European Database for Cartonboard and Carton Production 2023

12
Figure 2
Typical layout of a carton production plant 3
The design for a carton is either sent to the carton producer or developed by them. The
graphics are prepared on a computer and colour separation is carried out. From this a
printing plate for each colour is prepared. At the same time a “layout” is designed, with
the aim of achieving the optimal board usage and therefore minimising shape waste
(many cartons can be printed on each sheet of cartonboard and so a layout is worked out
to ensure that as little cartonboard as possible is left unused). The layout is also used to
prepare the cutting and creasing forms that are used later in the production process.
The cartonboard, in either sheets or reels, is loaded into the printing machine and
printed in one pass with each colour being added in turn. A variety of printing processes
may be used, including for example offset/lithographic, flexographic and gravure
processes. In some cases, digital printing may also be used. This is an emerging
technology that is expected to become more important for carton production in the
future.
Most cartons are printed using six colours at a time but less or more can also be used. As
well as the colours, a varnish to improve gloss, or to add a highlight, is also usually
printed after the colours.
At the end of the print machine, the sheets are stacked up and moved to the next stage of
production – cutting and creasing. The printed sheets of cartons are taken to a machine
that cuts the cartons and also puts in the creases that enable it to be folded in a later
operation. This is done using a form into which are set knives and creasing rules to
achieve the desired result. It is also possible to add embossing during this operation.
Accuracy is critical to ensure the cuts and creases are in exactly the right position.
3 Source: https://www.procarton.com/why-cartons/carton-production/
© RISE Research Institutes of Sweden