EPTDA was founded as the European Power Transmission Distributors Association in 1998 on the initiative of a group of power transmission and motion control (PT/MC) industrialists who believed in bringing together PT/MC distributors and manufacturers on one unique platform. It has since become the largest organisation of PT/MC distributors and manufacturers in EMEA and is one of the most powerful and respected B2B executive platforms for the industry worldwide.
EPTDA’s mission is to strengthen its members in the industrial distribution channel to be successful, profitable, and competitive in serving customers to the highest standards. The association takes great pride in its values which focus on being a premier community for qualified members through open dialogue and mutual respect; acting with integrity, honesty, and fairness; and ensuring continuous growth and learning.
EPTDA continually strives to develop relevant tools for its members, helping them stay competitive in a constantly evolving marketplace and business environment. As part of the development of tools and resources for members, this document is designed to add value to their commercial understanding of specific markets and production line processes. This document, on the packaging industry, follows reports on several industries, including, Soft Drinks, Confectionery, Material Handling, Recycling, Bakery and most recently, Pulp and Paper, and marks the 10th report in this Production Line Intelligence series.
Purpose of this document
The purpose of this document is to provide distribution management and their sales forces with market and production line intelligence on the packaging industry. This document explores trends, identifies products used in the production of paper-based packaging, clarifies key challenges, and considers the opportunities for distributors and how these can be capitalised, commercially.
This document has been divided into three parts:
1. Industry Overview
Pages 4-11
This first section provides an introduction and overview to the Pulp and Paper industry and gives key background information, market intelligence, and major players within the industry. It has been organised as follows:
a. Definition, segments within the industry, and market share
b. Market size and coverage
c. European sales data and evolution
d. Current and future market trends
e. Overview of challenges
f. Key producers
g. Major machine & system builders
2. Production Line Intelligence Pages 12-19
This section illustrates the production and processing of pulp and paper, with a fully detailed production line schematic, so as to provide an understanding of what is involved and where the opportunities lie. Key customer challenges, major product groups, typical maintenance, and improvement projects are identified throughout the line, as well as highlighting potential areas of commercial opportunity for the distributor. This production process, whilst being typical, does not represent how all types of packaging are produced. This is because actual plant processes may vary according to the type of paper-based packaging produced such as folding box-board, corrugated paperboard or even variety in end use such as coffee cups and egg carton boxes.
3. Use of this Document
Pages 20-21
The opportunities within Paper-based packaging, both for MRO and OEM distribution, are significant – a minimum combined ‘scale of opportunity value’ (SOV) of 125M€ has been estimated as available for distribution of Power Transmission products in the paperbased packaging aftermarket. The final section proposes how the document could be used and provides open-ended questions that can be asked of prospective customers in order to reinforce the knowledge gained in parts one and two and to maximise the available opportunities
PART ONE Paper-based packaging industry overview
Definition, segments within the industry and market share
The packaging industry involves the design, manufacturing and distribution of materials used for enclosing, protecting, and transporting products as well as providing product information and assisting brand visibility.1 The industry caters to a wide range of sectors such as food and beverage, healthcare and pharmaceuticals, electronic, e-commerce, and industrial goods. Each sector has unique packaging demands and regulatory standards.2
Global distribution of packaging demand in 2019, by material type4
There are various ways in which we can segment the packaging industry. Firstly, it can be separated into its end destination i.e., which sector it is used for. Alternatively, it can be separated into rigid packaging (such as bottles, cans and boxes) and flexible packaging (including pouches, bags and wraps).3 The easiest way to segment is by the individual materials that make up the packaging industry such as; paper packaging, plastics, metal, glass and other materials..
Paper-based packaging is the most widely used packaging material, specifically paper that is converted into paperboard. Over 265 million metric tonnes of paper packaging was produced in 20225 and it is the most used packaging material worldwide, accounting for 33% of packaging material consumption 6. Following on the next stage from the Production Line Intelligence report on pulp and paper (2023), this report will focus on the paper-based packaging industry’s use of paperboard.
The different uses of paper-based packaging
Rigid Plastics
Flexible plastics
The different types of paperboard packaging
Paperboard
Corrugated Board
• Made from multiple layers of heavy paper pulp.
• Outer liners, typically made from virgin fibres.
• Inner fluted (wavey) layer, often made from recycled fibres.
• CCNB is made by coating one side of the paperboard with a layer of clay
• Made from recycled fibres
• Heavier consumer products
• Products where package branding is not so important
• Carton inserts
• Low-cost folding carton packaging
• Fast food packaging
• More natural look and feel
• High strength at lower cost
• Eco-friendly –very easy to recycle
• Lightweight
• Environmentally friendly
• Consists of recycled materials
• Lightweight
• Smooth coated surface to print on
• Dividers
• Paperboard not in view
Folding Box Board (FBB)
• Multiply
• One or more mechanically pulped layers
• Between two layers of chemically pulped layers
• Consumer goods packaging
• Least expensive paperboard grade
• Eco friendlyrecyclable
• High-quality
• Strong and durable
• Stiffer composition (compared to SBS)
• Ideal for transportation
• Smooth surface makes it suitable for high-quality printing
• Suitable for embossing and debossing, hot foil stamping and UV printing
• May not be suitable for packaging that requires vibrant colours
• Not as durable as other paperboard grades
• Low tensile strength
• Unsuitable for products requiring higher moisture resistance or weight capacity.
