Paperboard

Guide
 Contents

Contents 2 7. End uses 36

Introduction 3 7.1 Graphical 39

1. Information about Stora Enso and 7.3 Chocolate and confectionery 41
Consumer Boards 4
1.1 Stora Enso in brief 5
1.2 Stora Enso Consumer Boards 6
1.3 Sustainability in packaging 7
2. Paperboard making and
paperboard grades 8
2.1 Paperboard making 9
2.2 Paperboard grades 11
3. Barrier coating 15
4. Paperboard handling
recommendations 18
7.2 Beverage and multipack 40
7.4 Cigarette 42
7.5 Cosmetics and luxury 43
7.6 Detergents and household 44
7.7 Food 45
7.8 Pharmaceutical 46
7.9 Food Service 47
7.10 Liquid 47
8. Stora Enso Consumer Boards production
and service facilities 48
8.1 Paperboard mills 49
8.2 Extrusion coating plants 51
8.3 Partner services 52
9. Testing methods 53

5. Printing methods 19 10. Glossary 57

5.1 Offset printing 21

5.2 Gravure printing 22
5.3 Flexo printing 23
5.4 Inks 24
5.5 Digital printing 25
5.6 Practical printing instructions 26

6. Converting and Finishing 28

6.1 Varnishing 29
6.2 Embossing 31
6.3 Hot-foil stamping 31
6.4 Die-cutting and creasing 32
6.5 Glueing 34
6.6 Lamination 35

Paperboard Guide
 Introduction

Creating innovative packages and bril-
liant graphical products from advanced
paperboard materials is both a science
and an art. As a rule of thumb, the sky
is the limit as to the implementation of
artistic designs or demanding print-
ing and finishing effects. However, the
more we know about the behaviour of
paperboard in various refining processes
and individual end use environments,
the better the result.
accurate information that helps make
excellence out of the ordinary.
As is characteristic of educational
material, a lot of the subject matter
deals with concepts, definitions, ab-
breviations and principles. In addition
to explaining the basic vocabulary, the
Guide presents an overall picture of the
paper-board world and clarifies some of
the key issues related to it.

This Paperboard Guide has been

compiled to that very end – to serve
our partners and their customers with

Welcome to the enchanting world of paperboard.

Pasi Ahokas
VP, Graphical Boards

3 Paperboard Guide << Contents

 Information
about Stora Enso

and Consumer Boards

<< Contents Stora Enso Consumer Boards 4

Information
about Stora Enso
and Consumer Boards
1.1 Stora Enso in brief
Stora Enso is an integrated paper,
packaging, and forest products company,
producing publication and fine paper, Customers include publishers, printing houses, and mer-
packaging board, and wood products
– all areas in which the Group is a global tion industries – and are mainly concentrated in Europe,
market leader.
Stora Enso’s sales totalled EUR 13.2 billion in 2005.
The Group has some 46 000 employees in more than
40 countries on five continents. Stora Enso has an annual
production capacity of 16.9 million tonnes of paper
and board and 7.7 million cubic metres of sawn wood
products, including 3.3 million cubic metres of value-
added products. Stora Enso’s shares are listed in Helsinki,
Stockholm, and New York.
committed to
sustainability
5 Stora Enso in Brief
Stora Enso serves its mainly business-to-business custom-
ers through its own global sales and marketing network.
A global presence provides local customer service.
chants, as well as the packaging, joinery, and construc-
North America, and Asia. As Stora Enso moves into the
future, the Group is focusing on expanding its opera-
tions in new growth markets in China, South America,
and Russia.
The Group has production facilities in Europe,
North and South America, and Asia. Modern produc-
tion capacity, combined with efficient raw material and
energy sourcing and efficient processes, ensure excellent
continuity of production.
Stora Enso is committed to sustainability – economic,
environmental, and social responsibility underpins our
thinking and our approach to every aspect of doing busi-
ness. The Group builds accountability into its operations
by being transparent and engaging in open dialogue
with its stakeholders. Group-wide targets and clear
governance are used to monitor and measure how well
Stora Enso performs in terms of sustainability.
<< Contents

1.2 Stora Enso Consumer Boards
– providing packaging solutions worldwide
Fibre-based materials enjoy a strong and well-deserved
status in the packaging world. Paperboard is smooth
and strong, light and bright, versatile and cost-effective.
A generous printing surface and superb print quality
makes paperboard cartons ideal information carriers and
brand builders. Reliability in high-speed filling lines saves
money and minimizes production downtime. Renew-
able fibres also make a particularly well-founded choice
environmentally.
The ultimate challenge, however, lies in using the full
potential of the material intelligently and innovatively
to create solutions and concepts that will have a com-
petitive edge – in product protection, material savings,
production and logistics costs, trade preference, con-
Stora Enso Consumer Boards
Liquid Ambient Liquid Fresh
<< Contents
Information
about Stora Enso
and Consumer Boards
sumer acceptance, shelf presence or recycling efficiency.
Such solutions do not materialize out of thin air. They
stem from active interaction with the whole packaging
community. And that is where the offering of Stora Enso
Consumer Boards really comes into its own.
We produce a wide selection of paperboards in every
category and provide the largest variety of polymer coat-
ings. We have strong and modern pulp and board mills
that, together with our sales staff and ServiceCentre fa-
cilities, ensure consistent quality, fast service and reliable
deliveries. But even more than that, we are committed
to vertical innovation in the way we cooperate with our
partners across the board to promote the efficiency and
sustainability of fibre-based packaging.
Stora Enso Consumer Boards 6
Information
about Stora Enso
and Consumer Boards
1.3 Sustainability in packaging
Sustainable development in packaging means solutions
that satisfy present needs in an optimal way without
compromising the ability of future generations to meet
their own needs. Fibre-based boards provide a powerful
means of achieving those goals throughout the pack-
age’s life-cycle. Here are some of the basic issues:
Wood, a renewable and recyclable resource, is the main
raw material in our packaging boards. We apply the prin-
ciples of environmental and social responsibility for wood
procurement and sustainable forest management.
Paperboard is produced at an integrated mill, using
mainly renewable energy derived from the wood in the
pulping process.
Versatile and light paperboard packages prevent product
loss by effectively protecting packed materials against
7 Sustainability in Packaging
physical damage, contamination and light. Product in-
formation can be printed directly onto the surface of the
paperboard, so no extra labels are needed.
Space-saving designs are particularly economical in
transportation. Efficient logistics reduce fuel consump-
tion and emissions to the atmosphere.
Paperboard packaging is a valuable resource in itself,
with many potential uses. Packaging boards are made
from fibres with good strength properties and can be
recycled for a number of paper and paperboard grades.
In the case of polymer-coated boards, the plastic fraction
can be used for energy production, replacing fossil fuels,
or can be recycled when appropriate.
For a more detailed presentation of sustainability in pack-
aging, view the multimedia.
<< Contents
 Paperboard
making and

paperboard grades

<< Contents Paperboard making and paperboard grades 8

Paperboard
making and

paperboard grades

2.1 Paperboard Making

The basic principles of paper and paperboard making
have not changed for more than two thousand years.
Fibres gained from timber are evenly distributed in
water. Multiple layers of furnish are applied, one after the
other, on a wire. The water is drained from the pulp and
the layers are formed into a strong fibre mat. A smooth
surface is achieved by coating and calendering. The
excellent quality of Stora Enso paperboards is the result
of advanced technology and the use of high-quality raw
materials.

Raw Materials used for Paperboard Production

Chemical Pulp
Wood chips are cooked with appropri-
ate chemicals in an aqueous solution
at high temperature and pressure. The
objective is to dissolve the lignin and
separate the fibres intact. The pulp can
be used unbleached or bleached to the
brightness needed.
Mechanical Pulp
Groundwood
Logs of debarked softwood
are pressed against a rotating
grinding stone while water is
added in order to separate the
fibres.
CTMP (Chemi Thermo
Mechanical Pulp)
Wood chips are impregnated
with appropriate chemicals and
heated before separating the
fibres by a mechanical refining Secondary fibres
process. The pulp is bleached are gained from sorted
and washed in several steps. recovered paper or
board by purifying and
sometimes deinking and
bleaching.

Hardwood
Pulp made of deciduous broad-leaved
trees such as birch, oak, beech, aspen or
eucalyptus. Characteristic are the short
fibres.

Softwood
Pulp produced of Wet-end Additives
pine, spruce, or and Retention Aid
other conifers. The e.g. starch and aluminium sulphate.
fibres are long.
Sizing Agents
such as natural resin or synthetic
sizes are added to increase strength
and decrease absorbance.

Water
means of trans-
port and solvent.

Components Coating Colour

rheology modifiers

Pigments Latex
Natural coating pigments and Water dispersion of organic binder
fillers. Ground Calsium Carbonate for the coating pigment.
(GCC) and Kaolin Clay.

9 Paperboard making and paperboard grades << Contents

 Paperboard
making and

paperboard grades

Paperboard Production
The picture below illustrates one typical example of
paperboard machine lay-out.

Wire Section Press Section Pre-Drying Section

Wire Section: The web is formed in the wire section by pumping
a mixture of water and pulp from the headboxes onto the wire. The
water content is over 99%, which is why this part of a paperboard
machine is also known as the wet end. The water is drained off and
the fibres bond together. The individual layers of fibre are couched.
An even fibre formation is vital to ensure optimum strength, surface
smoothness and uniformity. After the wire section water content is
80%.
Press Section: In the press section, water is removed from the wet
web by mechanical compression in the nips formed by two rolls. The
removed water is received by a felt. After press section water content
is approximately 60%.
Pre-Drying Section: The paperboard web is further dried by a series
of steam-heated drying cylinders.

Pre-Drying Section Post-Drying Section 1 Coating Section

Glazing Cylinder Shoe Calender Post-Drying Section 2

Glazing Cylinder: The top side of the web can be smoothed by
contact with a Yankee cylinder having a highly polished surface or
with so called shoe calender. Not every paperboard machine has
these options.
Post-Drying Section 1 and 2: Additional reduction of moisture
content.
Coating Section: Depending on the quality required, the web can
be coated with one, two or three coating stations per side.

Reeler Section Winding Paperboard Reel

Gloss Calender

Calendering: The smoothing calender further regulates the surface

quality. Depending on the grade, the surface is additionally calend-
ered with the hot surface of the gloss calender.
Winding: The finished paperboard is wound up to a jumbo reel
which is then rewound into narrower reels and according to customer
requirements, either sent to customers in reels or cut into sheets.
Extrusion coating
For some end-uses paperboard can be extrusion coated.
Extrusion coating is a separate process after the paper-
board production. For more information on the barrier
coating options see chapter 3.0.

<< Contents Paperboard making and paperboard grades 10

Paperboard
making and

paperboard grades

2.2 Paperboard Grades

A great variety of grades are commercially available and FBB (Folding Boxboard)
the terms used to describe them vary from market to
market. Below the grade categories are based on fibre
Double / triple coating
grades and production technology. Each grade may be Bleached chemical pulp
tailored for many end uses and for individual customer Bleached mechanical pulp
needs. Bleached chemical pulp
(Coating)

Paper and paperboard are made with the same base

technology. Paper provides mainly the printing surface,
paperboard both printing surface, stiffness, strength and
other properties necessary in packaging and graphic end
uses. Usually basis weight, caliper and stiffness are higher
than those of paper and also most of the paperboard
grades are multiply products.
A layer or layers made of mechanical pulp is between
layers of chemical pulp. Mechanical pulp may be
stone-ground wood (GW), pressurized groundwood
(PGW), thermo mechanical pulp (TMP) or chemi-ther-
momechanical pulp (CTMP). The top layer is bleached
chemical pulp and the reverse layer can be bleached or
unbleached chemical pulp. The top and reverse side may
be coated with mineral or synthetic pigments.

