Corrugated board
Corrugated board - stock
Corrugated Board
Manufacturer: Norboard
Norboard grades are produced in a wide range of flute and liner combinations, to meet the varying requirements of our many customers. Made at a dedicated plant the range offers excellent print and design properties to ensure outstanding brand impact in packaging and display.
The liners available include
- Kraft and Test Liners with Whites being a particular speciality
- Fully coated liners, including coated Kraft, coated Test and Clay Coat
- Light coated liners specifically for flexographic print which are also suitable for other processes
- Unlined chip liners
- Pre printed liners
All the main print and impression processes are possible on Norboard including,
- Offset litho (sheet fed)
- Flexo (sheet-fed)
- Digital
- Silk Screen
- Preprint
- Blind embossing
- Roller embossing
- De-bossing
- Foil blocking
- Engraving, lamination processes.
Resources
Environmental Issues
Most Norboard grades already contain substantial percentages of recycled fibres (up to 85% in most cases). Norboard liners/grades, where applicable, are supported by chain of custody accreditation, i.e. FSC and PEFC. Every generic board grade is also 100% recyclable and complies with EC regulations concerning recyclability, biodegradability and compostability.
Norboard also complies fully with regulations concerning heavy metal content and DIPENs (Di-isopropylnaphthlanese). Where applicable Norboard food grade liners are supported by the appropriate compliance certification.
Storage and Handling
Corrugated Board: Storage and Handling
PRESENTATION
Norboard is manufactured to specific tolerances and cured before any further working of the material. The majority of Norboard is reworked once stable and put through an aerator-jogger to clean and tidy the pallet stack.
The board is cured in stable, controlled conditions before re-working, to ensure that there are no moisture and temperature variations in the board. Without this control, there would be a danger of board movement post-despatch, which might affect the shape and surface quality.
Once cured, Norboard sheets are stacked one side up with no reverse handfuls. This is of course critical in offset and silkscreen printing. All print process materials are presented press ready. For offset grades, the boards are singularly orientated. It is important to specify if the board is to be printed both sides, to guarantee correct presentation.
Finally the pallets are enclosed in pallet wrap rather than shrink wrap, to ensure better board stability in transit. Pallet wrap also offers far better board protection against the elements.
STORAGE
As a natural product, Norboard is susceptible to environmental changes just like any other board. The stringent curing protocol ensures that the board is despatched in the most stable condition possible. During the manufacturing process all grades are continually checked for stability using an Absolute moisture/reader tester. As long as the board is stored in constant conditions and not moved regularly between different environments, it should remain in a pristine condition.
One thing to bear in mind is that sometimes storage areas are very dry environments, so dry in fact (especially in winter) that the R.H. (relative humidity) of the surrounding air around the pallet can drop below 40%.
This will lead to excessive static build up in the board which can result in productivity loss. For offset litho it can prevent the board feeding on press.
It is essential to keep the pallets wrapped until required, and to unwrap them, as detailed in the next section, as the ambient R.H at Norboard ensures that the boards' own R.H is fit for purpose.
Do not stack Norboard pallets more than three high, as the compression exerted will lead to board crush and loss of performance. On offset printing grades, the over compression will potentially lead to an unfeedable board shape, or reduce board performance.
HANDLING
Norboard is supplied in a stable, cured, press ready condition and should not be unwrapped prior to use. This is especially pertinent for printing, particularly offset, as potential further "conditioning" could lead to board shape movement and feeding difficulties. The only time that we would condone unwrapping prior to use would be if the board store area were controlled for temperature and R.H. Otherwise, unwrap and go straight to press, or to the pile turner if you wish to use one.
Once printing is over, please ensure that the board is kept stable to ensure trouble-free finishing. A good tip is to re-use the original pallet top boards by replacing them back on the stacks.