• Clay coating can make it more difficult to recycle
• Low strength
• Most expensive grade
• Not eco-friendly
• Requires virgin fibres
• Challenging to recycle due to multi-layered composition
Corrugated paperboard
Corrugated paperboard is the most widely used paperboard within the packaging industry (64% of all paper packaging in Europe is corrugated) so will be a focus of this report8. Corrugated paperboard refers to a type of paperboard which is made up of thick paper stock or heavy unbleached paper-pulp. This then creates a thick arrangement of card which, in turn, develops into a strong board perfect for packaging. Unlike usual paperboard, which is usually single or multiply, corrugated board consists of multiple layers of heavy paper. The outer liners are often crafted from virgin fibres, whilst the inner layer, known as the medium, can be sourced from recycled or virgin fibres. The medium, with its distinctive fluted design, giving corrugated board its characteristic wavy texture, can be altered to meet specific Corrugated paperboard is the most widely used paperboard within the packaging industry (64% of all paper packaging in Europe is corrugated) so will be a focus of this report. Corrugated paperboard refers to a type of paperboard which is made up of thick paper stock or heavy unbleached paper-pulp. This then creates a thick arrangement of card which, in turn, develops into
Raw material consumption
When looking at paperboard manufacturing, the source of paper pulp used in production should be considered. In Europe in 2022, 96.6 million tonnes of raw materials were consumed for paper and paperboard production. At integrated mills, paper pulp is produced and is subsequently made into paperboard at the same site. In 2022, 21% of raw material consumption occurred at an integrated paper mill. Market pulp, pulp produced in one location and is shipped to another to be processed, made up 18% of raw materials consumed in paper and paperboard production. Non-fibrous materials, such as those made from non-wood fibres such as straw9, made up only 12% of raw material consumption. The most significant amount of pulp was sourced from recycled paper which provided 49% of raw materials for paper and paperboard production10. Recycled paper used as a raw material has increased by almost 36% since 1990.
Raw materials consumption for paper and paperboard, by type, 202211
a strong board perfect for packaging. Unlike usual paperboard, which is usually single or multiply, corrugated board consists of multiple layers of heavy paper. The outer liners are often crafted from virgin fibres, whilst the inner layer, known as the medium, can be sourced from recycled or virgin fibres. The medium, with its distinctive fluted design, giving corrugated board its characteristic wavy texture, can be altered to meet specific requirements by changing the size of the flutes. Additionally, the outer liners provide a smooth surface for printing.
The benefit of using corrugated board is that it is a stronger paper packaging material. It is good for transporting goods as it can withstand knocks and crushing due to its multi-layered design and is ideal for larger and more fragile items. Corrugated paperboard is relatively environmentally friendly and will breakdown over time. It is a lightweight packaging option, as well as being easy to handle and cut, making it a versatile material. It is also a cost-effective choice due to the low cost of machinery needed during its manufacture.
Market size, coverage, and sales evolution
Paperboard packaging market share by region, 202312
The global packaging market is expected to reach 1.14 trillion USD in 2024 and grow at a compound annual growth rate (CAGR) of 3.89% to reach 1.38 trillion USD by 202913. As the most used packaging material worldwide, the global paperboard packaging market is estimated at 398.65 billion U.S. dollars in 2024 and is forecast to reach just over 500 billion U.S. dollars by 202914. Asia is the largest producer of paper packaging, however, Europe produces almost a quarter.
Production of paper packaging in Europe from 1991 to 202215
European paper packaging industry
The increase in European production of paperboard packaging has been significantly influenced by the growth of the e-commerce industry. Between 2010 and 2022, paper packaging production increased by 28%16, further demonstrating the influence of the growing e-consumer culture and most recently further propelled by the effects of the COVID-19 pandemic between 2020 and 2022 on consumer behaviour. This increase in production meant that in 2022, paper packaging accounted for 60.1% of European paper production.17
Case materials, such as corrugated paperboard packaging, is the most produced paper grade worldwide, accounting for 64% of all paper packaging produced in Europe18. It is forecasted that global corrugated board will increase at a CAGR of 3.8% between 2020 and 2025 to reach a value of over $200 billion19. In Europe, this increase is partially due to the EU-backed phase-out of plastic packaging. The volume of corrugated board consumed worldwide is predicted to increase, but at a slightly slower rate when compared to production, to 193.2 million tonnes by 202520
Comparison of production and consumption of
Production by region
Whilst China was the largest producer in 2022, producing 79.07 million metric tonnes of paper packaging22, Europe was the second largest, producing 60.8 million metric tonnes. Within Europe, Germany produces the most paper packaging, producing 20.7% of Europe’s total in 2022, the equivalent to 12.5 million tonnes of paper packaging23, 24
Paper packaging exports
Although Europe is not the biggest producer in terms of global market share, European countries are the main markets for exports, accounting for 36.7% of total exports. In comparison, Asia accounts for 23.9% and North America 12.5%25. In 2022, Europe exported 38.8 million tonnes of paper packaging, with Germany and Sweden the biggest exporters of paper packaging26
European paper packaging exports in millions of tonnes and percentage of total European exports by region, 2022
in Europe declined by over 50%, whilst mills dedicated to paper and paperboard production declined by 43.5% to just 720 mills in 2022. This decline in mills, particularly for paper mills, has been attributed to the high prices of pulp, energy and transportation costs28. It may also be a result of the increasing use of recycled paper and fibres, reducing demand for virgin or fresh paper before it is then turned into paperboard.