SBS (Solid Bleached Sulphate)

Double / triple coating

Bleached chemical pulp
Bleached chemical pulp
Bleached chemical pulp
Single/double coating

Paperboard entirely made of bleached chemical pulp.

The top side and reverse may be coated with mineral or
synthetic pigments.

SUB (Solid Unbleached Board) / SUS (Solid Unbleached

Sulphate)

Double / triple coating

Bleached or unbleached chemical pulp
Unbleached chemical pulp
(mixed with CTMP / recycled fibres)
Unbleached chemical pulp
(mixed with CTMP / recycled fibres)

(Coating)

Paperboard made mainly of unbleached chemical pulp.

To achieve a white surface, it may be coated with miner-
al or synthetic pigments, sometimes in combination with
a layer of bleached fibres under this layer. Some CTMP
or recycled fibres may partly replace the unbleached
sulphate pulp.

11 Paperboard making and paperboard grades << Contents

 Paperboard
making and

paperboard grades

WLC (White Lined Chipboard) LPB (Liquid Packaging Board)

Double / triple coating

Bleached chemical pulp /
white recovered pulps

Two-sided PE coating
Recovered paper or PE Coating
paperboard brown / grey
Board
Bleached chemical pulp / PE Coating
any of the pulps above
(Coating)

Multi-layer paperboard comprising at least one mid-
dle layer of mainly recovered fibres. The top layer is
bleached virgin chemical pulp or white recovered pulps.
Between the top layer and the middle layer(s) there can
be a layer of chemical, mechanical or deinked recycled
fibres. The reverse layer can be made from selected recy-
cled fibres or bleached and / or unbleached virgin fibres.
The top and reverse side may be coated with mineral or
synthetic pigments.
PE coating
Board
Barrier layer
PE coating
Liquid Packaging Boards (LPB) are used for the packag-
ing of liquid foods, such as milk or juice. The baseboard
may be either coated or uncoated FBB, SBS or SUB.
The paperboard is plastic coated – often with PE (Poly-
ethylene), high-barrier - or foil-laminated for long-life
beverages.

<< Contents Paperboard making and paperboard grades 12

Paperboard
making and

paperboard grades

Overview of Paperboard Nomenclature

Definition (DIN 19303) Type Description Pulp Stock

uncoated coated

AZ SBS Cast-coated solid bleached board with white back Fully bleached chemical pulp

AC1 FBB Cast-coated folding boxboard with white back Chemical and mechanical pulp

AC 2 FBB Cast-coated folding boxboard with cream back Chemical and mechanical pulp

UZ GZ SBS Solid bleached board Fully bleached chemical pulp

GN1 SUS /SUB /CNK Solid unbleached board with white back Unbleached chemical pulp

GN4 SUS Solid unbleached board with brown back Unbleached chemical pulp

UC1 GC1 FBB Folding Boxboard with white back Chemical and mechanical pulp

UC2 GC2 FBB Folding Boxboard with cream back Chemical and mechanical pulp

UT1 GT1 WLC White lined chipboard with white back Secondary fibres

UT2 GT2 WLC White lined chipboard with cream back Secondary fibres

UT4 GT4 WLC White lined chipboard with brown back Secondary fibres

UD1 GD1 WLC White lined chipboard high bulk ≥ 1,45 cm3/g Secondary fibres

UD2 GD2 WLC White lined chipboard high bulk < 1,45 cm3/g, > 1,3 cm3/g Secondary fibres

UD3 GD3 WLC White lined chipboard high bulk ≤ 1,3 cm3/g Secondary fibres

According to DIN 19303, any paperboard can be

described by a combined code of two letters or two
letters and one figure.

The first letter describes the type of surface treatment: Except for the D grades the figure defines the colour
A = cast-coated of the reverse side:
G = pigment-coated 1 = white
U = uncoated 2 = cream
3 = brown
The second letter stands for the main furnish:
Z = bleached chemical pulp
N = unbleached chemical pulp For the D grades, the figure describes the bulk
C = mechanical pulp of the paperboard:
T = secondary-fibre pulp with white, 1 = ≥ 1.45 cm3/g
cream or brown reverse 2 = < 1.45 cm3/g, > 1.3 cm3/g
D = secondary-fibre pulp with grey reverse 3 = ≤ 1.3 cm3/g

13 Paperboard making and paperboard grades << Contents

 Barrier
Coating

<< Contents Barrier Coating 14

 Barrier
Coating
3. Barrier Coating – Optimal Packaging
Solutions using Barrier Coatings
Stora Enso’s barrier coating range is the widest on the
market, offering solutions for practically all packaging
needs. The role of coating in the packaging boards is
to produce the desired barrier properties for the pack-
age, resulting in superior product quality and prolonged
shelf-life. Creative use of different coatings, together with
individual matching of the most suitable baseboards for
the purpose, optimizes package performance, ensures
high visual quality, saves materials, simplifies converting
and packaging, and reduces waste.
Barrier coatings typically form a tight film on the paper-
board in order to provide the desired barrier and other
functions. Generally, barrier coating in packaging boards
refers to the use of polymers as extremely thin layers on
the baseboard. These polymers give excellent product
protection properties plus substantial economical and
ecological benefits. Polymer coatings produce effective
barriers for a wide variety of products, including perish-
able foodstuffs.
The main purpose of coating is to protect the product
from the undesirable effects of such factors as light, oxy-
gen, humidity, and microbes. Depending on the applica-
tion, coating functions also include improved grease-
proofness, heat resistance or peelability, or enhanced
printing and finishing properties.
15 Barrier Coating
Application of coating polymers
Extrusion is the most commonly used barrier coating
technology for polymers such as:
• PE (polyethylene) , PP (polypropylene)
and other polyolefins
• EVOH (ethylene vinyl alcohol) and PA (polyamide)
as high-barrier multilayer coatings
• special polymers such as PET (polyethylene tereph-
thalate) and PBT (polybutylene terephthalate).
Polymers can also be applied as water dispersions by
using traditional pigment coating methods. A new group
rapidly gaining ground consists of biopolymers tailored
for full biodegradability.
Structure of polymers e.g. polyethylene:
Polyolefin coatings
Polyolefin barriers such as PE-LD, PE-HD and PP polymers
give good humidity protection. For heat resistance, PP
coating is superior compared to the PE grades.
Typical uses: PE coated packages and cups for beverages,
frozen food, ice cream and yoghurt; PP coated packages,
trays and plates for prepared or semi-prepared foods
suitable for microwave heating; PE-HD coated packages
for moisture-sensitive dry foods.
<< Contents
 Barrier
Coating

Special Polymer Coatings

Polyolefin coatings: 3 Light
Special coatings can perform both barrier and other
2
functions. Typical examples are PET coatings that provide
Grease 1
Oxygen heat resistance together with excellent grease barrier fea-
0 tures and good WVTR (Water Vapour Transmission Rate)
properties. PBT polymers are similar to PET in their func-
tions, but enhanced with excellent release properties.

Typical uses: Oven-usable trays and reheatable product

Heat, Humidity
peelability packages, and non-stick trays for bakery products.

Special barrier coatings:

Light
High-barrier coatings 3
2
Patented Ensobarr high-barrier coatings consist of multi- 1
Grease Oxygen
layer EVOH and/or PA polymer structures. They provide
0
excellent light, oxygen, humidity and aroma protection.
Ensobarr Silver grade has an additional silver-coloured
layer to provide maximum protection against light. The
high-barrier coated boards are also greaseproof.
Heat, Humidity
Typical uses: various delicate foods, including chocolate, peelability
cereals and dairy products; dry foods, such as candy,
savoury and processed snacks, coffee and tea, milk
and cocoa powders; liquid products such as juices, soft Biopolymer Coatings
drinks, green tea, water, soups and desserts, as well as
light-sensitive beverages such as wines and long shelf-life Biodegradable coatings are tailor-made polymers provid-
juices; non-food products such as liquid detergents and ing humidity and oxygen barriers as well as sealability.
fabric softeners. The coating can be composted into humus in organic
recycling.

High-barrier coatings: Biopolymer coatings:

3 Light 3 Light

2 2

Grease 1 Grease 1
Oxygen Oxygen
0 0

Heat, Humidity Heat, Humidity

peelability peelability

Performance:
1. Moderate 2. Good 3. Excellent

<< Contents Barrier Coating 16

 Paperboard
Handling
Recommendations

<< Contents Paperboard Handling Recommendations 17

Paperboard
Handling

Recommendations

4. Paperboard Handling Recommendations

Due to their structure, all boards are ‘living’ material. An
unwrapped sheet of paperboard reacts with the air very
quickly. Before printing, you must make sure that the
internal relative humidity and temperature of the sheets
are in balance with the conditions of the press room.
Large differences in these parameters can lead to prob-
lems such as curling of the sheets and slow ink drying.
Make sure that the paperboard is acclimatized to where
it is going to be printed. The necessary time for settling
can be found on our pallet labels.
Example: If the size (volume) of the pallet is 1 m3
(1m x 1m x 1m) and the temperature difference be-
tween the pallet and the press room is 20°C, the settling
time needs to be 46 hours in the press room.
For paperboard, the ideal humidity of both the ware-
house and the press room is 50-55% relative humidity
and the ideal temperature 20-23 °C.
Increased relative humidity can cause drying and rub-
resistance problems in the printed surface. Another
possible reason for slow drying may be a shortage of the
oxygen that is needed for ink polymerization.
Remove the wrapping just before printing. This will
ensure even and smooth settling of the pallet. The wrap-
ping also protects the sheets from dirt and damage.

pallet m3 Difference in temperature between the press room and pallet

5°C 10°C 15°C 20°C 25°C 30°
0.3 7h 14 h 21 h 31 h 43 h 60 h
0.4 7h 17 h 26 h 36 h 41 h 64 h
0.6 9h 20 h 31 h 42 h 55 h 76 h
0.7 11 h 21 h 31 h 44 h 58 h 79 h
1 12 h 23 h 33 h 46 h 62 h 87 h
2 13 h 24 h 35 h 49 h 66 h 90 h

18 Paperboard Handling Recommendations << Contents

 Printing
Methods

<< Contents Printing Methods 19

Printing
Methods
5. Printing Methods
The final print quality is influenced by many variables,
such as paperboard properties, printing press and proc-
ess parameters, and ink properties. For optimal results, it
is important to understand the interaction between vital
paperboard properties and the chosen printing process.
This chapter describes the most common printing meth-
ods, although the information below focuses mainly
20 Printing Methods
on the sheet-fed offset process, which is the dominant
printing technique for paperboards. The information will
facilitate the processing of our paperboards and enhance
the quality of the print work. Moreover, these guidelines
may serve as a token of our ongoing endeavours to add
our manufacturing experience to the expertise of the
printing and converting industries.
<< Contents
 Printing
Methods

5.1 Offset printing

The dominant printing method is offset, which is divided fountain solution. The pH should be between 4.8 and
into three different processes: 5.3, hardness between 7 and 15 °dH and conductivity
50-200 mS/m to achieve the best printing result.
• sheet-fed (sheets) SFO for paper and paperboard
• heatset web offset (reels) HSWO for paper and
low-grammage paperboard
• coldset web offset (reels) CSWO for newsprint Sheet-fed offset printing unit

Water rollers
Offset printing is based on physicochemical reactions
Ink rollers
between the ink, fountain solution, printing plate and
blanket. Lithoplate cylinder
Water

The printing plate is made of aluminium. The plate is

chemically treated so that image areas accept greasy ink Offset blanket cylinder
(oleophilic) and are water-repellent. The non-printing
areas are hydrophilic, meaning that they repel ink but Paper
accept fountain solution.
Impression cylinder/roller
The average thickness of the ink layer carried by the
plate is 2-3 µm and that of the water layer 1-2 µm.

