was. And then when I hit the part about rubber being used on die boards to make sure only the parts of the board are cut that they want to be...I nearly threw a chair. I understand the video is meant to be for general knowledge for inexperienced people, but at least have knowledgeable people make videos and not just make false claims to sound good.

[@InternationalPlastics]

Shawn, thank you for pointing those items out and hopefully those particulars will be taken note of by the viewers of the video. You are right, this is certainly for general knowledge and much more simple terms that are more readily understood needed to be used because of the amount of time that all of this information was needed to be crammed into this video. Hopefully, the video does enough of a good job, even though it is not perfect, that it helps to educate and entertain the viewer. just enough. Thanks again for all of those years you put in and for making the rest of us aware of those items that need to be considered.

[@redblade8160]

Shawn Grubb The rubber sponges is to push the material off the cutters, thus, stopping the material sticking to the blades.

[@mn_mt0964]

I work for Menasha this video needs lots of help

[@shawngrubb9287]

@@mn_mt0964 watching this again I just noticed the part about folding the boxes along the scores put in by the corrugator 🤣 must be a fancy corrugator that's able to put in scores in the same direction as the flutes.

[@mn_mt0964]

For real I mean they can do lines but the reason isn't for the machine to fold that's why we use die boards to make lines and cut lmfao

[@mariozaragoza1758]

I was high searching for this no other reason 😂

[@bloopydude227]

oh, the curious high mind 🎀🍃

[@armandomeza3501]

Cmon line that up you’re gonna jam me up on the knife! Hahaha

[@michaelmccray3207]

You're watching this because you're BORED

[@cranke99]

👍

[@dreamersparadise919]

Not in my case. I came here so I can figure out why the shopkeepers hand me a thin piece of weak cardboard when I ask for the type which is used in packages.

[@piranhaplant1238]

I ❤️ cardboard

[@box.cardboard]

thank you

[@jodymortimer5014]

i used work in a factory we would stack it by hand robot s and taking away jobs

[@kingofthenattys8740]

I'm only here because of my design and technology a level which was probably made in the 10th century like this video

[@InternationalPlastics]

Ha ha.

[@LaughOutFrikinLoud]

1:50 and here I am running 19,000 per hour

[@magicraftmods1945]

That was pretty interesting, so I'm glad I stumbled upon this!

[@InternationalPlastics]

Thanks Magicraft Mods. Our aim is to help provide a better understanding of flexible packaing.

[@ethanator4051]

*insert dislike number* squidwards didn't want to watch stuff about boxes

[@noir66146]

our society uses so many boxes, but hasn't evolved into differentiating between boxes containing clothe fabrics and food yet huh ? just hit em with a one size fits all every single time right ?

[@redblade8160]

Lots of things are wrong in this video, even the narrator has been told the wrong things to say...

[@beng9690]

Corrugated.

[@stanpatterson5033]

Somebody edited out the tail end of the episode where all of the puns usually are....

[@salvadorda5792]

San po Ang location nyon po para ako nalang pupunta po

[@InternationalPlastics]

Greenville, South Carolina, USA. or you can visit www.interplas.com

[@CSDM15]

@@InternationalPlastics bro that’s where I’m from

[@box.cardboard]

my home

[@mn_mt0964]

Can someone go to the basement grab the board stretcher plz

[@lincongielis3234]

Thanks for letting me know the info

[@InternationalPlastics]

You are very welcome

[@alexanderthegreat2678]

Boxen

[@ibrahimvardag7638]

Where can I get free cardboard

[@InternationalPlastics]

Craigslist will usually have people offering some for free.

[@sammyreynolds8873]

Very interesting 🌾🌼

[@InternationalPlastics]

yers it is.

[@Big_Chico]

But how is the paper made🤔

[@sergeilosev1416]

i work as at factory😊😊

[@akhtarsahi3451]

Job corrugated

[@someone-if8ce]

Can i have 30 of those pls pls pls pls 😔😔😔😔

[@InternationalPlastics]

Wish we could just give our products away but we wouldn't be around too long. 😀 since we have the lowest guaranteed price you can be rest assured that if you decide to order 30 boxes from www.interplas.com/corrugated-boxes they will be at the lowest price possible

[@stjimmy3623]

8000? That’s slow. I was running the Martin Transline between 10-14,000 an hour. 😏

[@mn_mt0964]

I run a boost max speed 11k

[@mn_mt0964]

Bobst

[@orangutan8125]

*BEN* has learned something

[@box.cardboard]

hello

[@healthkitchen9058]

Thank u for sharing😀😃😀😃😀

[@InternationalPlastics]

Thank you, Mahalakshmi. We are always glad to help expand the knowledge of any flexible packaging product.

[@luisteran6326]

BHS 110 INCH WET END OPERATOR HERE 💪

[@xxxuchihairl9732]

Im bet all the board you make is warped to fuck

[@emperorhobbes4443]

Box, I like

[@InternationalPlastics]

Glad you do Emperor.