Corrugated Print Quality: ECT vs. Bursting (Mullen) Test Board
When choosing corrugated board for packaging, print quality is often a critical consideration. Two common board types—ECT (Edge Crush Test) board and Bursting Test board, also called Mullen Test board—have distinct surface characteristics that impact the final print results, especially when using flexographic (flexo) printing. While both boards serve their structural purposes, their composition affects ink absorption, print clarity, and overall aesthetics.
Why Does ECT Board Struggle With Print Quality?
ECT board is designed primarily for stacking strength rather than printing quality. It is rougher and more porous compared to Test board, which results in the following print challenges:
- Ink Absorption Issues: The more porous nature of ECT board allows ink to spread unevenly, leading to a muddy, less defined print.
- Uneven Surface Texture: Rough fibers on ECT board prevent fine details and crisp lines from transferring properly, resulting in a blurry or inconsistent appearance.
- Reduced Ink Holdout: Because the ink penetrates deeper into the material, colors may appear duller and less vibrant compared to smoother boards.
Can You Improve Print Quality on ECT Board?
For brands requiring higher-quality graphics on an ECT board, one option is to order virgin kraft liners instead of standard recycled liners. Virgin kraft liners:
- Have a smoother, more uniform surface, allowing for better ink adhesion and sharper details.
- Reduce ink absorption, leading to brighter, more vibrant prints.
- Are stronger and cleaner-looking, improving the overall aesthetic of the packaging.
When to Use Bursting Test Board Instead
Test board, made from a mix of virgin and recycled fibers, tends to be smoother than ECT board, allowing for better ink retention and detail clarity. If print quality is a priority, a Test board with a higher-quality white or coated liner can significantly improve the final result.
Final Considerations
If your primary concern is cost and stacking strength, ECT board is a solid choice, but expect compromises in print quality when using flexo. For higher-quality branding and graphics, consider upgrading to a Test board or requesting virgin kraft liners to enhance your print results.
Need help selecting the right corrugated board for your packaging? Contact Brown Packaging today to find the best option for your needs!
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Corrugated boxes lose a significant portion of their original compression strength during prolonged storage, especially under load. Understanding the mechanics of compression creep and the environmental factors at play allows packaging engineers to design boxes that maintain structural integrity throughout their intended shelf life. Why Compression Strength Declines Material Creep: Fibers gradually deform under constant load, reducing box stiffness. Humidity Impact: Elevated RH accelerates creep, with potential strength losses of 40–60% in humid conditions. Stacking Configuration: Poor pallet patterns or uneven weight distribution compound stress points. Testing and Standards ASTM D4577: Measures compressive creep over time in shipping containers. ASTM D642: Evaluates initial compression strength, serving as a baseline before long-term storage. Design Strategies to Reduce Loss Select Higher ECT Boards: Provides a stronger starting point, delaying the drop below critical load thresholds. Moisture Control: Use desiccants, ventilation, or moisture-barrier coatings in high-humidity warehouses. Pallet Pattern Optimization: Uniform stacking prevents concentrated stress on corner posts. Application Considerations Long-term storage in non-climate-controlled facilities should factor in 30–50% compression loss for safety margins. Double-wall or reinforced designs are advised for seasonal inventory stored for extended periods. References ASTM International. (2015). ASTM D4577-15: Standard test method for compressive creep of shipping containers. ASTM International. https://www.astm.org/d4577-15.htmlASTM International. (2015). ASTM D642-15: Standard test method for determining compressive resistance of shipping containers. ASTM International. https://www.astm.org/d0642-15.html (714)300-0650 request@brownpackaging.com Most Recent Posts: Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Custom Corrugated Boxes Facebook Twitter LinkedIn Pinterest Relevant Posts
Packaging labels and graphics serve as the face of a product, making them an integral part of brand identity and consumer appeal. However, the longevity of these visual elements can be compromised by factors such as UV radiation, moisture, temperature fluctuations, and physical handling. In this blog, we’ll explore effective strategies to safeguard packaging labels and graphics, ensuring they retain their vibrancy and impact throughout the product’s lifecycle. Understanding the Challenge Before we delve into preventive measures, it’s important to understand why packaging labels and graphics fade: UV Radiation: Exposure to ultraviolet (UV) radiation, whether from sunlight or artificial light sources, can break down the pigments and dyes in inks, causing colors to fade over time. Oxygen and Moisture: Oxidation and moisture exposure can lead to chemical reactions that alter the properties of inks and substrates, resulting in fading and degradation. Temperature Fluctuations: Rapid temperature fluctuations can cause materials to expand and contract, potentially leading to