The ink is transferred from the printing plate to the print-

ing blanket, then onto the surface of the paperboard.

The structure of the printing blanket is a texture of 2-4

layers covered with rubber layers. The blanket has differ-
ent hardness levels (70-85 ShoreD), the harder blankets
being more durable and meant for higher printing
speeds. By using a soft blanket, better contact with the
paperboard can be achieved. The blanket is not allowed
to react with ink solvents during the printing process. - dots are uniformly covered with ink
- edges are ragged
The printing blanket transfers the printing image from
the printing plate to the surface of the printing material.

The offset inks are very tacky and require high surface
strength in the print material. The sheet-fed inks dry by
absorption and oxidation, heatset inks by evaporation
(aided by dryers). UV (Ultraviolet) offset inks need UV
light to dry by polymerization.
The inking unit transfers an even ink layer to the printing
plate, makes the ink fluid and flexible and keeps it at the
correct temperature.
The fountain solution forms a thin water layer on
non-printing areas of the printing plate. The pH, hard-
ness and conductivity are important properties for the
Waterless offset (dry offset)
In waterless offset printing, no water is involved in the
printing process.
In the dry offset (waterless offset) process, more tacky
inks are used and special printing plates treated with
silicone are needed. The silicone material of the printing
plate has a very low surface energy and makes up the
non-printing area of the plate. This material will resist
the ink, provided the ink’s viscosity is such that it has a
greater affinity for itself than it does for the silicone.

<< Contents Printing Methods 21

Printing
Methods

Temperature control of printing inks is very important. 5.2 Gravure printing

The temperature should be stable. The optimum tem- Gravure is used for long print runs on paperboard, mag-
perature range for dry offset inks is narrower than for azine paper and plastic films, and for security printing.
conventional offset inks. If the temperature is too low,
the viscosity of the ink increases, resulting in poor fluid- The printing ink is transferred from the printing cylinder
ity/rheology of the ink and inferior ink transfer. In printed cells to the surface of the printing material.
areas, this results in picking, ghosting, mottling (uneven-
ness), low printed gloss and problems resulting from
poor ink transfer. If the temperature is too high, the ink Gravure printing
viscosity decreases, causing some of the ink to be trans-
Impression cylinder/roller
ferred to the unprinted areas of the printing plate, result-
Impression cylinder/roller
ing in doubling problems (dye toning: weaker ghost dots
next to true dots whose position is out of register).

Gravure cylinder
The operating temperature ranges for dry offset inks are
Image elements are equally
26-35°C for black, 24-31°C for cyan, 22-28°C for ma- Gravure
spaced but differ in area and
genta and 20-29°C for yellow. The exact temperatures cylinder
volume (variable depth and
depend on the manufacturer of the ink and the ambient variable area)

conditions.
Blade

Waterless offset printing is environmentally friendlier Ink fountain

due to the absence of wastewater and residues from IPA
(isopropyl alcohol) or additives.

- broken shape of dots

- missing dots
- donut shaped dots

The metallic printing cylinder and soft rubber backing

roll form the printing nip. The pressure at the printing
nip is high to ensure optimal ink transfer.

The most important requirement for the print mate-

rial is smoothness to ensure good contact between the
paperboard, the ink and the printing cylinder. Because of
the high pressure at the printing nip, the compressibility
of the paperboard is also important.

The printing ink is solvent- or water-based with a very

low viscosity level. The inks dry by evaporation in the
drying unit.

22 Printing Methods << Contents

 Printing
Methods

5.3 Flexo printing

The printing ink is transferred by an anilox roll to the
printing plate. The surface of the anilox roll is full of
small, engraved cells and extra ink is wiped away by
using an oscillating doctor blade or a chamber doctor
blade.
The flexo inks are water- or solvent-based with a very
low viscosity level. UV inks can also be used.
Water- and solvent-based inks dry by evaporation in a
drying unit that normally follows each printing unit. UV
inks need UV light to dry by polymerization.

The surface energy plays an important role in flexo

Flexo printing
Printing plate (soft)
Printing substrate
Impression cylinder (hard)
Elastic printing plate with
raised image elements
printing. The surface energy should increase in printing
order (lower for ink than for printing material) to ensure
optimal ink transfer and adhesion.
Flexo printing is mainly used for printing on flexible
packaging, labels, paperboard and fluting board,
plastic bags and newsprint.

Anilox
roller

Ink supply
(Chambered doctor
blade system)

Cells of the anilox

roller filled with ink Inked up image element

- ink is pressed to edges

- shadow in the edge of text

The printing plate is made of photopolymer or rubber.

The uplifting parts of the printing plate transfer the ink
from the plate to the printing material.

The soft printing plate and hard steel backing roll form
the printing nip. The pressure at the printing nip should
be very light (“kiss”).

<< Contents Printing Methods 23

Printing
Methods
5.4 Inks
The main components in a printing ink are:
• Pigment that creates the colour and colour same kind as for conventional inks.
strength and gives the ink its optical properties
• Binder that binds the pigments into the printing The adhesion of metallic inks to the printed base is
material and affects ink drying and ink gloss
• Solvent that adjusts ink viscosity and has an ef- ment amount in the ink. However, these are known facts
fect on ink setting and drying. The solvent dissolves when using metallic inks, and any problems are caused
the binder
• Additives (dryer, wax, antiskinning agent, anti-
foaming agent and surfactants/flexo, gravure)
Sheet-fed offset inks dry by oxidation + absorption and
heatset offset inks dry by evaporation.
Offset UV inks dry by polymerization. The ink contains
photo initiators that absorb UV emission. The ink mono-
mer has to react with UV emission. Drying progresses
through the ink layer from top to bottom and is depend-
ent on ink layer thickness and ink type (dark or light ink
shade).
Offset UV inks are slightly tackier than the conventional
inks, which means that the paperboard needs a higher
degree of picking resistance. No odour or taint problems
normally occur with UV inks if the drying capacity and
time are optimal. The UV-printed surface is now ready
for further processing.
Flexo and gravure inks can be solvent- or water-based
and both inks dry by evaporation.
Metallic inks for offset
The amount of metal pigment in silver inks is 25-30%
and in gold metallic inks up to 50%. The metals used
in gold inks are copper and zinc. The gold colour shade
(copper red to greenish yellow) is dependent on the
proportions of copper and zinc. Aluminium is used in
silver inks.
The platy metal pigments are produced using the ball
mill process (gold and silver) or the foil process (silver).
The particle size of the metallic pigment is larger than
that of conventional ink pigments.
All metallic inks have good coverage. The metallic ink
dries through absorption and oxidation. The setting of
24 Printing Methods
the ink does not differ from conventional inks. When
metallic inks are used, the fountain solution can be the
weaker due to the lower binder amount and higher pig-
by the inks, not by the paperboard to be printed.
If the base board is very rough or has very high poros-
ity, it should be sealed before printing with metallic inks.
The technique known as underprinting can also be used.
Underprinting with yellow, red or orange ink can be
used under gold ink, and cyan ink under silver inks. The
shade of the ink will remain unchanged and the rub-off
resistance will be improved.
The best paperboard grade for metallic printing is pro-
duced in neutral or alkali processes to avoid ink shade
differences. Printing with metallic inks is best done in the
last printing unit.
The rub resistance of metallic inks is lower than with
conventional inks but can be improved by varnishing the
printed surface.
A typical procedure when using metallic
inks is as follows:
• metallic ink + varnish
• sealing of base board + metallic ink + varnish
(when the base board is very rough)
• underprinting of base board + metallic ink +
varnish (shade of ink and rub-resistance
will be better)
The adhesion of varnish to the surface of the metallic ink
layer is poor, partly because the ink layer is slippery. The
metallic ink should not contain wax – or at any rate as
little as possible. The ink layer should be thoroughly dry
before varnishing, to improve adhesion. The amount of
varnish used should also be as low as possible.
The best varnishing process for a metallic ink layer is:
metallic ink + water-based varnish + UV varnish.
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5.5 Digital Printing
Traditional and Digital Production Printing Technologies
Page description file
Ripping (Raster Image Processing)
Computer to film Computer to plate/master
Film processing
Plate making Plate/master manufacturing
Printing using a non-variable master
Offset, Gravure, Flexo
One classification of the traditional and digital production printing technologies.
A digital printing system can be defined as a system that
prints images directly from ripped information without
a static master, so that every consecutive print can be
different. Until recently, electrophotography was the only
technology used in production-type colour digital print-
ing machines, but new solutions for production-speed
digital colour printing are being developed, based on
technologies such as ink-jet and electrocoagulation.
Digital printing is gradually entering the field of con-
sumer goods packaging. Promising new technologies
are being discovered and existing technologies are being
refined. Here, two of the most common digital print-
ing methods are discussed briefly and some comments
are given regarding the special requirements for each
method.
Electrophotography
Paperboard grades work satisfactorily in a variety of
sheet- or web-fed electrophotographic production ma-
chines. Either direct or indirect dry toner, or alternatively
indirect liquid toner, can be used. Machine suppliers in
the dry toner category are Punch Graphix (Xeikon), Xer-
ox (DocuColor, iGen3) and e.g. Kodak (NexPress), and in
the liquid toner category, Hewlett-Packard (Indigo).
<< Contents
Printing
Methods
Computer to plate Computer to press
on press Digital Printing
Electrophotography
Inkjet
Electrocoagulation
Ionography
Magnetography
In general, it can be said that paperboard runs better in
dry toner machines in which either indirect or single-step
direct toner transfer is used and the path for the board
inside the printing machine is as straight as possible.
Most production printing machines are included in this
category. More problems can arise with some home,
small office or network printers in which toner is trans-
ferred to the board in several separate steps and the path
for the board is not as straight. In this category, compat-
ibility should be evaluated in each separate case.
For the HP Indigo press (liquid toner), the board surface
needs to be treated with primer prior to printing.
The treatment can be applied with a flexographic coat-
ing or printing unit or with an offset printing machine.
The primer solution should be used as received. The
treatment lasts for 2-3 months. Excessively high primer
concentrations reduce the durability and impair liquid
toner compatibility, which may cause yellowing.
Inkjet
Paperboards are highly suitable for printing with UV
inkjet inks and for one-colour inkjet printing (black). The
compatibility with other inkjet inks depends on the ink
composition and should be evaluated case by case.
Printing Methods 25
Printing
Methods
5.6 Practical printing instructions
Choose the right ink
Choosing the right type of ink is important. The follow-
ing criteria must be taken into consideration:
• desired print gloss
• processing/converting of the product
• drying time of the ink
• desired scuff resistance
• number of colour units
• possibility of IR/UV drying
• tack
• special features required from the job
(odour/taint etc.)
• subsequent UV varnishing
Certain properties of the ink depend on each other. The
most important of these are print gloss, setting speed,
scuff resistance and ageing in the press. These properties
are closely interrelated. For instance, if a high-gloss ink
is chosen, more time has to be reserved for drying. For
more detailed information, it is best to contact the ink
supplier.
Amount of fountain solution during printing
The entire offset process is based on the balance be-
tween ink and water. However, as much as 30% of the
fountain solution may emulsify into the ink in normal
printing circumstances.
There is no benefit to using an excessive amount of foun-
tain solution in the press. It quickly affects the quality of
the end product, causing, for example, drying problems,
print gloss reduction and weaker colours. When the
amount of fountain solution is increased during print-
ing, it also increases the amount of water on the surface
of the paperboard, either in the ink or on the unprinted
areas. The correct fountain solution level exists on the
press when there is the minimum possible amount of
water on the plates to achieve an optimum printing
result (adequate ink film) and when the fountain solu-
tion pH is correct, i.e. 4.8-5.3. Under these conditions,
the paperboard does not absorb an excess of fountain
solution, from either unprinted or printed surfaces.
26 Printing Methods
Furthermore, this ensures quick ink drying, the desired
print gloss and the correct colour balance on the printed
surface.
Amount of ink
Ink density is one of the most important features meas-
ured from the printed surface. Remember that print
contrast is reduced if excessive ink is carried. Ink film
thickness also has an influence on the ink drying time
and on the risk of set-off. During printing, the contrast of
each colour should be maximized by attaining the opti-
mal density level. The smaller the amount of ink needed
to achieve maximum contrast, the finer the screen that
can be used in reproduction, resulting in the sharpest
possible image in the final product.
Drying of the ink
Drying of standard sheetfed offset colours is affected
by a chemical reaction. If you want to speed up drying,
the printed sheets can be acclimatized by turning them,
either manually or using a pile turner.
The reason for a drying problem may be:
• too high humidity in the press room
• temperature changes in the press room
• too short a settling time of pallets before printing
(the material is cold or moist)
• unsuitable ink or ink series for the paperboard
being used
• excessive amount of water or ink
• fountain solution too acid
• IR (infrared) dryer temperature too high
The drying of UV inks starts within a fraction of a second
due to polymerization. The sheets are ready for further
processing immediately after printing.
<< Contents