Number of mills in Europe, by type29
Despite the growing demand for the production of paperboard products, the number of pulp, paper and board mills in Europe is declining. Between 1991 and 2022, the number of pulp mills
Current and future market trends and opportunities
Recycling and environmental sustainability
Today’s customers are more environmentally conscious than ever before and are beginning to choose a more sustainable packaging choice. Paper packaging is the resounding choice over other options due to its more environmentally friendly qualities. It is more biodegradable and compostable, and it is derived from natural and sustainable resources, unlike other packaging options30. It is also the most recycled packaging material, with over 80% of all paper-based packaging recycled in 202031. Furthermore, paper packaging not only has a significantly lower carbon footprint compared to plastic packaging but also avoids contributing to the harm caused by non-biodegradable waste32
Amount of packaging recycled in Europe in 2020, by type
Pulp Paper and paperboard
In a study conducted by IBM and the National Retail Federation, involving 18,980 consumers across 28 countries33, they found that almost 8 out of 10 consumers value sustainability and that more than 70% of respondents would pay, on average, 35% more for eco-friendly brands34. Additionally, the Paper and Packaging Board survey found that 78% of consumers would be more likely to buy paper and paperboard packaging products because it is more environmentally friendly35. This shows that there is continuing consumer demand for paper packaging.
The sustainable packaging market is projected to grow to $348 billion dollars by 2026, a 40% increase from 201936. Many cosmetic, food and Fast-Moving Consumer Goods (FMCG) companies are making the move into more sustainable paper packaging. For instance, Procter and Gamble, has announced in Germany that from September 2023, the entire range of its Lenor line will be available in recyclable paperboard packaging37.
Similarly, JDE Peet’s has revealed their intent to launch a new recyclable paper packaging for their soluble coffee ranges, which will be the first of its kind on the coffee market38. Coca-Cola, who has previously been extremely reliant on plastic is also looking to move into the paper packaging market and began trialling a paper-based bottle for its products in Europe in 202139
In May 2022, Kraft Heinz company collaborated with the packaging company Pulpex Ltd, to develop a paper-based Heinz ketchup bottle. The bottle is manufactured from environmentally sourced wood pulp and is renewable and recyclable40. In the UK, Aldi is launching its own-brand wines where the bottles are made from 94% recycled paperboard, making them fully recyclable and also nearly five times lighter than a standard glass bottle41
This shift to more environmentally friendly packaging as demonstrated by these large consumer brands is expected to further increase paper packaging market growth.
Aseptic packaging is an expanding market that is becoming increasingly integrated into the European market and is expected to grow to $81 billion by 2027, due to its recycling abilities42 This material alternative, made from paper with a thin coat of polyethylene, could significantly reduce the need for plastic packaging. It’s commonly used for beverages as well as food and pharmaceutical products.
One of the many challenges facing the paper packaging industry is changing consumer habits. According to the Recycling Association, newspaper circulation was down by 20-30% which has an impact on the amount of waste entering the recycling
facilities. To recycle paper packaging consumers must return the packaging back to the recycled network and into the mills so it can be converted and reused43. With 93% of Europe’s corrugated board being produced from recycled fibres44, the supply and availability of recycled paper to the industry may be a concern for producers of paper packaging, who must consider consumer behaviour as having a key influence on the supply of packaging material45
Utilisation of paper for recycling by country in 202246
Netherlands
Austria
Poland
Other European Countries
Paper packaging also faces the competition of returnable plastic containers (RPCs). There has been an increase in the use of RPCs due to changing regulations put forward by the Packaging and Packaging Waste Regulations (PPWR) across Europe. RPCs are used for moving goods from a local distribution hub to the retailer providing there is a close-looped network47. However, over longer distances and more complex supply chains they become less convenient, and paper packaging is likely more effective.
Although there are many environmental positives to paper packaging over other types of packaging, there are also some challenges. Paperboard production is water intensive, it generates emissions and can contribute to deforestation. Most paper can only be recycled 5-7 times before the fibres become too short, compared to some plastics which can be recycled over and over.
Additionally, the energy used to create paper packaging requires more energy than some plastic packaging. For example, manufacturing 1,000 paper bags requires 3.4 times more energy than traditional plastic48. Paper packaging also takes up more space than plastic, so subsequently the logistics footprint of paper-based materials can sometimes be higher than plastic49
Regulations
The European Union has recently implemented new regulations around packaging and packaging waste which could have a big impact on European paper consumption. The recent Packaging and Packaging Waste Regulation (PPWR) aims to hold EU Member States accountable for the amount of packaging waste they produce and is likely to come into force by the end of 2024.
The new regulation puts an emphasis on reusing rather than recycling, where packaging can be used multiple times before it is recycled. For example, the PPWR has proposed that 10% of all goods shipped inside the EU must be transported using reusable packaging by 2030 and 50% for e-commerce by 2040. It will also introduce new controls for single-use packaging by restricting packaging formats. The corrugated paperboard packaging industry could be affected by the PPWR, as corrugated paperboard is almost exclusively single-use, needing to be recycled after first use.
