New Quality Level of Packaging Components from Paperboard through Technology Improvement in 3D Forming

Three-dimensional forming is a key technology for the application of sustainable materials, like paperboard, in packaging technology. Until now, deep drawing is not considered as a suitable process for manufacturing of packaging components with advanced geometrical design because of the sensitive process and a large number of failure mechanisms. To better understand and apply the physics of deep drawing, the process was studied by experimental investigations. Therefore, an evaluation strategy for formed parts was developed to describe their quality by measurable values. The influence of the technological parameters temperature configuration, moisture content of material and blank holder force on the quality of formed parts was described by a statistic regression model. This model gives an indication of the quantity and the direction of effects that parameter changes have on the quality of 3D-formed parts. An optimization of the process according to quality criteria showed that, in a first step, the quality of cylindrically drawn paperboard parts was increased drastically compared with that of the state of the art. Furthermore, the existing limits in the height of formed parts were exceeded, and the geometrical shape of the base offered far more opportunities for packaging design than expected. The process turned out to be suitable for a flexible manufacturing of packaging components for multipart packages from paperboard, which are highly sustainable in terms of recycling and reuse of fibres and thereby able to compete in the marketing-oriented packaging sector. Copyright (C) 2011 John Wiley & Sons, Ltd.