Grain direction (Machine direction)
The direction in which most fibers lay in a finished sheet
of paperboard is referred to as grain. Fibers flow parallel
to the direction in which the paperboard travels on the
board machine during manufacture.
The end use of the product must be taken into consider-
ation when choosing the grain direction. It is important
to know how the end product will be used and what
requirements are related to its function. For example, the
direction of a score or fold or the required sturdiness of
the end product should determine the grain direction
when the sheets are ordered.
Another important factor for choosing grain direction is
the printing press. Almost without exception, the run-
nability of the paperboard is better if printed with the
grain direction parallel to the cylinders. The paperboard
is more flexible in the sharp curves of the press and
problems can be avoided even at high speeds. This fac-
tor becomes even more important when the grammage
of the paperboard is higher.
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Printing
Methods
Moisture
Remember also that the moisture applied in the press
increases the dimensions of the sheet. Because of the
structure of the paperboard, the fibres generally expand
more in diameter than in length. It is obvious that if the
grain direction of the sheet is the same as the direction
of print, a register problem can occur. The likelihood of
this problem occurring is greater if large formats are to
be printed with a very precise register. To avoid such
problems, the orientation of the sheet should be planned
by taking into consideration both the end product and
the printing press.
Printing Methods 27
 Converting
and Finishing

<< Contents Converting and Finishing 28

Converting
and Finishing
6. Converting and Finishing
Paperboard packaging offers marketers and
their designers an incomparable creative the pores in the coating layer are small, the varnish has
medium. This is important when it comes difficulty penetrating into the coating layer and tends to
to communication, positioning and branding.
A strong construction accepts attention-
grabbing embossing without cracks or breaks
and a polished finish melds with foils and
holograms for vibrancy and depth. The skillful
use of these printing enhancements in
paperboard design helps to attract consumers
and often adds value to the products.
6.1. Varnishing
Varnishing improves the visual appearance of the printed
surface. Varnishes may be matt or glossy. Spot-varnish-
ing can also be used to highlight certain areas and make
them more prominent.
The varnish should be resistant to mechanical rubbing
and solvents. A glossy varnish lowers the friction coef-
ficient (COF) of the paperboard which should be high
enough in order to secure good runnability of the pa-
perboard in the following converting process. Normally
when having matt varnish the COF level is high.
29 Converting and Finishing
The final gloss level of the varnished surface is depen-
dent on paperboard properties, the thickness of the
varnish layer and the chemistry of the varnish used. If
remain on the surface.
If the surface is very rough, two varnish layers are
needed; the first one closes the surface and the second
one smoothes out the roughness.
Solvents in the varnish should not react with the coating
binder or the ink binder, since such a reaction may result
in softening of the varnished layer.
Yellowing of the varnished layer can be prevented by
choosing the right binder system for the varnish. Varnish-
ing will improve the rub-resistance of the printed surface.
Varnishing can be carried out by using an ink unit (offset
varnish), online varnish unit (flexo unit for water-based
varnish) or a separate varnish unit. Glueing should be
carried out on unvarnished areas.
On-line varnishing can be divided into
three main methods:
Offset varnish
• composed like offset inks, but without pigment
• 1-2 g/m2 as dry
• approximately 75% solid content
• chemical drying (oxidation)
Water-based varnish
• approximately 40-50% solids acryl dispersion
• 2-5 g/m2 as dry
• physical drying (IR, air => evaporation +
penetration)
UV varnish
• dries by UV radiation
• 3-8 g/m2 as dry
• virtually the entire coating substance polymerizes
into a solid film
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 Converting
and Finishing

The advantages and disadvantages of each method are as follows:

Offset varnish

+ processed like ink - slow drying,

- slow drying
+ easy to do spot
+ processed varnishing
like ink, - thin layer,
- thin layer
+ good moisture
+ easy to do spotprotection
varnishing, - risk of yellowing
- risk yellowing,
+ good moisture protection - requires powdering
- requires powdering,
- low gloss,
- low gloss
- odour and
- odour and taint
tasteproblems
problemsmay
mayoccur
occur

Water-based varnish

+ good gloss - spot application more complicated

+ very good abrasion resistance - risk of sheet stretch or shrinkage with lower
+ fast drying grammages due to the high water content
+ little or no set-off powder needed - smearing because of too high varnish amount
+ high piling stability or too effective drying power
+ no yellowing
+ neutral odour
(dependent on drying conditions)

UV varnish

+ the highest gloss - high cost of varnish and energy

+ very hard and resistant - not totally odourless
+ instantly dry (dependent on drying conditions)
+ no set-off powder needed - difficult to process online with conventional
+ very high abrasion resistance inks (-> adhesion problems)
- yellowing of varnish over time (can be avoided
by using waterbased varnish as primer and
increasing the viscosity of UV varnish)
- varnish may irritate eyes and skin

If UV coating is applied over conventional offset inks, the ink

surface must be absolutely dry before coating, and/or the
inks must be carefully selected. Otherwise, the result may be
a lower coating gloss or flaking of the coated surface.

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Converting
and Finishing

6.2 Embossing 6.3 Hot-foil Stamping

Embossing is done to emphasize printed area or print
impression or even unprinted surface.
Required paperboard properties,
if all other properties are the same, then
• chemical fibre is better than mechanical fibre
• long fibres are better than short fibres
• higher moisture is a benefit (inhibits cracking)
• thick paperboard is better than thin
• strength properties, especially bursting strength, kind of debris or dirt will have a negative influence on
are important
• the coating should be flexible to avoid cracking
• multi-layer boards are better than single-layer
boards
Hot-foil is a technique using very thin aluminium foil in
a variety of metallic colours, such as red, blue, silver or
gold. The metallic foil is (loosely) fixed to a carrier film. A
tool bearing the image to be hot-foiled strikes this web.
Through heat and pressure, the image is transferred to
the paperboard.
Care should be taken when applying hot-foil stamping
on varnished paperboard. For best results the foil needs
to adhere strongly to the substrate. The presence of any
the end result. The printing and coating therefore need
to be flawless and adhere strongly to the paperboard.

Although a bulky paperboard might seem easier to

emboss, the aim is usually to achieve a certain height so
that the embossing is more pronounced. A bulky paper-
board will respond in a more spongy way. High-density
boards give more pronounced embossing (at the same
tool height).

The embossing machine must be correctly adjusted for

the paperboard grade to be processed.

31 Converting and Finishing << Contents


6.4 Die-cutting and creasing
Introduction
Characteristics differ between different types of paper-
boards, such as solid bleached paperboard (SBS), folding
boxboard (FBB) or white lined chipboard (WLC). All
grades can be cut and creased, but to obtain the best
result for each application it is important to fine-tune
the treatment. The operating window of die-cutting and
creasing varies according to the type of paperboard and
its individual properties.
It is true of all paperboard types that results differ
depending on the grain direction, moisture content,
thickness, and the amount and type of surface treatment
(pigment, plastic, foil, etc.). Moisture content and thick-
ness are the most important factors. Tool life will also be
affected by the paperboard type chosen.
For cutting and creasing, there are basically two meth-
ods in use: Rotary or Flat-bed. These different methods
place different demands on the paperboard. The main
difference between them is:
- In rotary cutting, the knife does not meet the
“anvil.” There is a gap of some 5 microns.
- In flat-bed cutting, the knife should just touch due to incorrect rubbering and results in flaking and pre-
the counter plate for best results.
In addition, flat-bed cutting can be performed either in-
line or off-line. All of these variables will to some extent
place different demands on the paperboard. For rotary
cutting, the web must stick together, rather than fall
apart, until the blanks enter the splitter/collector/stacker.
At the same time, clean cuts are desired. This can be
achieved by using specially adapted qualities, but speed
of the die-cutting equipment is of course also important.
In off-line flat-bed cutting, almost the opposite could
be said to be true. While clean cuts are still desired, the
paperboard should separate easily in the puncher. The
following description mainly focuses on flat-bed cutting.
<< Contents
Converting
and Finishing
Die-cutting
A good cut should be clean and free from loose fibres
and particles.
The most important strength properties of the paper-
board are tear and tensile strength. These properties
differ between different paperboard types and the die-
cutting process has to be adjusted according to those
properties.
The correct moisture content is essential for both run-
nability and quality during the die-cutting process. Too
high a level will make the paperboard stronger, tougher
and more difficult to cut. Too low a moisture level will
make the paperboard more brittle and difficult to trans-
fer, and may cause dusting. Difficulties in cutting may be
caused by the paperboard thickness, moisture variation
or tool wear and adjustments. It is important to control
the climate to keep the moisture content unchanged.
Controlled climate helps to achieve a precise register
between the work stages.
If the cutting knives are sharp and meet the counter die
correctly, the cutting occurs as desired. A problem may
occur if the sheet moves during the process. This is often
mature tearing of the back layer of the paperboard. This
is observable as a torn area next to the cut. Damage will
also occur to the knife if it presses too heavily against the
metal plate. The knife wears and becomes blunt, leading
to dust and hairy-cut edges.
Plastic-coated or laminated products with an extra tough
layer (for instance PET) should preferably be die-cut from
the plastic-coated side.
Creasing
A crease forms when paperboard is pressed into a groove
with a rule. This causes a plastic deformation in the pa-
perboard, allowing the paperboard to fold easily without
cracking. A good crease is sufficiently deep and narrow
to enable precise folding. The main factor for setting the
adjustments is the thickness of the paperboard. The type
of the paperboard is also important. Obviously the pres-
sure of the die-cutter also affects the creasing.
Converting and Finishing 32
Converting
and Finishing

During creasing, the paperboard is weakened in well-de-
fined folding lines, which then act as hinges for folding
packaging and graphical products. Creasing is carried
out by using a thin strip of steel with a round smooth
edge and an accurately cut groove in a thin hard mate-
rial known as the counter plate. The creasing rule pushes
the paperboard into the groove of the counter plate,
located under the paperboard, creating a permanent
crease.
A good, functional fold occurs when the paperboard
delaminates in the crease into as many thin, undamaged
layers as possible. Ply bond strength must be a compro-
mise, so that delamination occurs easily in a crease while
the structure holds together in other areas.
Thicker boards require a wider rule and groove. Bulky
boards are easy to crease. Creasing requires a flexible
coating and strong surface layers. The fibre composi-
tion and number of layers are important. A multilayer
structure in creasing is desirable. Because thick material
cannot fold without breaking the structure, the fibre
layers delaminate in a crease. The bonding between the
layers weakens in creasing, causing them to loosen from
each other more easily in folding.
The creasability properties depend on the fibre orienta-
tion. A crease in the machine direction usually has worse
folding properties, because the stiffness is lower in the
cross-fibre direction. Stable moisture content is impor-
tant, because dry paperboard can crack more easily,
while moist paperboard has a lower stiffness, resulting in
difficulties with delamination.
The creasing properties can also be analyzed by making
a “creasing window.” At laboratory scale, the Marbach
equipment is used by changing the groove width and
depth, blade/rule width and the penetration of the creas-
ing rule into the groove. The bending forces of creases
are measured. The creases should have certain stiffness
after bending – in MD (machine direction), 45-60% and
in CD (cross direction), 55-65%.
A visual judgment of creases is also made. If the paper-
board has a large operating window, the creasability is
good.
In general, plastic surface layers improve the creasability,
because they have very good elongation before they
break and tend to reduce the risk of surface cracking in
the creases, compared with plain paperboard.