Finishing Information
Corrugated Board: Finishing Information
Cutting and Creasing
Most Norboard grades are suitable for cutting and creasing. The only exception is Norboard Display Board in calipers of 2000 micron which should be scored in the same way as solid display boards, using enough depth on the score to pierce the top liner and expose the fluting. This will ensure the fold is successful.
For all other Norboard grades, we recommend full matrix creasing. The creasing formula is based upon the crushed caliper of the board rather than the total caliper of the board before crushing. For example, for a G flute carton grade with a thickness of 900 microns, the crushed caliper will be around 550/600 microns so you would be able to choose between two and three point rule.
Normally you can use a finer creasing rule when creasing with the flute direction than when creasing across the flutes. The main reason for this is to ensure that the rule width does not exceed the flute tips and want to follow the flute rather than the creasing rule. Across the flutes you can afford to use wider creases as they will not be affected by the flute tips.
Cito recommendation of die creasing specification
Norboard material | Cutting rule | Creasing rule | Cito recommendation |
1000 Display - crush caliper 0.750 | 23.80 | 23.00 - 3 point | 0.8 x 2.7mm RY+Profile |
1250 Display - crush caliper 0.750 | 23.80 | 23.00 - 3 point | 08 x 2.7mm RY+Profile |
OR | 08 x 2.7mm IK+Profile | ||
900CWB - crush caliper 0.560 | 23.80 | 23.20 - 2 point | 06 x 1.9mm RY+Profile |
900CKB - crush caliper 0.585 | 23.80 | 23.20 - 2 point | 06 x 1.99mm RY+Profile |
900CBB - crush caliper 0.500 | 23.80 | 23.25 - 2 point | 06 x 1.9mm RY+Profile |
In all of the above cases please bear in mind that RY can be substituted by IK
It is critical when die cutting corrugated board, the Shore A hardness of the rubber does not exceed 30o Shore A. Most solid board rubber hardness will be at least double this figure and will damage the crease by collapsing the walls and creating cracking. This is especially prevalent on recycled grades with their shorter fibres. All cutting forms should be based upon a 23.80 cutting height.
Creasing depths will vary due to the nature of the crease and the material itself. Either 15mm or 18mm Ply baseboard should be used, dependent upon the thickness of the material being cut and creased. When forming for corrugated, it is always advisable to chamfer or taper flaps into straight creases or better still to use radii. This will elevate cracking and provide proper creasing.
Before die cutting Norboard you should ensure that the pallet of board has not been crushed by any previous treatment. This would be apparent from the "wedge" shape in the stack. If the pallet displays such characteristics then the previous treatment (normally printing) needs addressing. Obviously the flatter the board the better the die cutting and there should not be any subsequent gluing problems.
Norboard grades, with their inherent strength and lightness, die-cut beautifully without any productivity problems.
GLUING
Norboard is both suitable for PVA and hot melt gluing and behaves impeccably through all applicable gluers as long the die cutting has been accurate. Any problems created during die cutting will lead to misaligned cartons/displays which in some cases will be rejected or will fail during use. Therefore you should ensure that the die cutting is correct before questioning the material.
Some recycled grades can be weakened by gluing, especially with spot glue on flaps, resulting in the possibility of the carton/box opening when it should not. If in any doubt please discuss the board composition with our technical department to ensure that this does not occur.
GUILLOTINING
With the finer fluted Norboard grades that use G or certain F flute profiles, you can use standard guillotine setups. The only stipulation is that the clamp plate pressure should not normally exceed 1000kgs and the bundle heights should not exceed 50mm/2". This is because, despite having small flute profiles, they still crush under pressure and the board will mark. To compensate for this, it is always beneficial to back trim Norboard when guillotining.
For all forms of corrugated board, a flexible clamp plate is a must! This creates the effect of a shock absorber and alleviates crushing by the clamp plate. Having the flexible clamp plate will allow larger bundles of board to be cut on the finer flutes than the 50mm/2" limit mentioned above and for bigger flutes, such as B, E or twin(double) wall,will allow guillotining without clamp marks or crush. The bundle heights would depend upon the material specifications, however 100mm/4" should be possible. Some jobs, especially those printed with heavy UV solids (inks) or UV varnishes which are prone to cracking (this is due to the heat in the UV process drying the board out) will again benefit from back trimming.
