7 Questions You May Ask About Biodegradable Poly Mailers

What is a biodegradable poly mailer?

 

A biodegradable poly mailer is an environmentally friendly packaging solution made from materials that can naturally break down over time. Unlike traditional plastic mailers, which can take hundreds of years to decompose, biodegradable poly mailers decompose through processes like photodegradation, oxidation, and biological degradation, thus reducing environmental pollution. These mailers are known for their transparency, heat resistance, high tensile strength, impact resistance, rigidity, and toughness, with low heat shrinkage rates.

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What materials are used to make biodegradable poly mailers?

 

Biodegradable poly mailers are primarily made from natural high molecular weight materials and biodegradable polymers. Here are some common types:

 

  • Starch-based plastics: Made by blending starch with plastics, typically polyethylene, along with degradation agents and plasticizers.
  • Polylactic acid (PLA): A biodegradable polyester derived from lactic acid through polymerization.
  • Cellulose: A natural high molecular weight material used in creating biodegradable plastic mailers.
  • Aliphatic polyesters, polylactic acid, polyvinyl alcohol: Biodegradable polymers created through microbial fermentation or synthetic processes.
  • PBS (polybutylene succinate): This material can be produced from petrochemical raw materials or through the fermentation of renewable crops like starch and cellulose.

 

These materials are derived from natural plant fibers or biomass, making them edible, biodegradable, and relatively safe. Under composting conditions, they break down into carbon dioxide, water, and other natural substances. However, during production, chemicals may be added to enhance toughness and stability, which could have potential health and environmental risks. Therefore, it’s important to verify the biodegradability claims of these mailers through recognized certifications.

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What are the benefits of using biodegradable poly mailers?

 

Biodegradable poly mailers offer several key advantages:

 

  • Environmental friendliness: They naturally decompose over time, reducing long-term environmental pollution by breaking down into water, carbon dioxide, and other natural substances.
  • Pollution reduction: Unlike traditional plastics, which can persist in the environment for centuries, biodegradable plastics decompose much faster, alleviating the burden of plastic waste.
  • Biocompatibility: Some biodegradable plastics are compatible with biological tissues, making them suitable for medical applications like surgical sutures and drug carriers.
  • Sustainability: These mailers are often made from renewable resources like plant starch and cellulose, reducing reliance on finite petroleum resources.
  • Versatility: Biodegradable plastics offer similar, if not superior, performance to traditional plastics, making them suitable for various packaging needs.
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What certifications should biodegradable poly mailers have?

 

Biodegradable poly mailers should be certified by authoritative institutions to ensure their degradation performance, compliance with environmental standards, and quality control during production. Key certifications include:

 

  • Degradation performance certification: Tests ensure that the mailers decompose into environmentally friendly substances within a specified period. These tests may include biodegradation and photodegradation assessments.
  • Environmental standard certification: Compliance with international standards like ISO 14855-1, ISO 14855-2, and EU standard EN 13432 is essential. In China, national standards such as GB/T 20197-2006 and GB/T 21961-2008 apply.
  • Quality certification: This includes quality control of raw materials, production processes, and product safety.
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What types of biodegradable poly mailers are available?

 

There are several types of biodegradable poly mailers, each designed for specific needs:

 

  • Microorganism-composed biodegradable poly mailers: Made from biopolymers like bio-polyesters, these mailers are fully decomposable by natural microorganisms.
  • Polylactic acid (PLA) biodegradable poly mailers: Derived from lactic acid produced by microbial fermentation, these mailers degrade after use and are suitable for medical materials.
  • Starch-based poly mailers: Containing over 90% starch, these mailers degrade quickly (within 1 month to 1 year), leaving no pollution.
  • Organic biodegradable poly mailers: Made from organic substances like polycarbonates, these mailers degrade without producing harmful substances.
  • Biomimetic biodegradable poly mailers: Combining natural high molecular weight materials with synthetic ones, these mailers degrade without harming the environment.

 

These mailers can be further categorized by use, such as flat bags, carry bags, self-sealing bags, express delivery bags, garment bags, etc. Consumers should choose based on specific needs and ensure the products are certified for quality and environmental performance.

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How are biodegradable poly mailers manufactured?

 

Raw Material Selection and Preparation:

 

  • Material Selection:The process begins with selecting biodegradable materials such as PLA (Polylactic Acid) and PBS (Polybutylene Succinate). These materials are chosen for their eco-friendly properties, including their ability to degrade naturally over time.
  • Preparation:The selected materials undergo cleaning and crushing to remove any impurities and ensure a consistent quality. This preparation is crucial for achieving uniformity in the final product.

 

Addition of Additives:

 

  • Enhancement of Properties:Additives are mixed into the biodegradable materials to enhance specific properties. For instance, degradation agents are added to control the rate at which the material breaks down, while plasticizers improve the flexibility and tensile strength of the poly mailers.

 

Mixing and Pelletizing:

 

  • Blending and Pelletizing:The biodegradable materials and additives are thoroughly blended to create a homogeneous mixture. This mixture is then extruded through a pelletizing machine, forming small, uniform pellets. These pellets serve as the raw material for the subsequent molding process.

 

Blow Molding:

 

  • Film Extrusion:The pellets are fed into an extrusion machine, where they are melted and formed into a continuous film through blow molding. This process involves inflating the molten material into a thin, flexible tube, which is then cooled to create the film used for the mailers.

 

Printing:

 

  • Customization:The extruded film is passed through a printing machine, where customized designs, logos, or branding information is printed onto the material. High-quality printing ensures that the branding remains clear and durable throughout the product’s lifecycle.

 

Bag Making:

 

  • Shaping and Cutting:After printing, the film is processed in a bag-making machine, where it is cut and sealed to form the poly mailers. The machine precisely shapes the bags according to the required dimensions, ensuring consistency in size and shape.
  • Sealing:The bags are sealed at the edges to ensure they are airtight and secure, which is critical for protecting the contents during shipping.

 

Each step requires strict quality control to ensure the mailers perform well and meet environmental standards.

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What are the future trends for biodegradable poly mailers?

 

Future developments in biodegradable poly mailers will prioritize technological innovation, focusing on enhancing degradation speed, material strength, and durability to meet the diverse needs of various industries. Additionally, there will be ongoing efforts to optimize environmental performance by reducing energy consumption during production, lowering emissions, and improving recyclability. As costs decrease, these advancements will facilitate market expansion, allowing biodegradable poly mailers to find broader applications in sectors such as medical, agriculture, and construction, driven by the increasing demand for eco-friendly products.

 

As the demand for eco-friendly packaging solutions continues to grow, Package N’ Go stands at the forefront as a trusted supplier of biodegradable poly mailers. With a commitment to quality and sustainability, we offer a comprehensive range of biodegradable mailers that cater to various industries, from e-commerce to agriculture. Our mailers are crafted using cutting-edge technology and rigorously tested to ensure they meet the highest environmental standards. By choosing Package N’ Go, businesses not only reduce their environmental footprint but also align with global trends towards greener, more sustainable packaging practices. Contact us now, let us partner with you in making a positive impact on the environment while meeting your packaging needs with excellence.

10 Questions You Want to Ask About Zip Lock Bags

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What is a Zip Lock Bag?

 

A zip lock bag is a versatile type of plastic packaging commonly used for items like clothing, shoes, bags, food, cosmetics, medicines, and more. Its standout feature is the zip-lock closure, which is easy to use, quick to seal, and provides clear visibility of the contents. This design ensures a clean, attractive, and hygienic protection for various products.

 

What are the Benefits of Zip Lock Bags?

 

Zip lock bags offer numerous benefits, making them essential in both household and industrial settings:

 

Reusable: They can be used multiple times, offering a cost-effective and environmentally friendly solution.

 

Air-Tight Seal: The interlocking mechanism ensures that the contents remain sealed, protecting them from moisture, air, and contaminants.

 

Transparency: The clear material allows for easy identification of contents without opening the bag.

 

Space-Saving: These bags are compact and can be stored flat or folded, conserving valuable storage space.

 

Versatile: Available in various sizes, they are suitable for storing food, organizing small items, or protecting documents.

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What are the Uses of Zip Lock Bags?

 

Zip lock bags have a wide range of uses due to their versatile and convenient design. Here are some common applications:

 

Food Storage: They help keep food fresh by sealing in moisture and preventing contamination. Ideal for leftovers, snacks, and portioning ingredients.

 

Organization: Useful for organizing small items like office supplies, craft materials, or travel accessories. They help keep things tidy and easy to find.

 

Travel: They are handy for packing toiletries, travel documents, or other essentials, keeping items contained and easily accessible.

 

Clothing Protection: They protect clothing from dust, dirt, and moisture, making them great for storing seasonal garments or packing clothes for travel.

 

Medical and Cosmetics: They can be used to store medications, first-aid supplies, or cosmetics, keeping them organized and secure.

 

Hygiene: Ideal for maintaining cleanliness and hygiene, especially for items like diapers, wipes, or sanitary products.

 

Securing Items: They provide a tamper-evident seal, which is useful for ensuring the integrity of products or preventing accidental spills.

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What is a Zip Lock Bag Made of?

 

Polyethylene (PE)


Polyethylene is a flexible, non-toxic plastic ideal for high-pressure bags and tote bags. It is known for its softness, impact resistance (from -40°C to 90°C), moisture resistance, and good chemical resistance. PE comes in two main types:

 

Low-Density Polyethylene (LDPE): Molecular weight between 1000 and 3000, offering good impact and heat resistance.

 

High-Density Polyethylene (HDPE): Molecular weight between 3000 and 9000, known for excellent impact, corrosion, and heat resistance.

 

Polypropylene (PP)


Polypropylene is a tough, versatile plastic used for high-transparency films, self-sealing bags, and vacuum-formed boxes. It features easy colorability, excellent moisture and chemical resistance, high hinge strength, and strong impact resistance. PP has a high melting point (~100°C) and good thermal stability with a Vicat softening temperature of ~150°C. However, it can be difficult to extrude into complex shapes, is susceptible to UV degradation, and is challenging to bond.

 

Chlorinated Polyethylene (CPE)


CPE zip lock bags are made from cast film and processed with features like color and anti-static functions. They are available in various colors and are used to meet specific packaging needs.

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What Are the Available Sizes of Zip lock Bags?

 

Zip lock bags come in a variety of standard sizes to accommodate different needs. Some common sizes include:

 

Small: 4 x 6 inches

Medium: 6 x 8 inches

Large: 9 x 12 inches

Extra Large: 12 x 15 inches

 

These sizes cover a range of uses from storing small items to larger objects. However, we also offer customization options, allowing you to specify any size to meet your particular needs.

 

Are Zip Lock Bags Recyclable?

 

Yes, zip lock bags are recyclable, though they should be clean and dry before being placed in recycling bins. Not all recycling programs accept plastic bags, so it is essential to check with local facilities.

 

Are There Zip Lock Bags Made of Recycled Materials?

 

Yes, many zip lock bags are now made from recycled materials, helping to minimize the environmental impact of plastic production. These bags maintain the same durability and effectiveness as those made from virgin materials. We offer a variety of recycled zip lock bags to meet your needs while supporting sustainability.

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Are There Biodegradable and Compostable Zip Lock Bags?

 

Yes, we offer biodegradable and compostable zip lock bags designed to break down more easily in the environment. Made from materials that decompose naturally, these bags are an excellent choice for those looking to reduce their ecological footprint. They offer the same convenience and functionality as traditional zip lock bags, but with the added benefit of being environmentally friendly. By choosing these options, you can help minimize waste and support a more sustainable approach to packaging.

 

What Are The Factors Affecting the Prices of Zip Lock Bags?

 

The price of zip lock bags can be influenced by several key factors:

 

Material: The type of plastic used, such as polyethylene, polypropylene, or biodegradable materials, can affect the cost. Specialized materials or those with environmental benefits may be more expensive.

 

Size: Larger zip lock bags generally cost more than smaller ones due to the increased amount of material used.

 

Thickness: The thickness of the bag, which affects its durability and strength, can also impact the price. Thicker bags typically cost more due to the higher material and production costs.

 

Customization: Options such as custom sizes, colors, prints, or features like zip-lock closures and additional security measures can influence the price. Customization adds to the production complexity and, consequently, the cost.

 

Order Quantity: Bulk orders usually result in cost savings. Purchasing larger quantities often reduces the per-unit price, making it more economical.

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How Are Zip Lock Bags Made?

 

Raw Material Preparation: Begin by preparing plastic sheets, waterproof zippers, and other auxiliary materials. The choice of plastic sheets depends on the size and intended use of the zip lock bags, ensuring they meet thickness and material requirements.

 

Film Blowing: This step involves heating plastic granules and blowing them into thin films. Films from new granules are clean and suitable for food packaging. In contrast, films made from recycled granules may require color masterbatch and can exhibit issues like uneven coloring and brittleness, making them less suitable for direct food contact.

 

Printing: Patterns, text, and other designs are transferred onto the film using methods such as flexographic or gravure printing. Screen printing is another option, though it often requires manual curing.

 

Bag Making: The printed film is combined with a zipper, then heat-sealed and cut using a bag-making machine to create the final zip lock bags. For screen-printed films, manual curing with tools like electric irons or heat sealers is necessary.

 

Inspection and Packaging: Finished bags are inspected for quality, then packaged according to customer specifications and prepared for shipping.

 

Package N’ Go is an excellent supplier of custom zip lock bags, offering a wide range of high-quality, customizable options to meet various needs. With a commitment to superior materials and precise manufacturing processes, Package N’ Go ensures that each bag meets your specific requirements for size, thickness, and design. For more information or to discuss your specific needs, contact us today and discover how Package N’ Go can deliver exceptional value and quality in every custom zip lock bag. 

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What is a Glassine Bag And How Can it Help Your Business

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Glassine bags are an essential packaging solution in numerous industries due to their unique properties and versatility. Crafted from high-quality glassine paper, these bags are known for their dense, uniform texture, translucency, and resistance to high temperatures, moisture, and oil. Their eco-friendly nature, combined with their functionality and aesthetic appeal, makes them an excellent choice for businesses looking to enhance their packaging solutions.

 

This article explores the various uses, benefits, and production processes of glassine bags, as well as the factors influencing their pricing and quality standards, to help businesses understand how these bags can add value to their operations.

 

1. What is a Glassine Bag?

 

Glassine bags are crafted from glassine paper, a high-quality specialty material known for its dense, uniform texture and high internal strength. This paper is also characterized by its translucency, high temperature resistance, moisture resistance, and oil resistance. These features make glassine bags suitable for packaging in various industries, including food, clothing, electronics, home decor, and gifts.

 

 

2. What Are the Uses of Glassine Bags?

 

Glassine bags are versatile and widely used across various industries due to their unique properties. Here are some common uses:

   

Food Packaging: Glassine bags are popular for packaging food items like baked goods, nuts, candies, and dried fruits because they are grease-resistant and can keep the contents fresh.

 

Pharmaceuticals: They are used to package pharmaceuticals and medical products, offering protection from contamination and moisture.