Creasing
d

a = creasing groove width

b = creasing groove depth
c = board thickness
e d = creasing rule tip thickness
e = creasing rule height
f = thickness of groove bottom

c b
f
creasing counter part

creasing plate

33 Converting and Finishing << Contents

 Converting
and Finishing

6.5 Glueing

Side seam or point glueing is often the final operation in
the carton-making process.
The most common glue types used for packaging pur-
poses are waterbased dispersion and hot-melt glues. Set-
ting of the glues proceeds by chemical reaction, cooling
down or reduction of solvent.
The glue can be applied using a glue wheel/disk or a
nozzle system. Water-based glues are applied using both
systems, while hot-melt glue is applied by nozzles.
The amount of glue applied is dependent on the paper-
board and glue types – varying with the glue’s viscosity
for example – as well as on the application system (disk
or nozzle).
The glue dries as the water penetrates into the paper-
board surface. Penetration is dependent on the moisture
and porosity of the paperboard surface. A portion of the
glue itself should also penetrate into the paperboard.
The recommended penetration depth is 1-3 times the
fibre diameter.

When the delamination (breakdown of the seam) occurs
in the fibre layer, the seam is acceptable assuming the in-
ternal strength of the paperboard is on acceptable level.
If it breaks in the coating layer, there may be a problem
during use. Delamination in the glue layer is a theoretical
possibility.
The smoothness and porosity of the paperboard surface
have an effect on the mechanical adhesion of the glue.
The glue should be anchored to the paperboard surface.
The absorption of the top and reverse layers must not be
too different since this would result in penetration of the
glue mostly to the highly absorbent side. The glue must
wet the surfaces properly. For printed and varnished sur-
faces, the seam areas are often devoid of ink and varnish
to assist adhesion. It is important to correctly adjust the
glueing machine settings to the most suitable open time,
compression time and force.
Hot-melt glues are used to glue materials with a low
porosity level (plastic coatings and metallic laminates) or
in processes that require short setting time of the glue
(e.g. in-line glueing in packaging machines). Hot-melt
glue contains resin (affecting adhesion), wax (creating a
suitable rheology for the melted glue) and polymer (for
cohesion). Hot-melt glue is melted and applied to the
surface at a temperature of 120-200°C. When glueing
plastic-coated board, the glue must be so hot that it will
melt the plastic to some degree. Care should be taken
when using hot-melt glues in cold surroundings or under
cold conditions.

Normally the glues are water-based dispersions of poly-

vinyl acetate (PVAc). The most important parameters for
glueability are the paperboard and the glue type. Surface
energy and smoothness play an important role. The
surface energy of the paperboard surface must be higher
than that of the glue to ensure good adhesion.

With plastic-coated surfaces, the corona treatment is

used to increase the surface energy of the surface. The
lower limit for surface energy of the paperboard surface
seems to be 38 mN/m – anything lower may cause
problems.

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Converting
and Finishing

6.6 Lamination

It is to some degree incorrect to talk about lamination as
a component of finishing. Paperboard is often bought by
a converter and laminated, then sold to a printer. If this
is the case, there are basically two main applications for
lamination. Both of them typically involve paperboard in
reels:
• Lamination of polypropylene, aluminium foil or drying unit is needed.
metallized polyester film onto a paperboard
• Lamination of one or more boards to a core-web
of paperboard, foam or similar
No solvents and no drying are used in solventless lami-
nation. The adhesives are 100% solid materials, used in
single-component or two-component systems.
The glue in wet lamination is normally water-based PVAc
glue (solid content about 50%). The glue dries through
absorption of the water by the paperboard surface. No
It is recommended that the paperboard be sheet-cut on-
line just after the lamination to avoid curling problems.

The idea of the first process is often to give a luxurious
look after printing on the pack. The other application is
more typically intended to produce a display paperboard
for advertising purposes. In this second lamination proc-
ess, two or more webs are glued and pressed together
to obtain a paperboard grade with a higher grammage
level. As described above, a centre layer of some type is
often included to give a thick product.
The lamination may be:
• wax lamination
(molten wax is applied to the paperboard surface)
• glue lamination
(two or more webs are glued together)
- wet lamination
- dry lamination
- solventless lamination
• extrusion lamination
• hot melt
It is also important that the webs to be glued together
have similar caliper and grammage profiles. Smooth-
ness of the paperboard is often very important in these
processes. Other factors, such as the glue, will also affect
the end result, but a smooth paperboard has a higher
chance of delivering the desired result.
The paperboard surface must be sufficiently absorbent to
ensure the penetration of the glue solvent.
Paperboard can also be glued onto a medium (other
paperboard, foam, etc.) as sheets. This is normally done
after printing and the process is known as pasting or
paper-lining. In other words, the process is different but
the end result may look similar.

Wax or resin-modified wax is used as a hot-melt adhesive

in wax lamination. The wax is heated, applied to the
surface and cooled.

In wet lamination, one of the webs must be porous to

ensure absorption of the solvent, while the other web
may be porous material, aluminium foil or plastic web.

In dry lamination, the glue layer is dried after applica-

tion. Dry lamination can be carried out by hot lamina-
tion. The dried glue layer is sticky at high temperatures
after emerging from a drying unit. Extrusion and hot-
melt lamination are hot lamination processes.

35 Converting and Finishing << Contents

 End uses

<< Contents End uses 36

End uses

7. End uses

Stora Enso Consumer Boards is the market leader in its
field. We produce a wide selection of premium boards in
every category and provide the largest variety of barrier
coatings.
Top-quality materials and innovative solutions opti-
mize the performance of each individual package in its
particular user environment and marketing situation.
Consumer Boards’ offering is based on end-use oriented
business competence, backed up by innovation and lo-
gistics support through our InnoCentre facility and other
partner services.
For the brand owner, designer, converter or printer, the
superiority of paperboard as such is not the heart of the
matter. The packaging requirements for luxury cosmetics
are quite unlike those for oven-to-table frozen foods. It
is a question of finding the combination of paperboard
properties, grade and grammage that will optimize the
performance of each individual package, whether the
requirements are superior stiffness, creasability, odour
and taint neutrality, ageing resistance or superior hot foil
stamping.

Beverage & Chocolate & Cosmetics & Detergent &

Product Names Multipack Confectionery Cigarette Luxury Household
Aurocard

Chromocard

CKB

Cosmocart T

Cupforma

Ensocard

Ensocoat

Ensogloss

Koppargloss

Kopparprint

Kopparwhite

Microliner

Natura

Neocart

Performa

Printocart

Tambrite

Tamfold

Tamwhite

Trayforma

Triplex Blanco

Triplex Gris

Triplex Madera

37 End uses << Contents

 End uses

Understanding the customer’s business is more than
a ubiquitous business phrase. It is the most important
single catalyst behind innovative packaging solutions
and proactive partner service. Therefore, the organiza-
tion of Stora Enso Consumer Boards is based on the Busi-
ness Segment Management principle, which combines
production efficiency and product streamlining with
end-user-driven business concepts.
All our customers are served by dedicated teams. The
major end uses served by Stora Enso Consumer Boards
are presented below. By clicking on a specific product in
the table, you can download the latest product specifica-
tions (requires internet connection). You can also access
the same information by going directly to Consumer
Boards’ website at www.storaenso.com/consumerboards.

Product Names Food Food Service Graphical Liquid Media Pharmaceutical

Aurocard

Chromocard

CKB

Cosmocart T

Cupforma

Ensocard

Ensocoat

Ensogloss

Koppargloss

Kopparprint

Kopparwhite

Microliner

Natura

Neocart

Performa

Printocart

Tambrite

Tamfold

Tamwhite

Trayforma

Triplex Blanco

Triplex Gris

Triplex Madera

<< Contents End uses 38

End uses

7.1 Graphical

Wide spectrum of paperboard options

Stora Enso offers a comprehensive range of products for
the graphical industry, from WLC (white-lined chip-
board) through FBB (folding boxboards) and advanced
multilayer CTMP (chemi-thermomechanical pulp) boards
to SBS (solid bleached sulphate) boards. Whatever the
application, there is an optimal choice available, de-
signed for the best in smoothness and brightness, print-
ability and runnability, and consistent high quality from
batch to batch.

Applications

End uses of Stora Enso Graphical Boards

• Covers for magazines, books, brochures,

Working with the graphical industry is a unique experi- annual reports, maps, notepads, and manuals
ence. You enter an environment where the printer’s ex-
acting professionalism is matched only by the designer’s • Cards: greeting cards, postcards, collecting cards,
boundless imagination in creating ever new solutions to recipe cards
capture the interest and acceptance of the target audi-
ence. • Media: audio and video CD/DVD packs, display
boards, tickets and tags, calendars, folders
More strength and durability
Stora Enso’s graphical boards are made by combining
various pulps into multilayer constructions in order to
utilize the best properties of individual pulps. This tech-
nology gives the boards their sturdy and rigid structure,
unattainable in corresponding wood-free coated papers.
As a result, our graphical boards have precisely the right
strength and stiffness for optimal performance during
the printing and subsequent finishing stages. Sturdy
boards also give superior durability in final use.

This excellent performance is fully compatible with im-

proved economy. Compared with alternative solutions,
Stora Enso Graphical Boards produces a final product
with considerably less total weight, resulting in more
products from less raw material.
Smooth and efficient finishing
Our graphical boards are fully compatible with the mate-
rial requirements of various finishing methods. They are
suited to varnishing treatments, as well as die-cutting,
embossing and creasing.
Backed up by ServiceCentres with high sheeting capacity
and available via an active network of specialized mer-
chants, Stora Enso graphical boards are fully equipped
to meet the demands of today’s fast-moving and rapidly
developing graphical industry.
For more information, visit our dedicated site at
www.storaenso.com/graphical.

