Preventing Score Cracking in Folding Cartons
Score cracking—visible fiber breakage along a fold—can ruin a carton’s appearance, weaken its structure, and cause failures on automated lines. Understanding the causes and engineering solutions is critical for producing folding cartons that maintain both strength and visual quality.
What Causes Score Cracking
Score cracking occurs when fibers along the fold line break instead of bending cleanly.
- Low Moisture Content: Dry board becomes brittle and less pliable (ASTM D685-22).
- Improper Score Depth: Shallow scores increase folding resistance; deep scores can cut fibers.
- Incorrect Grain Direction: Folding parallel to the grain increases cracking risk.
- Surface Coating Rigidity: Gloss varnish, films, and metallic layers reduce fiber flexibility.
Material Selection
- SBS (Solid Bleached Sulfate): Generally folds cleanly but can crack with heavy coatings or low EMC.
- CUK (Coated Unbleached Kraft): Higher tear resistance; better for humid conditions.
- FBB (Folding Boxboard): Softer surface layers reduce cracking risk in coated applications.
Tip: Match fiber composition and surface finish to the intended folding radius and production environment.
Moisture and Conditioning
- Pre-Production Conditioning: Allow board to reach equilibrium moisture content (TAPPI T402).
- Humidity Control: Maintain 40–60% RH in converting and packing areas.
- Target EMC: Typically 5–8% for most paperboard grades.
Coating and Lamination Adjustments
- Scoring After Coating: Where possible, score post-coating to reduce fiber breakage.
- Film Selection: Thinner, more flexible films reduce cracking risk.
- Relief Scoring: Adding micro-perfs in the coating layer only can relieve stress without affecting the substrate.
Testing and Quality Control
- Bend Tests: Assess crack formation on sample folds before full production.
- High-Speed Trials: Score cracking can be magnified at higher folding speeds.
- Visual Standards: Establish acceptable limits for cosmetic cracking based on brand requirements.
References
ASTM International. (2022). ASTM D685-22: Standard practice for conditioning paper and paper products for testing. ASTM International. https://doi.org/10.1520/D0685-22
Soroka, W. (2014). Fundamentals of packaging technology (5th ed.). Institute of Packaging Professionals. ISBN: 978-1-930268-37-2
TAPPI. (2019). T 402: Standard conditioning and testing atmospheres for paper, board, pulp handsheets, and related products. TAPPI Press.
Twede, D., & Goddard, R. (2021). Cartons, crates and corrugated board: Handbook of paper and wood packaging technology (2nd ed.). DEStech Publications. ISBN: 978-1-60595-120-5
Subscription packaging continues to expand across beauty, food, lifestyle, and specialty products. Buyers must balance branding, protection, and sustainability while keeping fulfillment efficient. This checklist highlights the critical areas buyers
As budgets tighten in 2026, packaging buyers are under pressure to reduce costs without increasing damage rates. Cutting too aggressively can lead to product loss, higher return rates, and frustrated
Product damage is one of the most expensive risks in packaging. Beyond replacement costs, damaged goods lead to lost sales, returns, and reputational harm. In 2026, complex e-commerce, global shipping,
Retail packaging continues to evolve as brands balance sustainability, supply chain performance, and consumer experience. In 2026, buyers face new challenges shaped by material innovation, compliance requirements, and rising consumer
By submitting your information, you agree to our terms and conditions and privacy policy.