Many paper packaging companies are concerned about the new regulations; that they may have a reverse effect, reducing sustainable practices and increasing carbon footprints. The legal obligation requiring that packaging can be reused and not only single-use, will likely lead to logistical challenges along the supply chain such as requiring space for storage and increased transportation costs and emissions50
European Paper Packaging Alliance (EPPA) remarked that recyclable, paper-based packaging used in the food delivery and takeaway sector offered significant environmental advantages over reusable systems across 12 'impact categories' including climate change, freshwater consumption and resource depletion51 They also concluded that in quick service restaurants, single-use paper-based packaging consumes less energy and water than reusable packaging and produces far less CO252
The regulation also aims to ensure all packaging in the EU market is recycle-ready by 2030. Despite being single-use, corrugated paperboard is one of the most recycled packaging types in Europe, with a recycling rate of over 90% and an average recycled
content of 89%53 from a renewable source. Single-use containers can also often provide greater flexibility for storage and transportation, as well as for branding and design on the packaging itself.
Aside from the PPWR, the UK has introduced a plastic packaging tax which could see an increase in paper packaging demand. The new tax which charges £200 per ton on any plastic packaging containing less than 30% recycled content, will encourage businesses to switch to paper packaging54. Spain and Italy have also recently passed laws applying tax to plastic packaging (€450 per ton of taxable plastic), with Spain’s regulation coming into force in 2023, while Italy has postponed implementation55.
Geopolitical conflict
The ongoing conflict between Russia and Ukraine has had impacts on the paper packaging supply chain. Ukraine serves as a major supplier of raw materials, like pulp and paper and in 2022, the European production of pulp decreased by 3.7% partially due to this conflict56. In 2022, Smurfit Kappa – one of Russia’s largest corrugated paper companies, and Finnish food packaging provider Huhtamäki joined the growing list of packaging businesses exiting Russia. The ongoing conflict is causing companies operating in the area with strong financial ties to the region to leave Russia. Ball Corp, Coca-Cola, Carlsberg, and AB InBev, are among the other companies that have closed Russian operations57. Additionally, the conflict has hampered transportation routes and logistics, making it difficult for manufacturers to obtain raw materials and deliver their products58
The effects of the COVID-19 pandemic
During 2020 and 2021 the paper packaging demand saw some of its fastest growth in history due to the COVID-19 pandemic with the sudden surge in ecommerce. The prices of paperboard packaging rose by as much as 55% due to the increase in demand, often leading to shortages as the stress of demand outpaced production. Despite this, the demand for paper packaging in 2024 has still increased compared to that of pre-COVID. Paper packaging production increased by 5.8% in 2021, returning to pre-Covid level59
Key producers in the paper and paperboard packaging industry
*WestRock had a revenue of over 20 billion USD in 2023, of this 50% was generated by its corrugated packaging segment.
Many of the world's leading paper packaging companies are headquartered in Europe. Stora Enso's packaging materials segment accounted for almost 40% of the company’s sales in 2021, as with WestRock where corrugated packaging generated 50% of its total annual revenue in 202360. Collectively, the top 10 packaging companies in Europe generated revenue of over $100 billion in 2023.
Key machine builders for the paperboard packaging industry in Europe
Göpfert Maschinen | Germany | www.goepfert.de
Göpfert Maschinen is a German company that designs and manufactures machinery used in the processing of corrugated cardboard. They specialise in machinery for printing, die-cutting, folding and glueing and material handling. Their offering includes machinery which can be installed alongside existing corrugators to produce printed and finished corrugated board.
Specialising in automated packaging solutions aimed at optimising the packing process, Sparck Technologies machines create custom-sized packaging for each order. Their automated packaging line includes corrugated in-feeders and a folding and glueing section. Their primary customers are based in retail, manufacturing and third-party logistics.
Panotec is renowned for its on-demand packaging systems that create custom-sized boxes for each product or order. Their machines reduce the need for a large inventory of different box sizes and minimise material waste. Their product range also includes closing and glueing systems and printing systems.
General machine builders
BHS Corrugated | Germany | www.bhs-world.com
BHS corrugated is a leading provider of machinery and systems for the production of corrugated paperboard. BHS can provide the complete production line used to produce corrugated paperboard, including single facers, double backers and other components such as cutters and creasers, essential in creating corrugated paperboard packaging. Other machines include those used for digital printing and automation and control systems.
Sacmi | Italy | www.sacmi.it
Sacmi manufactures machines for packaging of food and nonfood products including cartons, case packaging and packing. These machines consist of forming machines which produce boxes or trays, closing machines which consist of gluers, and also wrap-around machines which produce boxes from flat blanks of paperboard.
Heidelberg specialises in printing and finishing of paperboard packaging. Their offering ranges from pre-configured printing machines to individually configured special machines, including digital, offset, narrow web, screen and flexo printing. Their product range also includes finishing machines such as diecutting, folding, glueing, embossing and hot foil stamping.
BW Papersystems, a division of Barry-Wehmiller, combines brand’s innovative technologies and long-standing experience in the packaging, corrugating and finishing industries. BW Papersystems is a combination of 10 brands that work together in manufacturing in the paper process industries. They operate under brand names: BW Bielomatik, BWP Zerand, JAG SYNCHRO, Kugler-Womako, MarquipWardUnited, Questec, SHM, VortX, WillPemcoBielomatik and Wrapmatic. Providing machines for corrugated board manufacturing, including corrugators and single facers, BW Papersystems can provide packaging solutions for various industries. Alongside this, they also provide machinery for converting and printing.
Specialist machine builders52
Bahmüller | Germany | www.bahmueller.de
Bahmüller provides advanced machinery for the packaging and paper converting industries. Their equipment includes solutions for die-cutting, folding, and glueing, enabling the production of high-quality packaging materials such as corrugated boxes and cartons. Their systems are designed to be integrated into existing production lines, enhancing overall efficiency and reducing labour costs. Automation solutions include robotic handling, automated loading/unloading, and process monitoring.