39 End uses << Contents


7.2 Beverage and Multipack
Packaging Beverages
The basic functions of packaging – to protect, distrib-
ute, inform, attract and sell – also apply to beverage
products. However, the world of beverages is unique in
its abundance and variety of products, with the most ex-
clusive liquor brands, backed by hundreds of years of his-
tory, coexisting with fashionable sports tonics launched
only yesterday. Paperboard cartons in beverages packag-
ing offer a unique combination of brilliant imaging qual-
ity, functionality, versatility and cost-effectiveness.
Applications
Stora Enso’s beverage and multipack boards are used for
secondary packaging in various constructions and set-
ups, of which the mainstream variants are:
• Solid cartons made of high-caliper paperboard
• Laminated combinations using top liners and
stiffeners
• Litho lamination to a single/double face
corrugated base
Foil or metallized film lamination is employed in a large
portion of applications, especially for premium brands.
Beverage cartons
Typical product groups for single-pack cartons are whis-
ky, spirits, liqueurs, wine and champagne. In individual
applications, elaborate graphics and finishing treatments
(embossing, hot foil stamping, spot varnishing, etc.)
often play a major role.
<< Contents
End uses
Solid cartons are used for all principal product groups of
alcoholic beverages, while laminated and litho laminated
cartons are predominantly used for cognacs, cham-
pagnes and wines.
Bag-in-box applications containing up to 3 liters of wine
have quickly captured a large share of sales, especially
in the low and medium-priced categories. The basic
construction has great potential for further refinement
and new designs.
Multipacks
Beer multipacks have firmly established themselves as
just the tool to attract supermarket buyers and secure
maximum turnover from minimum space. That, how-
ever, is not the whole picture. Adaptable to individual
needs, distribution methods and marketing strategies,
multipacks work for a multitude of products and mar-
kets. The eye-catching pack is light and strong, and easy
to buy, carry, open and recycle.
The suitability of paperboard for innovative constructions
and novel packaging concepts is a major marketing as-
set, evident in such bestsellers as multipacks for beer and
liquor and ingenious bag-in-box wine packages.
A generous printing area and excellent full-colour quality
make paperboard cartons both a global branding tool
and a superb vehicle for communication, able to create
enhanced shelf presence and long-term customer loyalty.
More important still, paperboard cartons offer a wealth
of options for promotional uses and segmentation,
localization and testing purposes.
The crucial factor is to know what paperboard packaging
can do and how to initiate the innovative process.
To learn more about how Stora Enso does this, access
the Partner Services section at our website.
To find clear answers to a host of industry-specific pack-
aging issues visit www.storaenso.com/beverage.
End uses 40
End uses
7.3 Chocolate and Confectionery
A box of assorted chocolates is more than a very
practical container. It is a signal, a promise, a personal
message. No wonder, then, that the package is made
of fibre-based paperboard – a material that combines
rational functionality with seductive charm.
Applications
Packaging solutions based on Stora Enso’s chocolate
and confectionery packaging boards come in a variety
of innovative forms, designs and sizes, made possible by
the material’s universal applicability to a whole range of
converting, printing, finishing and filling methods and
techniques, as well as a number of advanced barrier
coating options.
Every individual packaging project sets its own demands.
As a rule of thumb, paperboard properties that play a
crucial part in the selection process include:
• organoleptic performance for maximum safety
and user satisfaction
• optical properties and print quality for optimum materials. For more information visit
shelf presence and brand differentiation
• convertibility and runnability for trouble-free
pro duction
• per-unit cost-efficiency for profitable packaging of
relatively low-priced products.
41 End uses
Odour and Taint Performance
The sensoric safety of Stora Enso packaging boards rests
on four pillars:
• purity of the baseboards
• barrier properties of proprietary polymer coatings
• track record over many years
• in-house testing, research and development
Purity, Cleanliness, Homogenous Quality
The core segment of Stora Enso chocolate and confec-
tionery boards comprises SBS brands produced from
pure pulp, as well as a range of boards with CTMP
added for extra strength and yield and the traditional
FBB grades. The choice is extended by the WLC range
made of recycled fibres, elaborately refined and tested
for use in demanding food packaging applications.
Polymer Coatings
Stora Enso baseboards coated with proprietary barrier
substances such as PE, PET and High Barrier polymers
preserve the original flavour of the product and provide
protection against undesirable effects caused by light,
oxygen, humidity or grease.
Matching the most suitable baseboard with the proper
barrier coating is a perfect way of maintaining superior
product quality and prolonging shelf-life.
For consultation on the planning and implementation
of your own packaging projects, please contact us. Also,
our dedicated Internet site offers a comprehensive view
of packaging based on innovative use of fibre-based
www.storaenso.com/chocolate.
<< Contents
 End uses

7.4 Cigarette

Just-in-time deliveries to printers are secured by four

highly efficient mills in three countries. The services are
backed up by various R&D projects which support brand
owners and printers to create superior product designs
and applications.

Finding an optimal board material is facilitated when

all of the options can be obtained from a single source
– a major benefit to customers. A strong partnership
between brand owners, printers and Stora Enso enables
the most cost-efficient solutions to be found and applied
in all areas of the value chain.

Stora Enso Cigarette Boards offers a wide and cost-effec-

tive range of tobacco-packaging solutions. The prod-
uct offering includes FBB (Folding Boxboard), CTMP
(chemi-thermomechanical pulp) and SBS (Solid Bleached
Sulphate) options to meet all needs. The wide selection
provides the right board chooice for the desired position-
ing of an individual cigarette brand.

<< Contents End uses 42

End uses
7.5 Cosmetics and Luxury
Finding an optimal carton material for packaging cos-
metics and perfumes is a demanding task where general
rules of thumb are not easy to find. However, some of
the key points are listed below for easy reference in order
to ensure that the package fulfils its major functions
– protecting the contents throughout the supply chain,
attracting potential customers and building distinctive
brand images.
Strength and structure for maximum protection
Ability to withstand mechanical stress – vibrations,
impacts, blows and bumps – is an absolute necessity for
cosmetics cartons. The inner structure of the material
must be such that the various layers of the paperboard
do not become delaminated under any circumstances.
For perfume cartons, on which solid printing, heavy tints
and colourful graphics are often used, the paperboard’s
structure must provide excellent smoothness as well as
superior cracking resistance at the fold.
43 End uses
High whiteness for superb visual image
High whiteness ensures good contrast in printing – im-
perative for top-quality results. Furthermore, whiteness
associates strongly with desired product features such
as purity and cleanliness. If the package design employs
large unprinted areas, high whiteness of the paperboard
becomes all the more important.
A significant feature relating to whiteness is the paper-
board’s ability to withstand UV radiation without yellow-
ing. This is a vital consideration, especially if the carton is
to be exposed to sunlight for extended periods.
Full choice of printing and finishing options
The quality of the carton must mirror or even enhance
the quality of the contents. Printing techniques should
include offset, flexo and gravure. Suitability for digital
printing is also rapidly gaining weight.
More important still is the possibility to use a whole
range of finishing treatments and special effects, such as
pearlescent pigment printing, satin UV varnish, glossy
hot-foil stamping, positive blind embossing, or laser
cutting. Depending on the design, the visual appearance
of the paperboard’s reverse side and its printability can
also be decisive factors, taking into consideration that
on cosmetics cartons there is usually a need for a lot of
product information.
Odour neutrality
The carton must be very neutral in its organoleptic prop-
erties to ensure that, even after extended storage, no
undesired odours will be emitted from the paperboard.
Only the desired fragrances, those of the product itself,
must be there for the consumer to enjoy.
For more information visit our dedicated site at
www.storaenso.com/cosmetics.
<< Contents
 End uses

7.6 Detergents and Household

Stora Enso is the world’s leading producer of packaging

paperboard and developer of new packaging concepts.
Our product range is second to none. At one end of the
product spectrum are the household product packag-
ing boards, which can be folded into an endless variety
of shapes. At the other are the detergent packaging
boards, whose key development principle is user safety.
In between the two extremes is a wide range of prod-
ucts, varying in the raw materials, strengths, mechanical
properties, bleaching degrees and surface finishes used.

All household packaging boards are available with ap-

propriate polymer coatings. Material options also include
LumiLabel flexible packaging papers as well as corru-
Packaging solutions must serve many ends. The product gated packaging.
on the shelf must be highly visible and representative
and also communicate high quality. At the same time, For consultation on the choice of material or other pack-
it is important to produce ecologically sound packaging aging issues, please contact us.
without sacrificing such vital functions as product safety
and user convenience. Paperboard is unique in its ability
to satisfy these conflicting requirements. Paperboard
cartons are lightweight and strong, functional, eye-
catching and as cost-efficient in production as they are in
recycling.

<< Contents End uses 44

End uses
7.7 Food
There is no substitute for fibre-based paperboard as the
best material for imaginative, exciting and functional
food packaging. Paperboard is smooth and strong, light
and bright, versatile and cost-efficient. It lends itself per-
fectly to all the shapes, sizes, designs and constructions
that different products and market situations call for.
The material is also ideal to use with metal detectors and
other safety measures.
Applications
Packaging solutions based on Stora Enso food packaging
boards cover a multitude of forms, designes and sizes in
all major product segments:
• Chilled Foods: Vegetables and salads, meat and spectrum of effective barriers against moisture, oxygen,
fish, processed food, puddings and dressings, etc.
• Frozen foods: Ready meals, fish and seafood, ice Read more about the food sector and the many options
cream, bakery products, etc.
• Dry foods: Biscuits, cereals, candy, drink powders, www.storaenso.com/food.
teas, snacks and chips, spices, etc.
• Pet foods: Wet/dry cat foods and dog foods, etc.
45 End uses
For primary packaging purposes, vital factors in the
selection of the paperboard include:
- Organoleptic performance of the baseboard/poly-
mer coating combination
- Optical properties (brightness, printability, smooth-
ness, ageing resistance)
- Convertibility and runnability (creasability, flatness,
no-dusting performance)
- Strength in relation to the size and weight of the
contents (bending stiffness, tear resistance,
glueability)
In secondary packaging, cost-effectiveness, source
reduction capacity, stiffness and, especially in the case
of promotional packs, suitability for digital printing are
properties that usually play a more prominent role.
However, every project has its own specific demands. For
consultation on your specific packaging tasks, please feel
free to contact us.
The essential companion: barrier coatings
In food packaging, preserving the freshness and palat-
ability of even the most delicate foods is an absolute
must. A full range of polymer coatings makes it possible
to create cups, trays and cartons which perform optimal-
ly in specific environments for specific products. Ingen-
ious combinations of baseboard and coating create a full
light, grease or heat.
for packaging foods at our special site:
<< Contents

7.8 Pharmaceutical
The range of pharmaceutical products is enormous, from
the most potent prescription drugs to ordinary over-the-
counter medicines. Accordingly, the role of packaging
ranges from ensuring product safety and patient compli-
ance to providing a versatile tool for communication and
brand building.
Applications
Stora Enso’s pharmaceutical boards are used in cartons
for all forms of primary packaging – aluminium and com-
posite blisters, glass and plastic bottles, rigid and collaps-
ible tubes, and pouches. In general, cartons for prescrip-
tion medicines (antibiotics, cardiacs, potent painkillers,
etc.) use fewer colours and more subdued designs, while
OTC (over the counter) products (vitamins and micronu-
trients, painkillers, cold medicines and skin creams etc.)
invest in attention value, attractive designs and elaborate
finishing.
<< Contents
End uses
Sheet offset with water-based varnish is the dominant
printing method.
Basic variable data (lot number, use-by date) is imprinted
during the packing process, using stamping, flexo, inkjet
or laser techniques.
Narrow Web flexo printing with inline converting may
be a cost-efficient alternative for small order lots and is
already applied by several converting companies.
Digitally printed cartons are beginning to gain ground as
a viable marketing and testing option.
The choice of paperboard material must be made indi-
vidually in each case. Typical variables include:
• optical properties (brightness, printability,
ageing resistance)
• strength (bending stiffness, tear resistance,
glueability)
• runnabilility in packaging lines (creasability,
flatness, no-dusting performance, laser codability)
• quality and hygiene considerations
(material consistency, purity, cleanliness and
homogeneity, odour and taint neutrality)
• technical suitability to case-specific technologies
(digital printing, etc.).
The applicable grammage is determined by such factors
as box dimensions (bigger sizes need stiffer paperboard
in order to perform well in the packing process) and the
weight of the contents (improved compression resist-
ance is needed for cartons containing heavy products,
such as liquids in glass bottles).
Visit our website, www.storaenso.com/pharma to learn
more about the pharmaceutical packaging markets,
innovative packaging concepts and the choice of paper-
board for individual applications.
End uses 46
End uses

7.9 Food Service

Food Service products derive their strength from a

unique material that combines specially-developed base-
boards and proprietary polymer coatings to create the
best quality in terms of purity, functionality, printability
and convertibility.

