The Most Significant Development Within Our Industry In The Last One Hundred Years

 

 

Papermaking is a highly efficient process where natural fiber alignment maximizes machine speed and efficiency. Machine Direction (MD) and Cross Direction (CD) values in papers are structural opposites, MD fiber alignment is stronger. Currently, corrugations in the medium paper(s) are formed in the CD direction. As a result, all MD values are at 90 degrees to the corrugations. Therefore, the collective MD value of the papers does not find its way into the corrugated structure. 

 

For over a Hundred Years, attempts have been made to realize the benefits of MD fiber alignment. Many patents have been published describing various methodologies for achieving Linear Corrugating. None of these have been commercially viable.  However, CSI has successfully developed and patented the NXTCorr™ methodology of Linear Corrugating, demonstrated it on a conventional 98” Corrugator and developed an entire family of new and innovative corrugated products. 

 

The DOE-Chapman study identified a 49% improvement in Box Compression Test (BCT) when flutes are aligned with the MD values of the liners. NXTCorr™ takes this a significant step further in that the MD value of all papers involved have MD alignment along with flutes.  The Chapman study states that lineal corrugated boxes, manufactured on conventional finishing equipment, have equal box strength values with 30% less fiber. 

 

Linear corrugating can utilize improved flute profiles that are not possible with conventional corrugating. This brings compound advantages in board structure above and beyond MD flute and fiber alignment.

 

NXTCorr™ can be characterized as the most significant development change within our industry in the last Hundred Years. To fully utilize the promise that total MD-Unity brings, we have

FIRST, preserved and employed all the initial paper qualities as manufactured; SECOND, redesigned the corrugating process to enable MD-Unity board production; and THIRD, redesigned the converting process for the production of corrugated materials, so that the qualities of paper, board and box construction are fully realized. 

 

 

 

Major Benefits

 

Material

 

  • No appreciable take-up to the fluted paper

  • Utilizes significantly less fiber due to MD paper benefits

  • Greater strength to weight ratio when compared to conventional corrugated

 

Process 

 

  • Engineered flute profiles for specific applications

  • Designed flute form contact points

  • Flute design can govern the relationship between board caliper and flute pitch

  • Profile advantages – straight flanks – will use less paper

  • Continuous glue line application - “No snap back”

 

 

 Board Performance

 

 

  • Enhanced stiffness and strength in the MD direction 

  • Reduced washboard and warp characteristics

  • Improved ECT and BCT

  • Increased stiffness in flute and cross-flute directions

  • Improved substrate laminating 

  • No appreciable take-up of fluted medium paper

  • Reduction in basis weights and/or caliper in corrugated board

  • Lineal process enhances box structure and strength

  • Triangulated flute profiles add structure and uses less paper

  • Basis weight reduction

  • Caliper and profile combinations engineered for specific applications

  • Glue line width independent of flute form

  • Lighter paper combinations for double wall

  • Bi-directional panel strength stiffness

 

 

 

 

 

 

 

Packaging Applications

 

  • Displays

  • Signage

  • Utility bins

  • Beverage (Bag-in-a-box)

  • Produce

  • Consumer

  • Industrial

  • Club store

  • Protective

  • Singleface designs

  • Performance packaging

  • Micro-flute applications

  • Folding carton

  • Boxboard replacement

  • Clam-Shells

  • Premium flat sheets for post-print – Flexo, Litho, Digital, etc…

  • Foam-core and Sintra replacement

©2021 by Corrugated Synergies International, LLC