 

Collectibles and Archival Storage: Glassine bags are ideal for storing and protecting collectibles such as stamps, coins, photographs, and other archival materials due to their acid-free and pH-neutral nature.

 

 

Stationery and Craft Supplies: These bags are used to package and organize stationery items like greeting cards, stickers, and craft supplies, ensuring they remain clean and undamaged.

 

Industrial Applications: In industrial settings, glassine bags are used to protect and separate small components, parts, and hardware during storage and transportation.

 

Art Supplies: Artists use glassine bags to protect their artwork, sketches, and prints from smudging and damage during storage and handling.

 

Cosmetics and Toiletries: Glassine bags are used for packaging small cosmetic products and toiletries, providing a moisture-resistant barrier.

 

Seeds and Agriculture: Farmers and gardeners use glassine bags to store and organize seeds, as they provide an excellent barrier against moisture and pests.

 

Retail and Gift Packaging: Retailers use glassine bags for packaging small gifts, jewelry, and other boutique items, offering a sleek and protective solution.

 

 

3. What Are the Benefits of Glassine Bags?

 

Glassine bags have a lot of benefits.Glassine bags offer numerous benefits, including transparency for easy identification of contents, durability with a dense texture and strong internal structure that provides excellent protection, and oil and water resistance to keep contents clean and extend their lifespan. Their versatility makes them suitable for a wide range of applications, while their smooth surface ensures clear and legible printing.

 

4. Are Glassine Bags Eco-Friendly?

 

Yes, glassine bags are eco-friendly due to their biodegradability, renewability, and low toxicity. They decompose naturally and are made from renewable resources.

 

 

5. What Factors Influence the Prices of Glassine Bags?

 

Several factors influence the prices of glassine bags, making the cost structure multifaceted. First, raw material costs are a major determinant, heavily influenced by the prices of pulp and associated transportation expenses. When the cost of raw materials rises, it directly impacts the overall price of the bags. Second, the quantity of bags ordered significantly affects the unit price; larger orders typically benefit from economies of scale, resulting in lower per-unit costs.

 

Additionally, the complexity of the production process plays a crucial role. More intricate designs or custom features can increase manufacturing expenses, thus raising the price. Market demand and supply fluctuations also have a notable impact. High demand or limited supply can drive prices up, while an oversupply or reduced demand can lower them.

 

Lastly, environmental policies are increasingly influencing production costs. Regulations aimed at reducing environmental impact can lead to higher manufacturing expenses, as companies may need to invest in sustainable practices and materials. All these factors combined create a dynamic pricing environment for glassine bags.

 

 

6. How Are Glassine Bags Made?

 

Glassine bags are made through a detailed and precise manufacturing process involving several key steps.

 

Printing

 

The process begins with layout design and plate making, where designs are created and adjusted to meet specifications. In the prepress preparation stage, plates are thoroughly checked, and materials are prepared to ensure everything is ready for printing. During the printing stage, ink is applied to the bags with careful attention to quality, ensuring the designs are clear and vibrant.

 

Composite

 

The composite process starts with gluing and bonding, where adhesive is applied to bond materials together. This is followed by heat pressing and curing, which uses heat to ensure strong and durable bonding. Finally, the cooling and shaping step quickly sets the shape of the bags, ensuring they maintain their form and structure.

 

Die Cutting

 

The die-cutting process begins with installing the die-cutting plate, setting up the machine to cut the bags to the desired shape and size. During the die-cutting operation, the materials are precisely cut and folded. Post-cutting processing involves additional steps such as hole punching or other customizations to complete the bags.

 

These combined processes ensure that glassine bags are made with high quality and precision, ready for their various applications.

 

 

7.What Is the Typical Turnaround Time for Glassine Bags?

 

The typical turnaround time for producing glassine bags can vary widely, ranging from a few days to several weeks. This variation depends on several factors, including the order size, with larger orders generally taking more time to produce than smaller ones. Customization requirements, like special sizes, shapes, or features such as die-cutting or spot UV printing, often involve more detailed and time-consuming procedures.

 

8. What Are the Quality Inspection Standards for Glassine Bags?

 

Quality inspection standards for glassine bags are comprehensive and ensure that each bag meets high-quality criteria before reaching customers. Key standards include printing quality, where designs must be clear, sharp, and free from smudges or misalignment. Bag dimensions are carefully checked to ensure they fall within acceptable deviation limits, maintaining consistency in size and shape. Sealing detail is critically inspected to guarantee proper sealing, ensuring the bags provide adequate protection for their contents.

 

Additionally, the bags are examined for structural integrity, ensuring there are no tears, weak spots, or defects. Material quality is assessed to confirm that the glassine paper is of the appropriate thickness and meets industry standards for durability and resistance to oil and water. These rigorous quality inspection standards help ensure that glassine bags are reliable, functional, and aesthetically pleasing, meeting the needs of various applications.

 

 

9. How Can Glassine Bags Help Your Business?

 

 Glassine bags offer businesses a versatile and eco-friendly packaging solution with numerous benefits. Their durability, oil and water resistance, and transparency make them suitable for a wide range of industries, from food packaging and pharmaceuticals to collectibles and retail. By using glassine bags, businesses can ensure their products remain fresh, protected, and visually appealing.

 

Additionally, their biodegradability and renewable nature align with sustainability goals, enhancing a company’s environmental credentials. The detailed manufacturing process and strict quality inspection standards guarantee that each bag meets high standards of quality and reliability, contributing to overall customer satisfaction. The cost-effectiveness and customization options further add value, allowing businesses to efficiently tailor their packaging to specific needs, thereby improving brand presentation and operational efficiency.

 

Package N’ Go is a leading manufacturer offering customized premium packaging solutions. Contact us with your specific requirements to meet your packaging needs with precision and reliability.

Everything You Need to Know About Gravure Printing

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1. Introduction to the Process

 

Gravure printing is a direct printing method where ink from the recessed cells of the gravure cylinder is transferred directly onto the substrate. In gravure printing, the image areas of the printing plate are below the surface of the plate, with varying depths corresponding to the tonal variations of the image. The non-image areas are raised and on the same plane. During printing, ink fills the recessed cells, excess ink on the surface of the plate is wiped away by a doctor blade, and the plate is then pressed onto the substrate with sufficient pressure to transfer the ink from the cells onto the substrate, completing the printing process.

 

2. Process Flow

 

The main steps of the gravure printing process include:

 

2.1 Design and Plate Making

 

Designing and creating the gravure printing plate according to the requirements of the print job. The plate must be precise, with clear details to accurately transfer the image.

 

2.2 Plate Making

 

Transferring the designed image onto the plate. Common methods include chemical etching, photomechanical processes, and mechanical engraving. The completed plate is inspected and refined to ensure quality and accuracy.

 

2.3 Printing Preparation

 

This includes adjusting the plate, setting up the printing press, mixing inks, and selecting the printing substrate, ensuring the smooth operation of the press.

 

2.4 Printing

 

Placing the prepared plate on the printing press, adjusting machine parameters, and beginning the printing process. During printing, temperature, humidity, and printing speed must be strictly controlled to ensure print quality.

 

2.5 Quality Inspection

 

Inspecting the printed materials for quality, including color, image clarity, and paper flatness, to ensure they meet the required standards.

 

2.6 Packaging and Shipping

 

Packaging the printed materials and shipping them according to customer requirements.

 

 

3. Characteristics of the Process

 

3.1 Image Areas Below Surface

 

The depth and size of the recessed cells determine the tonal variations of the image.

 

3.2 Clear Lines and Rich Details

 

Gravure prints are characterized by sharp lines, dense ink layers, and detailed, aesthetically pleasing images.

 

3.3 Complex Plate Making

 

Plate making is relatively difficult, with long cycles and high costs.

 

Overall, gravure printing, with its unique principles and process flow, holds a significant position in the printing and packaging industry.

 

 

4. Importance

 

Gravure printing demonstrates its importance in several fields:

 

4.1 High-Quality Printing

 

Produces high-resolution, high-quality prints due to its unique principle, ensuring precise ink transfer from recessed cells to the substrate.

 

4.2 Vibrant Colors and High Saturation

 

The thick ink layers result in vibrant, saturated colors, which is crucial in packaging and advertising to attract consumer attention and enhance product appeal.

 

4.3 Wide Range of Substrates

 

Suitable for various substrates including paper, plastic films, and aluminum foil, making it versatile in the packaging industry.

 

4.4 Strong Anti-Counterfeiting

 

Complex plate making makes reproduction difficult, offering strong anti-counterfeiting features, especially valuable in currency and securities printing.

 

 

4.5 Environmental Considerations

 

With increasing environmental awareness, gravure printing is continually improving its processes and materials to meet environmental standards, such as using water-based inks and solvent-free inks to reduce harmful emissions.

 

4.6 Adaptability

 

Can handle different batch sizes and requirements, whether for large-scale industrial production or small-batch custom jobs.

 

4.7 Economic Efficiency

 

Despite high plate making costs, the fast printing speed and high durability of the plates make it cost-effective for large-scale production.

 

In summary, gravure printing is essential for high-quality, vibrant, and secure prints across various substrates. With ongoing technological advancements, it continues to offer unique value and advantages in diverse fields.

 

 

5. Impact on Products

 

Gravure printing impacts products in the following ways:

 

5.1 Product Quality and Appearance

 

Vibrant Colors and Depth: Ensures vibrant colors and strong detail reproduction, providing high-quality prints with clear, rich images.

 

Thick Ink Layers: Creates dense, visually striking ink layers that attract consumer attention.

 

High Durability: The high durability of the printing plates allows for consistent quality in large print runs.

 

5.2 Production Efficiency and Costs

 

Fast Printing Speed: Automated production lines allow for rapid image transfer and printing, significantly boosting production efficiency.

 

Cost Reduction: Reusable plates and high-speed printing reduce material and unit production costs.

 

5.3 Special Effects and Customization

 

Special Effects: Can achieve various special effects like gloss, three-dimensionality, and holographic effects, adding artistic elements and enhancing visual appeal.

 

Customization: Capable of personalized customization to meet specific customer needs.

 

5.4 Wide Application Range

 

Used extensively in packaging, magazine and book printing, financial and insurance printing, and cosmetics and personal care product printing due to its high quality, versatility, and adaptability.

 

In conclusion, gravure printing significantly enhances product quality, production efficiency, and customization options, making it an ideal solution for various printing needs.

 

 

6. Common Issues and Solutions

 

6.1 Common issues

 

6.1.1 Slow Drying Speed

 

Symptoms: Causes roller contamination, adhesion issues, and high residual solvents.

 

Causes: Slow solvent drying, deep plate cells, insufficient drying capacity, and fast printing speeds.

 

6.1.2 Surface Bubbles

 

Symptoms: Presence of bubbles in the print, affecting the doctor blade’s effectiveness.

 

Causes: Properties of the ink (especially water-based ink) and defects in the ink circulation system.

 

6.1.3 Skinning

 

Symptoms: A dry layer forms on the surface of the ink in the ink tray, which can transfer to the cylinder.

 

Causes: Fast-drying ink and air leakage from the drying system.

 

6.1.4 Set-Off

 

Symptoms: Ink from one sheet transfers to the next sheet’s surface.

 

Causes: The ink layer from the previous print dissolves on the next print’s surface.

 

6.1.5 Moire Pattern

 

Symptoms: Ink transferred to the substrate forms a dot pattern, creating isolated spots.

 

Causes: Fast-drying or high-viscosity ink and wide screen angles during plate making.

 

6.1.6 Ink Migration

 

Symptoms: Ink transfers to non-image areas, creating uneven tones.

 

Causes: Deep plate cells, low ink viscosity, and low ink temperature.

 

6.1.7 Adhesion Issues

 

Symptoms: Ink layers stick to each other, causing ink stripping and print contamination.

 

Causes: Poor drying, increased ink softness due to high temperatures, and excessive winding tension.

 

6.2 Solutions

 

Slow Drying Speed

 

Use appropriately fast-drying solvents, combine fast-drying solvents with deeper plates, and adjust printing speed to match drying capacity.

 

Surface Bubbles

 

Add defoamers in moderation and improve the ink circulation system.

 

Skinning

 

Adjust ink drying speed, ensure balanced airflow in the drying system, and cover the ink tray to avoid exposure to air.

 

Set-Off

 

Use weaker solvents for subsequent ink layers and maintain appropriate printing speeds.

 

Moire Pattern

 

Use slower-drying solvents, check for air leaks in the drying system, and print with low-viscosity inks.

 

Ink Migration

 

Use fast-drying solvents, high-viscosity inks, adjust screen angles, and preheat ink if necessary.

 

Adhesion Issues

 

Fully utilize cooling rollers, store prints in cool conditions, manage winding tension, and consult ink manufacturers for appropriate measures.

 

These solutions are for reference and should be adjusted according to specific production conditions and printing requirements.

 

 

7. Application Examples

 

7.1 Example 1: Gravure Printing on Plastic Film Packaging

 

1. Materials and Equipment

 

  • Materials: BOPP (Biaxially Oriented Polypropylene) film.
  • Equipment: Gravure printing press, electro-engraved cylinders (depths may be 20µm or 40µm).

 

2. Printing Parameters

 

  • Printing Speed

-Case 1 (laminated CPP): 200m/min

-Case 2: 110m/min

  • Dryer Length: 1.8m
  • Dryer Temperature: 80°C

 

3. Printing Results

 

  • High-definition print images with vibrant, rich colors.
  • High-speed printing and high production efficiency.

 

7.2 Example 2: Eco-Friendly Water-Based Gravure Printing on Plastic Packaging Bags

 

1. Technical Features

 

  • Uses water-based ink, offering eco-friendliness and pollution-free benefits.
  • PET (Polyethylene Terephthalate) film as the printing layer, with degradable and decolorizable image structures.

 

2. Printing Steps

 

  • Prepare the printing layer (PET film).
  • Prepare water-based ink.
  • Print water-based ink onto one side of the PET film using gravure printing equipment.
  • Heat press the printed PET film onto the surface of plastic packaging bags, with the unprinted side of the PET film facing the plastic bag surface.

 

3. Printing Results

 

  • Clear image structures with vibrant colors.
  • Eco-friendly water-based ink reduces environmental impact.

 

7.3 Case Summary

 

These examples demonstrate different applications of gravure printing on plastic packaging products. The first case highlights the capability of achieving high-speed, high-quality prints on plastic films. The second case showcases the application.

 

8. Environmental Friendliness

 

The environmental friendliness of the plastic gravure printing process can be clearly analyzed and summarized from the following aspects:

 

8.1 Ink Usage

 

Solvent-Based Inks: Traditional plastic gravure printing processes heavily use solvent-based inks. These inks contain up to 50% volatile solvents, such as xylene and toluene. During printing, these solvents evaporate in large quantities, causing air pollution and potentially harming the health of operators.

 

Water-Based Inks: In recent years, with increased environmental awareness, the use of water-based inks in plastic gravure printing has gradually increased. Water-based inks do not contain harmful solvents, reducing air pollution and better complying with environmental regulations. However, due to issues with adhesion on plastic surfaces, color saturation, cost, and usage habits, over 70% of the flexible packaging sector still uses solvent-based inks.