For more information, visit our dedicated site at

www.storaenso.com/cupforma.

Convenience for Food Service

Stora Enso offers a full range of advanced materials and
integrated solutions for the food service market that ca-
ter to the many different needs of today’s active consum-
ers, whether it is eat-on-the-go or oven-to-table meal.

7.10 Liquid

untainted for the entire life of the product. The carton

must also be attractive, build brand image and boost
sales. In addition it must comply with today´s best envi-
ronmental practices.

Read more about liquid packaging at our special site

www.storaenso.com/liquid.

Fluid Solutions, Full Protection

The overriding requirement for liquid packaging is to
keep the contents fresh and hygienic, unchanged and

47 End uses << Contents

 Stora Enso
Consumer Boards Production and
Service facilities

<< Contents Stora Enso Consumer Boards Production and Service facilities 48
 Stora Enso
Consumer Boards Production and

Service facilities

8. Stora Enso Production and Service facilities

Stora Enso Consumer Boards’ products are manufactured and WLC grades. Extrusion coating plants in Finland and
in Finland, Germany, Spain and Sweden. The total an- Sweden complement the production of baseboards with
nual capacity of the six modern and well-managed mills comprehensive facilities for moisture and oxygen barrier
is close to 2.6 million tonnes of SBS, FBB, CTMP, SUB coatings.

8.1 Paperboard Mills

Baienfurt Mill, Germany

Baienfurt Mill produces packaging boards for a variety of

general packaging applications serving customers in pharma-
ceutical, cosmetics, confectionery, cigarette and other major
industries. In addition, the Baienfurt offering includes a selec-
tion of graphical boards.

Annual capacity: 205 000 tons of FBB *

Machines: BM 3, machine width 476 cm

Barcelona Mill, Spain

Barcelona Mill produces WLC boards based on recycled fibres.

The products of the mill serve a great variety of markets from
food, confectionery, detergent and pharma packaging to book
covers and labelling applications.

Annual capacity: 170 000 tons of WLC coated on both sides *

Machines: BM 1, machine width 400 cm

Fors Mill, Sweden

Fors Mill produces fully coated folding boxboards for vari-

ous market segments including chocolate, confectionery and
cigarette packaging.

Annual capacity: 380 000 tons of FBB and CTMP boards *

Machines: BM 2, machine width 372 cm
BM 3, machine width 543 cm

49 Stora Enso Consumer Boards Production and Service facilities *) in 2006 << Contents
 Stora Enso
Consumer Boards Production and

Service facilities

Imatra Mills, Finland

Paperboard production at Imatra Mills comprises liquid pack-

aging boards for all packaging systems, cupstock and other
food service boards, packaging boards for the cosmetics, food,
confectionery and cigarette industries as well as a selection of
graphical boards.

Annual capacity: 930 000 tons of SBS, LPB and CTMP boards *
280 000 tons of polymer coated boards *
Machines: BM 1, machine width 440 cm
BM 2, machine width 560 cm
BM 4, machine width 630 cm
BM 5, machine width 490 cm
Coating machines: PE 2, machine width 230 cm
PE 3, machine width 230 cm
PE 5, machine width 280 cm

Ingerois Mill, Finland

Ingerois Paperboard Mill offers high-bulk folding boxboards

for food, health care, pharmaceutical, liquor and household
industries.

Annual capacity: 205 000 tons of FBB *

Machines: BM 4, machine width 458 cm

Skoghall Mill, Sweden

Skoghall Mill is a large-scale producer of liquid packaging

boards and the multilayer kraft back CKB concept.

Annual capacity: 745 000 tons of LPB, FBB, WTL and

CKB boards *
Machines: KM 7, machine width 540 cm
KM 8, machine width 810 cm

<< Contents *) in 2006 Stora Enso Consumer Boards Production and Service facilities 50
 Stora Enso
Consumer Boards Production and

Service facilities

8.2 Extrusion Coating Plants

Forshaga Mill, Sweden

Forshaga Mill produces a range of barrier polymer coatings

including foil and film application on base boards. Typical
end uses include liquid cartons, food packaging, lunch boxes,
noodle cups and other carton packaging.

Annual capacity: 140 000 tons of multilayer polymer coated

packaging boards *
Coating machines: BL 922, machine width 200 cm
BL 923, machine width 200 cm

Karhula Mill, Finland

Karhula Mill is specialised in co-extrusion technology combin-

ing different polymers to produce polymer coated boards for
liquid and food packaging applications.

Annual capacity: 45 000 tons of multilayer polymer coated

packaging boards *
Coating machine: PE 4, machine width 201 cm

51 Stora Enso Consumer Boards Production and Service facilities *) in 2006 << Contents

8.3 Partner Services
Stora Enso Consumer Boards’ partner services focus on
promoting innovativeness and enhancing the efficiency
and profitability of fibre-based packaging, thus adding
permanent value to our cooperation with the packaging
community.
ServiceCentres for reliability and maximum efficiency
The mission of Stora Enso ServiceCentres is to meet
customers’ individual material needs with maximum ef-
ficiency, flexibility and reliability. Major European markets
are supplied with prompt deliveries of premium boards
and grades coming from various Stora Enso mills. The
ServiceCentres are located in the middle of main market
areas and equipped with high-performance sheeting
machinery.
Based on a massive sheeting capacity of 80 tonnes per
day, ServiceCentre Baienfurt in Germany offers the
concept of 2-5 servicing. This means ex-mill deliveries of
boards from Baienfurt and other European mills within
two working days from standard sheet stocks and within
five working days from reel stocks. system integration possibilities utilizing PapiNet XML
ServiceCentre Cartiberia in Spain serves customers
in the general packaging and graphical industries with
boards from the Barcelona, Ingerois, Skoghall and Imatra
mills. The ServiceCentre has a standard delivery time of
three to five days ex-factory.
Other ServiceCentres are in operation in Germany, Swe-
den and the UK.
Location of Stora Enso
ServiceCentres
<< Contents Stora Enso Consumer Boards Production and Service facilities 52
Stora Enso
Consumer Boards Production and
Service facilities
InnoCentre
InnoCentre presents a new interface to the future of
fibre-based packaging. On the strength of major invest-
ments made in people, machinery and equipment,
InnoCentre functions as a vehicle for vertical innovation,
proactively testing new technology and devising innova-
tive packaging concepts. The results of the development
work can take many forms, including improved logistics
solutions and novel packaging business models. The
services of InnoCentre are available to all our partners in
the packaging value chain.
PartnerWeb
PartnerWeb is Stora Enso’s dedicated online real-time
software system for managing the supply chain. The so-
lution employs an ordinary Internet interface to access a
customer-specific application that lets the user track and
manage the entire order-to-delivery process. PartnerWeb
is used daily by an increasing number of our key part-
ners for improved operational efficiency and drastically
reduced routine work. PartnerWeb also supports direct
messaging.
For more information visit our dedicated site at
www.storaenso.com/partnerservices.
OSKARSHAMN
LUMIPAPER LÜBECK
BAIENFURT
CARTIBERIA
 Testing
Methods

<< Contents Testing Methods 53

Testing
Methods

9. Testing Methods

Automated laboratory testing

This chapter describes the testing methods
used for different types of paperboards. These
measurements are made in order to guaran-
tee the consistent, high quality of our
products. In the mill environment, testing is
conducted using online, autoline and manual
laboratory measurements.
The most important routine quality con-
trol tests of different products are described in • Basis weight
this chapter.
There are automated laboratory test stations (later referred
as Autoline) in the paperboard laboratories. These testing
devices can be equipped with instruments such as:
• Two-sided gloss
• Caliper (thickness)
• Two-sided smoothness (PPS)
• Two-sided roughness (Bendtsen)
• Porosity (Bendtsen)
• Burst strength (Mullen)
• TSO (Tensile Stiffness Orientation)

The Autoline measuring devices measure and move 30

Testing standards and calibration
The tests apply to ISO, SCAN and TAPPI standard
methods. If standards are not available, the mill’s own
methods, or methods developed in cooperation with
customers, are used to predict the properties of the
product. Testing is performed using modern devices and
most of the tests are made in standard conditions. The
standard conditions are: 23°C temperature and 50%
relative humidity according to the standard ISO 187
(SCAN-P 2:75).
cm-wide cross-profile samples automatically. The results
are saved in the computer and transferred automatically
to a quality-data handling system.
Manual laboratory testing
Sheets across the machine reel are delivered to the
laboratory for manual testing by the machine person-
nel. The size of a single sheet is 30 cm x 30 cm and the
number of sheets depends on the width of the paper-
board machine. Testing is performed seven days a week
in three shifts.

Testing methods Every machine reel is tested according to the procedures

described in the ISO 9001 system. Some of the proper-
Online testing ties are tested across the web in many positions and
some in one position only. In quality control, most of
Online testing is used to measure the most important the tests are performed immediately after production,
properties of the paperboard. The measuring head of without air conditioning.
the process computer measures basis weight, caliper
and moisture continuously from every machine reel. The
online measurement provides data throughout the entire
machine reel and enables the machine personnel to
control the basic properties of the paperboard simultane-
ously.

The machine personnel check the entire machine reel

visually at every reel change. They also check impurities,
colour and formation from the cross-profile sample. The
online measurement properties – grammage, caliper,
moisture and brightness – are also calibrated or tested in
the laboratory.