BOBST | Switzerland | www.bobst.com
BOBST is a global leader, operating in over 50 countries, in the design, manufacture, and distribution of equipment and systems used in the production of packaging materials, including folding cartons, corrugated boxes, flexible packaging, labels, and more. BOBST offers a comprehensive range of coating, printing and converting equipment, meeting the requirements of food, beverage, pharmaceutical, and other industries.
Koenig & Bauer Group | Germany | www.koenig-bauer.com
Koenig & Bauer AG is one of the oldest and largest manufacturers of printing presses based in Germany. The company offers a comprehensive range of printing presses and systems for various printing applications, including sheetfed offset printing, digital printing, and flexo printing.
Müller Martini | Switzerland | www.mullermartini.com
Müller Martini specialises in print finishing solutions for various printing processes like offset, digital, and gravure printing. They offer packaging machinery for folding cartons, corrugated boxes, and flexible packaging. Additionally, they produce digital printing and finishing solutions for short-run and personalised printing applications.
Production of paper-based packaging
PART TWO Paperboard production line market intelligence
This schematic and the following describe the typical processes used for paper-based packaging. Whilst being typical, these processes do not represent all forms of paper-based packaging. This is because actual production lines may vary according to the application of the paper-based packaging, production line scale and facility. However, the key stages described here will be common to most types of facilities and there will be similarities that can be seen across all types of paper-based packaging.
Paperboard makes up the internal layer of corrugated paperboard, so it is important to understand its production first before considering other paper-based packaging for example, corrugated paperboard or more specialty-based applications such as moulded paper-based packaging, e.g., egg cartons and fruit and vegetable packaging.
At the 'wet end' of the production line. The pulp slurry, containing between 0.1 and 1% pulp fibres by weight, is sprayed onto the mesh belt wire.
The slurry passes through a slit 2-6 mm wide (in the head box) and is spread onto the moving mesh belt wire wich is the full width of the paper machine. The pulp is distributed very uniformly and consistently.
3. The web is pressed
Still in the 'wet end' of the production line, the paper board web, sandwiched between fabrics, is passed between rubber-covered steel rolls which removes excess water by pressure and suction.
The paper web consistency leaving the press section can be above 40%. the paper machine. The pulp is distributed very uniformly and consistently.
Drying Section
4. The sheet of paperboard enters the dryer
The paperboard sheet enters the paper machine dryer section- it is about 50% water.
It must be dried to less than 10% water for the finished product.
5. Size pressed
The dried sheet is pressed to increase strength, smoothness and printability
A starch solution, sometimes pigmented, is applied to either one or both sides of the paperboard at the size press. The surface sizing prevents surface fibre shedding from uncoated surfaces and improves strength, smoothness and printability.
1. Paper pulp slurry is sprayed on to the wire
2. Pulp is spread over wire
Wire Section - Wet End
Press Section - Wet End
Coating
6. Coating applied
Coatings are applied next and smoothed out with a coating blade.
Coatings can be a mixture of white pigments and binders depending on the disired finish and intended application e.g., for food and beverage - polyethene coating.
7. Multiple coats can be applied
Sheets can be coated multiple times to achieve the required finish.
Coating
8. Plastic is melted
If a polyethene (PE) coating is required e.g., for products used in the food and beverage industry, the coating is applied via a process called extursion where the PE is melted, mixed and pushed through a die.
9. Plastic is applied to the paperboard
While the film is still hot, it is pressed along with paper around a roller thereby coating the paper.
10. The plastic is spread over the paperboard
A flat die is used to form a thin layer on top of the paperboard.
11. Cooled
When cooled the process forms laminated paper.
Finishing
12. Reeler
The board is wound into a jumbo reel where it can be cut into smaller reels dependent on specifications.
Production of paper-based packaging
Process
Other
applications of paper-based packaging
Corrugated paperboard
1. Loading
Rolls of paper are loaded on to the roll stands.
- A roll of outer liner
- A roll of the inner medium layer
2. Unreeling and Feeding
The paper rolls are fed through the splicer where they are unwound. The paper can then be fed into the single facer.
3. Heating
The paper is heated up to temperature by passing over heated rollers.
4. The medium is fluted
The inner layer is folded to create a wavey texture (flutes) by interlocking corrugated rollers.
5. Glueing
Glue is applied to the outer liner and the tips of the fluted medium by a glue roller.
6. Creating a single-faced web
The outer liner and the medium are joined with the adhesive under pressure and heat to create a single faced web.
7. Transfer
The single faced web is transported to the next stage of production.
8. Heating
The single faced web is heated up to temperature again using heated rollers.
The second outer layer is also heated here.
9. Glueing
Adhesive is applied to the second outer liner.
If producing a double walled corrugated board, glue is applied to a separate single faced web.
10. Joining
The outer liner to the single-faced web by applying pressure and curing the glue in the double backer.
11. Cutting
The completed board is cut, removing any damaged lengths or to mark the end of production of the grade of paperboard.
12. Slit and Scored
The corrugated board is slit and scored to the required specifications. The paperboard cannot be reeled as this would damage the corrugated structure.
13. Cutting off
The larger sheets of the board are further cut to the required specifications.
14. Stacking
The sheets are stacked into the specified quantities ready to be sent to the converting process, where they will be made into packaging.
Production of paper-based packaging Process
1. Thermo-Mechanical Pulping (TMP) Woodchips are washed, digested and fed into a ThermoMechanical Pulping (TMP) refiner using a high-pressure screw feeder.