 

8.2 Exhaust Emissions

 

Sources of Exhaust: During the printing process, gravure printing presses require high-powered infrared or electric heating to dry the inks, producing large amounts of exhaust gases. These exhaust gases contain volatile organic compounds (VOCs), which pollute the environment.

 

Emission Volume: Given the large ink volumes and high printing speeds of gravure presses, the emission volume is relatively high. Therefore, effective exhaust gas treatment measures must be taken during the gravure printing process to reduce environmental impact.

 

8.3 Wastewater Treatment

 

Sources of Wastewater: Wastewater generated during the gravure printing process mainly includes the waste water from cleaning plates and printing equipment. This wastewater contains ink and solvents, which can pollute the environment if discharged untreated.

 

Treatment Methods: Current methods for treating gravure printing wastewater include recycling solvents and adopting new environmental technologies. Solvent recycling is a relatively traditional treatment method but has limited recovery rates and may produce other pollutants. New environmental technologies, such as the NOAH Plasma Method, use plasma generated by high-voltage, high-frequency electric fields to decompose VOCs, offering higher treatment efficiency and lower energy consumption.

 

8.4 Industry Development Trends

 

Environmental Regulations: With increasingly strict environmental regulations, the gravure printing industry is gradually moving towards green and sustainable development. Companies need to comply with relevant regulations, take environmental measures, and reduce their environmental impact.

 

Technological Innovation: To reduce the environmental impact of gravure printing, companies need to continuously innovate and develop new technologies. This includes developing new eco-friendly inks, improving printing equipment and processes, and optimizing exhaust and wastewater treatment technologies.

 

The environmental friendliness of the plastic gravure printing process is influenced by various factors, including ink usage, exhaust emissions, and wastewater treatment. To reduce the environmental impact of gravure printing, a series of measures need to be taken, such as using water-based inks, reducing exhaust emissions, effectively treating wastewater, and innovating technologies. With increasingly strict environmental regulations and growing consumer demand for eco-friendly products, the gravure printing industry is gradually moving towards green and sustainable development.

 

 

9. Conclusion

 

9.1 Development Trends

 

Green and Sustainable Development: With the strengthening of environmental regulations and increasing consumer awareness of environmental protection, the plastic packaging industry is gradually moving towards green and sustainable development. The gravure printing process must keep pace with this trend by strengthening the development and application of environmental measures.

 

Technological Innovation: Through technological innovation, the gravure printing process can be continuously optimized to improve printing efficiency and quality while reducing environmental impact. This includes developing new eco-friendly inks, optimizing printing equipment and processes, and improving exhaust and wastewater treatment efficiency.

 

International Cooperation and Exchange: Strengthening cooperation and exchange with international peers to learn and adopt advanced environmental technologies and experiences can jointly promote the green development of the gravure printing process.

 

9. 2 Conclusion

 

While the plastic packaging industry’s gravure printing process provides high-quality printing results, it also faces challenges regarding environmental friendliness. By adopting a series of environmental measures and technological innovations, the environmental impact of the gravure printing process can be significantly reduced. With stricter environmental regulations and continuous technological advancements, it is believed that the gravure printing process will achieve more green and sustainable development in the plastic packaging industry.

 

At Package N’ Go, we provide top-tier custom packaging services designed to meet your specific requirements. Get in touch today, and let’s create something amazing together!

Detailed Explanation of Embossing and Debossing Techniques

Table of Contents

1. Introduction to the Technique

 

Embossing and debossing, also known as relief printing or raised printing, are post-press techniques that create a three-dimensional effect on paper or other substrates. By using pre-made embossing dies and applying pressure, the surface of the substrate is shaped into raised or recessed designs or text.

 

This technique highlights specific areas of a printed piece, making them more prominent and visually appealing.

 

2. Principle of the Technique

 

Plate Making: First, create the embossing (raised) and debossing (recessed) dies based on the design. This is usually done through engraving, which can involve woodcuts, copper engravings, or steel engravings. The engraving process distinguishes the primary from the secondary layers in the design, using depth to emphasize the main elements and adding details for secondary elements.

 

Embossing and Debossing Process: During printing, place the substrate between the embossing and debossing dies and apply significant pressure. Under pressure, the substrate undergoes plastic deformation, creating raised or recessed designs and text. This process does not use ink but relies on the pressure from the printing machine.

 

Visual Effects: Embossing and debossing techniques create noticeable relief effects, enhancing the three-dimensional feel and artistic appeal of the printed piece. The tactile differences provided by the raised or recessed designs add richness to the visual experience. Additionally, these techniques can produce various shapes and patterns, capturing details and textures to create unique visual effects.

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3. Types of Embossing and Debossing Techniques

 

3.1 Raised Plate

 

This technique creates a raised surface structure that makes the entire design stand out, following the outline of the design for a print-like effect. The height of the raised design can be adjusted as needed.

 

3.2 Plain Embossing

 

In this method, the embossed area and its surroundings have no printed patterns, relying solely on the embossing technique to leave a clean and sophisticated design on the paper surface.

 

3.3 Stamped Embossing

 

Leave blank areas during printing and apply embossing to these areas to present a complete design. This method requires precise craftsmanship.

 

3.4 Multi-level Embossing

 

Also known as relief embossing, this technique uses laser-engraved plates with clear layers and significant height differences. Suitable for substrates with sufficient thickness, toughness, and surface tension, it can produce combined embossing and debossing templates for enhanced artistic effects.

 

3.5 Gold Foil Embossing

 

Also known as 3D gold stamping, this technique combines embossing and hot foil stamping in one process. Typically using brass molds for precision and durability, it adds a three-dimensional gold foil effect.

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4. Components and Materials

 

4.1 Components:

 

Feeding System: Feeds the paper, fabric, or other materials stably to the printing area, including feed racks, feed rollers, and tension control systems to ensure material flatness and stability.

 

Printing Plate (Embossing or Debossing): Key to creating the embossed or debossed effect, engraved with the required designs or text.

 

Ink Roller System: Evenly applies ink to the printing plate, including components like ink fountains, ink rollers, and doctor blades.

 

Impression System: Transfers the ink from the printing plate to the material, forming the embossing effect. The impression roller and adjusting mechanisms apply the necessary pressure.

 

Drying System: Ensures proper ink adhesion and print quality, using methods like hot air, infrared, or far-infrared drying.

 

Collection System: Collects the finished prints, including collection tables, conveyor belts, and cutting devices for further processing or packaging.

 

Control System: Manages the operation and control of the entire embossing machine.

 

4.2 Materials:

 

Paper: Paper choice is critical for embossing. Typically, paper with a weight of 180g/m² or more is used to ensure sufficient thickness and toughness to withstand the pressure. Coated paper is commonly used due to its uniform thickness, high strength, and water resistance.

 

Ink: Choose ink based on the color, gloss, and durability requirements of the print. Vibrant, strong-pigment inks are ideal for colorful prints, while high-gloss inks are suitable for shiny prints.

 

Other Materials: Besides paper and ink, other materials like plastic film or fabric can be used, considering their surface properties, thickness, and toughness to ensure compatibility with the embossing process.

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5. Working Method and Process Flow

 

5.1 Working Method

 

Embossing techniques use pre-made engraved models (embossing dies) and pressure to create raised or recessed effects on paper or other materials. This technique highlights specific parts of the design, emphasizing their importance.

 

5.2 Process Flow

 

Printing Base Image: Usually, a color image is printed on the substrate using standard printing methods.

 

Making Embossing Die: The embossing die is made from copper or steel plates, etched and engraved to create the recessed mold. The quality of the die determines the final print quality.

 

Creating Embossing Die: The recessed die is used to make the raised die through traditional plaster casting or new polymer materials.

 

Embossing Process: The printed substrate is placed between the raised and recessed dies and subjected to significant pressure. The process does not use ink and relies on the pressure to create the embossed effect.

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6. Advantages of Embossing and Debossing

 

Visual Impact: Creates a three-dimensional effect, enhancing the visual appeal and making the print more eye-catching.

 

Unique Tactile Experience: Provides a distinctive tactile feel, allowing consumers to physically interact with the design.

 

Highlighting Key Elements: Emphasizes important content like brand logos or headlines, making them more noticeable and memorable.

 

Increased Product Value: Enhances product quality and perceived value, helping products stand out in competitive markets.

 

Anti-counterfeiting: The complexity of embossing makes it difficult to replicate, providing a level of security against counterfeiting.

 

Versatility: Applicable to various materials and compatible with other printing techniques like hot foil stamping and UV printing for diverse effects.

 

Durability: Embossed designs are resistant to wear and tear, maintaining their clarity and three-dimensional effect over time.

7. Applications of Embossing and Debossing

 

Book and Magazine Covers: Adds unique texture and visual appeal.

 

Packaging Boxes: Widely used in packaging for cosmetics, high-end gifts, and beverages to enhance brand recognition and product quality.

 

Trademarks and Brand Logos: Used by many brands to make their logos more distinctive and attractive.

 

Promotional Materials: Enhances the attractiveness of promotional flyers, posters, and business cards.

 

Shopping Bags and Envelopes: Adds a special and personalized touch to everyday items.

 

Greeting Cards: Creates creative and artistic designs, enhancing the recipient’s emotional experience.

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8. Common Issues and Solutions

 

8.1 Common Issues

 

Unclear Printing: Caused by insufficient pressure, improper ink viscosity, worn-out printing plates, or incorrect adjustments.

 

Poor Embossing Effect: Due to unreasonable die design, uneven pressure distribution, or inappropriate material selection.

 

Ink Accumulation: Ink buildup on raised areas causing blurred designs or uneven colors.

 

Paper Damage: Paper may tear, crease, or suffer from deep impressions during the embossing process.

 

8.2 Solutions

 

For Unclear Printing:

 

  • Adjust printing pressure to ensure adequate ink transfer.
  • Adjust ink viscosity to match the printing process and paper absorbency.
  • Replace or repair worn or damaged printing plates.
  • Ensure proper settings and adjustments of the printing machine.

 

For Poor Embossing Effect:

 

  • Ensure the die design matches the desired effect.
  • Adjust pressure distribution for even application.
  • Choose appropriate materials for the best embossing effect.

 

For Ink Accumulation:

 

  • Adjust ink viscosity to prevent excessive buildup.
  • Clean the printing plates to remove excess ink and debris.
  • Experiment with different ink types to suit the printing process and materials.

 

For Paper Damage:

 

  • Choose paper suitable for embossing, considering thickness, toughness, and absorbency.
  • Adjust printing machine pressure and speed to avoid excessive pressure.
  • Use specialized paper handling equipment to minimize damage.

 

Preventive Measures:

 

  • Pre-check and treat paper to ensure quality and suitability.
  • Regularly clean and maintain printing machines.
  • Use high-quality inks and materials for optimal results.
  • Monitor the embossing process closely to address issues promptly.
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9. Environmental and Sustainability Considerations

 

Environmental Material Selection:Use renewable paper and paperboard. Choose water-based or UV inks to reduce air pollution and facilitate wastewater treatment.

 

Energy Efficiency:Optimize printing equipment for better energy efficiency and use LED curing lamps to reduce power consumption. Improve printing processes to minimize energy use.

 

Sustainable Product Design:Design recyclable and biodegradable products. Encourage customers to use eco-friendly packaging and printing materials.

 

Certification and Compliance:Participate in environmental certifications like ISO 14001. Comply with national and local environmental regulations.

 

Innovation and R&D:Continuously develop new eco-friendly technologies and materials to enhance the environmental performance of embossing

10: Trends in Embossing and Debossing Techniques

 

Environmental Protection and Sustainability: With the increasing global emphasis on environmental protection, embossing and debossing techniques will increasingly focus on sustainability. This means considering the environmental impact in material selection, production processes, and waste management. For example, using eco-friendly inks, renewable paper materials, and optimizing production processes to reduce energy consumption and waste emissions.

 

Technological Innovation: Technological innovation is a key driver for the development of embossing and debossing techniques. As technology advances, printing techniques will continuously improve, enhancing print quality and efficiency. The application of digital and automated technologies will make the printing process more precise and efficient, reducing production costs. Additionally, the development of new materials and technologies will bring more innovative possibilities to embossing and debossing printing.

 

Personalization and Customization: The increasing consumer demand for product personalization will drive the customization of embossing and debossing techniques. Companies can meet customers’ personalized needs through customized designs and services, enhancing the added value and competitiveness of products. This trend will also promote the expansion of embossing and debossing applications in packaging, decoration, and other fields.

 

Intelligent Development: With the widespread adoption of smart technologies, embossing and debossing techniques will move towards intelligent development. By introducing smart sensors, intelligent robots, automated control systems, and other technologies, it is possible to achieve flexible adjustments, energy savings, and quality monitoring on the production line. This will help improve production efficiency and product quality while reducing production costs.

Package N’ Go offers premium custom packaging solutions that enhance your product presentation. Contact us today to learn more about our innovative options!

Die-Cutting Process for Paper Products

Table of Contents

1. Process Overview

 

The die-cutting process is a critical technique in paper product processing. It utilizes molds to cut paper, cardboard, and other materials into specific shapes and sizes. Currently, the main die-cutting processes are flat-bed, rotary, and cylindrical die-cutting. Among these, flat-bed and cylindrical die-cutting are the most common.

 

1.1 Flat-Bed Die-Cutting

 

Flat-bed die-cutting can be divided into vertical semi-automatic die-cutting machines and horizontal automatic die-cutting machines.

 

Vertical Semi-Automatic Die-Cutting Machine: Known for its simple structure, easy maintenance, and ease of operation, this machine is widely used in smaller production facilities. However, it has high labor intensity and low production efficiency, typically operating at 20-30 cycles per minute, making it suitable for small batch production.

 

Horizontal Automatic Die-Cutting Machine: This machine is safe and reliable with a high degree of automation and production efficiency. Due to its small platen stroke, manual loading and unloading of cardboard is challenging, so it usually includes an automatic feeding system. The overall structure is similar to a sheet-fed offset press, consisting of an automatic paper feeding system, die-cutting section, paper output section, and electrical control and mechanical transmission components, sometimes equipped with an automatic waste removal system. It is well-suited for micro-corrugated cartons and paper box forming.

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1.2 Rotary Die-Cutting

 

Rotary die-cutting replaces the platen with a cylindrical pressure roller, with the cutting die positioned below the roller. This method shifts from “surface contact” to “line contact,” distributing the machine’s pressure over a longer period, making the load more stable. It can handle a wide range of materials with varying thicknesses, including cardboard, corrugated board, honeycomb paperboard, plastic hollow board, rubber board, plywood, and MDF.

 

However, rotary die-cutting typically operates in intermittent or single/double rotation cycles, resulting in low efficiency. Hence, its use in carton manufacturing is limited.

 

1.3 Cylindrical Die-Cutting

 

Cylindrical die-cutting machines feature continuously rotating cylinders, offering the highest production efficiency among die-cutting machines. However, the plate-making and installation are complex and costly, requiring advanced technical skills. This method is commonly used for large batch production.

