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International Journal of Latest Research in Science and Technology ISSN (Online):2278-5299 Volume 4, Issue 6: Page No.65-69, November-December 2015 https://www.mnkpublication.com/journal/ijlrst/index.php

DESIGN OF CORRUGATED FOR LONG TRANSPORTATION OF BATTERIES

1 Madhava Rao .B, 2 Kosaraju Srinivas,3Murthy.KSN, 4 Jagadish .M Material Development Division, Research and Analysis, Amararaja Batteries Limited

Abstract- The basic objective of the present work is to arrive at the optimal design for corrugated used for the transportation of the batteries to the ware houses and customers. The corrugated box was designed taking account of load condition that corrugated box experiences. In this context, considered vital parameters like safety, moisture content and nature of load those influence the performance of the corrugated box. With the help of this simple and practical design approach, the suitability of the design for the long transportation was arrived at and importance of influencing parameters was discussed.

Keywords -; Corrugated box, , corrugated box damage, transportation

I. INTRODUCTION II. CARTON BOX: The prime objective of any industry is to sell the goods in a good condition to the customers. Right quality of goods develop customer satisfaction and their loyalty. Even though so much of care is taken during the production of goods, improper packing of goods and subsequent transportation can result in damage of goods. To avoid this kind of situation one need to address the packing stability and its suitability in conjunction with mode of transportation chosen and the product nature i.e. fragile, hazardous etc.. Packaging may be looked in different ways, and it may be described based on the product that is going to be packed. Categorization of the packaging is as follows

Corrugated boxes are industrially prefabricated boxes, primarily used for packaging goods and materials. Specialists in industry often use the term cardboard because it does not denote a specific material

A. Global Trends of Corrugated Box:

World demand for corrugated boxes is forecast to increase by 4.2 % per year to 234 billion square meters in 2017, slightly outpacing real (inflation-adjusted) gains in GDP(1). Primary packaging is the material that first envelops the product and holds it. This usually is the smallest unit of distribution or use Growth factors include rising industrial activity, and the package is in direct contact with the contents. particularly in the manufacturing sector, which often requires corrugated packaging to protect and transport  Secondary packaging is outside the primary packaging, goods. In addition, ongoing developments in small flute and used to group primary packages together. high-quality graphic board allow corrugated boxes to  Tertiary packaging is used for bulk handling, penetrate traditional applications, especially storage and transportation. The most common form is a in the developed world. Greater interest in corrugated palletized that packs tightly into packaging as a point-of-sale display in applications will also boost demand for value-added boxes. The fastest increase in demand for corrugated boxes will The primary packaging category was chosen for our study i.e. occur in developing regions; both Asia/Pacific and the to arrive an optimal design of corrugated box. Africa/Mideast regions will both outpace the global average.

Publication History IMSaSnNusc:r2ip2t 7R8ec-e5iv2e9d 9 : 8 D e c e m b e r 2 0 1 5 65 Manuscript Accepted : 16 December 2015 Revision Received : 25 December 2015 Manuscript Published : 31 December 2015

International Journal of Latest Research in Science and Technology. India and China will see the fastest gains as a result of strong growth in industrial output and consumer product ’ markets. China, which surpassed the US as the world s largest corrugated box market in 2011(1), will account for almost half of the increase in global demand over the forecast period. Advances will be supported by greater As evident, the load or force applied on the square cm urbanization and industrialization, expanding international carton was calculated as 0.25kgs (rounded up). The required trade and rising consumer income levels. Bursting strength and GSM of the corrugated box for this pre- determined load should then be arrived by considering the B) Designs of Corrugated box: factors that influence the performance of the corrugated box. The design of a corrugated box is vital. The design is nothing but the process of matching the performance of corrugated fibreboard boxes in line with end-use requirements. The process oBf ) Factors influencing the strength of corrugated box: selecting the correct package design for a particular product ha s Corrugated board cannot be considered as an engineering become more complex as new technologies and materials presenmt aterial due to the fact that its strength characteristics are not ever-increasing challenge. The ways in which corrugated board canp redictable within its normal range of use. Humidity and be used are practically limitless. The most common box style is thete mperature changes affect corrugated box greatly. Further Regular Slotted (RSC). All flaps are the same length fromD rops, vibration, compression, etc. reduce the score to edge. Typically, the major flaps meet in the middle whereast rength of flute structure. Misalignment of vertical edges from the minor flaps do not. The manufacturer's joint is most often joinedo ne box on top of another can reduce the carrying capacity of with but may also be taped or stitched. The box is shippedth e box. Because of all these things, it is a common practice to flat (knocked down) to the packager who sets up the box, fills it, andc onsider influencing "factors" while calculating the needed closes it for shipment. Box may be by tape, adhesivec, ompression strength of a corrugated box. Calculated dead staples, , etc. The size of a box can be measured for eithelro ad is multiplied by these corresponding factors in order to internal (for product fit) or external (for handling machinery omr ake up for the hazards of distribution listed below which palletizing) dimensions. Boxes are usually specified and ordered byim pair the strength of corrugated board. the internal dimensions. The following are a few corrugated box  designs (2). Moisture factor  Load Conversion factor  Safety factor