Printing and Laminating Information
Corrugated Board: Printing and Laminating Information
OFFSET LITHO PRINTING
G Flute is most commonly used for direct litho printing with increasing numbers of printers now using F Flute and some printers with specialist presses are printing direct offset onto E Flute.
- It is not necessary to pile turn the board.
- Push or Pull sidelays are fine.
- Specialist blankets are not required
- Extended feed tables are not necessary.
- Norboard is suitable for printing with both conventional inks and UV inks.
FLEXOGRAPHY HQPP
For top end Flexo work, Norboard provides a full range of suitable materials tailored to customers specific requirements and palletised to suit your feeder style. The Norboard development team is also following changes in flexo technology to ensure their products can support new developments.
- E, B, C, FE, FB, EE, EB and BC Flute can be succesfully fed depending on press configuration. Adjustments to the machine may be necessary for G and F Flutes.
- Flute shadow is greatly reduced when using a grade with a small flute e.g. F Flute.
- Whenever possible board should be fed in the flute direction.
- Special flexographic inks are not generally needed on a HQPP press, however a faster drying resin should be used for assisting the drying on clay coat liners.
- UV varnishes are commonly applied to HQPP work on microflutes.
- Generally all HQPP is produced upon coated board.
- It is necessary to "fingerprint" the press before printing Norboard materials.
DIGITAL
This is a rapidly developing area in which Norboard products are being used and all the Display grades are suitable for Digital printing. With the flexibility on the corrugator Norboard are able to provide board sizes and stability to cope with the exacting demands of Digital. They are also able to provide pre-primed materials to meet digital press demands.
- All Norboard display grades are flat and will accept digital print without warping.
- The coating on the sheets generally accept digital printing.
SCREEN
There are many Norboard grades suitable for silk-screen printing, including all the usual clay-coated grades plus coated white lined chips and light-coated liners, in a range of flute profiles. However, with the increasing demand from customers for more colours, better graphics and reduced or removed flute shadow, Norboard offer alternative fluting types and combinations, these include the new FB flute unique to Norboard.
The superior printing surfaces Norboard offer by grades allow you to run finer screens, saving on ink and wastes whilst improving the graphics.
- Norboard is not affected by multiple passes through screen printers and UV dryers.
- Flute profile does affect the quality of the print. It can be more cost effective in the long run to use a higher flute profile. i.e. FE would be better than using B Flute.
- For two sided printing Norboard recommend using Norboard Display Board.(See makings page).
LAMINATION
Grades available:
- Single faced B and E flutes
- Open faced EB or FE
- Specific lined E, B, EB, EE, FE or FB flutes
Norboard specifically line the grades to ensure correct moisture adherence and material balance to counter potential post-lamination warp and or de-lamination. All materials are supplied palletised correctly to optimise the lamination process controls. Please refer to the sales office for further information concerning successful lamination.
PREPRINT
Norboard grades can be manufactured using preprinted liner supplied by their sister company, Smurfit Kappa Preprint. They use larger polymer printing plates with a maximum size of 2032mm x 1320mm. Deckles range from 800mm to 2300mm, with a maximum print width of 2236mm, and print cut to mark ranges from a minimum of 790mm to a maximum repeat of 2010mm. there is no minimum or maximum linear metreage and most substrate types can be used with grammage from 60gsm up to 360gsm.
- Preprinted liners are available in up to 6 colours excluding varnishes.
- they can Pantone colour match.
- they can offer 100% flood print, laser engraved continuous print and fine screen Anilox with the ability to print at 120lpi.
- Barrier coating and natural metallic inks can be used with preprinted board.
- Preprinted liners are available with both UV and Acrylic varnishes.
