Ch 7 Paperboard Cartons

Question 1

What is a significant advantage of using PAPERBOARD?

Answer 1

Low cost for tooling compared with that for materials for plastic.

Question 2

What are the two major design classifications for FOLDING CARTONS?

Answer 2

TUBE STYLE & TRAY STYLE

Question 3

What are the first things to consider when selecting a carton design? (3)

Answer 3

• Examine the product
• Select the carton style: tube style vs tray style
• Select the closure type

Question 4

What is a SLIT LOCK TUCK CLOSURE when are they typically used?

Answer 4

SLIT LOCK TUCK CLOSURE incorporate small slits between the tuck flap and top closer. When the carton is closed, the slits engage the shoulders cut into the dust flaps.

Used for products with one time entries.

Question 5

It is recommended to utilize a SIMPLE or PLAIN TUCK FLAP CLOSURE for these kind of product considerations? (2)

Answer 5

1) If the carton is to hold another package (such as a bottle)
2) If the consumer wishes to see the product before purchase (via carton window)

Question 6

If the product is heavy what kind of closure is recommended?

Answer 6

LOCKING TABS such as a tongue or edge lock that provide a positive tuck-flap lock.

Question 7

When a carton is manually erected what kind of bottom closure should you use?

Answer 7

HIMES LOCK or 1-2-3 LOCK as the bottom closure

Question 8

When do cartons have to be double glued on the seal end?

Answer 8

Needed for siftproof or contamination free cartons.

Question 9

What type of carton loading is preferred for granular or powdered products?

Answer 9

VERTICAL END LOADING cartons

Question 10

Which carton style is preferred when loading through the largest opening possible? Conversely, what is a disadvantage of this style?

Answer 10

TRAY STYLE CARTONS are preferred.
The disadvantage is that most trays cannot be shipped knocked down flat after it is glued.

Question 11

How is a BRIGHTWOOD TRAY formed?

Answer 11

These are pressed through a forming frame and glued to a stiff-rigid carton shape.

Question 12

What is the definition of STRUCTURAL CONSIDERATIONS? What are some examples? (4)

Answer 12

STRUCTURAL CONSIDERATIONS deal with the physical strength characteristics needed to hold the product successfully during shipping.
Some examples: puncture resistance, stiffness, tensile strength, Z direction.

Question 13

Which characteristics of the paper surface finish are considered during the printing and decorating process? (6)

Answer 13

Color
Brightness
Opacity
Surface Formation
Ink Compatibility
Dimensional Stability

Question 14

List the recommended board thickness for each of the following product weights:
> 0.5 lb
1 lb
2 lb
2 lb <

Answer 14

15 pt - 18 pt
20 pt - 24 pt
28 pt - 32 pt
E or F-flute corrugate

Question 15

Resilient pads on cutting dies are usually made of this material?

Answer 15

TYMPAN

Question 16

What are the first three steps of the CARTON DESIGN PROCESS?

Answer 16

1) IN DEPTH REVIEW - of customer’s needs an objectives
2) CAD SAMPLE - provided to the customer for review
3) SIGN-OFF - on either a CAD sample or hand sample

Question 17

There are 2 congruent paths after SIGN-OFF in the CARTON DESIGN PROCESS. What are the next 3 steps in the DIE-MAKING path?

Answer 17

1) ONE-UP DIE
2) MACHINE TEST
3) PRODUCTION DIE

Question 18

There are 2 congruent paths after SIGN-OFF in the CARTON DESIGN PROCESS. What are the next 5 steps in the GRAPHICS department pathway?

Answer 18

1) DIGITAL PROOFS
2) SIGN-OFF ON PROOFS
3) PRE-PRESS
4) PRINTING PLATES
5) MOUNTING

Question 19

What’s a GABLE TOP carton design and what products are they used for?

Answer 19

GABLE TOP is a tube style carton design where all flaps are gusseted.
Commonly used for dairy products and fruit juices.

Question 20

What is the 5TH PANEL of cartons used for?

Answer 20

Can be used as hangars or to create additional surface area for graphics.

Question 21

What is a GUSSETED BELLOWS CLOSURE and what products is it used for?

Answer 21

Closure that’s used to improve carton appearance by eliminating visible cut edges.
Commonly used for frozen food trays.

Question 22

What is a FOUR CORNERS BEER TRAY and what products are they used for?

Answer 22

FOUR CORNERS BEER TRAY are made in pairs with one slightly larger than the other.
Commonly used for clothing and gift boutiques

Question 23

What is a CHARLOTTE FLAP? Why is it used and on which style of tray carton?

Answer 23

Flaps that are placed on the cover panel. These are used to stiffen and flatten the cover panel and usually used for SIX CORNERS BEER TRAYS.

Question 24

What is a BRIGHTWOOD TRAY (4 OR 6 corner variations) and what advantage do they have?

Answer 24

BRIGHTWOOD TRAYS have a connected enclosing cover to the base but do not have the diagonal slit scores that allow them to be knocked down for shipment (unlike BEERS TRAYS).
Advantage = they are stiff and hold their shape even when empty.

Question 25

WALKER TRAYS and PINCH LOCK TRAYS are the simplest manual setup trays. Describe their locking mechanism.

Answer 25

These trays have doubled end panels that lock in place with a locking slot on the bottom panel.

Question 26

Describe a SIMPLEX TRAY

Answer 26

One of the most popular manual setup trays. They are double walled on all sides which makes them stiffer than WALKER and PINCH-STYLE trays.

Question 27

What kind of paperboard is used for BEVERAGE BASKETS?

Answer 27

They use strong kraft-based paperboards with bleached liners to provide a smooth printing surface.

Question 28

What are the advantages (2) and disadvantages (2) of SET-UP BOXES?

Answer 28

Adv = Can be used as a long-term storage unit. Can also serve as low-cost shippers Dis = Cannot be knocked down flat. Require significant labor to erect and cannot be used for high-speed production.

Question 29

How are SET-UP BOXES formed?

Answer 29

They start as a cut flat sheet that is folded to the box shape and held in place with stay tape.

Question 30

What are some of the used covering materials used for SETUP BOXES (4)?

Answer 30

Printed label stock, vinyl, imitation leathers, and foils

Question 31

What is a WORKING SCORE? Where are they located on the carton?

Answer 31

They are the score flattened during shipping. They are located non-adjacent to the glue flap.

Question 32

What is a FOSE carton and what type of products are they used for?

Answer 32

FOSE stands for full-overlap seal-end carton which is a tube style carton where the closure panels as long as the carton width. These are used for fine granular or powdered products.