Industrial processes

Process by which individual products or primary packages are collated, oriented, and placed into a pre‑formed or erected case or carton according to a defined packing pattern, using manual, semi‑automatic, or automatic equipment.

Carton tray forming is a packaging process in which a flat carton blank is folded along pre‑creased lines to create an open‑top tray, using mechanical folding with optional gluing or locking systems.

Coating is process in which a thin, continuous layer of material is applied to the surface of a packaging substrate (paper, board, plastic, metal, or glass) to modify its functional, protective, or aesthetic properties. It is engineered to provide barrier performance (against moisture, oxygen, grease, or light), adhesion properties, mechanical resistance, printability, or decorative effects.

Process by which variable or static information is generated and applied directly onto a packaging material, packaging component, or product surface using non‑contact or contact marking technologies such as inkjet, laser, thermal transfer, or embossing.

Corrugation is the process of shaping a paper medium into a wave-like (fluted) structure under heat and pressure, which is then laminated between flat paper liners to form corrugated board. This fluted core provides strength, rigidity, and cushioning, making corrugated boards ideal for packaging.

The flutes can be produced in different sizes and profiles (e.g. A, B, C, E, F flute), each offering a specific balance of cushioning, stacking strength and material thickness.

Corrugated board can be single-faced, single-wall, double-wall or triple-wall, depending on the number of fluted layers and liners combined, allowing the structure to be tailored to different load-bearing and protection requirements. Thanks to its lightweight yet resistant structure, corrugated board is widely used for shipping cartons, secondary packaging and point-of-sale displays across virtually every industry.

Creasing is the formation of a groove in paperboard by compression between tools, intended to facilitate folding without surface rupture.

During the operation, the paperboard is weakened along well-defined lines that then act as hinges for folding, since attempting to fold uncreased paperboard typically causes the surface plies to crack or the fold line to remain undefined. The crease is formed using a creasing rule, a thin steel strip with a round, smooth edge, which presses the paperboard into a matching groove cut into a make-ready (also called matrix or counter-die) positioned beneath it, producing a permanent deformation. The relationship between the crease's width and depth is critical to quality: a crease that is too shallow or wide makes folding difficult, while a deeper, narrower crease generally produces a cleaner, lower-resistance fold.

Grammage also affects the process: thin papers (below roughly 180 g/m²) are often folded without any surface preparation, whereas heavier paperboard (above roughly 600 g/m²) typically requires multiple creases or scoring prior to folding.

Extrusion coating is a process whereby molten plastic is applied to a thin substrate (paperboard, paper, plastic film, aluminium foil etc.) and subsequently chilled to form an extremely thin, smooth layer of uniform thickness.

The molten plastic can be used as an adhesive to laminate a plastic film or a metal foil.

In addition to lamination, extrusion coating is mainly used to provide protection against moisture, act as a barrier to gases (water vapour, oxygen, aromas, etc.), offer grease resistance, ensure heat-sealability and create an attractive appearance (glossy surfaces).

The process is carried out by extruding the molten polymer through a flat slot die directly onto the moving substrate, which is then pressed against a chill roll to rapidly cool and solidify the coating while defining its surface finish.

Low-density polyethylene (LDPE) is the most commonly used resin due to its good adhesion, sealability and processability, although other polymers such as polypropylene (PP) or ethylene vinyl acetate (EVA) can be used to achieve specific barrier or performance properties.

Because the coating is formed directly on the substrate in a single continuous pass, extrusion coating is typically faster and more cost-effective than conventional adhesive lamination for high-volume applications.

Dry forming is a fiber-based packaging technology that combines airlaid cellulose fibers with 3D thermoforming to create rigid, renewable packaging without the use of water or traditional wet pulp methods.

The process begins by separating cellulose fibers from the raw material and distributing them, through a dedicated air system, into an airlaid forming station, where they are evenly deposited and interlocked into discrete pads (or, in some process variants, a continuous web) of consistent grammage.

The formed fiber structure is then transferred to a 3D pressing stage, where heat and pressure are applied to bind the fibers together and shape them into the final packaging geometry, again without the addition of process water.

Depending on product requirements, finishing operations such as trimming, cutting or surface treatment may follow, and chemical additives can be incorporated to enhance properties such as water or oil resistance and mechanical strength.

Folding‑gluing is the converting process that transforms a flat, die‑cut, and pre‑creased carton blank into a finished folding carton by folding its panels along defined creases and bonding them with adhesive (typically hot‑melt or cold glue) in a continuous inline operation.

Blanks are fed individually into the machine and precisely aligned before critical creases are pre‑broken, or pre‑folded, to a partial angle in order to condition the board and ensure reliable, high‑speed folding downstream.

Adhesive is then applied to defined glue flaps in a precise pattern synchronized with blank position and machine speed, after which the panels and flaps are folded into their final position through a sequence of belts, rails, hooks and guides, bringing the glued surfaces into contact.

The folded cartons subsequently pass through a compression section that maintains pressure for a defined time to allow the adhesive to set and reach adequate bond strength before being discharged.

Finished cartons are then counted, formed into shingled streams or bundles, and made ready for packing, palletizing or direct feeding to downstream cartoning or case-packing equipment.

Gluing is a joining process in which an adhesive substance is applied between two surfaces, creating a bond through adhesion to the substrates and cohesion within the adhesive layer as it cures, forming a permanent or semi‑permanent joint.

Handmade packaging consists of performing the sequence of assembly, folding and filling the package partially or entirely by hand.

Heat sealing is the process of joining thermoplastic films by the application of heat and pressure for a specific period of time, causing the surfaces to soften or melt and fuse together into a continuous bond.