In today’s fast-paced world, protective packaging plays a crucial role in safeguarding products during transportation, handling, and storage. It acts as a shield against various external factors, including impacts, vibrations, moisture, temperature variations, and more. However, businesses often face the challenge of balancing the cost of packaging materials and the level of protection required. This blog explores the delicate balance between cost and protection and provides detailed insights into optimizing packaging choices. Understanding the Importance of Protective Packaging Protective packaging serves two primary purposes: preserving product integrity and minimizing damage risks. Whether it’s fragile electronics, delicate glassware, or perishable goods, proper packaging ensures that products reach customers in pristine condition. It helps prevent loss, enhances customer satisfaction, and maintains brand reputation. Factors Influencing Packaging Choices Nature of the Product Fragility: Fragile items, such as glass or electronic components, require extra layers of cushioning to protect against impacts and vibrations. Perishability: Perishable goods, like food or pharmaceuticals, may require temperature-controlled packaging to maintain product freshness and quality. Transportation Method Air Transportation: Air freight involves multiple handling points and potential turbulence. Packaging for air transportation should be designed to withstand these challenges, providing adequate protection against impacts and pressure changes. Sea Transportation: Shipping by sea introduces the risk of moisture and salt exposure. Packaging materials should be moisture-resistant and provide corrosion protection. Land Transportation: Road or rail transportation involves various vibrations and rough handling. Packaging should be robust enough to withstand these conditions. Storage Conditions Duration of Storage: If products are stored for an extended period, protection against environmental factors such as humidity, dust, and temperature fluctuations become crucial. Packaging materials should provide insulation and barrier properties as needed. Storage Environment: Warehouses or storage facilities may have specific conditions that impact packaging requirements. For example, if products are stored outdoors, packaging should offer protection against UV radiation and weather elements. Regulatory Compliance Industries such as pharmaceuticals, hazardous goods, or food products have specific packaging regulations to ensure safety and compliance. Packaging materials must meet these requirements, which may impact costs. Cost Considerations in Protective Packaging Material Selection Traditional Materials: Bubble wrap, foam inserts, corrugated cardboard, and air pillows are widely used and cost-effective options for protection. They provide cushioning, shock absorption, and product support. Sustainable Materials: Eco-friendly packaging materials, such as recycled paper, biodegradable plastics, and compostable materials, offer a more environmentally responsible option. While these materials may have a higher upfront cost, they can enhance brand image and customer perception. Quantity and Volume Discounts Businesses that require large volumes of packaging materials can explore bulk purchasing options. Suppliers often offer discounts for bulk orders, reducing the overall packaging costs. Customization Tailoring packaging solutions to the specific needs of the product can optimize costs. Custom-sized boxes, inserts, or dividers can reduce material waste and improve overall protection. Custom packaging also provides a more tailored and professional presentation. Optimizing Cost-Effective Protection Packaging Design Efficient designs maximize the use of materials, reduce waste, and minimize costs. Packaging engineers can create innovative designs that achieve optimal protection while using fewer materials. Utilizing standardized packaging sizes can improve efficiency in terms of storage space, transportation, and handling. Testing and Prototyping Conducting thorough testing and prototyping can help identify the minimum level of protection required. By simulating real-world conditions, businesses can determine the most cost-effective packaging solution that meets the necessary protective standards. Testing may involve drop tests, compression tests, or vibration tests. Supply Chain Collaboration Collaborating with suppliers and logistics partners can provide valuable insights into cost-effective protective packaging solutions. By working together, it’s possible to identify opportunities for efficiency improvements and cost reduction. Partnerships can also facilitate the sharing of best practices and industry knowledge. Sustainable Packaging Solutions In recent years, sustainability has become a significant concern for both businesses and consumers. Balancing cost and protection while also addressing environmental considerations is essential. Opting for eco-friendly materials, reducing packaging waste, and adopting recyclable or biodegradable options can align cost savings with environmental responsibility. These measures can enhance brand reputation, attract eco-conscious customers, and contribute to a greener future. If you are interested in protective packaging or packaging designed to protect your product, then partner with Brown Packaging today. Our experts will help you maintain cost, while optimizing your product’s protection. (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
High Impact Polystyrene, commonly known as HIPS, is a versatile and widely used thermoplastic renowned for its unique blend of properties. This material is crucial in various industries, including consumer goods and packaging, due to its high-impact strength, rigidity, affordability, and ease of processing. Essential Properties of HIPS HIPS boasts several properties that make it an excellent choice for numerous applications: High Impact Strength: Provides durability and resistance to physical impacts. Rigidity: Maintains shape and structural integrity under stress. Chemical Resistance: Withstands exposure to many chemicals, oils, and greases. Biological Resistance: Resists degradation from biological factors like fungi and bacteria. Water Resistance: Impermeable qualities make it suitable for applications requiring moisture resistance. Fatigue Resistance: Capable of enduring repeated stress without losing its form, ideal for components like living hinges. Thermal Insulation: Offers significant insulation properties, beneficial in both