- There is no flute shadow on pre-printed work.
- The board can be pre-printed on both sides.
- All Norboard flute profiles can be used with preprint.
- All preprinted liners are printed with waterbased inks and are environmentally friendly.
EMBOSSING AND BLOCKING
The finer flutes G and F, are eminently suitable for embossing and blocking. It is important to take care in setting up and make ready. The main consideration must be the compressibility of the board; therefore allowances need to be made on the hit pressures and on the sizes of rhe male and female components. For certain designs of blind embossing greater relief is preferable.
Caliper Range
Norboard Caliper Range
The range of calipers that Norboard offers is made up from a combination of flute profiles and liners.
Norboard tolerances are based upon the following
- Caliper+/- 5% (caliper=thickness)
- Board dimensions +/- 1mm
- Nominate total board weight +/- 5%
The average caliper range based upon flute profiles is as follows
Single Wall Sheet Double Wall Sheet
E Flute | 1500 - 3200 microns | EE Flute | 2700 - 4600 microns |
B Flute | 2600 - 3300 microns | EB Flute | 3800 - 5500 microns |
Product Range
B flute 180dc/120kb
Part
Description
Width
Length
CORRB-2800-1067-1575
DIGIFLUTE B FLUTE 180DC/120KB *FSC* 1067(F) X 1575
1067
1575
Part | Description | Width | Length |
CORRB-2800-1067-1575 | DIGIFLUTE B FLUTE 180DC/120KB *FSC* 1067(F) X 1575 | 1067 | 1575 |
E flute 180dc/120kb
Part
Description
Width
Length
CORRE-1600-1067-1575
DIGIFLUTE E FLUTE 180DC/120KB *FSC* 1067(F) X 1575
1067
1575
CORRE-1600-1575-1067
DIGIFLUTE E FLUTE 180DC/120KB *FSC* 1575(F) X 1067
1575
1067
CORRE-1600-1600-1040
DIGIFLUTE E FLUTE 180DC/120KB *FSC* 1600(F) X 1040
1600
1040
CORRE-1600-1600-2152
DIGIFLUTE E FLUTE 180DC/120KB *FSC* 1600(F) X 2150
1600
2150
CORRE-1600-1600-2452
DIGIFLUTE E FLUTE 180DC/120KB *FSC* 1600(F) X 2450 *1/S PRINT ONLY*
1600
2450
Part | Description | Width | Length |
CORRE-1600-1067-1575 | DIGIFLUTE E FLUTE 180DC/120KB *FSC* 1067(F) X 1575 | 1067 | 1575 |
CORRE-1600-1575-1067 | DIGIFLUTE E FLUTE 180DC/120KB *FSC* 1575(F) X 1067 | 1575 | 1067 |
CORRE-1600-1600-1040 | DIGIFLUTE E FLUTE 180DC/120KB *FSC* 1600(F) X 1040 | 1600 | 1040 |
CORRE-1600-1600-2152 | DIGIFLUTE E FLUTE 180DC/120KB *FSC* 1600(F) X 2150 | 1600 | 2150 |
CORRE-1600-1600-2452 | DIGIFLUTE E FLUTE 180DC/120KB *FSC* 1600(F) X 2450 *1/S PRINT ONLY* | 1600 | 2450 |
E flute 185kg/185kg
Part
Description
Width
Length
CORRE-1600-1600-2451
E FLUTE 185KG/185KG *FSC* 1600(F) X 2450
1600
2450
Part | Description | Width | Length |
CORRE-1600-1600-2451 | E FLUTE 185KG/185KG *FSC* 1600(F) X 2450 | 1600 | 2450 |
Eb flute 180dc/120kb
