Cardboard Production Process: From Fiber to Packaging

Cardboard is an indispensable material in the modern world, widely used in the manufacture of packaging, boxes and industrial products. Its versatility, durability and recyclability make it a sustainable option for various applications. But how is cellulose fibre transformed into the cardboard we see every day? This technical and sophisticated process combines advanced technology and a strong commitment to sustainability. In this note, we explore the fundamental stages of the cardboard production process, from raw materials to the final product.

1. Collection and Preparation of Raw Materials

The process begins with the collection of raw materials, mainly cellulose fibres from sources such as virgin wood and recycled paper. The combination of these fibres ensures a balance between strength, flexibility and sustainability.

• Virgin fibers: They come from sustainably managed trees on certified plantations.

• Recycled fibers: They are obtained from recycled paper and cardboard, reducing the need for natural resources and the environmental impact.

Once harvested, the raw materials are transported to the production plant for preparation.

2. Pulp Production

At this stage, cellulose fibers are converted into pulp, the basis of cardboard. The process may include:

• Chemical method: Used to produce high quality fibers, ideal for outer layers of cardboard that require greater resistance.

• Mechanical method: More efficient, but produces less resistant fibers, suitable for the inner layers of cardboard.

Recycled fibers are broken down in water to form a pulp, removing impurities such as ink, adhesives and staples through flotation and screening processes.

3. Sheet Formation

The cellulose pulp is diluted with water and spread onto a moving belt in a sheet forming machine. At this stage, the fibres begin to interlock as the water drains away, forming a wet sheet of cardboard.

The thickness and characteristics of the sheet are adjusted according to the type of cardboard to be produced, whether corrugated cardboard, solid cardboard or recycled cardboard.

4. Pressing and Drying

The wet sheet passes through press rollers that remove excess water and compact the fibres, improving the density and strength of the board. The sheet is then dried using heated rollers or air dryers, reducing the moisture content to the appropriate level to ensure dimensional stability.

5. Lamination and Corrugation (in the case of corrugated cardboard)

If the final product is corrugated cardboard, the dried sheet is subjected to a corrugating process in which waves or flutes are created by heated rollers. These waves provide strength and cushioning to the cardboard.

Corrugated cardboard is formed by combining layers of smooth paper (liners) with flutes using adhesives, creating single-, double- or multi-faced cardboard-like structures, depending on the application.

6. Cut and Format

The produced cardboard is cut to the dimensions required for its end use. Cuts may include specific shapes for boxes, trays or other custom products. This step ensures that the cardboard meets the customers' design and functionality requirements.

7. Printing and Finishing

For products that require visual or informative elements, such as packaging boxes, cardboard is subjected to printing processes using techniques such as flexography, offset or digital printing. These processes allow for the addition of logos, graphic designs, instructions and barcodes.

Additional finishes, such as laminates or coatings, are applied as needed to improve the durability, water resistance, or appearance of the board.

8. Quality Control

Each batch of cardboard undergoes rigorous quality controls to ensure it meets technical specifications and customer standards. Tests include crush, tear and burst resistance, ensuring a reliable and functional product.

9. Packaging and Storage

The finished cardboard is stacked and wrapped for easy transport and storage. Storage conditions are controlled to protect the cardboard from moisture and ensure that it reaches the customer in optimal condition.

10. Distribution and Use

Cardboard is distributed to companies in various sectors, such as retail, the food industry, electronics and logistics. Its versatility and sustainability make it an ideal solution for a wide range of applications.

Commitment to Sustainability

Cardboard production is a prominent example of a circular economy. The industry integrates sustainable practices, such as the use of recycled fibres, the optimisation of water and energy resources, and the reduction of carbon emissions. In addition, cardboard is 100% recyclable and biodegradable, which minimises its environmental impact.

Conclusion

The cardboard production process combines technology, precision and a firm commitment to sustainability. Each stage, from the collection of raw materials to distribution, is designed to guarantee a high-quality product that meets market needs and respects the environment.

At Acciomate Engineering & Projects , we offer engineering and project services that optimize each stage of this process, helping companies in the paper and cardboard sector to improve their competitiveness, efficiency and sustainability.