Common Issues in Corrugated Boxes and Solutions

Introduction

Corrugated boxes, as one of the most widely used packaging materials globally, are favored for their lightweight, cost-effectiveness, and recyclability. However, issues such as structural deformation, poor adhesion, and printing defects frequently occur due to design flaws, material limitations, or environmental factors. This article analyzes common problems in corrugated boxes and provides practical solutions to enhance quality control.

1. Structural Design Issues

1. Bulging or Swelling

Phenomenon: Expansion of box sides or tops, reducing stacking stability.

Causes:

Inappropriate Flute Selection: Type A flutes offer vertical compression resistance but weak planar strength, leading to deformation during transportation.

Excessive Stacking Load: Long-term static pressure causes "creep" in bottom-layer boxes.

Inaccurate Height Design: Insufficient height tolerance (e.g., only 2mm higher than the product) worsens deformation.

Solutions:

Use Type B or C flutes for balanced strength;

Limit stacking height and reinforce bottom layers;

Optimize box dimensions considering dynamic pressure.

2. Score Line Breakage

Phenomenon: Cracks along fold lines, weakening box integrity.

Causes:

Incorrect pressure from scoring rollers;

Low-quality base paper with poor fiber strength.

Solutions:

Adjust roller pressure and adopt dual-stage scoring;

Select high-tensile base paper to avoid over-folding.

2. Material and Production Issues

1. Corrugated Board Warping

Phenomenon: Curvature in transverse or longitudinal directions.

Causes:

Moisture imbalance between liner and medium layers8;

Improper tension control during production.

Solutions:

Balance moisture via spraying or preheating;

Optimize tension systems and reduce single-face board accumulation.

2. Poor Adhesion

Phenomenon: Delamination of board layers ("false bonding").

Causes:

Unsuitable adhesive formulation (e.g., mismatched gelatinization temperature);

Worn corrugating rolls or insufficient glue application.

Solutions:

Adjust adhesive temperature seasonally (55–57°C in winter, 57–59°C in summer);

Replace corrugating rolls after 3 million linear meters of production.

3. Printing and Appearance Issues

1. Blurred Printing or Plate Smudging

Phenomenon: Fuzzy edges or merged graphics.

Causes:

Excessive printing pressure crushing flutes;

Ink penetration reducing board strength.

Solutions:

Avoid printing near score lines; use low-pressure rollers;

Print small graphics first, followed by large-color blocks.

2. Layout Design Errors

Phenomenon: Incorrect text or non-compliant symbols.

Causes:

Ignorance of national standards (e.g., GB190-85 for hazardous goods);

Inadequate proofreading.

Solutions:

Adopt standardized templates with 20mm edge margins;

Implement a three-stage proofreading process.

4. Storage and Transportation Issues

1. Humidity Damage

Phenomenon: Reduced compression strength due to moisture absorption.

Causes: Warehouse humidity exceeding 40% softens fibers.

Solutions:

Control humidity using desiccants;

Adopt "first-in-first-out" inventory management.

2. Transportation Damage

Phenomenon: Crushed corners or cracks.

Causes:

Rough handling or tilted stacking;

Mismatch between box strength and cargo weight.

Solutions:

Use palletized transport to minimize manual handling;

Conduct simulated stacking tests (e.g., ISTA standards).

5. Quality Testing and Improvement

1. Key Testing Metrics

Compression Strength: Simulate stacking to verify load capacity;

Edge Crush Test (ECT): Measure vertical load resistance;

Puncture Resistance: Evaluate impact protection.

2. Continuous Improvement Strategies

Automate production to reduce human error;

Regular staff training on quality control5.

Conclusion

Addressing corrugated box issues requires a holistic approach spanning design, production, and logistics. By adopting advanced materials, optimizing processes, and implementing rigorous testing, manufacturers can enhance product reliability. Future trends will focus on lightweight eco-friendly designs and AI-driven quality management systems.