 

Cylindrical die-cutting is divided into hard cutting and soft cutting. The primary difference lies in the material of the cutting roller, which can be a hard steel roller or a soft plastic roller. Hard cutting involves direct contact between the die-cutting blade and the roller surface, causing rapid wear. Soft cutting uses a layer of engineering plastic on the roller surface, allowing the blade to cut into the material slightly, protecting the blade and ensuring complete cuts but requiring periodic replacement of the plastic layer to maintain accuracy.

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2. Importance

 

The die-cutting process holds a vital position in paper product processing, significantly influencing the following aspects:

 

Shape Diversity: Die-cutting allows paper products to be cut into various complex shapes, enhancing their diversity and aesthetics.

 

Increased Production Efficiency: Using specialized die-cutting machines and die plates, the process enables fast and precise cutting, significantly improving production efficiency and reducing costs.

 

Product Quality Assurance: Precise cutting ensures paper products meet design specifications, avoiding manual cutting errors. It also enables special processes like creasing, further improving quality.

 

Expanded Application Range: Die-cutting is suitable for various materials, broadening the application range of paper products, such as in packaging for boxes and bags.

 

Enhanced Product Value: Die-cut paper products often exhibit higher aesthetic and practical value, attracting consumers and boosting sales.

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3. Impact on Products

 

Die-cutting impacts products in various ways:

 

Aesthetic Appeal and Attractiveness: The process allows for complex shapes and patterns, enhancing product appeal, especially in packaging.

 

Precision and Consistency: High-precision machines ensure exact cuts and consistent product quality, crucial for items requiring precise assembly.

 

Functionality and Usability: Die-cut designs can improve usability, such as easy-open features or display windows.

 

Production Efficiency and Costs: Automation increases production speed and reduces labor costs, with reusable die plates further lowering expenses.

 

Innovation and Customization: Die-cutting offers creative freedom for unique designs and customization to meet specific client needs.

 

Environmental Sustainability: As a recyclable and renewable material, paper’s use in die-cutting promotes environmental sustainability, reducing waste and environmental impact.

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4. Process Steps

 

Key steps in the die-cutting process include:

 

4.1 Designing the Blueprint

 

Based on client requirements or product specifications, design the blueprint for the paper product, including its shape, size, and features.

 

4.2 Making the Die Plate

 

Drawing: Create a die-cutting diagram based on the blueprint.

 

Cutting the Template: Use materials like plywood or high-density board to cut the template.

 

Installing Cutting and Creasing Lines: Attach cutting blades and creasing lines to the template.

 

Opening Connection Points: Add connection points for assembly after die-cutting.

 

Attaching Foam Strips: Apply foam strips to protect blades and prevent paper damage.

 

Test Cutting: Ensure accuracy and stability with a test cut.

 

Making Creasing Base Plates: Prepare base plates for necessary creases.

 

Trial Die-Cutting and Production Approval: Conduct trial runs and approve samples for production.

 

 

4.3 Die-Cutting Machine Operation

 

Adjusting the Machine: Set parameters like pressure and speed based on material specifications.

 

Placing Materials: Load materials onto the machine and secure them.

 

Die-Cutting: Start the machine for cutting and shaping.

 

4.4 Folding and Assembling

 

Assemble the cut parts into the final product.

 

4.5 Post-Processing

 

Perform additional treatments like removing waste, sanding, or painting.

 

4.6 Inspection and Packaging

 

Inspect quality, package, and label for storage and transport.

 

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5. Suitable Paper Types

 

Die-cutting is suitable for various paper types, including:

 

Kraft Paper: Durable and strong, ideal for protective packaging.

 

SBS: High-quality and versatile, used in printing, packaging, and creative projects.

 

CCNB: Known for its high whiteness, smoothness, moderate thickness, strong ink absorption, good stiffness, and dimensional stability. It is widely used in office, education, advertising, and other fields.

 

Printing Paper: Such as writing paper and coated paper, for labels and manuals.

 

Synthetic Paper: Made from high polymer materials, offering water resistance and tear resistance for outdoor or special applications.

 

In the die-cutting process, the choice of paper primarily depends on the product’s intended use, performance requirements, and cost considerations. Different types of paper have distinct characteristics and suitable applications, so it is necessary to select based on the specific situation.

 

Additionally, the die-cutting process needs to be adjusted and optimized according to the properties of the paper to ensure product quality and processing efficiency.

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6. Process Features

 

Die-cutting has several distinctive features:

 

High Precision: Uses precise equipment and pre-designed plates for accurate cuts and shapes.

 

Strong Adaptability: Applicable to various paper types and adaptable to different product requirements.

 

High Efficiency: Automation enables mass production, increasing efficiency and reducing costs.

 

High Aesthetics: Produces intricate shapes and patterns, enhancing product appearance.

 

Environmental Friendliness: Uses recyclable materials and sustainable processes, minimizing environmental impact.

 

It is important to note that the die-cutting process for paper products has certain limitations. For example, complex shapes like very small circles or intricate folds might not be fully achievable through die-cutting.

 

Additionally, the process must consider the material, thickness, and hardness of the paper, as these factors can affect the outcome. Therefore, when choosing a die-cutting process, it is essential to comprehensively consider the specific product requirements and production conditions.

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7. Common Issues and Solutions

 

Paper die-cutting processes in production may encounter some common problems. Here are some common issues and their solutions:

 

7.1 Common Issues

 

Inaccurate die-cutting position: This may result from inaccurate die-cutting plate production, machine positioning errors, or unstable paper movement.

 

Formation of “burst lines” and “dark lines” in die-cutting creases: “Burst lines” are typically caused by excessive die-cutting pressure leading to fiber breakage, while “dark lines” are due to improper selection of die-cutting plates or creasing steel wires, improper die-cutting pressure adjustment, etc.

 

Paper fuzzing or dusting after die-cutting: This may occur due to the use of unsuitable die-cutting blades or improper die-cutting pressure settings.

 

Misalignment or incomplete crease lines, leading to inadequate folding of products.

 

Residual ink or glue from the die-cutting plate on the paper after die-cutting, affecting product appearance.

 

7.2 Solutions

 

Inaccurate die-cutting position:

 

-Check the accuracy of die-cutting plate production to ensure consistency with design drawings.

 

-Regularly inspect the positioning system of die-cutting machines to ensure accuracy.

 

-Use appropriate paper and adhesive to ensure paper stability during die-cutting.

 

Formation of “burst lines” and “dark lines” in die-cutting creases:

 

-Choose suitable die-cutting plates and creasing steel wires that match the paper type and thickness.

 

-Adjust die-cutting pressure appropriately to avoid excessive or insufficient pressure.

 

-Pre-treat paper with glossing or lamination before die-cutting to reduce paper deformation.

 

Paper fuzzing or dusting after die-cutting:

 

-Choose suitable die-cutting blades (straight or cross-cut) based on paper type.

 

-Adjust die-cutting pressure to avoid excessive fuzzing.

 

-Regularly clean die-cutting machines and plates to reduce dust accumulation.

 

Misalignment or incomplete crease lines:

 

-Check the installation position and height of creasing steel wires.

 

-Increase die-cutting pressure appropriately to make crease lines more complete.

 

-For thicker paper, deeper creasing steel wires may be necessary.

 

Residual ink or glue from the die-cutting plate:

 

-Regularly inspect die-cutting blades and sponge strips, replacing worn parts promptly.

 

-Clean residual ink and glue from the die-cutting plate before die-cutting.

 

-Use appropriate ink and glue to prevent excessive penetration into the paper.

 

Additionally, improving automation of die-cutting equipment, optimizing production processes, and enhancing employee training can help reduce these problems.

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8. Application Examples

 

Die-cutting has extensive applications, including:

 

8.1 Packaging Industry:

 

Food Packaging: Chocolate or candy boxes with unique shapes and patterns.

 

Cosmetic Packaging: High-end cosmetic boxes with intricate designs.

 

Electronic Product Packaging: Custom-fit packaging for electronics like phones and tablets.

 

8.2 Book Binding:

 

Hardcover Books: Decorative grooves on covers and spines.

 

Pop-Up Books: Complex shapes and structures.

 

8.3 Advertising Materials:

 

Posters: Unique shapes for visual impact.

 

Brochures: Custom shapes and patterns.

 

8.4 Office Supplies:

 

Business Cards: Unique shapes like rounded corners.

 

Folders: Grooves or openings for easy file storage.

 

8.5 Gift Packaging:

 

Gift Boxes: Unique shapes and patterns for added appeal.

 

Greeting Cards: Three-dimensional effects.

 

These examples illustrate the versatility and broad application range of die-cutting.

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9. Environmental Sustainability

 

The environmental friendliness of paper die-cutting processes is mainly reflected in several aspects:

 

Material selection:Paper products, as renewable resources, have natural environmental advantages compared to non-renewable materials like plastic. Die-cutting processes primarily use paper for processing, ensuring environmental friendliness from the source.

 

Pollution control during production:Measures can be taken during die-cutting production to control pollution. For example, using eco-friendly inks and adhesives, ensuring treated production wastewater before discharge, employing low-noise, low-energy equipment, etc., all help reduce environmental pollution during production.

 

Waste management:Waste generated from die-cutting processes includes paper trimmings and discarded die-cutting plates. These wastes can be recycled or used as raw materials for recycled paper, promoting resource recycling and reducing waste and environmental pollution.

 

Energy conservation and emission reduction:Companies can reduce energy consumption and carbon emissions during die-cutting production by optimizing production processes, improving equipment efficiency, etc. For instance, using efficient die-cutting equipment, energy-saving lighting systems, and scheduling production efficiently.

 

Green supply chain management:Paper die-cutting companies can establish green supply chain management systems that emphasize environmental protection and sustainable development at every stage, from raw material procurement to production, transportation, and sales. By selecting eco-friendly suppliers, promoting green packaging and logistics, the environmental impact of the entire supply chain can be reduced.

 

Paper die-cutting processes have natural advantages in environmental friendliness and can be further improved through various measures. With increasing societal focus on environmental issues, paper die-cutting processes are expected to gain wider applications and development in the future.

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10. Conclusion

 

Paper die-cutting processes are essential in paper product processing, offering precise cutting and shaping using specialized equipment and tools. With technological advancements and diverse consumer demands, paper die-cutting processes face new opportunities and challenges. Key trends include:

 

10.1 Technological trends:

 

Higher precision: Advancements in CAD/CAM systems, CNC technology, and laser technology enable more precise cutting and shaping, meeting complex and personalized design requirements.

 

Automation and intelligence: Transitioning towards automation and intelligence helps improve production efficiency, reduce labor costs, and minimize human errors.

 

10.2 Environmental sustainability:

 

Environmental protection and sustainable development are crucial directions for paper die-cutting process development. Using renewable materials, eco-friendly processes, and reducing pollution and waste during production are essential.

 

Adopting eco-friendly inks, adhesives, promoting green packaging and logistics not only reduces environmental impact but also enhances brand image and competitiveness.

 

10.3 Market demand and application prospects:

 

Personalized demand: Increasing consumer demand for personalized products presents significant market opportunities. Offering customized products and services can boost market competitiveness.

 

Packaging industry applications: The rapid growth of e-commerce and logistics industries provides a vast market space for paper die-cutting processes. The demand for packaging materials is high and diverse, offering great opportunities for paper die-cutting companies. However, meeting consumers’ high standards for packaging quality and appearance presents both challenges and opportunities.

 

In summary, paper die-cutting processes play a crucial role in paper product processing and face new development opportunities and challenges. Continuous adoption of new technologies, optimization of production processes, improvement of product quality, and environmental awareness will enable paper die-cutting companies to better meet market demands and achieve sustainable development. We look forward to seeing paper die-cutting processes create more innovations and value, contributing significantly to the development of the paper product industry.

Detailed Explanation of the Lamination Process

Table of Contents

Introduction to the Process

 

Principle

 

Lamination is a surface finishing process in printing, also known as post-press coating, post-press lamination, or post-press film application. It involves covering the surface of printed products with a transparent plastic film (primarily BOPP and PET materials) of 0.012 to 0.020 mm thickness using a laminating machine, forming a paper-plastic composite product through adhesion.

 

Advantages

 

Enhanced Durability: Lamination enhances the durability of packaging by adding a protective film to paper boxes and gift boxes, effectively preventing scratches, stains, and other damage. This extends the packaging’s lifespan and ensures products remain undamaged during transport and storage.

 

Improved Visual Appeal: Lamination can significantly enhance the visual appeal of packaging. By choosing transparent or colored laminating materials, the packaging can appear more vibrant and attractive, capturing consumer attention and increasing product appeal.

 

Additional Design Space: Lamination offers extra design possibilities. Using materials with special effects or textures, such as matte or glossy finishes, can add unique and sophisticated elements to the packaging, enhancing the product’s perceived quality and value.

 

Working Methods and Process

 

The lamination process can be divided into wet lamination and pre-coating lamination based on the materials and equipment used. Wet lamination involves using a freshly applied adhesive, which can be solvent-based or emulsion-based. Pre-coating lamination uses a pre-coated film with heat-melting or solvent-evaporating adhesives.

 

Wet Lamination Process

 

 

Process Preparation: Proper preparation ensures smooth production and high efficiency. This involves checking printed materials, selecting plastic films, and preparing adhesives.

 

Film Installation: Cut the selected film to appropriate widths and install it on the laminating machine’s film feed mechanism, ensuring the film is smooth and uniformly tensioned.

 

Adhesive Coating: Adjust adhesive viscosity based on paper quality, ink thickness, drying tunnel temperature, and machine speed. Ensure even adhesive coating thickness.

 

Drying: The drying process removes solvents from the adhesive, retaining its solid content. The drying tunnel temperature should be between 40-60°C. Proper drying enhances bonding strength and prevents bubbling or delamination.

 

Adjusting Heat and Pressure: Set heat and pressure based on the ink layer’s thickness, paper quality, and climatic conditions. Maintain appropriate temperatures to prevent film deformation and ensure strong adhesion.

 

Controlling Machine Speed: Adjust machine speed according to heat and pressure requirements, ensuring optimal lamination quality.

 

Sample Testing: Conduct sample testing to ensure surface smoothness and absence of wrinkles or bubbles.

 

Trimming and Cutting: For pre-coated laminations, immediate cutting is necessary. For coated paper and cardboard, allow 24 hours before cutting to ensure strong bonding.

 

Pre-coating Lamination Process

 

The pre-coating lamination process omits the adhesive preparation, coating, and drying steps, simplifying the operation.

 

 

Classification of Lamination Films

 

Gloss Film: Includes BOPP and PET gloss films with high surface glossiness (≥100 degrees).

 

Scratch-resistant Gloss Film: Features scratch resistance, preventing surface damage.

 

Matte Film: Commonly used matte film with low glossiness (≤3 degrees).

 

Scratch-resistant Matte Film: Offers a metallic texture and moderate glossiness (3-6 degrees).

 

Touch Film: Provides a velvety texture and allows UV printing and hot stamping.

 

Holographic Film: Produces various holographic effects through embossing.