Moisture Factor: Because the board material is hygroscopic in nature, the strength properties of corrugated board products are very much dependent on the relative humidity. More precisely, it is the actual moisture content in the corrugated material that affects its strength. The increase in moisture content in the material breaks the bonds between cellulose fibres, affecting the mechanical properties. Recent research has shown that, as the moisturecontent of corrugated package is increased from III. ARRIVING AT OPTIMAL DESIGN: 7.7% to 16.4%, its compressive strength got reduced by 52%(3,4, and 5). Such a significant reduction of box strength The main parameters that influence the strength of the corrugated can lead to packaging collapse, thus causing further box are burstingstrength (BS) and Grams per square meter mechanical damage to the product.The study intend to (GSM). The required GSM and BScan be determinedby taking consider moisture factor of 2 (the strength decreased to half accounting of  due to moisture) in order to retain the box strength at required Load exerted on the box. level.  Factors influencing the strength of corrugated box: A) The first step is therefore to calculate the load for The Bursting strength by accommodating Moisture unit area: correction factor is 2X Where X = Pre determined load / Sq.Cm 1: Load Conversion Factor: In case of pre-determined load, the load considered is static in nature. During inventory, static load exerted which is primarily considered to arrive at bursting strength. Nevertheless, dynamic load is becomes significant during the transportation stage. Indeed more difficult to measure, analyse and estimate is dynamic loading as compared to static load. Load range (or more accurately stress range) is the most important parameter in analysis (6). Loads can vary in Case 2: time andspace. After a review of literature (6,7, 8)Load a

ISSN:2278-5299 66

International Journal of Latest Research in Science and Technology. factor of 3 was considered to accommodate the exertion of validation was done by shipping the packed goods to dynamic loads during transportation. different parts of the country The above Bursting strength by accommodating Load a) Studies: conversion correction factor is (2*3) X The following tests were carried out as a part of lab Where X = Pre determined load / Sq.Cm validation Safety Factor: 1. Drop test 2. Stacking test Though the two major influencing parameters are taken care by incorporating the relevant correction factors, it is still Drop test: Laboratory drop test was conducted to ensure the worthy to have safety margins to take care of any unforeseen ability of the corrugated box to face the rough handling. incidences. ASTM recommends safety factors ranging from Drop test was conducted as per the standard 49CFR §178.603 1.5 to 8.0, depending upon the value of the product and and the test procedure is as follows (4, 10, and 11) percentage of load supported by corrugated (7). Experience has shown that a safety factor of about five seems right for 1. The test consists of a series of drops, using a free-fall corrugated boxes and corrugated inserts supporting the drop tester, on various surfaces and corners of the majority of compression load (7). Nevertheless in the present package. case the safety factor of 8 was considered because the battery 2. The packageis inspected for any damage. If noticeable terminals have to be protected due the frictions developed in damage exists, the test is to be stopped and have to be between the layers which would otherwise result in documented. explosion. 3. Identified edges and corners by the numbers of the The net Bursting strength by accommodating all the surfaces that meet to form them. correction factor is (2*3*8) X In the present study 5 Samples were subjected to the drop test Where X = Pre determined load / Sq.Cm and the samples dropped at 30 inch i.e. 750 mm Calculation of bursting strength with all the relevant factors for a given load Bursting strength = Pre determined load / Sq.Cm* factors (Moisture, Load Conversion, Safety) Bursting strength = 48* predetermined load / Sq. Cm Bursting strength = 48 * 0.25 = 12 Kg/cm2

I. VALIDATION OF OPTIMAL DESIGN: We at Amararaja batteries, supplying about 10 Million carton box packed batteries to the customers per anum. Batteries are packed into corrugated boxes as primary Fig. 1 showing the drop position of the corrugated box packing and the same is stretch wrapped as a secondary packing along with the skid. The are stacked as layers Table 1 :Drop Test observations are as follows: on the skid with honeycomb pad separating each layer and the stretch wrapped for the safe transportation. For validating the optimal design, two different design options were explored namely under design and optimal design. GSM was achieved based on the bursting strength. As a part of manufacturing, GSM was adjusted to achieve the requirement by Duplex, Flute and bottom with variable Bursting factors (9).