2. Pulp refined
The pulp is refined by two giant metal grinding plates which shred the chips into papermaking fibres.
Afterwards, the fibre is screened to make sure they are all separated. Any rejected fibre is sent back for further refining.
3. Pulp added to mould
The refined pulp is added to the mould which determines the shape of the paper-based packaging.
vacuum pump helps the moulding process.
Heated
The mould is heated causing the pulp to solidify. 5. Mould removed
The mould is opened and the paper-based packaging is removed. An air compressor helps this process.
are
the
1. Transport cart delivers paper Transport carts keep feeders topped up with stacks of paperboard.
2. Unreeling and Feeding
The paper rolls
fed through
splicer where they are unwound. The paper can then be fed into the single facer.
3. Transfer
6. Moulds are dried
After demoulding, the wet trays need to be dried.
This can be done naturally or by brick or metal drying line (more automated with the use of sing a conveyor belt and hot air and/or conveyor belt dryers. Drying
7. Ink printing
Ink printers can be used to add a design onto the packaging. Finishing
8. Hot pressing
The paper-based product can be hot pressed against a mould to improve strength and toughness.
10. Stack pressing
After being stacked, the stacks may be pressed again to achieve a more closely-packed stack which can be more easily shipped.
9. Stacking
The moulded paper-based products are counted and stacked at a stacking machine.
11. Preparing for shipment
Stacks are strapped, ready for shipment.
The design is printed on to the paperboard.
The paperboard is cut into the desired dimensions ready to be folded into packaging. Cutting
After cutting, the edges of the paperboard are scrubbed to remove any loose material and soften sharp edges.
7. Transferred to stacker
Via transfer belts, the cut paperboard is transferred to the stacker. Stacking
Sheets are shingled to slow down the speed when they reach the stacker in order not to damage their edges.
This method leaves the box unglued and flat, ready to be folded.
It can produce multiple boxes from each sheet.
4. Printing
5. Die Cutting
6. Scrubbing
9. Stacked
8. Shingled
Production of paper-based packaging
Explaining the opportunities and projects
Key critical projects within the paper-based packaging industry have been highlighted along the schematic to make it easy to identify which areas of the process have the most opportunity.
Key products and opportunities Paperboard
1. Loading / Feeding
Key product groups Opportunities / challenges
• Backlash-free couplings
• Bearings – CARB bearings, spherical roller bearings and housing units
• Belts – dualsided teeth belts synchronous belts and v-belts
• Clamping elements
• Compressors
• Dewatering foils
• Electric motors
• Forming board
• Gears and motors
• Hydrofoils boxes
• Lubrication systems
• Pumps
• Rollers – breast rollers, dandy rollers, suction rollers and wire rollers
• Precision-controlled pumps and valves, supported by high-quality bearings, can help improve the efficiency and consistency in applying the paper pulp onto the wire mesh and distributing it evenly.
• Dual-sided teeth belts can be used where counter rotating rolls are required. This is a low maintenance solution.
• Process has a lot of moisture so air handling systems for the building should be efficient and maintenance free using v-belts. This reduces costs from maintenance and down time.
• Very wet operating environment – suction rolls with large bore (>300 mm) spherical roller bearings have a risk of roller skidding.
2. Press Section
Key product groups Opportunities / challenges
• Bearings – CARB bearings, spherical roller bearings and housing units
• Efficient ventilation and drying mechanisms can be enhanced with high-precision bearings in fans and other rotating components, leading to more uniform drying and lower energy consumption.
• Synchronous belts for driving rollers, pumps and compressors.
• Operating in high temperatures with risk of thermal shock.
• Lightly loaded conditions possible with vertically nipped rolls.
• Slow speed conditions during start up and boil-out (cleaning).
4. Coating
Key product groups Opportunities / challenges
• Bearings – cylindrical roller bearings, spherical roller bearings and bearing units
• Belts
• Rollers – coater rolls
• Electric motors
• Gears and motors
• Lubrication systems
• Sealing technologies
• Conveyor – screw conveyor
• Pulleys
5. Finishing
• Risk of roller skidding in lightly loaded applications.
Key product groups Opportunities / challenges
• Bearings – cylindrical roller bearings, spherical roller bearings and bearing units
• High-capacity belts with high shock load resistance are used for driving the paper winder.
• Locking devices are used to connect break discs where torque is usually between 50-200nm. This is a relatively standard item although torque transmission capabilities are crucial to ensure items do not break prematurely.
• High inertia and possibility of high loads from emergency stops.
Production of paper-based packaging
Key products and opportunities
Explaining the opportunities and projects
Key critical projects within the paper-based packaging industry have been highlighted along the schematic to make it easy to identify which areas of the process have the most opportunity.
Corrugated paperboard
1. Loading / Feeding
Key product groups Opportunities / challenges
• Automatic bulge clamps
• Couplings – backlashfree couplings and hysteresis couplings
• Spherical roller bearings are more commonly used in newer-designed machines.