 

Common Adhesives for Lamination

 

Solvent-based Adhesives: Includes EVA, acrylic, polyurethane, polyester, styrene-butadiene rubber, and isobutylene rubber adhesives.

 

Alcohol-soluble Adhesives: Includes acrylic, polyurethane, and polyester adhesives.

 

Water-soluble Adhesives: Includes EVA, acrylic, polyurethane, and polyester adhesives.

 

 

Lamination Methods

 

Wet Lamination: Involves applying adhesive, combining the film with the substrate, and drying it in one process.

 

Dry Lamination: Adhesive is applied and dried before combining with the substrate in one machine.

 

Pre-coated Lamination: Adhesive is pre-applied and dried on the film before lamination, eliminating the need for adhesive application and drying on-site.

 

Impact of Lamination on Print Color and Solutions

 

Lamination enhances color brightness and contrast, potentially causing color shifts. To manage this:

 

New Standards: Brightness deviation should be within specified limits.

 

Sample Testing: Use sample tests to predict and adjust color shifts.

 

Simulation: Use transparent tape to simulate lamination effects.

 

Effect on Matte Film: Generally, colors appear redder and less saturated with matte lamination.

 

Common Issues and Solutions in Lamination

 

Blistering and Spotting

 

Causes: High paper moisture, improper adhesive concentration, excessive ink additives, dust on surfaces, uneven adhesive application.

 

Solutions: Dry printed products, adjust adhesive concentration, clean surfaces, and maintain uniform adhesive application.

 

 

Wrinkling of Printed Products

 

Causes: High paper moisture, uneven roller pressure, misaligned paper.

 

Solutions: Control environmental humidity, adjust roller pressure, align paper correctly.

 

Film Wrinkling

 

Causes: High temperatures, excessive film tension, fast lamination speed.

 

Solutions: Adjust temperature, tension, and lamination speed.

 

Curling During Processing

 

Causes: Moisture in paper, high environmental humidity, excessive film tension.

 

Solutions: Control humidity, adjust roller pressure and film tension.

 

Poor Adhesion

 

Causes: Undried ink layers, low pressure, high speed, low temperature.

 

Solutions: Extend drying time, increase pressure, adjust speed and temperature.

 

Surface Whitening

 

Causes: High environmental humidity, trapped moisture.

 

Solutions: Control temperature and humidity.

 

Composition and Classification of Laminating Machines

 

Components

 

Adhesive Section: Equipped with adjustment mechanisms for adhesive application.

 

Drying Section: Includes infrared lamps and fans for adhesive drying.

 

Heat Press Section: Critical for adhesion, consisting of rollers with adjustable temperature and pressure.

 

Types of Laminating Machines

 

Wet Lamination Machines: Include adhesive application, drying, heat pressing, and film rewinding sections.

 

Pre-coating Lamination Machines: Simplify the process by pre-coating the film with adhesive.

 

Discussion on the Environmental Impact of Lamination

 

As environmental awareness deepens and relevant industry laws and regulations continue to improve, the printing industry must also keep pace with these developments, adjusting its practices to meet green and sustainable printing requirements.

 

Current Pollution Problems

 

The in-line lamination process uses a large amount of organic solvents, which have several drawbacks. The adhesives used contain benzene solvents, which are harmful to human health, potentially causing leukemia and skin allergies with a latency period. Prolonged exposure to these environments can lead to acute and subacute benzene poisoning.

 

The complexity of the in-line lamination process involves blending adhesives, applying adhesive coatings, and drying. Increasing concentrations of organic solvents can easily lead to fires due to static electricity generated by the film materials.

 

Residual harmful substances in products can negatively impact consumer health. Benzene and alcohol compounds are highly volatile, and while most evaporate during and shortly after the lamination process, some residues remain and can volatilize over time, contaminating the consumer environment and posing health risks.

 

In China, 80% of paper fibers are sourced from recycled materials, including waste paper, trimmings, etc. If lamination, particularly in-line lamination, is widely used and the paper cannot be separated from the plastic film, these laminated paper products cannot be recycled, leading to economic losses and resource wastage.

 

Countermeasures

 

Eliminate in-line lamination technology and use pre-coated film processes

 

Pre-coated film technology is an advanced, environmentally friendly lamination process that is poised to replace in-line lamination. It involves pre-applying hot-melt adhesive to BOPP (biaxially oriented polypropylene) film, which, upon reheating and pressing, securely bonds the film. This method is already used in pharmaceutical and food packaging.

 

Advantages of pre-coated film

 

No toxic gas emissions during production, improving the work environment and eliminating fire hazards.

 

Simplifies the lamination process, improving quality and efficiency. It enhances color saturation and clarity without harmful residues, avoiding common issues like bubbling, delamination, and curling.

 

Safe for use in book covers, food packaging, tobacco, alcohol, and pharmaceuticals, posing no threat to consumer health.

 

Develop new materials to enhance recyclability and environmental friendliness

 

To meet rising standards for print quality and market demand, the lamination industry must adjust its structure to reduce environmental impact.

 

Adhesive requirements:

 

-Adhesives must not contain toxic organic solvents like benzene, toluene, xylene, or halogenated hydrocarbons.

 

-Benzene, toluene, and xylene content in adhesives must be less than 1000 mg/kg, with benzene content below 100 mg/kg.

 

-Halogenated hydrocarbon content (measured as dichloroethane) must be less than 1000 mg/kg.

 

Strict adherence to international standards in raw material selection is essential. Safe, non-toxic adhesives like Nubond Instant, which does not contain harmful isocyanates, can be used. Environmentally friendly water-based adhesives like XS-109, suitable for food-grade paper containers, and XS-101, used for high-transparency and brightness applications, are recommended.

 

Standardize operational procedures

 

To prevent fires in lamination workshops, particularly those using in-line adhesive processes, strict operational norms are essential. Fire hazards are most likely to occur above the adhesive tray due to static electricity generated during film stretching and cutting.

 

 

Fire prevention measures:

 

-Ensure good grounding for machinery, preferably using a ring-shaped grounding network. Handle adhesives and solvents gently to avoid sparks from metal containers. Install self-sensing static eliminators on equipment.

 

-Increase humidity around the lamination machine using humidifiers or by sprinkling water, reducing static electricity accumulation.

 

-Maintain good ventilation to lower the concentration of volatile substances.

 

-Enforce strict no-smoking policies, avoid open flames, and ensure operators wear anti-static clothing and shoes.

 

As environmental awareness, health consciousness, and business philosophies evolve, outdated technologies will be replaced. The lamination process must move toward “non-toxic, harmless, green” methods, and Chinese enterprises should proactively address these environmental challenges responsibly.

 

Application Cases and Product Demonstrations

 

-Book and magazine covers, brochures, and commemorative albums

 

-Postcards, calendars, and maps

 

-Color boxes, card boxes, and fine boxes

 

-Shopping bags, envelopes, and business cards

 

-Hang tags, cards, and labels

 

Future Trends in Lamination

 

In developed countries, the lamination market is saturated, with many large printing and packaging companies owning their own lamination equipment. However, emerging markets in Asia, South America, and the Middle East are growing rapidly.

 

Future Trends Analysis

 

-Technological innovation: Advances like nanotechnology will improve scratch resistance and cleanliness of lamination films.

 

-Environmental requirements: The demand for eco-friendly materials and equipment will increase. Water-based lamination technologies will replace traditional solvent-based methods.

 

-Automation and intelligence: Lamination machines will become more automated and intelligent, enhancing production efficiency and quality while reducing labor costs.

 

-Personalized demand: Customized lamination machines will meet the diverse needs of different industries and customers.

 

-International cooperation: Global collaboration will drive technological and market advancements in the lamination industry.

 

In conclusion, the lamination process will continue to innovate and evolve. As environmental awareness and technology advance, the lamination industry will face broader prospects and opportunities.

Everything You Need to Know About Biodegradable Poly Mailers

Table of Contents

Chapter 1: Understanding biodegradable poly mailers

 

1.1 What is a biodegradable poly mailer?

 

A biodegradable poly mailer is an eco-friendly packaging option made from biodegradable materials. It can decompose over time through various techniques like photodegradation, oxidation, and biological degradation, thereby avoiding environmental pollution. These mailers have good transparency, heat resistance, high tensile strength, impact resistance, rigidity, and toughness, with low heat shrinkage rates.

 

1.2 What are biodegradable poly mailers made of?

 

The main raw materials for biodegradable poly mailers include natural high molecular weight materials and biodegradable polymers. Specifically, there are several types:

 

Starch-based plastics: These are made by blending starch and plastics through a specific process. The primary materials are starch and polyethylene, along with certain degradation agents and plasticizers.

 

 

Polylactic acid (PLA): This is a biodegradable polyester plastic made from lactic acid through polymerization.

 

Cellulose: Another natural high molecular weight material, cellulose can also be used to make biodegradable plastic mailers.

 

 

Aliphatic polyesters, polylactic acid, polyvinyl alcohol: These are produced from microbial fermentation or synthetic biodegradable polymers.

 

PBS (polybutylene succinate): This material can be produced using petrochemical raw materials or through fermentation of renewable crops like starch, cellulose, glucose, etc.

 

 

These raw materials are extracted from natural plant fibers or biomass such as starch, making them edible and biodegradable, hence relatively safe. Under composting conditions, these materials can degrade and dissolve due to biological reactions, ultimately breaking down into carbon dioxide, water, and other new biomass.

 

However, despite the environmental friendliness of these raw materials, the production process of biodegradable poly mailers may involve adding chemicals to enhance their toughness and stability. These additives could potentially pose hazards to human health and the environment. Therefore, when choosing and using biodegradable plastic mailers, it’s important to ensure that their biodegradability claims are certified and supported by recognized standards.

 

1.3 Benefits of biodegradable poly mailers

 

Biodegradable poly mailers offer several significant advantages, making them valuable in terms of environmental protection and sustainable development. Here are some key advantages:

 

Environmental friendliness: The primary advantage of biodegradable plastics is their ability to naturally decompose over time, avoiding long-term environmental pollution. These materials can break down into water, carbon dioxide, and other natural substances under microbial action, reducing pollution of soil and water bodies.

 

Pollution reduction: Compared to traditional plastics, the use of biodegradable plastics can significantly reduce environmental pollution from plastic waste. Traditional plastics take a long time to degrade in natural environments, even hundreds of years, whereas biodegradable plastics decompose much faster, helping to lighten the environmental burden.

 

Biocompatibility: Some biodegradable plastics exhibit good biocompatibility, meaning they can coexist with biological tissues or cells without causing adverse reactions. This makes them promising for a wide range of applications in the medical field, such as surgical sutures, drug carriers, etc.

 

Sustainability: The raw materials for biodegradable plastics often come from renewable resources like plant starch, cellulose, etc., enhancing their sustainability. Using these materials can reduce reliance on finite petroleum resources and contribute to sustainable development.

 

Versatility: Biodegradable plastics perform similarly to traditional plastics and even excel in some aspects. They can possess good transparency, strength, toughness, etc., making them suitable for manufacturing various packaging, containers, and disposable items.

 

 

Chapter 2: Certifications from authorities

 

Certification by authoritative institutions for biodegradable poly mailers primarily involves several aspects, including the degradation performance of the product, compliance with environmental standards, and quality control in the production process. Here are some key points regarding certification by authoritative institutions for biodegradable poly mailers:

 

Degradation performance certification: Authoritative institutions rigorously test the degradation performance of biodegradable poly mailers to ensure they can completely decompose into environmentally friendly substances within a specified period. These tests may include biodegradation tests, photodegradation tests, etc., to verify the speed and extent of degradation of the plastic mailers.

 

Environmental standard certification: Biodegradable poly mailers need to comply with relevant environmental standards and regulations, such as international standards ISO 14855-1 and ISO 14855-2, EU standard EN 13432, as well as Chinese national standards GB/T 20197-2006 and GB/T 21961-2008, among others. Authoritative institutions conduct tests and verification against these standards to ensure product compliance.

 

Quality certification: In addition to degradation performance and environmental standards, authoritative institutions also certify the quality control of the production process for biodegradable poly mailers. This includes quality control of raw materials, compliance of production processes, and safety performance of products.

 

In China, some well-known certification institutions such as China Quality Certification Center (CQC) and China Environmental Labeling Product Certification Committee (CEC) provide certification services for biodegradable poly mailers. These institutions conduct comprehensive testing and evaluation of biodegradable poly mailers based on relevant standards and regulations to ensure they meet environmental requirements and market demands.

 

It is important to note that certification standards and requirements may vary across different countries and regions. Therefore, when selecting a certification institution, it’s crucial to ensure that the institution is authoritative and internationally recognized. Additionally, businesses should actively understand and comply with local environmental laws and standards to ensure product compliance and sustainable development.

 

As for the specific certification process and application method, businesses typically need to first contact the certification institution to understand the requirements and procedures. They then submit the required application materials and undergo testing and evaluation as per the requirements. Upon certification, businesses receive the corresponding certification certificate and label to prove the environmental performance and quality level of their products.

 

 

Chapter 3: How to customize biodegradable poly mailers

 

3.1 Different types of biodegradable poly mailers

 

There are various types of biodegradable poly mailers. Here are some common types:

 

Microorganism composed biodegradable poly mailers: These bags contain biopolymers such as bio-polyesters, bio-cellulose, polysaccharides, and polyamino acids, which can be completely decomposed by microorganisms in nature.

 

Polylactic acid microorganism biodegradable poly mailers: These bags are made from lactic acid produced by microbial fermentation, and they actively degrade after use. Polylactic acid can be processed into fibers and films with excellent mechanical properties, and it hydrolyzes into lactic acid and acetic acid in biological organisms, further metabolized by enzymes into carbon dioxide and water. They are especially suitable for medical materials.

 

Starch poly mailers: These bags contain over 90% starch and other additives that can completely degrade. They degrade very quickly, usually within 1 month to 1 year, leaving no traces and causing no pollution. These bags can be used to make various containers, bottles, film bags, and garbage bags.

 

Organic biodegradable poly mailers: These bags contain organic substances like polycarbonates, which can degrade under environmental conditions such as light, temperature, and humidity, without producing harmful substances, making them environmentally friendly.

 

Biomimetic biodegradable poly mailers: These bags are produced by combining natural high molecular weight materials with synthetic materials. They degrade without producing any harmful substances, making them non-polluting to the environment.

 

Additionally, based on their different uses, biodegradable poly mailers can also be categorized as flat bags, carry bags, self-sealing bags, vest bags, express delivery bags, garment bags, etc. These bags are fully biodegradable, breaking down into water and carbon dioxide without impacting the environment.

 

When selecting biodegradable poly mailers, consumers can choose the appropriate type based on their specific needs and purposes. Furthermore, to ensure quality and environmental performance, consumers can also pay attention to the certification status and compliance with environmental standards of the products.

 

 

Chapter 4: Processing techniques

 

The process of manufacturing biodegradable poly mailers mainly involves the following steps:

 

Raw material selection and preparation: Choose materials that meet biodegradability requirements, such as polylactic acid (PLA), polybutylene adipate terephthalate (PBAT), and other biodegradable materials. The raw materials need to be screened, cleaned, and crushed to ensure quality and purity.

