Materials science - everything you need to know about our raw material
Some refer to waste paper as waste, for us waste paper is the source to create something new. Waste paper is our most important raw material in order to be able to produce paper first and then various types of cardboard. Produced by similar processes, our packaging materials differ in terms of their grammage or area-related mass.
In the production of paper, we will remain true to the basic principles that have existed for around 2000 years. Although we have taken advantage of technical advances in the meantime, we still need wood fibres, water and energy for paper production. The difference between artisanal and mechanical production is that individual sheets were created manually, while today's machine production results in an endless paper web.
Today, it is hard to imagine everyday private and professional life without paper, despite the rapidly advancing digitalization. As the only manufacturer of corrugated base paper in Switzerland, we produce around 410,000 tons of corrugated base paper annually with our three paper machines. Through our investment in a paper mill in Eilenburg, located in the east of Germany, our volume will increase accordingly in the future.
We value the pursuit of awareness. Therefore, it is a pleasure for us to make an active contribution to the circular economy with the production of environmentally friendly packaging materials.
Paper, a lightweight material, gains exceptional strength when corrugated or ribbed. That is why the wave is the characteristic, the "soul" of every corrugated board.
A kind of lightweight construction made of paper creates a stable packaging material/packaging material. The secret of stability lies in the shape of the wave. A paper that is only bent or folded would not have the same effect.
Corrugated base paper is the material from which corrugated board is made. For this purpose, the corrugated paper web requires an outer and inner ceiling made of paper. The quality of the papers used determines the quality of the corrugated board. For this reason, a precise knowledge of the corrugated base paper types that are processed into corrugated board is required.
The papers for the production of corrugated board are:
- Blanket papers (testliners, kraftliners, schrenz)
- Corrugated papers (corrugated material, semi-pulp)
The quality of the papers is largely dependent on the raw materials from which it was made. Papers for the production of corrugated board are made from the raw materials pulp and waste paper. Both raw materials have fibers that are obtained from wood. They are the starting points for paper production.
In the case of corrugated board, the name already provides information about the properties. The corrugated base paper produced by Model is used to glue different paper webs together and to create a corrugated cardboard. At least one fluted paper web, the so-called shaft, is glued between two smooth paper webs, the ceiling papers.
The corrugated board is produced in corrugators (WPAs). We refer to the semi-finished products produced on our WPAs as "corrugated sheets". The corrugated sheets intended for further processing are produced in various qualities, as well as one-, two- or three-shaft. The different paper qualities and shaft types enable us to meet the most diverse customer requirements for packaging in further processing.
To give the shaft its shape, a special corrugating roller is used and the corrugated base paper is formed by means of heat, pressure and moisture. The next step is a smooth blanket paper, which is glued to the shaft track.The resulting, one-sided corrugated board can now be glued with further ceiling and corrugated papers or finished directly with an outer ceiling. According to the respective composition, one speaks of single-wave, two-wave or three-wave corrugated board.
The constellation between the number of shafts and the ceiling paper thus determines the nature of the respective corrugated board. Quality aspects can be checked on the basis of various features such as edge compression resistance*, pushability or burst factor. Model's blanket papers are particularly stable due to their own production and can be printed well both outside and inside. Model loves quality and our closed paper cycle enables us to always meet our own quality requirements as well as those of our customers.
The heart of the Model Group beats in our packaging production. The production covers various areas, from the production of corrugated board to the creation of simple transport packaging to high-quality displays. A team of experienced employees from all areas support the entire order fulfillment process.
* possibly short explanation for the layman: what is edge compression resistance etc.
Characterized by a massive material density, a homogeneous structure and reliable robustness, the product experience is guaranteed not only visually but also haptically. This is our solid board or also called cardboard. The cardboard made of up to 100% recycled material has become indispensable in various industries, such as .B the food or cosmetics industry.
Solid board consists of one or more gaudged or several glued layers. The packaging material solid board is particularly robust and resistant because, unlike corrugated board, there is no air between the paper webs. Moisture is not primarily a challenge, as the packaging material is not very sensitive thanks to its high density. The smooth surface has optimal printing possibilities and is therefore suitable for unique and extraordinary designs.
In the production of solid board, waste paper and pulp are also used. With the help of the pulper, a large mixing vat, the waste paper is dissolved together with water to form a liquid fibre pulp. Via a roller, the fiber pulp reaches a wire sieve, which is constantly moving and through which the excess water can drain. What remains is a wet fibre fleece, which then passes between several rollers. Through this process, the water is squeezed out and the fibers are increasingly compressed into different caliber thicknesses from 200 g to 1,050 g/m². This results in the well-known solid board. By merging different layers, different cardboard qualities are obtained. A leeway that enables us to respond to the individual functions of the packaging and to offer you as a customer a tailor-made packaging solution.
In the packaging industry, lamination is when a corrugated board is supplemented with a high-quality printed surface. Rolls or individual sheets of corrugated cardboard can be used as carriers for lamination. Blanket paper is usually coated paper, which in turn is merged with the carrier by a pre-printed roll or individual printed sheets.
Inline, offline and sheet-sheet lamination are the three methods of the lamination process. The method to be used is determined on the basis of the desired packaging properties. In addition, certain laminating systems can also be used for productions in which the carrier is a one-sided corrugated board.
A laminating system is divided into different stations with different configurations. The lamination station is responsible for applying the crouched blanket paper to the corrugated board material. To ensure that the different materials can be glued together, glue is applied to the shaft tips of the one-sided corrugated board or to the ceiling paper of the corrugated board in the gluing plant. The laminated cardboard can then be cut to the desired length if no individual sheets have been used.
In the last step, the delivery station, the product goes through two drying phases of the laminating machine. The first phase serves to press the sheets again in the single press section, while the second phase guarantees optimal glue binding by means of a belt press.
The demand for effective packaging and eye-catching displays at the point of sale (POS) is continuously increasing. With our passion for packaging, we are able to offer you as a customer concealed products that meet your needs and wishes and convince you with high quality.