Part
Description
Width
Length
COREB-3900-1040-1600
DIGIFLUTE EB FLUTE 180DC/120KB *FSC* 1040(F) X 1600
1040
1600
COREB-3900-1067-1575
DIGIFLUTE EB FLUTE 180DC/120KB *FSC* 1067(F) X 1575
1067
1575
COREB-3900-1575-1067
DIGIFLUTE EB FLUTE 180DC/120KB *FSC* 1575(F) X 1067
1575
1067
COREB-3900-1600-1040
DIGIFLUTE EB FLUTE 180DC/120KB *FSC* 1600(F) X 1040
1600
1040
COREB-3900-1600-2150
DIGIFLUTE EB FLUTE 180DC/120KB *FSC* 1600(F) X 2150
1600
2150
COREB-3900-1600-2452
DIGIFLUTE EB FLUTE 180DC/120KB *FSC* 1600(F) X 2450
1600
2450
COREB-3900-2150-1600
DIGIFLUTE EB FLUTE 180DC/120KB *FSC* 2150(F) X 1600
2150
1600
Part | Description | Width | Length |
COREB-3900-1040-1600 | DIGIFLUTE EB FLUTE 180DC/120KB *FSC* 1040(F) X 1600 | 1040 | 1600 |
COREB-3900-1067-1575 | DIGIFLUTE EB FLUTE 180DC/120KB *FSC* 1067(F) X 1575 | 1067 | 1575 |
COREB-3900-1575-1067 | DIGIFLUTE EB FLUTE 180DC/120KB *FSC* 1575(F) X 1067 | 1575 | 1067 |
COREB-3900-1600-1040 | DIGIFLUTE EB FLUTE 180DC/120KB *FSC* 1600(F) X 1040 | 1600 | 1040 |
COREB-3900-1600-2150 | DIGIFLUTE EB FLUTE 180DC/120KB *FSC* 1600(F) X 2150 | 1600 | 2150 |
COREB-3900-1600-2452 | DIGIFLUTE EB FLUTE 180DC/120KB *FSC* 1600(F) X 2450 | 1600 | 2450 |
COREB-3900-2150-1600 | DIGIFLUTE EB FLUTE 180DC/120KB *FSC* 2150(F) X 1600 | 2150 | 1600 |
Ee flute 18odc/120kb
Part
Description
Width
Length
COREE-2750-1600-2200
DIGIFLUTE EE FLUTE 180DC/120KB *FSC* 1600(F) X 2200
1600
2200
Part | Description | Width | Length |
COREE-2750-1600-2200 | DIGIFLUTE EE FLUTE 180DC/120KB *FSC* 1600(F) X 2200 | 1600 | 2200 |
Ee flute 185kg/120kb
Part
Description
Width
Length
COREE-3200-1600-2200
EE FLUTE 185KG/120KB *FSC* 1600(F) X 2200
1600
2200
Part | Description | Width | Length |
COREE-3200-1600-2200 | EE FLUTE 185KG/120KB *FSC* 1600(F) X 2200 | 1600 | 2200 |
Enviro mount
Part
Description
Width
Length
CORDN-1063-1570-0002
ENVIRO-MOUNT CORRUGATED BOARD 1063(F) X 1570
1063
1570
CORDN-1245-1845-0004
ENVIRO-MOUNT CORRUGATED BOARD 1245(F) X 1845
1245
1845
Part | Description | Width | Length |
CORDN-1063-1570-0002 | ENVIRO-MOUNT CORRUGATED BOARD 1063(F) X 1570 | 1063 | 1570 |
CORDN-1245-1845-0004 | ENVIRO-MOUNT CORRUGATED BOARD 1245(F) X 1845 | 1245 | 1845 |
B flute for lamination
Part
Description
Width
Length
CORLA-2800-1062-1571
B FLUTE LAMINATION GRADE 150KK/150KW *FSC* 1062(F) X 1570
1062
1570
Part | Description | Width | Length |
CORLA-2800-1062-1571 | B FLUTE LAMINATION GRADE 150KK/150KW *FSC* 1062(F) X 1570 | 1062 | 1570 |
E flute for lamination
Part
Description
Width
Length
CORLA-1600-0715-1016
E FLUTE LAMINATION GRADE 150KK/150KW *FSC* 0715(F) X 1015
0715
1015
CORLA-1600-1015-0716
E FLUTE LAMINATION GRADE 150KK/150KW *FSC* 1015(F) X 715