cracks, tears, and peeling of labels and graphics. Abrasion and Physical Handling: Rough handling during transportation and storage can cause labels and graphics to rub against surfaces or other packaging materials, leading to wear and tear. Effective Strategies for Prevention To ensure that packaging labels and graphics remain visually appealing and informative, consider implementing the following preventive measures: UV-Resistant Inks: Choose UV-resistant inks designed to withstand exposure to UV radiation. These inks are formulated to be less susceptible to fading and degradation. Protective Coatings: Apply protective coatings, such as UV-resistant varnishes or laminates, over labels and graphics. These coatings create a barrier that shields against UV radiation, moisture, and abrasion. Thoughtful Material Selection: Opt for packaging materials that offer inherent UV protection. UV-resistant films and substrates can serve as a barrier to minimize the impact of UV radiation on labels and graphics. Controlled Storage and Display: Educate retailers and consumers on the importance of storing products away from direct sunlight and fluorescent lighting to minimize UV exposure. Proper storage conditions can significantly extend the life of labels and graphics. Quality Inks and Printing Processes: Invest in high-quality printing processes and inks that are less prone to fading. Options may include pigment-based inks and digital printing technologies known for their durability. Regular Quality Control: Implement regular quality control checks to ensure that printing and labeling processes meet industry standards and are resistant to fading. Consistent quality assurance is essential. Temperature and Humidity Control: Maintain controlled environmental conditions in storage and display areas to prevent extreme temperature fluctuations and humidity levels that can damage labels and graphics. Gentle Handling: Train employees and handlers to practice gentle and careful product handling to avoid physical damage to labels and graphics during transportation and storage. Ensuring Long-Lasting Impact Preventing packaging labels and graphics from fading is not just a matter of aesthetics; it’s an investment in preserving brand identity, consumer trust, and the overall appeal of a product. By implementing these proactive strategies, businesses can ensure that their packaging remains vibrant and impactful, reinforcing brand recognition and delivering a positive consumer experience throughout the product’s journey from production to purchase. If you are interested in labels and custom packaging, then partner with Brown Packaging today to get started. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Custom Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
When choosing corrugated packaging, box style directly impacts cost, strength, speed of packing, and customer experience. Two of the most common options are the Regular Slotted Container (RSC) and the Roll-End Tuck-Top (RETT) mailer. While both protect products well, their design differences make each suited for very different needs. Regular Slotted Container (RSC) Design & Features Flaps of equal length meet in the center. Requires tape, glue, or staples for closure. Minimal board waste, highly efficient to manufacture. Advantages Strong and Stackable: Excellent compression strength for palletized loads. Cost-Efficient: Standardized design lowers production cost. Versatile: Common in nearly every industry. Limitations Slower Assembly: Tape or glue required for every box. Basic Presentation: Not designed for branded unboxing experiences. Roll-End Tuck-Top (RETT) Mailer Design & Features Single-piece die-cut design. Built-in dust flaps protect contents from debris. Cherry locks (small locking tabs) keep the lid secure without tape. Advantages Fast Assembly: Self-locking design saves time and eliminates tape. Premium Look: Ideal for branded unboxing and e-commerce. Better Closure: Dust flaps improve integrity; cherry locks prevent accidental opening. Limitations Higher Cost: Requires custom tooling and more board. Lower Stacking Strength: Not as durable for bulk palletized shipping. Less Flexible for Large Sizes: Best suited to small-to-medium e-commerce parcels. RSC vs. RETT: Side-by-Side Comparison Feature RSC Box RETT Mailer Closure Method Tape, glue, or staples Dust flaps + cherry locks (self-locking) Assembly Speed Slower Faster Stacking Strength High (pallet loads) Moderate Cost Lower Higher Branding & Unboxing Basic Premium Best For Bulk shipping, warehousing, palletization E-commerce, subscription boxes, retail-ready packaging Regular Slotted Container (RSC) Roll End Tuck Top (RETT) with cherry lock and dust flaps Buyer Takeaways Choose an RSC if you need maximum stacking strength and shipping efficiency. Perfect for palletized loads, warehouses, and industrial distribution. Choose a RETT mailer if your focus is branding, presentation, and fast assembly. Ideal for e-commerce, D2C shipments, and subscription boxes. Dust flaps and cherry locks make RETT mailers especially well-suited to online retail, where presentation and secure delivery both matter. References Fibre Box Association. (2023). Corrugated Box Styles and Design Guide. https://www.fibrebox.org Association of Independent Corrugated Converters (AICC). (2024). Corrugated Packaging Fundamentals. https://www.aiccbox.org (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Custom Corrugated Boxes Facebook Twitter LinkedIn Pinterest Relevant Posts