People often think about the “shelf life” of corrugated packaging in the same way they consider perishable materials that spoil (like food ingredients or oils) or substances that degrade, separate, or lose effectiveness over time (such as coatings or paints). However, while the same principles don’t apply to corrugated, its performance can be significantly impacted by improper handling and storage.
Proper Storage Conditions Are Key
A primary consideration in preserving the performance and durability of corrugated is controlling the environmental conditions it is exposed to in storage and throughout its distribution cycle to the end user. The ideal storage conditions for corrugated is a balanced environment with moderate humidity levels. However, corrugated materials do require some moisture to preserve their reliability. That is because the actual composition of containerboard is 92% fiber and 8% water. If corrugated is exposed to overly dry heat, it loses too much moisture making it more prone to tearing or cracking when folded. According to industry standards defined by TAPPI, corrugated should be stored at 72 degrees with 50% relative humidity. While minor fluctuations in humidity may not directly impact box life or performance, maintaining a stable environment is key to product performance.
However, there are some exceptions to that rule. Protective coatings for corrugated, like wax and wax alternatives, prevent corrugated boxes from absorbing moisture. Coated corrugated boxes are great for moisture heavy environments like produce packaging and cold chain shipping. Although the coating will help to prevent moisture, it does not render coated corrugated indestructible. Corrugated with coatings still must be handled properly and protected from extreme environmental exposures to preserve its durability and longevity.
How Improper Handling Can Affect Performance in the Warehouse and In the Field
Environmental and storage considerations are not the only elements that can directly contribute to how long corrugated will last and perform. Rough or careless handling can also cause damage that could lead to issues with strength and stability so proper handling is critical.
Corrugated is made by combining layers of linerboard with medium together to create corrugated board. The center part or the medium, known as the flute, is what provides the strength and cushioning properties in corrugated. Any damage to this strength core can alter its compression strength and cushioning ability. Ripped, torn or crushed edges can cause structural weakness. Any outside pressure or forces on the box is likely to result in the box collapsing, potentially damaging the product inside. But the pitfalls from using a damaged corrugated box can wreak havoc long before the box is headed for the end-user. Bent or crushed corrugated boxes can get jammed or stuck in automated equipment, resulting in production downtime and even lost product. Proper care and handling are fundamental to performance.
Maximizing the Longevity of Corrugated Boxes
How long corrugated boxes will last and how they perform are directly related to how they are handled, the temperatures they are exposed to, how they are used and more. However, PCA recommends that corrugated products should be used within several months, typically no later than 12 months, of their manufacture. To ensure the preservation of your corrugated, below are some key factors identified by the Fibre Box Association to help optimize the performance of your corrugated boxes:
- Store corrugated off the ground on a clean, well-preserved pallet.
- Corrugated should be stored flat with proper materials for load protection and stabilization.
- Store in a cool, dry place away from extreme temperature sources.
- Use a first in, first out system to minimize storage time.
- Consider the unit load design or how your boxes are stacked, don’t over stack.
- Handle corrugated loads with care to prevent damage to edges.
- Inspect boxes regularly for damage before using.
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