 

Addition of additives: To improve the physical and chemical properties of the materials, such as degradation rate, tensile strength, and thermal stability, additives like degradation agents, plasticizers, stabilizers, etc., can be added.

 

Mixing and pelletizing: Mix the cleaned and crushed raw materials with additives in a certain proportion, then extrude the mixture into pellets through an extruder. Pelletizing is done to facilitate subsequent extrusion molding.

 

Extrusion molding: Place the pelletized raw materials into an extruder, heat them to melt. The molten materials are then pushed through the extruder’s screw and molded using a customized mold according to the style and size of the plastic bags.

 

Post-processing: The plastic bags produced through extrusion molding need to undergo processes like cooling, stretching, and cutting. Cooling solidifies the plastic bags, stretching enhances their transparency and strength, and finally, they are cut into complete bag-shaped products.

 

It’s important to note that the degradation of biodegradable poly mailers requires specific conditions such as temperature, humidity, and microbial involvement. Under the right conditions, biodegradable poly mailers gradually break down into small molecular substances, eventually forming carbon dioxide, water, organic matter, and other natural substances without causing environmental pollution.

 

Furthermore, different biodegradable materials may require different molding processes, such as injection molding, compression molding, etc. The choice of specific processes should be based on the material’s characteristics and product requirements.

 

In summary, the process of manufacturing biodegradable plastic bags is complex and meticulous, requiring strict control of quality and conditions in each step to ensure the performance and quality of the final products. Adjustments and optimizations should be made during the actual production process to achieve the best production results.

 

 

Chatper 5: Common issues and solutions for biodegradable poly mailers

 

Biodegradable poly mailers may encounter various issues during production and use, involving production processes, material performance, usage conditions, and more. Here are some common problems and their corresponding solutions.

 

5.1 Issues in the production process

 

Retention of hot air

 

Problem: During the production process, biodegradable poly mailers may retain hot air, leading to bag deformation or poor shrinkage.

 

Solution: Increase the number of air vents to speed up air leakage; slightly reduce the conveyor belt speed of the packaging machine to allow more time for hot air to escape; increase the packaging machine temperature to facilitate air expulsion.

 

Blurring of plastic bag surface

 

Problem: The surface of biodegradable plastic bags becomes blurry, resembling a thin mist.

 

Solution: Lower the packaging machine temperature to reduce the heating time of the plastic; adjust the conveyor belt speed to ensure appropriate contact time of the plastic with heat.

 

Wrinkles on plastic bag surface

 

Problem: Wrinkles resembling fish eyes appear on the surface of biodegradable plastic bags.

 

Solution: Increase the working temperature of the packaging machine; adjust the conveyor belt speed to avoid rapid movements.

 

Poor shrinkage of plastic bag corners and edges

 

Problem: The corners and edges of plastic bags do not shrink properly, forming a series of wrinkles.

 

Solution: Reduce the number of air vents to prevent rapid air escape; lower the conveyor belt speed to ensure complete shrinkage of the plastic.

 

These solutions address common issues encountered during the production of biodegradable poly mailers, ensuring better quality and performance of the final products.

 

Printing issues

 

Problem: Printing colors are inaccurate or printing is blurry.

 

Solution: Provide clear printing requirements during customization, including colors, patterns, and printing methods.

 

5.2 Issues during use

 

Degradation conditions not met

 

Problem: Biodegradable poly mailers are difficult to degrade under normal environmental conditions.

 

Solution: Understand and follow the degradation conditions specified in the product instructions, such as specific temperature, humidity, and microbial environments.

 

Inaccurate specifications

 

Problem: The specifications of biodegradable plastic bags do not meet requirements, leading to inconvenience in use.

 

Solution: Provide accurate specifications during customization, including width, thickness, total width at folds, etc.

 

5.3 Other considerations

 

Storage: Biodegradable plastic bags should be stored in a dry, cool place, away from direct sunlight and high temperatures.

 

Recycling handling: Properly categorize and recycle biodegradable plastic bags to avoid mixing with regular plastic bags.

 

Addressing issues with biodegradable poly mailers requires considering multiple aspects such as production processes, usage conditions, storage environments, etc., and implementing appropriate solutions. Strengthening quality management and supervision is also essential to ensure that the product’s quality and environmental performance meet relevant standards and requirements.

 

 

Chapter 6: Future development directions

 

Technological innovation: With advances in technology, the future of biodegradable poly mailers will focus more on technological innovation. For example, improving production processes and material formulations to enhance the degradation speed and rate of biodegradable plastics; concurrently, developing biodegradable plastic materials with higher strength and durability to meet various industry needs.

 

Environmental performance Optimization: Environmental performance is the core competitive advantage of biodegradable poly mailers. In the future, as environmental requirements increase, biodegradable poly mailers will place more emphasis on optimizing environmental performance. For instance, reducing energy consumption and emissions during production to minimize environmental impact; simultaneously, improving product recyclability and recycling rates to effectively utilize resources.

 

Market expansion and diversified applications: With the maturation of biodegradable plastic technology and cost reduction, its application scope will continue to expand. Apart from traditional packaging, biodegradable poly mailers may also find applications in medical, agricultural, construction, and other fields in the future. Additionally, as international markets demand more environmentally friendly products, the market for biodegradable poly mailers will further expand.

 

In summary, the development journey of biodegradable poly mailers is full of challenges and opportunities. In the future, with technological innovation and increased environmental requirements, biodegradable poly mailers will be applied in more areas, making a greater contribution to environmental protection efforts.

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The Ultimate Guide to Shipping Box

Table of Contents

Chapter 1: Understanding shipping boxes

 

1.1 What is a shipping box?

 

The shipping box has a straightforward design, formed by folding and creasing a single piece of cardboard. It includes four three-dimensional panels: two long side panels and two short side panels, which can be folded and secured with adhesive tape or other methods. Usually, it also features a lid and a bottom that match its dimensions, enabling complete closure. Shipping boxes are used for packaging and transporting various products, known for their convenience, cost-effectiveness, and efficiency, making them widely used in the logistics industry.

 

1.2 What are the materials of shipping boxes?

 

1.2.1 Corrugated cardboard

 

Corrugated cardboard is one of the primary materials used in making paper boxes. It consists of one or two layers of corrugated cardboard and two or three layers of flat paper. There are various types of corrugated cardboard, classified based on the flute type as A, B, C, E, N, F, and N.

 

 

We can refer to the grammage of corrugated cardboard in this form:

 

 

1.2.2 Boxboard paper

 

Boxboard paper is the surface layer paperboard used in corrugated cardboard boxes, requiring high strength and good toughness, made from sulphate pulp. Depending on the quality and usage requirements of the boxes, boxboard paper is classified into five grades: A, B, C, D, and E. Grades A, B, and C are linerboard paperboards, while grades D and E are regular paperboards. Grade A boxboard paper is suitable for manufacturing large corrugated cardboard boxes used for fine, valuable, and refrigerated items packaging. Grade B boxboard paper is suitable for manufacturing corrugated cardboard boxes used for export (long-distance transportation) packaging. Grade C boxboard paper is suitable for manufacturing corrugated cardboard boxes used for packaging larger items. Grade D boxboard paper is suitable for manufacturing corrugated cardboard boxes used for packaging general items. Grade E boxboard paper is suitable for manufacturing corrugated cardboard boxes used for packaging light-load goods.

 

Boxboard paper comes in 14 varieties with grammage ranging from 200 to 530 g/m2, available in flat sheets and rolls.

 

The dimensions of flat sheets are: 787mm * 1092mm (31 * 43inch), 960mm * 1060mm (38 * 42 inch), and 960mm * 880mm (38 * 35 inch).

 

The roll paper widths are: 960mm (38 inches), 1100mm (43 inches), 1600mm (63 inches), and 1940mm (76 inches).

 

1.2.3 Linerboard

 

Linerboard typically requires a grammage of 110 GSM or higher. The standard dimensions for paper sheets are usually regular size 787 * 1092 mm (31 * 43 inches) and large size 889 * 1194 mm (35 * 47 inches). The common types of linerboard paper sheets are as follows:

 

Coated paper

 

 

Coated paper, also known as printing paper, is created by applying a layer of white pulp onto the original paper and then calendering it. It has a smooth surface, high whiteness, uniform fiber distribution, consistent thickness, minimal expansion and contraction, good elasticity, strong water resistance, and tensile properties. It’s also great for ink absorption.

 

There are different textures like cloth-coated and grain-coated paper, and it can be single-sided (one side coated) or double-sided (both sides coated).

 

A. Single-sided: Used for cartons, boxes, tote bags, and medium to high-grade printing.

 

B. Double-sided: Available in weights from 80g to 400g, suitable for high-grade printing.

 

When printing on coated paper, use offset resin ink and glossy ink to avoid pressure issues and back sticking. Employ anti-dirty agents, powder spraying, or other methods to prevent dirtiness.

 

Matte art paper

 

Matte art paper is distinguished from coated paper by its matte surface. It offers uniform fiber distribution, good thickness, high density, excellent elasticity, strong water resistance, and tensile properties. Although its ink absorption and acceptance are slightly lower than coated paper, it makes up for it with a slightly higher thickness. Matte art paper is mainly utilized for elegant, high-grade color printing, such as albums, cards, postcards, and exquisite product samples. It is typically available in grammages ranging from 80gsm to 350gsm.

 

SBS (Solid Bleached Sulphate)

 

 

SBS, made from bleached chemical pulp and fully coated with adhesive, is suitable for printing and product packaging, with a typical basis weight of 150gsm or higher. White cardboard, with three layers, has smooth white surfaces for double-sided printing, and a filler middle layer made from lower-grade materials. It’s rigid and versatile, used in high-end packaging like boxes, cigarette cases, cups, children’s books, and for binding purposes such as softcover book covers, pamphlets, manuals, and hard linings.

 

CCNB (Clay Coated News Back)

 

 

CCNB (Clay Coated News Back) is a white and smooth paperboard on the front side, with the back side typically being grey. It’s commonly used for making paper boxes after single-sided color printing, for packaging, or for crafting handmade products. CCNB comes in standard grammages ranging from 230 g/m² to 500 g/m², and more.

 

Fancy paper

 

Fancy paper refers to specialty papers designed for specific purposes with relatively limited production volumes. It includes various types of special-purpose papers and artistic papers. Today, sellers use the term “fancy paper” as a collective term for artistic papers like embossed paper, aiming to simplify the confusion arising from the wide variety of paper types.

 

1.3 What are the uses of shipping boxes?

 

 

Home appliances and hardware machinery products are typically packaged in rigid cardboard boxes due to their excellent moisture resistance, shock absorption, and protective properties.

 

Fragile items, food products, clothing, and daily essentials are best suited for corrugated cardboard boxes, which provide cushioning, protection, and secure packaging.

 

Watches, jewelry, cosmetics, small household appliances, and gifts are mainly packaged in carton boxes made from sturdy cardboard, suitable for protecting these valuable or fragile items.

 

Beverages, vegetables, fruits, and seafood are suitable for wave paper boxes due to their excellent waterproof properties.

 

Electronic products such as phones and computers are usually packaged in paper boxes to protect them from impact and compression.

 

Food items like cakes, bread, cheese, fruits, and vegetables are packaged in paper boxes to maintain freshness and taste.

 

Pharmaceuticals require strict packaging standards, and paper boxes can provide sealed packaging and double-layer protection to prevent contamination and damage.

 

1.4 Common sizes

 

Here are some common sizes of shipping boxes:

 

 

1.5 What are the benefits of shipping boxes?

 

Structural stability: The design of shipping boxes ensures durability and safety during transportation and storage.

 

Flexible sizing: Customizable based on product size and shape, meeting various packaging needs.

 

Cost-efficient: Compared to materials like wood, shipping boxes have lower production costs and lighter weight, reducing transportation expenses.

 

Easy storage and transportation: Foldable design saves storage space when not in use and facilitates transportation.

 

Environmentally sustainable: Shipping boxes are recyclable and biodegradable, meeting environmental standards and reducing pollution.

 

Water-resistant, mold-resistant, fire-resistant: Some types of shipping boxes (like double-wall corrugated boxes) possess these characteristics, effectively protecting enclosed items.

 

Suitable for various occasions: Whether for valuable items or regular goods, shipping boxes provide appropriate protection and convenient packaging solutions.

 

Customization options: Sizes, colors, and patterns can be customized to meet specific packaging and transportation needs.

 

Simple and quick sealing: The flap-style sealing allows for fast and convenient closure of the boxes, improving packing and unpacking efficiency.

 

1.6 Packaging methods

 

 

Normal stacking: Place the goods flat in the box, suitable for layering and applicable to most products.

 

Diagonal stacking: Place the goods diagonally in the box to save space, but be cautious of potential shifting.

 

Cross stacking: Invert and stack two goods in the box to prevent shifting and damage.

 

Raised design: Incorporate raised sections in the box design to protect and secure goods, reducing shifting and damage.

 

1.7 Storage

 

Choose appropriate environment: Store boxes in a dry, ventilated warehouse to avoid direct sunlight, rainwater, and ensure waterproofing and mold resistance.

 

Stacking method: Store boxes flat to prevent collapse, avoiding vertical stacking and maintaining a moderate stack height.

 

Avoid contact with harmful substances: Prevent contact with oils, acids, alkalis, etc., to maintain cleanliness and quality.

 

Regular inspection: Regularly inspect stored boxes for damage, moisture, pest infestation, etc., and address issues promptly.

 

Chapter 2: Eco-friendliness of shipping boxes

 

2.1 Are shipping boxes recyclable?

 

Shipping boxes are a widely used packaging material with high recycling value. After recycling, shipping boxes can be used to make recycled paper, paperboard, and other items. They can also be used to produce new shipping boxes, paper cups, paper boxes, and more. Recycling shipping boxes not only helps conserve raw materials and energy, reducing environmental pollution, but also enhances resource utilization.

 

 

2.2 How to recycle shipping boxes?

 

Determine the source: Before recycling shipping boxes, it’s essential to identify their source. Some shipping boxes may have come into contact with liquids or food substances, making them potentially contaminated and unsuitable for recycling.

 

Collect and organize: Gather recyclable shipping boxes together, avoiding dirt or damage as much as possible.

 

Remove stains: If there are stains on the surface of shipping boxes, gently wipe them with a damp cloth or use a cleaning agent, ensuring to maintain the integrity of the shipping boxes.

 

Disassemble shipping boxes: If shipping boxes are too large, they can be broken down into smaller parts. This reduces space occupancy and improves transportation efficiency.

 

Fold and stack: Fold and stack shipping boxes to save storage space. If a shipping box cannot regain its shape after being compressed, it may not be suitable for recycling.

 

2.3 Shipping boxes made of recycled materials

 

The recycling ratio of shipping boxes primarily depends on their type and purpose. For corrugated shipping boxes made mainly from waste paper, the waste paper content can exceed 90%. This is because waste paperboard constitutes a significant proportion of the recyclable materials in shipping boxes, accounting for approximately 86% to 90%.

