SUS(R) reduces carton deformation during freeze/thaw cycles- study

Research shows that Graphic Packaging International's coated unbleached kraft, sold under the brand name SUS(R), outperforms other paperboard substrates and corrugated products.

23/09/05 As the leading provider of coated unbleached kraft paperboard in the industry, Graphic Packaging International, Inc. has conducted extensive product comparison studies to assist consumer products companies in determining how to minimize carton deformation and compression damage through selection of appropriate paperboard materials for frozen food applications.  The research compared performance across leading paperboard product lines and determined Graphic Packaging International's coated unbleached kraft, sold under the brand name SUS(R), outperforms other paperboard substrates and corrugated products.

Illustrating the impact of typical handling in a retail setting, the tests provide great insight into how conditions could impact paperboard performance and ultimately the consumer's decision to purchase frozen products. Consumer perception of frozen food quality is affected by carton appearance. When handled by consumers in retail stores, frozen food cartons should not feel damp or soft, and should not have crushed edges or a wavy surface. These defects can create the perception that the frozen food has thawed, giving rise to consumer concern over food safety and therefore reducing purchase motivation. Such defects are often the result of condensation that occurs due to temperature changes during the distribution process and in the retail freezer case.  Moisture absorbed by paperboard can soften and buckle the carton.

Utilizing a unique carton profilometry device developed by Graphic Packaging International, the company performed extensive tests to measure resistance to carton deformation as characterized by the degree of buckling occurring in the top carton panel after the carton was exposed to a series of freeze/thaw cycles similar to those experienced by the carton as it moves from the filling line through the distribution chain to the retail freezer case.

The freeze/thaw cycling results in a several percent moisture increase, an associated decline in carton stiffness and compression strength, and varying degrees of main panel buckling.

The carton profilometer uses a non-contacting laser, and data is analyzed by a computer which generates a topographical image of the top carton panel.

SUS's strength and durability is attributed to its composition, which is primarily pine fiber. The length of pine fibers make the product much stronger than other, shorter types of fiber used to make other substrates. The unique three-ply construction of SUS folding carton grades enables the product to achieve superior resistance to compression and bulging, with the added benefit of hiding coating flakes in the interior ply so that the back of the board is blemish free. SUS is "hard-sized" to provide good moisture resistance, and natural resins in pine fibers further aid in water resistance.

Demand for stronger, more durable packaging has also enabled Graphic Packaging International to expand its Z-Flute offering into club stores, replacing traditional fluted packaging with a product that not only adds to production efficiency but also offers reliable packaging that provides significant distribution performance accompanied by higher speeds and greater throughput. These attributes, along with the high graphic capabilities Z-Flute offers, have resulted in Z-Flute sales doubling each year since its launch, due largely to the industry's desire to identify high-performing packaging products, such as Z-Flute, as more durable alternatives for mini-flute products in order to ensure greater reliability and more predictable performance.

Further studies show Graphic Packaging International's Z-Flute demonstrated superior compression performance when tested against comparable products. Composipac Z-Flute not only retained greater compression strength following freeze / thaw cycles, but demonstrated an increase in strength. Whereas comparable B Flute retained 40 percent of its compression strength, thereby reducing the safety factor of the carton, Z-Flute had retention of 90 percent or greater.

With significantly more consistent, reliable performance under standard freeze/thaw cycles and high humidity conditions, the success of this relatively new packaging product has further solidified Graphic Packaging International's leadership position.

Graphic Packaging International's high-performance products support the successful marketing of customer's brands, providing durable, quality products that ensure that at point-of-sale, consumers experience quality packaging that reflects the quality of the products they are purchasing.

Graphic Packaging International is a leading provider of paperboard packaging solutions to the beverage, food and other consumer product industries.

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