1 2 3 4
Key products and opportunities
3. Transportation
Key product groups
• Alignment devices
• Bearings
• Belts – incline belts
• Clamping elements
• Couplings – elastic couplings and hysteresis couplings
• Electric motors
• Feeding devices
• Lubrication systems
• Rollers
• Sealing technologies
• Tension adjustment devices
• Torque limiters
4. Double Backer
Key product groups
• Bearings
• Clamping Elements
• Conveyors – vacuum conveyor systems
• Couplings – backlash-free couplings and hysteresis couplings
• Electric motors
• Glue dams
• Hot plates
• Lubrication systems
• Rollers – applicator rolls and pre-heater rollers
• Sealing technologies
• Torque limiters
• Wrap arms
5. Finishing
Key product groups
• Bearings – roller bearings
• Clamping elements and table
• Couplings – backlash-free couplings and hysteresis couplings
• Electric motors
• Lubrication systems
• Rotary blades
• Scorers
• Sealing technologies
• Torque limiters
6. Stacking
Key product groups
• Bearings
• Belts – delivery belts
• Electric motors
• Lift platforms
• Lubrication systems
• Sealing technologies
Production of paper-based packaging
Key products and opportunities
Explaining the opportunities and projects
Key critical projects within the paper-based packaging industry have been highlighted along the schematic to make it easy to identify which areas of the process have the most opportunity.
Moulded paper-based packaging
Key product groups
• Bearings
• Belts – conveyor belts, link belts and synchronous belts
• Chain – conveyor chain and special drying oven chain
• Clamping elements
• Couplings – backlash-free couplings, elastic couplings and hysteresis couplings
• Synchronous belts in rubber and Thermoplastic Polyurethane (TPU) offer a maintenancefree way to drive multiple different types of machine and transport products.
• Standard PU belts can quickly wear out and require significant dismantling to replace. In comparison link belting can last over 10 months without causing any downtime, whilst also being easy to install, without needing to remove any components.
• Big size conveyor chain with high-wear resistance is used for entry and exit of the drying ovens.
Pulleys Sprockets
Key products and opportunities
Printing and cutting
Key product groups
• Bearings
• Belts – conveyor belts, link belts, timing belts and transfer belts
• Brushes
• Chain – conveyor chain (20mm pitch with carrierto-plate), double-pitched high-concurrency roller chain, drive chain and lifting chain
• Clamping elements
• Couplings – backlash-free couplings, elastic couplings and hysteresis couplings
• Link belts that do not require welding and are easy to install with one person can help save operational downtime.
• For accurate cutting: high-concurrency rotating knives to cut the cardboard precisely.
• There are lots of paper particles which can be aggressive, so highly sophisticated lubricants are used to keep chain in the best condition possible.
• If there is too much lubricant it can contaminate the product which is a high risk for printing. High viscosity of lubricant is needed to accommodate the high rotation speed of chain.
• The life-span of chain is rather long – if well-maintained they will run over 20,000 hours of operation and would be replaced every 2-3 years replaced. SOV: 0.5 million euros.
• There is minimal wear on sprockets as diameter is large. Lifespan is much longer than wear on chain (up to 10 years) and more likely to be sourced from the Original Equipment Manufacturer (OEM).
• Conveyor chain can be between 5 – 15 metres long, running at low speeds. Replacement of conveyor chain every 3-5 years. SOV: 250 - 750 euros.
• Pallets are used to protect the product whilst being transported by chain.
• In-time maintenance – area maintenance typically don’t look at machinery until broken down or misalignment occurs which indicates it is not functioning properly within the application. Opportunity to consider preventative maintenance measures.
• As chain is replaced, sprockets will also require replacing as the wear will have transferred to sprockets also.
The approximate value of PT aftermarket sales in the European paper-based packaging industry 125M euros
PART THREE Paper-based packaging questions
The following provides the reader of this document, particularly the members of the Sales Team, with some questions to help to generate revenue from this Production Line Intelligence document and so develop business within the paper-based packaging industry.
For many of these questions you may already know the answers. Others might be used on a regular basis when you visit customers and prospects in other industry sectors. It is meant as a prompt, to act as a reminder, allowing your business to fully capitalise on this market intelligence and production line information.
Preparing – before the visit
The producing company – makers of the ‘paperbased packaging’ (End user / Brand manufacturer)
• What type of plant are you visiting ?
– Is it a full production facility – that is, from pulping wood to finished paper? – or:
– Is it a limited production facility - that is, buying in the pulp – either from wood or from recycled cardboard –then using that to manufacture the end product?
• What do you already know about:
– Its size in terms of capacity, output etc.?
– The types of paper-based packaging it produces – paperboard, corrugated paperboard, other paperbased applications?
– The production system they use and the manufacturers of those systems?
• How old is the plant?
• How many people do they employ?
• Do they have their own maintenance engineers?
• Who makes the purchasing decisions – locally or at Group level?
• Does this company have other facilities in the region you service?
The people you might meet
• Who are you going to see?
• What is their role or speciality (production/maintenance/ repair/purchasing)?
• What do you know about them already? (hint: search LinkedIn)
There are three parts that deal with:
1. The preparation – this provides questions to consider before going to the site, in two sections:-
a. Detail of the company – is it part of a chain, or is it an independent?
b. Who are the people to be seen – technical, engineering, maintenance, production, purchasing?
2. The meeting itself – what to ask during the meeting to understand the concerns, needs, requirements and potential.
3. The follow up – questions to ask or to reflect on, at the end of the meeting or afterwards
• What are your initial thoughts about the main challenges they are likely to face?
• What is your opening question and how to tailor it to their role?
General
• What do you want to achieve from the meeting –your goal?
– Exploratory – trying to understand the pressures/ problems they face – starter question – ‘what are the main issues/challenges you face in keeping the plant running?’