 

However, for shipping boxes requiring better appearance and texture, such as high-quality white cardboard boxes or upscale gift boxes, a moderate amount of wood pulp is typically added. This adjusts the recycling ratio to approximately between 70:30 and 80:20, with 70% to 80% being recycled material and 20% to 30% being new material.

 

2.4 Biodegradable and compostable shipping boxes

 

The difference between biodegradable and compostable shipping boxes lies in their degradation processes and environmental conditions.

 

Biodegradable materials can break down naturally through the action of microorganisms like bacteria and fungi, converting into inorganic compounds, carbon dioxide, methane, water, and more. This process is influenced by environmental factors like temperature, humidity, and light exposure. Examples of biodegradable materials include certain plastics, papers, and wood products.

 

Compostable materials undergo a specific process where they biodegrade in human-managed environments and transform into compost. This process requires suitable conditions such as temperature, humidity, and oxygen levels, with the resulting compost enhancing soil nutrients without introducing toxicity. Home composting typically occurs at lower temperatures, while industrial composting involves higher temperatures for faster degradation.

 

2.5 Certifications from authorities

 

Certification for shipping boxes requires adherence to relevant environmental regulations, such as ISO 14001 certification. Quality certification entails meeting applicable product quality standards, like ISO 9001 certification, at the shipping box factory. Safety certification mandates compliance with relevant safety standards, such as CE certification, at the shipping box factory.

 

 

Chapter 3: Prices of shipping boxes

 

3.1 Shipping box pricing

 

Shipping box pricing encompasses various factors. Processing costs, which include expenses for cutting, printing, pasting, and other processing processes, are typically either fixed or based on the quantity and complexity of the boxes. Additionally, other costs such as transportation fees and binding fees may also be considered in determining the overall price of shipping boxes.

 

3.2 Factors that influence the pricing of shipping boxes

 

Order quantity: Bulk orders often result in lower prices due to optimized production efficiency and reduced transportation costs.

 

Printing and design: Printing and designing on shipping boxes increase craftsmanship and complexity, thus affecting the price.

 

Material quality: Differences in strength and durability impact costs; higher-quality shipping box materials come at a higher price.

 

Transportation distance and packaging requirements: Longer transportation distances and complex packaging requirements may incur additional logistics expenses.

 

Size and specifications: The size and specifications of shipping boxes determine the required material quantity and production difficulty; larger or specially sized shipping boxes tend to be more expensive.

 

Chapter 4: Customization of shipping boxes

 

4.1 Types of shipping boxes

 

 

Slotted-type box: The most common outer packaging shipping box, made of a single piece of corrugated cardboard, can be formed by stitching or gluing.

 

Set-up box: The body and cover of the box are separate, and they are assembled by fitting together when used.

 

Foldable box: Made of a single piece of corrugated cardboard, formed by folding to create the bottom, side panels, and cover.

 

Half-slotted carton (HSC): A regular slotted carton with only one pair of flaps, plus an additional cover.

 

Full telescope box: Also known as top and bottom cover box, where the top cover can completely cover the bottom cover.

 

4.2 Design recommendations for shipping boxes

 

Printing accuracy: Ensure that patterns and text on the box are printed clearly, accurately, and consistently in depth. The placement should be precise (registration error within ±1mm/0.04). Avoid ink smudging, typos, misprints, omissions, redundant patterns, or text. Limit white spots to no more than 5 per box within 1mm×1mm/0.040.04. Excess ink spots should not exceed 5 spots within 1mm×1mm/0.040.04 on the front side of each box and 2mm×2mm/0.8*0.8 on the side of each box. Barcodes must be readable.

 

Spacing and protection: Leave a gap between the shipping box and the product, cushioned with bubble wrap to prevent direct contact. Bubble wrap provides cushioning during transport, protecting the product from damage.

 

Surface integrity: Ensure the shipping box’s surface is free from damage, stains, rust, peeling, cracking, and other paper defects. Inside the box, the linerboard should not have joints, material deficiencies, exposed flutes, creases, glue penetration, color differences, or other sensory defects. Consistency in whiteness and material quality is essential.

 

Printing quality: UV coating on the box surface may have slight cracks but should not flake off. Pressure lines on the box should not exceed 12mm/0.47 in width, be centered, and avoid extra lines or defects affecting the folding experience.

 

Adhesive: Use corn starch glue for bonding, ensuring even, sufficient application without overflow. Adhesive must be neat, secure, with aligned joints, and minimal misalignment (up to 2mm/0.08) to avoid boxes sticking together.

 

 

Chapter 5: How are shipping boxes made

 

5.1 Demand-driven matching

 

The process involves aligning product design and craftsmanship, confirming pricing based on packaging and shipping needs, creating designs, finalizing materials and techniques, developing packaging and shipping plans, and other related tasks. Some of these responsibilities are handled by the client, while others are delegated to design companies. Typically, printing and packaging firms execute these tasks based on client requirements through their specialized departments. Once the design phase is complete, large-scale samples are produced, and production begins after client approval of these samples.

 

5.2 Prepress

 

The prepress department manages graphic design, document processing, typesetting, color calibration, standard die-cutting graphics, film output, CTP plate making, and other tasks. Its primary role is to ensure the accuracy and correctness of all documents before mass production printing, thereby facilitating seamless operations in the printing department.

 

 

5.3 Printing

 

Flexographic printing, offset printing, and screen printing are the primary conventional methods for printing on corrugated cardboard.

 

Flexographic printing

 

Conventional flexographic printing, also known as water printing due to its use of water-based inks, involves direct printing on corrugated cardboard. This method offers several advantages:

 

Firstly, flexographic printing machines have a significant size capability, ranging from 2.5m (98.43in) to 2.8m (110.24in) in width. This allows for handling large formats efficiently.

 

Secondly, it is cost-efficient. Flexographic plates are durable and reusable, contributing to lower production costs. Additionally, the ink costs are relatively low compared to other printing methods.

 

Thirdly, flexographic printing allows for integrated production. It can be seamlessly integrated with processes like slotting, creasing, box stitching or gluing, and bundling using a single machine, streamlining the production workflow.

 

Despite these benefits, flexographic printing has some limitations. It offers lower precision compared to offset printing, as it uses lower line screens (35 to 65 lines per inch). While suitable for text and line art, it may not be ideal for high-quality four-color image printing due to challenges in ink density control, leading to variations in print quality.

 

Despite these challenges, flexographic printing remains widely used for Type 1 corrugated boxes in box factories due to its overall cost efficiency and integrated production capabilities.

 

Offset printing

 

 

Conventional offset printing on corrugated paper uses an indirect method, printing the liner first and then applying it to the board. This method is popular for high-end sales packaging in China due to its ability to achieve fine printing patterns with PS plates. However, it’s limited to single-face corrugated machines, has smaller formats than flexographic printing, and higher printing costs. Yet, it offers stable print quality and options for surface finishing like lamination and gloss coating.

 

Screen printing

 

 

Screen printing on corrugated cardboard utilizes a direct printing approach with characteristics distinct from other methods. Its lower resolution, typically ranging from 60 to 80 lines per inch, results in less image accuracy. Screen printed corrugated boxes are notable for their suitability for various sizes, the ability to print before or after assembly, and the production of thick ink layers for high color saturation, especially in spot color printing. While not suitable for inline production, screen printing offers cost-effective plate making, lower printing costs, and relatively stable print quality.

 

5.4 Post-printing processes

 

Varnishing

 

After printing, the surface of the paper does not have strong adhesion to the ink, making the printed patterns susceptible to slight abrasion and color fading. To better protect the printed materials, we apply varnishing or coating for protection.

 

Matte Finish

 

This involves applying a layer of matte film on the surface of printed materials, creating a frosted appearance that distinguishes it as a matte finish.

 

Glossy Finish

This is achieved by applying a colorless transparent coating oil on the surface of printed materials, which, after leveling and drying, forms a thin and uniform transparent glossy layer on the surface.

 

UV Coating

 

This process involves using screen printing technology to apply UV ink or various UV oils onto the surface of the substrate.

 

Embossing

 

Embossing is a printing technique that creates a raised effect on specific parts of the paper.

 

Debossing

 

Debossing is the opposite of embossing, as it involves pressing text or patterns into the paper to create a recessed effect.

 

Foil stamping

 

Foil stamping commonly includes cold foil stamping and hot foil stamping.

 

5.5 Die-cutting

 

Die-cutting is a precision process that utilizes steel knives or wires set in a template to cut printed materials into specific shapes under high pressure. Adhering to international standards, the tolerances must be tightly controlled within +/- 0.005 inches (1.27 millimeters).

 

This technique is particularly suited for heavier paper materials weighing 157 grams or more, including stickers, labels, gift boxes, and various printed artworks.

 

It’s crucial to understand that die-cutting encompasses more than just cutting; it also involves creasing, punching, and perforating functionalities. The die-cutting board is segmented into cutting blades, creasing blades, and perforation blades, strategically allocated based on the intricacies of the design requirements.

 

5.6 Packaging

 

Packaging encompasses several key steps in the production process. These include waste removal, assembling finished products, conducting quality inspections, matching packing items, and counting them accurately. These steps are crucial as they represent the final stage of production, highlighting the significance of thorough inventory checks to ensure precise quantities and uphold quality standards.

 

Moreover, it’s essential to adhere to regulations concerning the attachment of box and pallet labels. These labels must meet international trade standards in terms of size and material to facilitate smooth operations and compliance.

 

5.7 Turnaround

 

Custom orders vary in scale, each with its production timeline. Small-scale custom orders, involving customized design and production, typically have a shorter production cycle of around 1.5 weeks. Medium-scale orders, on the other hand, have a slightly longer production cycle of about 3 weeks, covering activities from raw material procurement to manufacturing, quality testing, and packaging. For large-scale bulk production orders, the production cycle is extended due to additional production preparations, raw material supplies, and production line adjustments, requiring approximately one month to complete.

Chapter 6: Quality inspection

 

We prioritize maintaining the quality of our shipping boxes. Our commitment to quality control is evident in our comprehensive quality assurance process, which encompasses several crucial stages:

 

Comprehensive testing: We employ specialized testing equipment for assessments, such as edge crush tests and adhesive strength tests. These evaluations are vital for ensuring the strength and durability of our boxes.

 

The edge crush test (ECT) holds particular significance as it precisely measures the box’s ability to withstand stacking pressure. It assesses the compressive strength of corrugated board along its edges. In this evaluation, a small section of the board is vertically compressed between two solid boards at right angles to the flute direction until it reaches maximum load. The results are quantified in pounds per inch (lb/in) of load-bearing edge but are commonly expressed as ECT measurements.

 

External validation: We collaborate with reputable professional testing organizations like SGC (Sample Goods Certification) to verify whether our products meet industry benchmarks and standards. SGC is a globally recognized certification body specializing in assessing and validating product quality and safety.

 

 

Chapter 7: Development trends

 

As the global economy continues to integrate and technological advancements progress, shipping boxes, essential components of logistics and product packaging, are undergoing diverse changes and developments. Below is an in-depth analysis and discussion of the current trends shaping the shipping box industry:

 

Environmental focus: Shift towards eco-friendly materials and sustainable production methods to reduce environmental impact.

 

Technological innovation: Advancements improving box durability and customization options, especially with digital printing.

 

Industry standardization: Strengthening self-regulation and setting comprehensive standards to meet consumer expectations.

 

Cost control: Focus on optimizing processes and reducing production costs to enhance competitiveness.

 

Market competition: Intensifying competition driving companies to improve quality, services, and innovation.

 

Cross-industry collaboration: Increasing partnerships with e-commerce and logistics for expanded market reach and resource sharing.

 

Chapter 8: Package N’ Go makes it possible

 

 

We believe this guide will be of assistance to you. As you embark on your journey to select and customize the perfect shipping boxes for your needs, remember that your packaging is a reflection of your brand’s ethos, creativity, and commitment to delivering exceptional value. We stand ready to be your trusted partner on this journey, providing top-tier shipping boxes that reflect the essence of your brand and encapsulate your products with care. The future of shipping boxes is bright, and we are excited to be a part of your packaging evolution.

Our team of experts is committed to providing high-quality, tailored packaging solutions that fit your brand perfectly. Reach out today to explore your options!

Everything You Need to Know About Glassine Bags

Table of Contents

Chapter 1: Understanding glassine bags

 

1.1 What is a glassine bag?

 

Glassine bags are made from glassine paper. Glassine paper is a high-quality specialty paper material known for its dense and uniform texture, high internal strength, good translucency, and other characteristics. It also has functions such as high temperature resistance, moisture resistance, and oil resistance, making it widely used in packaging for industries such as food, clothing, electronics, home decor, and gifts.

 

1.2 What are the materials of glassine bags?

 

The raw materials used in manufacturing glassine bags consist mainly of the following components:

 

 

Furthermore, the coating materials for glassine paper include:

 

1.3 What are the uses of glassine bags?

 

Glassine bags are a versatile packaging solution widely used across various industries and product types. Here are some specific use cases:

 

Clothing packaging:

 

Glassine paper packaging bags are particularly suitable for clothing packaging due to their high temperature resistance, moisture resistance, and oil resistance. They can effectively protect clothing from environmental factors.

 

Environmental packaging:

 

As a material for eco-friendly, renewable, and plastic-free paper bags, glassine paper bags help reduce plastic pollution and serve as an “environmentally friendly attire” for numerous products.

 

1.4 Common sizes

 

 

 

1.5 What are the benefits of glassine bags?

 

Excellent transparency: Glassine paper boasts high transparency, allowing glassine bags to vividly display their contents, aiding in easy identification and inspection.

 

Dense texture and high strength: The dense texture and strong internal structure of glassine paper enable glassine bags to protect their contents effectively, minimizing the risk of damage or tearing.

 

Good oil and water resistance: Glassine paper exhibits excellent resistance to oil and water, enhancing the cleanliness and durability of glassine bags and prolonging their lifespan.

 

Versatile applications: Due to its high temperature resistance, moisture resistance, and oil resistance, glassine paper bags find wide application across industries such as clothing packaging and gifts.

 

Clear printing and smooth surface: Glassine paper’s smooth surface and excellent ink absorption ensure clear and legible printing of labels and information, making it ideal for high-speed automatic labeling and special tape applications.

 

1.6 Packaging and storing

 

Packaging requirements

 

Packaging materials: It is recommended to use kraft paper, polyethylene (PE) bags, or other packaging materials with moisture and dust resistance functions to package glassine bags.

 

Packaging method: Ensure that each bag is not damaged during the packaging process, avoiding excessive compression or folding. It is suggested to use roll or fold packaging for ease of storage and transportation.

 

Labeling and tags: Clearly indicate the product name, specifications, production date, manufacturer information, etc., on the packaging for easy identification and management.

 

Storage requirements

 

Environmental requirements: Store in a dry, ventilated, cool, and shaded environment, away from sources of heat and fire. Avoid direct sunlight and humid conditions to prevent deformation or mold growth of glassine bags.

