Corrugated Packaging Material With Low Weight and High Recyclable Strength

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Solution Overview

Problem

There is a need for a packaging material with lower weight and higher strength properties that can be easily recycled, while also addressing environmental concerns and facilitating sorting in recycling streams.

Innovation Solution

A corrugated packaging material is developed using 100% bleached pulp, with a grammage of 50 to 100 gsm and a bulk of at least 1.5 cm³/g, comprising an adhesive with starch and microfibrillated cellulose, allowing for high strength and recyclability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional corrugated board is used to achieve high strength, then strength is improved, but weight increases

Engineering Contradiction:

ImprovestrengthVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent changes the grammage parameter from conventional high values to 50-100 gsm, and adjusts filler content to below 5 wt%, achieving both lightweight and high strength properties through parameter optimization

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses a composite structure with specific liner paper (70-100 gsm) and fluted paper (50-100 gsm) combinations, creating a lightweight corrugated board that maintains high strength through optimized material composition

Inventive Principle:

Principle #40Composite materials

2Strength

If conventional corrugated board is used for packaging, then strength is improved, but recyclability deteriorates due to sorting complexity

Engineering Contradiction:

ImprovestrengthVSAvoidrecyclability

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent makes the packaging material homogeneous with office paper by using similar grammage ranges (50-100 gsm) and filler content (below 5 wt%), enabling automatic sorting and recycling together without complex separation processes

Inventive Principle:

Principle #33Homogeneity

3Strength

If filler content is increased to improve strength, then strength is improved, but weight increases

Engineering Contradiction:

ImprovestrengthVSAvoidfiller content

Core Design Contradiction:

StrengthVSQuantity of substance

Solution Approach 1:

The patent optimizes the filler content parameter to below 5 wt% (preferably below 2 wt%), achieving high strength properties without increasing filler quantity, thus avoiding weight increase

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The material achieves high strength, low washboard effect, and excellent print quality, with a lower weight and cost, suitable for industrial-scale production and easy recycling.

Implementation Method 1

the adhesive comprises starch and microfibrillated cellulose wherein the microfibrillated cellulose has a Schopper-Riegler(SR) value above 97

Methodology Applied

Scientific EffectAdhesive: Adhesive

Data Source

PatentEP3990697B1A light weight corrugated packaging material

Publication Date: 2025.12.17 STORA ENSO OYJ

Figure 1

AI summary

The invention discloses a corrugated packaging material with a low weight and high strength properties, which material can be recycled with the office paper recycling stream. The corrugated packaging material of the invention exhibits good strength and stiffness properties, a low wash board tendency and provides a good printing surface.