– Presentation – trying to suggest how your company’s service can help? – ‘these are the services we provide that might help you with those issues’
– Breadth of service – showing that you are not simply a component provider? – ‘energy saving/efficiency’ – ‘full range of MRO products’ – ‘support of manufacturer/suppliers’
• What will you fall back on, if your intended goal seems impossible?
– Ensure they know that you are interested/could add value?
– Ensure that they have your name, title, services to hand for the future?
– Confirm that they would be willing to meet you again, in the future?
• What is your plan for follow ups to this meeting?
• What kind of support material do you need to take with you – tailor made to the Pulp and Paper Industry rather/ as well as general information?
The actual meeting ‘Producers of paper-based packaging'
Some of the above can be asked during the meeting, but some research beforehand is preferable.
The plant or facility
• What types of paper-based packaging are produced e.g., paperboard plant, corrugated paperboard or specialtybased paper packaging?
• How many production lines are there and what types of products are produced?
– What types of finishing are applied to the paper-based packaging (if applicable) – printing, cutting, moulding?
– How do you deal with the change in product varieties?
• What are the processes used across the various stages of production (loading/feeding; producing the single-faced web; transportation; double-backer; finishing; stacking; packing)?
• How are the main machines maintained and repaired (internal team, external team, machine builder service engineers)?
Maintenance, planning and issues
• What sort of regular maintenance does the plant undergo?
– Regular shut-down periods? preventative? planned? or other?
• What is the estimated annual spend on maintenance and repair?
• What are the main issues/challenges in relation to maintenance or 'bottlenecks' in the process that affect speed or reliability?
– What are the main issues or concerns in relation to maintenance?
– What are they caused by?
– Are there on-going projects to deal with this?
The follow up
• What were the main points you learned from the visit?
• How and where are you going to store this information – does your company have a CRM system/process?
• How are you going to use this information for future business, either with this potential customer or others – discussing opportunities within the Company at Sales Meetings?
• Who in your business do you need to share this information with?
– Are you using partners – suppliers or distributors –to assist you in this process?
• Do you have existing projects carried out in relation to maintenance or energy management or sustainability, etc.?
– Are existing partners – suppliers or distributors – assisting?
• What are the key maintenance/industrial supplies objectives for the facility?
The most utilised products
• What parts are used most on an annual basis?
– What are the issues/challenges faced getting those parts?
• What are the main concerns in relation to type of components that are needed to maintain and improve the line e.g., bearings, chain, hydraulics, pneumatics, etc.?
• Where is the process most prone to failure or maintenance problems?
Suppliers
• What do you value most in relation to a supplier/ distributor like us?
• What kind of support do you look for from your service providers in relation to planned maintenance?
• What is your biggest current problem with your aftermarket suppliers?
– How do you like your supplier partners to assist?
• Next steps
– Can we come back with a proposal to help you with some of this?
• What are the next steps you need to take, when and how?
• What other types of follow up will you undertake and why?
– Do you have success stories to describe?
– Do other members of your team have such success stories?
– How can these be replicated?
• How will you ensure that these follow ups are completed?
Acknowledgements
Acknowledgements and a sincere thank you to the following manufacturer members of EPTDA for the generosity of the technical and commercial information and advice that they have supplied and which has given real authority to the document.
Also to our technical experts from distributor members of EPTDA operating in this sector, who have provided the concrete examples included in the text and without whose contribution the document would lack its operational and commercial relevance and power for distributors.
Finally to the individual members of the EPTDA Business Intelligence Task Group, who have freely given their advice, guidance and inputs throughout the process of producing this document.
Authored by:
Disclaimer:
The costed examples contained in this document are illustrations taken from real practice. They are, however, not predictions of future value achievable from various projects that can be undertaken in this sector. The authors, contributors and EPTDA do not accept any liability for any commercial decisions that may be taken as a result of these examples.
Sources:
1. Markets and Markets, ‘Packaging Market Research Reports & Consulting’
2. Ibid.
3. Ibid.
4. Statista, ‘Distribution of Packaging Demand Worldwide in 2019, by Material Type
5. Ibid.
6. Ibid.
7. PakFactory, ‘4 Popular Types of Paperboard Grades for Packaging’
8. Statista, ‘Global Paper Packaging Industry – Statistics & Facts’
9. FAO, ‘Non-wood Fibre and Global Fibre Supply’
10. Cepi, ‘Key Statistics 2022: European Pulp & Paper Industry’
28. Printing Impressions, ‘Paper Supply Issues, Mill Closures, and the Printing and Packaging Industries’
29. Cepi, ‘Key Statistics 2022: European Pulp & Paper Industry’
30. LinkedIn, ‘Embracing Change: Shifting from Plastic Packaging to Paper and Eco-friendly Materials’
31. Two Sides, ‘Paper Packaging is Recycled More Than Any Other Material’
32. LinkedIn, ‘Embracing Change: Shifting from Plastic Packaging to Paper and Eco-friendly Materials’
33. IBM, ‘Meet the 2020 Consumers Driving Change’
34. Seaman Paper, ‘Four Reasons to Use Paper-based Packaging for eCommerce’
35. Paper&Packaging, ‘The Paper and Packaging Board: Media Resources’
36. Smith Corona, ‘The Market Shift from Plastic to Paper’
37. Pack World, ‘Procter & Gamble’s Lenor Scent Booster in Board Packaging, Unilver’s Dirt is Good Detergent Sheets in Board Box, JDE Peet’s Coffee in Paper Pack’
38. Ibid.
39. Coca-Cola, ‘Coca-Cola Paper Bottle: Sustainable Prototype Set to Trial in Europe’