1015
715
CORLA-1600-1062-1571
E FLUTE LAMINATION GRADE 150KK/150KW *FSC* 1062(F) X 1570
1062
1570
CORLA-1600-1245-1846
E FLUTE LAMINATION GRADE 150KK/150KW *FSC* 1245(F) X 1845
1245
1845
CORLA-1600-1570-1062
E FLUTE LAMINATION GRADE 150KK/150KW *FSC* 1570(F) x 1062
1570
1062
Part | Description | Width | Length |
CORLA-1600-0715-1016 | E FLUTE LAMINATION GRADE 150KK/150KW *FSC* 0715(F) X 1015 | 0715 | 1015 |
CORLA-1600-1015-0716 | E FLUTE LAMINATION GRADE 150KK/150KW *FSC* 1015(F) X 715 | 1015 | 715 |
CORLA-1600-1062-1571 | E FLUTE LAMINATION GRADE 150KK/150KW *FSC* 1062(F) X 1570 | 1062 | 1570 |
CORLA-1600-1245-1846 | E FLUTE LAMINATION GRADE 150KK/150KW *FSC* 1245(F) X 1845 | 1245 | 1845 |
CORLA-1600-1570-1062 | E FLUTE LAMINATION GRADE 150KK/150KW *FSC* 1570(F) x 1062 | 1570 | 1062 |
Eb flute for lamination
Part
Description
Width
Length
CORLA-3900-1062-1571
EB FLUTE LAMINATION GRADE 150KK/150KW *FSC* 1062(F) X 1570
1062
1570
CORLA-3900-1245-1846
EB FLUTE LAMINATION GRADE 150KK/150KW *FSC* 1245(F) X 1845
1245
1845
CORLA-3900-1505-2046
EB FLUTE LAMINATION GRADE 150KK/150KW *FSC* 1505(F) X 2045
1505
2045
Part | Description | Width | Length |
CORLA-3900-1062-1571 | EB FLUTE LAMINATION GRADE 150KK/150KW *FSC* 1062(F) X 1570 | 1062 | 1570 |
CORLA-3900-1245-1846 | EB FLUTE LAMINATION GRADE 150KK/150KW *FSC* 1245(F) X 1845 | 1245 | 1845 |
CORLA-3900-1505-2046 | EB FLUTE LAMINATION GRADE 150KK/150KW *FSC* 1505(F) X 2045 | 1505 | 2045 |
Corrugated board - direct mill makings
Apart from the Clay Coated Sizes we keep in stock, Norboard is made to order at bespoke sizes, therefore there is a minimum order for each sheet size. For clay coated this is usually 500 square metres and lamination grade is usually 1000 square metres, whilst for other grades it is 1500 or 2000 square metres.
Always check with our sales office before ordering as to what is the minimum order quantity on the specific make up of board required.
The normal lead time for Clay Coat and Lamination grade bespoke orders is usually 3 to 4 working days with conventional grades lead time normally 2 to 3 days. It is always best to check delivery times before ordering as these can be extended at busy times.
Resources
Minimum and Maximum sizes
CORRUGATOR LIMITATIONS
CORRUGATOR 5 - Conventional
B, C and BC Flute
Minimum size 200mm x 540mm, Maximum size 2465mm x 4800mm
CORRUGATOR 4 - Clay Coat, Lamination and some conventional grades.
B, E, and EB Flute
Minimum size 200mm x 540mm, maximum size 2465mm x 2975mm
EE Flute
Minimum size 300mm x 540mm, Maximum size 2465mm x 2975mm
Please note for any board made under 600mm chopped length there is a surcharge of £10.00 per 1000 square metres.