The Best of Both Worlds Gets Better
March 2000
|
Still-smaller flutes and sophisticated print capabilities strengthen microflute's ability to perform double duty.
By Jessica Millward
For the past several years, microflute corrugated's marriage of structural strength and high-quality graphics has proven to be a match made in packagers' heaven. With the development of E- and F-flute boxes in the '90s, the line between folding carton and corrugated converters was blurred, and customers reaped the benefits. Time, and technology, marches on, however, and the microflute industry has kept pace with the evolution of still-smaller calipers and new ideas about printing.
The small flute segment comprises roughly 9 percent of total corrugated shipments in North America, according to Bob Nebeling, product business manager of corrugator equipment at the Bobst Group. He also reports that the annual growth rate of mini-flute applications is between 12 percent and 15 percent. It's clear that microflute is a growth market, but what isn't so clear is precisely what shape that growth will take. While the largest share of production continues to belong to E- and F-flutes, the introduction of N- and G-flutes may change statistics in the years to come.
Under the ‘micro'-scope
N-flute substrates, typically run on Asitrade sheet-to-web machines, possess 90 percent more flutes per foot than E-flute and 42 percent more than F-flute. As Nebeling observes, N-flute's folding, forming, and handling characteristics are much closer to carton board than E- or F-flute. In addition, using N-flute material significantly increases stack density (See chart).
Innovative Packaging Corp. (IPC) introduced the United States' first G-flute material, called GrafXflüt™, in December 1997. Measured at 178 flutes per lineal flute, it is similar in structure to N-flute, but is produced on a wide-web corrugator and uses starch as an adhesive on both sides. Dave Stucker, V.P. of sales and marketing at IPC, asserts with its opportunities for high-end graphics as well as embossing, G-flute "produces … a design breakthrough for the POP and folding carton industries."
Unfortunately, with more flute profiles on the scene, the problem of misidentification arises. Industry-wide standards have not been established, so F-flute = F-flute does not always hold true. The most accurate measure of any stock is its number of flutes per lineal foot.
The general rule of thumb holds that E-flute has approximately 90 flutes; F-flute, about 128 flutes per foot; and G- and N-flutes count 178 per foot.
Print prowess
As the development of microflute continues into its second decade, the question of its optimum printing process remains unanswered. For many printers, litho-laminating is the method of choice. Inland Consumer Packaging's litho-laminate system employs a three-ply process combining a kraft back liner and medium with a solid bleach sulfate top liner. Bruce Grube, Inland's senior V.P. of consumer packaging, maintains, for microflute, "lithography is still the highest-end printing process."
By Jessica Millward
For the past several years, microflute corrugated's marriage of structural strength and high-quality graphics has proven to be a match made in packagers' heaven. With the development of E- and F-flute boxes in the '90s, the line between folding carton and corrugated converters was blurred, and customers reaped the benefits. Time, and technology, marches on, however, and the microflute industry has kept pace with the evolution of still-smaller calipers and new ideas about printing.
The small flute segment comprises roughly 9 percent of total corrugated shipments in North America, according to Bob Nebeling, product business manager of corrugator equipment at the Bobst Group. He also reports that the annual growth rate of mini-flute applications is between 12 percent and 15 percent. It's clear that microflute is a growth market, but what isn't so clear is precisely what shape that growth will take. While the largest share of production continues to belong to E- and F-flutes, the introduction of N- and G-flutes may change statistics in the years to come.
Under the ‘micro'-scope
N-flute substrates, typically run on Asitrade sheet-to-web machines, possess 90 percent more flutes per foot than E-flute and 42 percent more than F-flute. As Nebeling observes, N-flute's folding, forming, and handling characteristics are much closer to carton board than E- or F-flute. In addition, using N-flute material significantly increases stack density (See chart).
Innovative Packaging Corp. (IPC) introduced the United States' first G-flute material, called GrafXflüt™, in December 1997. Measured at 178 flutes per lineal flute, it is similar in structure to N-flute, but is produced on a wide-web corrugator and uses starch as an adhesive on both sides. Dave Stucker, V.P. of sales and marketing at IPC, asserts with its opportunities for high-end graphics as well as embossing, G-flute "produces … a design breakthrough for the POP and folding carton industries."
Unfortunately, with more flute profiles on the scene, the problem of misidentification arises. Industry-wide standards have not been established, so F-flute = F-flute does not always hold true. The most accurate measure of any stock is its number of flutes per lineal foot.
The general rule of thumb holds that E-flute has approximately 90 flutes; F-flute, about 128 flutes per foot; and G- and N-flutes count 178 per foot.
Print prowess
As the development of microflute continues into its second decade, the question of its optimum printing process remains unanswered. For many printers, litho-laminating is the method of choice. Inland Consumer Packaging's litho-laminate system employs a three-ply process combining a kraft back liner and medium with a solid bleach sulfate top liner. Bruce Grube, Inland's senior V.P. of consumer packaging, maintains, for microflute, "lithography is still the highest-end printing process."
|
Chemistry for the Graphic Arts
What the Printer Should Know About Paper