industrial and consumer products. Electrical Insulation: Highly resistant to electricity, making it safe for use in electronic components. Affordability and Recyclability: Cost-effective and fully recyclable, supporting environmental sustainability. Diverse Applications of HIPS HIPS’s versatility allows its use across various sectors: Consumer Goods: Utilized in products requiring durability and impact resistance, such as toys, household appliances, and office supplies. Packaging Materials: Ideal for making clamshell containers, blister packs, and trays due to its moldability and cost-effectiveness. Automotive Industry: Used in components like interior trim parts, instrument panels, and exterior body parts due to its lightweight and sturdy nature. Construction Industry: Forms part of materials such as wall panels, ceiling tiles, and insulation boards, thanks to its insulation properties. Medical Industry: Common in the production of medical devices and packaging, valued for its chemical resistance and stability. Manufacturing Process of HIPS The production of HIPS involves several steps: Polymerization: Styrene monomers are polymerized using catalysts like benzoyl peroxide to form the HIPS polymer. Mixing: The polymer is blended with impact modifiers, stabilizers, and pigments to enhance its properties and appearance. Molding: HIPS can be shaped through extrusion or injection molding, allowing it to be formed into various products. Cooling and Finishing: Post-molding, HIPS is cooled and can undergo additional processing like trimming and polishing to achieve the desired quality. Environmental Considerations While HIPS is not biodegradable, it is recyclable. Recycling HIPS contributes to waste reduction and resource conservation, mitigating the environmental impact associated with plastic production. Frequently Asked Questions About HIPS Is HIPS food safe? Yes, when certified, HIPS is safe for food contact applications. Difference between HIPS and ABS? ABS is generally more robust with better temperature resistance, but HIPS is more cost-effective. Can HIPS be painted or printed on? Yes, HIPS can be easily painted or printed on, provided the surface is properly prepared. Color options for HIPS? Available in a broad spectrum of colors, including custom shades to meet specific project requirements. Conclusion High Impact Polystyrene (HIPS) stands out as a valuable material in the realm of plastics due to its excellent properties and wide range of applications. From packaging and automotive parts to household items and medical devices, HIPS continues to be a preferred choice for manufacturers seeking a reliable, cost-effective, and versatile material. As the industry advances, the sustainability and recyclability of HIPS make it even more significant in our ongoing journey towards environmental consciousness. For further details or inquiries about using HIPS for your packaging and manufacturing needs, please contact Brown Packaging. We are committed to delivering high-quality, sustainable packaging solutions tailored to your specifications. (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. Thermoform Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
High-speed automated packaging lines can run hundreds of cartons per minute, but only if the carton’s design and material are optimized for smooth feeding, folding, and sealing. Small structural or material missteps can lead to jams, misfeeds, and costly downtime. This guide covers the critical design, tolerance, and substrate considerations for folding cartons intended for high-speed automation. Dimensional Accuracy Automated lines demand tight dimensional control in die cutting. Die Cut Precision: Carton blanks must be within ±0.015 inches for consistent feeding and folding (Soroka, 2014). Blank Squareness: Even minor skew can cause issues with glue flap alignment or panel folding. Caliper Consistency: Variations in board thickness can change fold behavior and sealing pressure. Scoring and Creasing Profiles High-speed folding relies on scores that create predictable, repeatable folds. Score Depth and Bead Width: Too shallow causes spring-back; too deep risks cracking. Bead/Channel Ratio: Must match board caliper and fiber composition for clean folding at speed. Grain Direction: Scores parallel to grain can crack if bead pressure isn’t optimized. Glue Flap Design Flap dimensions and positioning are critical for automated glue application. Flap Width: Minimum 10–12 mm recommended for cold glue; narrower flaps risk bond failure. Glue-Free Zones: Essential near scores to prevent squeeze-out during folding. Coating Considerations: Gloss varnish or film lamination in glue areas requires corona treatment or glue type adjustment for proper adhesion. Material Selection Not all boards perform equally on automated lines. SBS: Smooth feeding, excellent fold consistency, best for high-graphic retail cartons. CUK: Added stiffness and moisture resistance for cold chain or beverage applications. FBB/Recycled: Economical, but may need adjusted scoring to reduce cracking at speed. Folding Sequence Compatibility Structural design must align with the machine’s folding sequence. Tuck End Cartons: Ensure flap lengths are balanced to avoid collision in the folding belts. Auto-Bottom Designs: Verify glue flap and lock panels don’t bind during machine erection. Full Seal End: Flap lengths and bevel angles must accommodate sealing jaws without interference. Surface Coatings and Friction Carton surfaces influence how blanks travel through feeders and conveyors. High Gloss Coatings: Can cause feeding slippage; mitigated with anti-slip varnish zones. Poly Coatings: Increase stiffness but may alter fold memory—test for score cracking before production. Matte Varnish: Generally more forgiving in high-speed feeders. Machine Trials and Prototyping Before committing to a production run: Run on the Target Machine: Testing on actual equipment verifies compatibility. Check Across Speed Range: A carton may run well at 100 cpm but fail at 300 cpm. Inspect Post-Run Samples: Look for misaligned folds, glue squeeze-out, or score fractures. References Soroka, W. (2014). Fundamentals of packaging technology (5th ed.). Institute of Packaging Professionals. ISBN: 978-1-930268-37-2 Twede, D., & Goddard, R. (2021). Cartons, crates and corrugated board: Handbook of paper and wood packaging technology (2nd ed.). DEStech Publications. ISBN: 978-1-60595-120-5 (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 Folding Cartons Facebook Twitter LinkedIn Pinterest Relevant Posts