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Istanbul Technical University Graduate School Of ISTANBUL TECHNICAL UNIVERSITY GRADUATE SCHOOL OF SCIENCE ENGINEERING AND TECHNOLOGY OPTIMIZATION IN FOLDING CARTON PACKAGING DESIGN M.Sc. THESIS Büşra TORGAY Department of Industrial Product Design Industrial Product Design Programme JUNE 2016 ISTANBUL TECHNICAL UNIVERSITY GRADUATE SCHOOL OF SCIENCE ENGINEERING AND TECHNOLOGY OPTIMIZATION IN FOLDING CARTON PACKAGING DESIGN M.Sc. THESIS Büşra TORGAY (502111916) Department of Industrial Product Design Industrial Product Design Programme Thesis Advisor: Dr. Demet GÜNAL ERTAŞ JUNE 2016 İSTANBUL TEKNİK ÜNİVERSİTESİ FEN BİLİMLERİ ENSTİTÜSÜ OLUKLU MUKAVVA AMBALAJ TASARIMINDA OPTİMİZASYON YÜKSEK LİSANS TEZİ Büşra TORGAY (502111916) Endüstri Ürünleri Tasarımı Anabilim Dalı Endüstri Ürünleri Tasarımı Programı Tez Danışmanı: Dr. Demet GÜNAL ERTAŞ HAZİRAN 2016 Büşra Torgay, a M.Sc. student of ITU Industrial Product Design student ID 502111916, successfully defended the dissertation entitled “Optimization in Folding Carton Packaging Design”, which she prepared after fulfilling the requirements specified in the associated legislations, before the jury whose signatures are below. Thesis Advisor : Dr. Demet GÜNAL ERTAŞ .............................. Istanbul Technical University Jury Members : Assist. Prof. Dr. Cem ALPPAY ............................. Istanbul Technical University Assist. Prof. Dr. Dilek HOCAOĞLU .............................. Gebze Technical University Date of Submission : 28 April 2016 Date of Defense : 09 June 2016 v vi To all people who can’t throw away a package, vii viii FOREWORD I would like to express my sincere gratitude to my advisor Demet Günal Ertaş for guiding me with her academic insight and encouraging words. Thanks to her support, I manage to see the accomplishment of this study. I’m grateful to Mr. Esat Yapça listening every information about the thesis and guiding me with his experience and precious books. I would like to thank my mother, father, brother and Özge, always doing their best to comfort me. Thanks to them, my life wasn’t totally around the work, but also the real world. My whole colleagues, both from Tuzla and Eskişehir Camiş Ambalaj, I’d like to thank them all for answering all my questions and giving their supports. They actually took part in the thesis; Gözde Küçükoğlu, Damla Kanık, Sevgi Dinç, Gavsi Başkurt, Melek Demir, Orhan Çelik, Murat Ataş, Kerem Bartık, Kemal Serhat, Esra Köroğlu. I’m also grateful to all my friends, they never leave me alone; Naci Gündüz, Gizem Akman, Başak Elbüken, Çağrı Varlı, Batuhan Balcı, Zehra Uzun, Özge Erdal, Gizem Hürkan, Elif Çankaya, Volkan Sarıcaer, Pınar Met, Cüneyt Baybura and Eren Soylu together with his songs. Last but not least, mon ami, Özgür Dönmezer, always trusting and cheering me. I can’t undervalue his contributions on my research. June 2016 Büşra Torgay Package Designer ix x TABLE OF CONTENTS Page FOREWORD ........................................................................................................... viii TABLE OF CONTENTS .......................................................................................... xi ABBREVIATIONS ................................................................................................. xiii SYMBOLS ............................................................................................................... xvi LIST OF TABLES ................................................................................................. xvii LIST OF FIGURES ................................................................................................ xix SUMMARY ............................................................................................................ xxv ÖZET ..................................................................................................................... xxvii 1. INTRODUCTION .................................................................................................. 1 1.1 Purpose of Thesis ............................................................................................... 1 1.2 Methodology ...................................................................................................... 2 1.2.1 Literature review ......................................................................................... 2 1.2.2 Research ...................................................................................................... 3 1.3 Hypothesis .......................................................................................................... 4 2. CYCLE OF THE PACKAGE ............................................................................... 5 2.1 Need of Package ................................................................................................. 5 2.2 Determining the Package Specifications ............................................................ 6 2.3 Decision of Suitable Material, Production and Print Method ............................ 7 2.3.1 Corrugated board and flute types ................................................................ 9 2.3.2 Paper types ................................................................................................ 11 2.3.3 Cartonboard types ..................................................................................... 13 2.3.4 Production and print methods ................................................................... 15 2.4 Determining Overall Appearance and Graphic ................................................ 18 2.5 Designing the Package ..................................................................................... 19 2.5.1 Studying suitable package design style for the product(s) ........................ 19 2.5.1.1 Tube type boxes ................................................................................. 24 2.5.1.2 Tray type boxes .................................................................................. 38 2.5.1.3 Sleeve types ........................................................................................ 47 2.5.1.4 Insert types ......................................................................................... 53 2.5.2 Material and its effects on the design ........................................................ 60 2.5.2.1 The edgewise crush resistance and edge crush test (ECT) ................ 61 2.5.2.2 Bending stiffness ................................................................................ 63 2.5.2.3 Box compression test (BCT) .............................................................. 64 2.5.3 Flute direction and its effects on design .................................................... 66 2.5.4 Diecut area usage and utilization on design .............................................. 66 3. RESEARCH ......................................................................................................... 69 3.1 Using McKee Formula and BCT Test .............................................................. 69 3.2 Introducing the Research Structure .................................................................. 70 3.2.1 Designs ...................................................................................................... 70 3.2.2 Topics ........................................................................................................ 71 3.2.2.1 Cost .................................................................................................... 72 xi 3.2.2.2 Strength .............................................................................................. 73 3.2.2.3 Speed .................................................................................................. 74 3.2.2.4 Environment ....................................................................................... 75 3.2.3 Research conclusions ................................................................................ 76 3.2.3.1 Conclusions on strength ..................................................................... 76 3.2.3.2 Conclusions on cost ............................................................................ 83 3.2.3.3 Conclusions on speed ......................................................................... 89 3.2.3.4 Conclusions on environment .............................................................. 93 4. CONCLUSIONS................................................................................................. 101 4.1 Introduction .................................................................................................... 101 4.2 Conclusion and Guideline .............................................................................. 101 REFERENCES ....................................................................................................... 109 APPENDICES ........................................................................................................ 111 CURRICULUM VITAE ........................................................................................ 145 xii ABBREVIATIONS A : Automatic BCT : Box Compression Test C : Customer Lock CCT : Corrugated Crushing Test CLT : Concora Liner Test ECT : Edgewise Crush Resistance (kN/m) FEFCO : European Federation of Corrugated Board Manufacturers FL : Fluting G : Glued Insert I : Interlocked KF : Kraft Liner kN : Kilo Newton L : Lock Tuck NSSC : Neutral Sulfite Semi Chemical R : Ready Glued RCT : Ring Crushing Test RSC : Regular Slotted Container S : Slotted SCT : Crushing Stiffness SI : Slotted Insert TAPPI : Technical Association of Pulp and Paper Industry
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