European Database for Cartonboard and Carton Production 2023

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10 Pulping and the paper machine The fibre is mixed with water in large hydropulpers until a very fine suspension is achieved. This is then cleaned to remove any contraries, refined to enhance strength and then pumped to the cartonboard machine where the cartonboard is manufactured. In the fibre preparation, before the board making, functional additives are used. The additives provide some degree of water resistance (hydrophobicity) and add internal and surface strength to the product. The dispersed fibres with the functional additives and water mixture from the preparation plant, is pumped to the cartonboard machine and this very thin mixture (< 1% fibres in water) is put onto several continuously moving wire meshes. As the water drains away through the wire mesh the fibres begin to 'set' and then each of the sheets are brought together to form a continuous sheet of cartonboard. This is then pressed between textile felts by large rollers to squeeze more water out and then passed over steam heated cylinders to evaporate the remaining water. When the cartonboard has reached the required moisture content, up to three layers of coating (typically made of clay/kaolin or starch) are added to the surface of the board. These coatings improve smoothness and gloss and are required to achieve the high-quality printing that is needed on cartons. Modern cartonboard machines are large. Typically, they are about 100 metres in length, about 6 metres wide and 25 metres high. They run 24 hours a day, 7 days a week and are only stopped occasionally for essential maintenance. Changes of the board to be made and changes of thickness or weight are carried out on the run and the whole operation is controlled by computers to ensure consistency of production quality. The effective production time on modern machines is in excess of 95%. At the end of the cartonboard machine, the cartonboard is wound into huge reels which are then moved to the finishing department. Here these reels are either cut into sheets of the size the printer requires or into smaller reels that can be used directly on a reel fed printing press. After cutting, the cartonboard is packed and dispatched to the carton producers. Modern cutting machines run continuously, have full computer control, automatic counting and stacking of sheets onto pallets. Customer reels and pallets are wrapped in moisture protective packaging and shipped to customers by ship, train or truck. The mode of transportation is a balanced choice between degree of service to the customer, cost and distance.
11 Figure 1 Understanding the manufacturing process 2 Carton production Carton production starts with the cartonboard delivered from the mills. Figure 2 shows a typical layout for a carton production plant and the types of processes involved. 2 Source: Carton and Board Making: Cartonboard, ProCarton, 2022 © RISE Research Institutes of Sweden
Page 1 and 2: European Database for Cartonboard a
Page 3 and 4: 3 Conclusions .....................
Page 5 and 6: 5 • For WLC, the collected data r
Page 7 and 8: 7 Description of the product system
Page 9: 9 When the raw material source is r
Page 13 and 14: 13 The individual cartons are then
Page 15: 15 Figure 3 Gate-to-gate system bou
Page 18: 17 Figure 4 Gate-to-gate system bou
Page 21: 19 Figure 5 System boundaries for t
Page 24 and 25: 21 Data collection for carton produ
Page 26 and 27: 23 Chemicals and other non-fibre in
Page 28 and 29: 25 Allocation of residues to paper
Page 30 and 31: 27 Transport The transport distance
Page 32 and 33: 29 treatment on the site, biogas or
Page 34 and 35: 31 Data Coverage and comparability
Page 36 and 37: 33 Table 2 Gate-to-gate life cycle
Page 38 and 39: 35 Recycled cartonboard Virgin cart
Page 44 and 45: 41 Method of disposal or recovery 9
Page 46 and 47: 43 surveys, it is no longer necessa
Page 48 and 49: 45 previous survey in 2018, the sha
Page 50 and 51: 47 Definitions Allocation - Techniq
Page 52 and 53: © RISE Research Institutes of Swed

European Database for Cartonboard and Carton Production 2023

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