 

Stacking method: Store flat or vertically to avoid excessive compression or bending. Adjust the stacking height based on actual conditions to ensure the glassine bags are not damaged.

 

Dust and moisture prevention: To prevent dust and moisture intrusion, consider using dust covers or moisture-proof pads in the storage area. Regularly check the moisture resistance of packaging materials to ensure the glassine bags are in good storage condition.

 

 

Chapter 2: Eco-friendliness of glassine bags

 

2.1 Are glassine bags eco-friendly?

 

Glassine bags are highly eco-friendly.

 

Biodegradability: Glassine bags are primarily made from natural plant fibers, exhibiting excellent biodegradability. In natural environments, these bags can decompose relatively quickly, reducing the need for landfill disposal and lowering environmental pollution.

 

Renewability: The raw materials for glassine paper mainly come from renewable resources such as wood and bamboo. This means that its production does not deplete limited natural resources, contributing to maintaining ecological balance.

 

Low toxicity: Compared to traditional plastic bags, glassine bags avoid the use of toxic substances in their production. They are free from heavy metals and harmful additives, making them safer for both human health and the environment.

 

2.2 How are glassine bags recycled and reused?

 

Collection and sorting: First, used glassine paper bags are collected and sorted. This helps ensure the purity of materials during the recycling process and improves recycling efficiency.

 

Pre-treatment: Collected glassine paper bags undergo pre-treatment, such as cleaning and stain removal, to eliminate surface stains and residues. This step is crucial for enhancing the quality of recycled materials.

 

Shredding and pulping: Pre-treated glassine bags are shredded into small pieces and processed into pulp through pulping. During this process, a suitable amount of chemical additives can be added to enhance the performance of the pulp.

 

Papermaking: The pulp is used in the production line of a papermaking machine, undergoing forming, pressing, drying, and other processes to produce recycled paper. This recycled paper can then be used again to make bags or other packaging materials.

 

 

2.3 Biodegradability and compostability of glassine bags

 

Biodegradability

 

Biodegradability refers to the natural breakdown of materials by microorganisms. For glassine paper, its biodegradability depends on factors like raw materials, manufacturing processes, and additives. Some glassine paper products may use biodegradable fiber materials, such as certain plant fibers, exhibiting good biodegradability. However, if non-biodegradable additives or processing agents are used, it can affect biodegradability.

 

To enhance glassine paper’s biodegradability, manufacturers can opt for more biodegradable raw materials and additives or employ special processing methods. Environmental factors like temperature, humidity, and microorganism types also affect biodegradation rates, so practical application scenarios should be considered when choosing biodegradability options.

 

Compostability

 

Compostability refers to materials breaking down into compost under composting conditions. Glassine paper can be compostable if its raw materials and additives meet composting requirements. This allows used glassine paper to be composted with organic waste, turning into fertilizer.

 

When choosing composting options, ensure glassine paper lacks harmful substances to avoid negative impacts on the composting process and resulting compost. Proper control of composting conditions is crucial for complete decomposition of glassine paper.

 

2.4 Certifications from authorities

 

ISO certification

 

The International Organization for Standardization (ISO) provides a range of standards for paper and paper products, covering aspects such as quality, production, and management. Glassine paper manufacturers may obtain certifications like ISO 9001 (Quality Management System) and ISO 14001 (Environmental Management System) to demonstrate compliance with quality management and environmental standards.

 

FDA certification

 

For glassine paper used in food packaging and related areas, certification from the United States Food and Drug Administration (FDA) may be necessary. FDA certification ensures that these papers meet safety standards for food contact materials and do not contaminate food products.

 

SGS certification

 

SGS is a leading global inspection, verification, testing, and certification company with expertise across various industries. For glassine paper, SGS can provide certification services related to product quality, environmental performance, and other aspects.

 

Forest stewardship council (FSC) certification

 

If glassine paper uses sustainably sourced wood fiber as raw material, it may obtain FSC certification. FSC certification ensures that wood and paper products originate from sustainably managed forests, promoting the sustainable utilization of forest resources.

 

Chapter 3: Performance of glassine bags

 

 

3.1 Chemical properties of glassine bags

 

Chemical composition of glassine bags

 

The primary chemical composition of glassine bags is cellulose. Cellulose is a natural polymer compound made up of glucose molecules linked by β-1,4-glycosidic bonds. During the production process of Glassine bags, cellulose undergoes chemical treatments such as bleaching and esterification to enhance its transparency and water resistance.

 

Chemical stability of glassine bags

 

Water resistance: Glassine bags exhibit good water resistance, primarily due to the tight structure of cellulose molecules and appropriate degree of esterification. Water molecules find it difficult to penetrate through the tight cellulose network, thus maintaining good stability in water environments.

 

Oil resistance: Glassine bags demonstrate good barrier properties against most oils, making them suitable for applications like food packaging to prevent oil penetration and leakage.

 

Chemical corrosion resistance: Glassine bags show a certain level of stability against common acids, alkalis, and organic solvents, offering resistance to chemical corrosion to a certain extent. However, strong acids, alkalis, and certain organic solvents may still cause damage, requiring caution during use.

 

Chemical reactions of glassine bags

 

Despite having good chemical stability, Glassine bags may undergo chemical reactions under specific conditions. For instance, under high temperatures or in strong acid or alkali environments, cellulose molecules may undergo hydrolysis reactions, leading to a decline in paper performance. Additionally, some oxidizing agents may react with components in Glassine bags, causing discoloration or damage to the paper.

 

 

Chapter 4: Prices of glassine bags

 

4.1 Factors influencing the prices

 

Raw material costs: The primary raw material for glassine bags is glassin paper, which directly impacts packaging costs. The price of glassin paper is influenced by various factors such as pulp prices, maintenance costs of papermaking equipment, and transportation expenses. Pulp prices are affected by international wood prices, supply and demand dynamics, and environmental policies, while equipment maintenance and transportation costs are influenced by technological advancements and logistics industry factors.

 

Product quantity: Quantity is a significant factor affecting Glassine bag prices. Generally, higher quantities lead to lower unit prices. This is because manufacturers can optimize production resources and reduce unit production costs during large-scale production, enabling them to offer more competitive prices.

 

Production process: The complexity of the production process impacts glassine bag prices. More intricate processes require additional equipment investment and labor costs, resulting in higher prices. Additionally, different production methods may affect product quality and performance, influencing market demand and pricing.

 

Market demand and supply: Market dynamics play a crucial role in determining Glassine bag prices. When demand exceeds supply, prices tend to rise, and vice versa. Seasonal fluctuations, consumer preferences, and market trends also influence pricing strategies.

 

Environmental policies: Increasing environmental consciousness has led to stricter environmental policies globally. These regulations may restrict certain materials or production methods, affecting the cost of glassine bags. For instance, limitations on non-recyclable or non-degradable materials could lead to higher production costs for packaging.

 

 

Chapter 5: Customization of glassine bags

 

5.1 Different types of glassine bags

 

Single-layer glassine bag: This is the simplest type of glassin paper packaging bag, consisting of only one layer of glassin paper.

 

Composite glassine bag: This type of packaging bag is composed of glassin paper and other materials (such as PE, PP, aluminum foil, etc.) to increase its strength, moisture resistance, oil resistance, or barrier properties.

 

Printed glassine bag: This type of packaging bag has been printed on the surface of glassin paper, allowing various patterns, text, or barcodes to be printed. Printed glassin paper packaging bags not only enhance the visual effect of the product but also improve its recognition and brand value.

 

Heat-sealed glassine bag: The mouth of this packaging bag is sealed using heat sealing technology, providing excellent sealing performance to effectively prevent leakage or moisture ingress of the contents. Heat-sealed glassin paper packaging bags are particularly suitable for products that require long-term storage.

 

Self-standing glassine bag: This type of packaging bag has a special structural design that allows the contents to stand upright, making it convenient for display and sale. Self-standing glassin paper packaging bags are commonly used for packaging snacks, beverages, and other goods.

 

5.2 Design recommendations

 

Structural design

 

Bag type design: Design appropriate bag types like self-standing bags, sealed bags, etc., based on product characteristics and user needs to improve packaging practicality and portability.

 

Size and capacity: Design the size and capacity of packaging bags reasonably according to product size and market demand to meet packaging needs while minimizing resource waste.

 

Opening method: Consider user convenience in design, ensuring easy opening and closing of packaging bag structures.

 

Below are design structure diagrams:

 

 

Visual design

 

Patterns and colors: Choose suitable patterns and colors based on product positioning and target audience to enhance the visual appeal of the packaging.

 

Brand identification: Place brand identification prominently on the packaging bag to boost brand awareness and recognition.

 

Text description: Clearly label product name, specifications, production date, etc., to help users understand product information.

 

Chapter 6: How are glassine bags made

 

6.1 Printing

 

Layout design and plate making

 

Create or adjust the layout design of paper bags, including patterns, text, logos, etc., based on customer requirements or market demand.

 

Once the design is finalized, send the design draft to the plate-making department to create a printing plate using specific plate-making techniques.

 

Prepress preparation

 

Check if the printing plate is intact to ensure consistency with the design draft.

 

Prepare materials such as ink, cleaning agents, wiping cloths, etc., needed for printing and adjust the parameters of the printing machine accordingly.

 

Printing

 

Place the glassine bag material in the feeding part of the printing machine, ensuring the material is flat and free of wrinkles.

 

Start the printing machine, transfer ink evenly onto the printing plate through rollers, and then print patterns and text onto the glassine bag.

 

During the printing process, closely monitor the printing effect and promptly adjust parameters such as ink density and printing pressure to ensure printing quality.

 

 

6.2 Composite

 

Gluing and bonding

 

Apply adhesive evenly on the surface of glassin paper or other materials using a specialized gluing machine as per design requirements.

 

Bond the adhesive-coated glassin paper with other materials to ensure smooth bonding without air bubbles or wrinkles.

 

Heat pressing and curing

 

Use heat pressing equipment to subject the bonded glassine bag to heat and pressure, rapidly curing the adhesive to ensure strong bonding between materials.

 

Control the temperature, pressure, and duration of heat pressing to prevent damage or reduced bonding strength due to excessive or insufficient heat and pressure.

 

Cooling and shaping

 

After heat pressing, cool the glassine bag to set its shape quickly and uniformly.

 

Ensure even and rapid cooling to prevent deformation or internal stresses in the paper bag.

 

6.3 Die cutting

 

Installing die cutting plate

 

Install the designed die cutting plate onto the die cutting machine, adjusting its position and pressure for proper alignment with the material.

 

Die cutting operation

 

Start the die cutting machine and feed the glassin paper material into it, using the die cutting plate to cut and fold as required.

 

Control the material feed rate and machine speed during cutting to maintain accuracy and ensure high-quality paper bags.

 

Post-cutting processing

 

Perform additional processes such as hole punching and folding on the die-cut glassine bags as needed.

 

6.4 Turnaround

 

The production cycle can be influenced by various factors, such as the order size, production complexity, raw material availability, production equipment efficiency, and manufacturer’s production capacity. Typically, the production cycle for glassine bags can range from two weeks to several weeks.

 

We are committed to delivering high-quality products within the agreed timeframe, tailored to our customers’ specific requirements.

 

 

Chapter 7: Quality inspection

 

7.1 Importance of quality inspection

 

The importance of quality inspection for glassine bags is evident in several key areas:

 

Material testing: The quality of materials directly impacts the overall quality of glassine bags. Rigorous testing of materials is necessary to ensure they meet national quality standards.

 

Production process monitoring: Every stage of the production process, such as printing, lamination, cutting, etc., requires meticulous control. Details in these stages directly affect whether the paper bags meet standards, including color ink ratios and spray thickness in printing, film thickness and bonding strength in lamination, as well as dimensions and smoothness in cutting.

 

Appearance and functionality checks: The appearance and functionality of glassine bags are vital quality indicators. Appearance checks include smoothness, shape, absence of contamination, and absence of damage. Functional checks such as sealing, leak resistance, tear resistance, etc., are also necessary to ensure the quality of the paper bags.

 

7.2 Quality inspection standards

 

 

Printing quality

 

Ensure clear and sharp printing with no blurred text or patterns, and no missing strokes.

 

Bag dimensions

 

Allow a deviation of up to 2mm in bag width and length.

 

Sealing detail

 

Provide detailed illustrations of the sealing process.

 

Packaging box material

 

Five-layer BC corrugated cardboard (160g/m² linerboard, 130g/m² medium paper, and 110g/m² inner linerboard). Seal using adhesive; avoid using nails. The outer box must have a shipping label, be sturdy, and not collapse or break after loading.

 

7.3 Common issues and solutions

 

Insufficient bag strength: The bags are prone to tearing or damage during use, failing to meet weight-bearing requirements.

 

Solutions: Utilize high-quality glassin paper as the primary material to guarantee strength and durability in the bags. Enhance overall bag strength by optimizing production processes like compression and die-cutting. Additionally, improve weight-bearing capacity by incorporating reinforcing ribs or other structural enhancements into the bag design.

 

Printing quality issues: Printing patterns on the bags appear blurry, colors are distorted, or there are misalignments.

 

Solutions: Choose suitable printing inks and processes to achieve clear and vibrant printing on the bags. Ensure accuracy by conducting regular maintenance and calibration of printing equipment. Strengthen quality control during printing, including sampling inspections, to promptly address any issues that may arise.

 

Inaccurate bag dimensions: Actual bag dimensions deviate from design requirements.

 

Solutions: Ensure precision in raw material measurements to meet design specifications accurately. Maintain and calibrate die-cutting equipment regularly to achieve precise cuts. Enhance size control during production and conduct batch size checks to ensure consistent accuracy in each batch.

 

Adhesive issues: The bags experience delamination or adhesive failure during use.

 

Solutions: Employ stable and suitably adhesive materials for bonding purposes. Maintain control over the amount and uniformity of adhesive application to achieve effective bonding. Ensure thorough drying and curing of the adhesive post-bonding to enhance overall bonding strength.

 

 

Chapter 8: Development trends

 

Environmental protection and sustainability: With increased environmental awareness and policy support, the production and use of glassine bags will prioritize environmental protection and sustainable practices. This includes using eco-friendly materials and processes to minimize pollution and enhance resource efficiency.

 

Technological innovation and product enhancement: Advancements in technology will drive continuous innovation in glassin paper production techniques, leading to improved product performance and quality. This opens up possibilities for developing bags with enhanced strength, moisture resistance, anti-counterfeiting features, and more.

 

Personalization and customization: Diverse market demands will drive a focus on personalization and customization in glassine bag design and production. Companies can tailor bags to meet unique customer preferences and requirements, offering unique appearances and performance characteristics for different industries and occasions.

 

Chapter 9: Conclusion

 

 

Glassine bags will play a key role in the packaging industry, offering efficient, eco-friendly, and visually appealing solutions across sectors, driving industry progress and development.

 

Package N’ Go is a leading manufacturer of glassine bags, offering high-quality packaging solutions. Contact us with your specific requirements, and we will customize premium packaging solutions tailored to meet your exact needs. Our commitment to excellence ensures that your packaging needs are met with precision and reliability.