The design of the corrugated boxes by variable Bursting strength and GSM was conducted at Srinidhi Raja Packaging, – Gajulamandyam Tirupathi.

II. EXPERIMENTAL WORK Experimental work comprises of laboratory studies as well as field validation for the optimal and under designs.Laboratory tests were conducted internally and field

ISSN:2278-5299 67

International Journal of Latest Research in Science and Technology. Stacking test:One of the important functions of a corrugated Field Validation 3: box is to provide crush resistance (product protection) and Existing Parameter Under Design adequate strength for stacking in . Design Box compression testing is a means of evaluating boxes, Skids Packed 20 20 stacks of boxes, and unit loads under controlled conditions. Field conditions of stacking and dynamic compression do not Batteries 2000 2000 have the same Ware House Delhi Delhi Degree of control, Compression strength can be estimated From factory in Kms 2115 2115 based on container construction, size, and use parameters: ’ actual is often conducted to verify these Rejection in Batteries (No s) 0 80 estimates. Rejection in Percentage (%) 0 4 Stacking test conditions are as follows

Following damages were observed in under designed model. 1. Bottom layer damage S. No Stacking Values 2. Tear off Parameter 3. De-bonding 4. Crushed edges 1 Height 5 Layers of the battery packing

2 weight 2 tons Approx.

3 Duration 2 Months (the actual retention period in the ware houses is 1 month only)

After the duration, verified the bottom corrugated boxes for the abnormalities and observed no deviations. The optimal design has passed in the Stacking test. Whereas in the under designed model observed the following deviations Fig. . 2a o Crushed edges o Bottom layer damages b) FIELD VALIDATION:

Batteries were packed in the optimized designs and 20 skids with each 100 batteries were sent to the warehouses to check the rejection percentages. Brief about the filed validation is as follows

Field Validation 1: Fig. 2b Field Validation 2: Under Under Parameter Existing Design Parameter Existing Design Design Design Skids Packed 20 20 Skids Packed 20 20 Batteries 2000 2000 Batteries 2000 2000 Ware House Mumbai Mumbai Ware House Gujarat Gujarat From factory in Kms 1200 1200

From factory in Kms 1871 1871 Rejection in Batteries 0 50 ’ Rejection in Batteries(No s) 0 72 Rejection in Percentage 0 2.5 Rejection in Percentage (%) 0 3.6

ISSN:2278-5299 68

International Journal of Latest Research in Science and Technology. Based on the above , the Optimized design exhibited good performance and the under designed model reflects 2.5 to 4 % rejections due to the corrugated box damages.

III. CONCLUSION The study shows the relevance of safety factors, and design incorporating such safety factors is important to enhance the performance of corrugated box. With the help of simulation study, the corrugated boxes can be designed to meet different hostile condition; thereby customer satisfaction can be enhanced.

REFERENCES

[1] http://www.freedoniagroup.com/industry-study/3042/world- corrugated-boxes.html [2] http://www.bennettpackaging.com/images/NonPhoto_elements/Ben nett_Packaging__Box_Styles_Reference.pdf

[3] Allaoui, S., Aboura, Z., &Benzeggagh, M. L. (2009). Effects of the environmental conditions on the mechanical behaviour of the corrugated cardboard. Composites Science and Technology, 69(1), 104e110.

[4] EVALUATION OF THE PERFORMANCE OF CORRUGATED SHIPPING CONTAINERS: VIRGIN VERSUS RECYCLED BOARDS by L. Lisa Zhao ,Victoria University of Technology, Master of Engineering. [5] Zhang, Y.-l., Chen, J., & Wu, Y. (2011). Analysis on hazard factors of the use of corrugated carton in packaging low- yogurt during . Procedia Environmental Sciences, 10, 968e973

[6] Ramamurtham S. (1995). Strength of Materials, Dhanpatrai and sons, New Delhi.

[7] Pzankaj B. Pathare, Umezuruike Linus Opara ,*Structural design of corrugated boxes for horticultural produce: A review 1 2 5 ( 2 0 1 4 ) 1 2 8 -1 4 0 € [8] Allansson, A., &Sv ard, B. (2001). Stability and collapse of corrugated board: Numerical and experimental analysis. Master's Dissertation. Sweden: Lund University.

[9] Corrugated box hand

[10] ASTM D 4169: Practice for Performance Testing of Shipping Containers and Systems [11] http://www.theswisscolony.net/documents/SAPkgTstGuidelinesSma ll-8-01-08_000.pdf

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