54 Testing Methods << Contents

 Testing
Methods

General properties Surface properties

Grammage Unit: g/m2 Roughness (Bendtsen) Unit: ml/min

ISO 536:1995 ISO 8791-2:1990

Grammage is determined by weighing a known area of a
sample. The grammage is measured both online and by
Autoline.
Thickness Unit: µm
ISO 534:1988
SCAN-P 7:96
Thickness is defined as the distance between the two
outer surfaces of a single sheet measured at 100 kPa
pressure and over a 200 mm2 test area. In addition to
the online testing, thickness is measured by Autoline.
Moisture Unit: % ring and the sample is measured by a flow meter, which
ISO 287:1985
Moisture is measured by the online testing. The mois-
ture content is also checked daily in the laboratory with
a measuring device that uses microwaves to determine
the moisture level. In addition to these measurements,
weekly calibration is performed by determining the loss
of weight of samples dried at a temperature of 105°C.
Roughness is defined as the flow of air which leaks be-
tween the surface of a sample and a metal ring pressed
against the surface under specified conditions. Rough-
ness is measured on both sides of the sheet and the test
is carried out by Autoline.
Smoothness (PPS) Unit: µm
ISO 8791-4/1992
In the Parker Print Surface (PPS) smoothness test,
smoothness is defined as the average distance between
the paperboard surface and a metallic ring pressed
against the sample under specified conditions. Air flows
inside the metal ring. The air leakage between the metal
converts the value to µm. The PPS smoothness testing
method provides more information about micro-scale
roughness than the Bendtsen method.
Porosity (Bendtsen) Unit: ml/min
SCAN-P 60:87
ISO 5636-3:1992

Porosity (ml/min) is determined by measuring the

Physical strength properties amount of air that flows through a given area of the
sample.
Stiffness (L&W) Unit: mN
ISO 2493:92
SCAN-P 29:95

Stiffness is determined by measuring the bending force

required to deflect a sample from its original position
when one end of the sample has been anchored. Stiff-
ness can be measured as bending stiffness DIN 5°, bend-
ing moment Taber or bending resistance L&W 15°. For
example, in the L&W bending resistance test, the bend-
ing distance is 50 mm for paperboard and 10 mm for
paper. Testing is conducted in both machine and cross
directions by a stiffness tester. Taber stiffness is measured
according to the TAPPI 489 standard.

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Testing
Methods
Optical properties
In Europe, the ISO standard is normally used to mea-
sure brightness. When the brightness is expressed as
ISO brightness, C/2 light must be used for the mea-
surements. Since C/2 light does not take into account
the effects of OBA (optical brightener) and dyes, this
measurement gives lower brightness values compared
to measurements using D65 light. D65 brightness takes
into account the effects of both OBA and dyes.
The CIE whiteness measurement uses a wider wave-
length and corresponds more closely to how human
eyes recognize the whiteness.
TAPPI brightness, measured with GE equipment, is used
in the US.
Brightness D65/10 Unit: % mined by calculating the difference between brightness
SCAN-P 3:93
Brightness C/2° Unit: %
ISO 2470:99
(ISO –Brightness)
CIE Whiteness D65/10 ISO 11475, SCAN-P 66:93
L*a*b* D65/10 SCAN-P 72
L*a*b* C/2 ISO 5631
Opacity Unit: % result is expressed as the percentage of light reflected.
ISO 2471
Brightness (%) is defined as the intrinsic reflectance
factor measured at an effective wavelength of 457 nm.
For measuring brightness, D65/10° illumination with a
defined amount of UV light is normally used.
56 Testing Methods
Although two sheets may have the same brightness,
there can be a large difference in visual perception. Vis-
ual differences can be estimated from differences in the
L* a* b* colour coordinates in the CIELAB colour space.
L* is the scale for the whiteness impression, ranging
from 0 (black) to 100 (white). a* measures shades in the
red/green area. Positive a* indicates red, while a negative
a* value indicates a green shade. b* measures shades in
the yellow/blue area. Positive b* indicates yellow, while a
negative b* value indicates a bluish shade.
CIELAB colour space
The L&W Elrepho method measures brightness, colour
properties, fluorescence and many other optical proper-
ties by using different lights and angles.
The amount of optical brightening agents is also deter-
D65/10 unfiltered and brightness D65/10 with a 420 nm
cut-off filter.
Gloss (Hunter) Unit: %
TAPPI T480 om-99
ISO 8254-1:1999
The surface gloss of the coated paperboard or paper is
determined as the reflectance of light from the sheet
surface. The light strikes the surface at an angle of 75°
and the reflection is recorded by a photoelectric cell. The
The gloss is measured by the Hunter Gloss Tester in the
Autoline and is calibrated with a test piece of known
reflectivity.
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 Glossary

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Glossary

10. Glossary

Technical Glossary
absorbency: ability of a paperboard to take up and retain a liquid with which it is in contact
blade coating: most widely used coating method, in which excess coating material is scraped off by a blade
bleaching: removal and/or modification of coloured components in pulp to improve brightness, carried out in
one or more consecutive stages
broke: paperboard discarded during manufacture or converting; usually repulped
bulk, specific volume: reciprocal of paperboard density, also known as specific volume
calendering: operation carried out by means of a calender on the, at least partially, dried paper or paperboard,
with the aim of improving the finish, the process permitting some control of the thickness of the
paperboard
caliper, thickness: thickness of paperboard
chemical pulp: pulp produced by using cooking chemicals which dissolve lignin, the glue in the wood,
to release the cellulose fibres
chemi-thermomechanical
pulp, CTMP: chemi-thermomechanical pulp; pulp produced by refining chemically impregnated,
preheated woodchips
China clay, kaolin: mineral used in paperboardmaking, as both filler and coating pigment
CIE whiteness: degree of whiteness measured according to recommendations of the CIE
(Commission Internationale de l’Eclairage)
CKB,
Coated Kraft Back Boards: paperboard consisting of either bleached chemical pulp or a mineral-coated top layer or both, an
unbleached back and a middle layer of unbleached chemical and/or mechanical pulp; used for
packaging food and non-food products
coating: process by which paperboard is coated with an agent to improve its brightness and/or printing
properties or its barrier properties; layer of extruded plastic on paperboard provides barrier
properties or good printability for the substrate; layer of pigments and binding materials, such as
latexes, improves printability of paperboard
CTMP, see: chemi-thermomechanical pulp
deinked pulp, DIP: recovered paper pulp which has been de-inked through chemical or mechanical processing
digital printing machine: printing machine that prints directly from a computer data file onto paperboard, using the same
image transfer techniques as are used in copiers and printers; often includes binding operation
DIP, see: deinked pulp
FBB, Folding Boxboard: multi-layer paperboard, often mineral-coated, with an outer layer of sulphate (kraft) pulp and middle
layer of mechanical pulp (groundwood, pressure groundwood or TMP; in top grades CTMP pulp may
also be applied); used primarily for consumer cartons for packaging of dry or moist foods, cigarettes
and other consumer products; also used in the graphical industry for catalogue covers, postcards and
folders, etc.
Folding Boxboard, see: FBB
filler: substance (often white pigment) added to the furnish in order to improve paperboard properties
fully bleached pulp: pulp that has been bleached to the highest brightness attainable
furnish: mixture of pulps and fillers which is processed by the paperboard machine to make paperboard
gloss finish: shiny and highly reflective surface quality of paperboard obtained by gloss calendering
grade: classification of paperboards differentiated from each other on the basis of their content, appearance,
manufacturing history, and/or their end use
grammage, gsm: mass of paperboard divided by area, typically expressed as g/m2; one of the basic units to specify
a paperboard grade

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 Glossary

gravure printing, rotogravure: printing process where the image is engraved (electronically or chemically) in the form of
cells in the surface of a metal cylinder
groundwood pulp, mechanical pulp: mechanical pulp manufactured by grinding wood, against a grindstone for example
gsm, see: grammage
hardwood: wood from a deciduous broad-leaved tree (such as birch, oak, beech, aspen or eucalyptus)
as distinguished from that of conifers
ISO brightness,
diffuse blue reflectance factor: intrinsic reflectance factor at an effective wavelength of 457 nm; measure for the bright
ness of paperboard
kaolin, China clay: mineral used in paperboard making, as both filler and coating pigment
laminated: product overlaid with a layer of plastic foil or veneer
lignin: polymer which binds the fibres in the wood together and gives them stiffness
long fibre pulp: pulp produced from softwood (softwood pulp)
matt finish: matt calendered surface resulting in a dull finish to the surface of paperboard and
having a diffuse reflection; opposite of gloss finish
mc, see: moisture content
mechanical pulp, groundwood pulp: mechanical pulp manufactured by grinding paperboard, against a grindstone for example
moisture content, mc: weight of water contained in wood, expressed as a percentage of the weight of the oven-
dry paperboard
offset press: printing press using an offset method, whereby the image is transferred from the plate
cylinder onto paperboard via a blanket, plate or impression cylinder
opacity: property of paperboard that prevents show-through of printing, the opposite of
transparency
optical characteristics: characteristics of the appearance of paperboard, the most important of which are
shade, brightness, opacity and gloss
permeability: ability of a surface or coating of paperboard to allow passage of a gas, liquid or vapour
permeance, porosity: combined volume of the pores, capillaries and other voids between the fibres and fillers in
a paperboard
plastic coating and laminating: coating of paperboard by polymers, typically polyethylene, and/or laminating with
other materials, typically aluminium foil, plastic film or other paperboard
plate: any material used to make a printed impression by letterpress, gravure or lithography
porosity, see: permeance
press: sets of opposing parallel rolls in a paperboard machine through which the paperboard web
passes during manufacture and between which it is subjected to pressure, at the same time
increasing the dryness of the paperboard
primary fibre, virgin fibre: wood fibre never before used to make pulp or paperboard
printability: function and interaction of paperboard with other components, e.g. the ink in the printing
process; subjective assessment judged from the printing result and covering all the paper-
board properties that influence the results of printing an image. Compare: runnability
recovered paper: Used paper and board separately collected for re-use as fibre raw material in paper and
paperboard manufacture
reel-fed web offset printing: printing on a continuous roll of paperboard in a printing press which uses a curved
printing plate mounted on the plate cylinder (HSWO)
rotogravure, gravure printing: printing process in which the image is engraved (electronically or chemically) in the form
of cells in the surface of a metal cylinder
roughness: degree of roughness of the surface of paperboard; opposite of smoothness

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Glossary

runnability: feature covering all the paperboard properties that create a trouble-free run through a
paperboard machine or printing press (also how well cartons run on an automatic
packaging line); see printability
SBS, Solid Bleached Sulphate Board: paperboard consisting of one or several layers of bleached chemical pulp, often also
pigment coated, used in the graphical industry and for various consumer cartons for
packaging dry or moist food products and in the non-food sector, typically for cigarette
and luxury goods cartons
sheet-fed offset printing: offset printing where individual pieces of paperboard are fed into the press
short fibre pulp: pulp produced from hardwood (hardwood pulp; e.g. birch, oak, beech, aspen, eucalyptus)
sizing: process where a sizing agent (e.g. starch, ASA) is added to the paperboard to increase
strength and decrease absorbance
smoothness: degree of evenness and regularity of the surface of a paperboard sheet; opposite of
roughness
softwood: wood of pine, spruce, or other conifers; with the advantage of having long fibres which
enhance the strength of paperboard
Solid Bleached Sulphate Board, see: SBS
specific volume, bulk: reciprocal of paperboard density, also known as specific volume
SUB (Solid Unbleached Board): paperboard used for food and non-food cartons, consisting of a bleached chemical pulp
or a mineral-coated top layer or both, an unbleached back and unbleached chemical
and/or mechanical pulp middle layers
sulphate pulp, kraft pulp: chemical pulp produced by cooking woodchips in an alkaline solution of sodium hydroxide
and sodium sulphide
tearing resistance: mechanical property of paperboard, force needed to tear paperboard
thickness, caliper: thickness of paperboard
TMP, thermomechanical pulp: mechanical pulp produced by the pressurized pre-steaming of woodchips prior to defibra-
tion in a refiner
web fed offset printing, web offset: offset printing on a roll of any substrate that passes continuously through a printing press
White Lined Chipboard, WLC: paperboard made mainly or wholly from recovered fibres, often mineral-coated, and
used for consumer cartons for dry food and non-food products as well as graphical
end uses
virgin fibre, primary fibre: wood fibre never before used to make pulp or paperboard
WLC, see: White Lined Chipboard

60 Glossary << Contents