Paperboard is thicker, stronger, and more durable than regular paper, making it ideal for packaging and rigid applications, while regular paper is thinner and primarily used for printing and writing tasks. Paperboard typically has a thickness of 0.3 mm to 1.0 mm, or about 12 to 24 points (1 point = 0.001 inches).

Paperboard can be made from virgin wood fibers or recycled materials and is typically used in applications such as boxes, cartons, and packaging containers due to its ability to be cut, folded, and shaped easily.

Types of Paperboard

There are several types of paperboard, including:

• Solid Bleached Sulfate (SBS) – White throughout and made from bleached virgin fibers, commonly used in high-end packaging like cosmetics or pharmaceuticals.
• Coated Unbleached Kraft (CUK) – Unbleached and typically brown or grey in color, this type is durable and used for heavier items such as beverage carriers.
• Folding Boxboard (FBB) – Composed of multiple layers of pulp, this type is stiff and often used for food packaging.
• White-lined Chipboard (WLC) – Made from recycled paper, it’s a cost-effective option used in applications like cereal boxes or tissue boxes.

According to the research paperboard boxes are used in many industries for packing and protection.

History of Papeboard

The history of paperboard began in 1817 when the first carton was made in England. This marked a significant innovation in packaging. By the 1860s, folding cartons became popular, as they were shipped flat to save space and were set up by customers as needed.

The development of mechanical die cutting and creasing in 1879 further revolutionized paperboard production, allowing for more efficient and precise shaping.

In 1911, the first kraft sulphate mill was built in Florida, which led to stronger paperboard products due to the kraft process.

The invention of the gable top milk carton in 1915, followed by its use in dairy plants by 1935, demonstrated the growing importance of paperboard in the food and beverage industry.

Paperboard evolved further with the introduction of ovenable versions in 1974, expanding its use to food packaging that could withstand heat.

How is paperboard produced?

Paperboard is made through a multi-step process that transforms wood fibers or recycled materials into sturdy, thick sheets. Here’s an overview of the process:

1. Raw Material

Wood Pulp: Paperboard is mainly made from wood fibers, usually from softwood trees like pine and fir for added strength, though hardwood fibers or recycled paper can also be used.

Recycled Pulp: Recycled paper is often used to produce paperboard, minimizing environmental impact.

2. Process of Pulping

Mechanical Pulping: The raw wood is chipped and ground down to produce wood fibers. This method keeps more of the original fiber content but produces a rougher pulp.

Chemical Pulping (Kraft Process): The Kraft process uses chemicals like sodium hydroxide and sodium sulfide to break down wood into pulp, producing stronger, more durable paperboard.

3. Forming the Paperboard

The pulp is diluted with water and spread onto a large screen using a Fourdrinier or cylinder machine, where water is drained and layers are added to achieve the desired thickness of the paperboard.

4. Pressing and Drying

The wet paperboard is pressed through rollers to remove excess water and compact the fibers for strength, then passed through heated cylinders to evaporate remaining moisture, producing a dry sheet.

5. Coating (Optional)

Depending on the intended use, paperboard can be coated with materials like clay, polyethylene, or other polymers to improve printability, moisture resistance, and strength.

6. Cutting and Finishing

Once the paperboard reaches the desired thickness and strength, it is cut into sheets or rolls for further use. Finishing processes like die cutting, creasing, or embossing may be added, particularly for packaging.