Carton breakage; reasons, solutions and the role of production quality in preventing it

In the packaging industry, carton strength plays a very important role in maintaining product integrity. Carton breakage is a common problem in this field, which not only ruins the appearance of the packaging, but can also lead to serious damage to the contents inside the carton. But what causes carton breakage? Is this problem preventable? And why do some cartons crack, tear, or break as soon as they are bent?

In this article, we will thoroughly examine the reasons for cardboard breakage in the production and use process, and finally explain why choosing a reputable factory like Raviya Cardboard Manufacturing can be the ultimate solution to solving this problem.

What is carton breakage?

Carton breakage is a condition where the physical structure of corrugated cardboard is broken down due to bending, compression, or even transportation. In this condition, the carton walls crack, the layers separate, or the surface of the carton is unacceptably damaged. This can occur at various stages of production or consumption.

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The main reasons for cardboard breakage in the cardboard sheet production process

1. Low quality of raw materials

One of the major causes of carton breakage is the use of poor quality or substandard recycled paper. If paper that lacks sufficient fiber and proper adhesion is used in the production line, the final carton will not have the necessary mechanical strength.

2. Improper humidity and temperature during production

The cardboard production line is very sensitive to environmental conditions.
High temperatures or low humidity can cause the cardboard layers to dry out too much. This makes the cardboard sheet brittle and greatly increases the likelihood of the cardboard breaking.

3. Roller pressure in the sheet metal forming machine

In sheet-forming machines, rollers must apply precise pressure to the paper. If the pressure is too high, it will cause the flutes to be over-compressed and the paperboard to be crushed, which will result in reduced flexibility and an increased chance of failure at bend points.

Technical reasons in the die cutting and cutting stage

4. Die-cutting blade not adjusted

In many cases, die-cutting blades are not precisely adjusted and apply excessive pressure to the cardboard layers during scoring. This pressure can cause tears or weakness at bend points, leading to cardboard breakage.

5. Unevenness of the line up

If the fold line is not created accurately and with balanced pressure, the cardboard will crack or break when folded instead of bending straight. This not only ruins the appearance of the cardboard, but also causes it to lose its strength.

Problems caused by glue and its composition

6. Low quality of adhesive used

One of the most important reasons for cardboard breakage is the use of weak or substandard adhesives. If the adhesive does not have sufficient bonding strength or its percentage composition is incorrect, it will cause the layers to separate when bent or pressed.

7. Adding too much water to the glue

To cut costs, some manufacturers over-dilute the glue with water. This may work in the short term, but in the long term, it reduces the strength of the cardboard layers and can be a major factor in cardboard failure.

Environmental factors during storage or use

8. Improper storage conditions

Even if the cardboard is produced with good quality, storage in very dry or very humid environments can cause the cardboard to become excessively dry or soft, and ultimately cause the cardboard to break.

9. Irregular handling in transportation

Some breakage occurs during loading, storage, or shipping. Pressure from heavy items or bending the carton at improper angles are other causes of breakage in the final stage.

What damage does broken cardboard cause to a business?

Packaging destruction and brand value reduction

Damage to goods during transportation

Increase in product return rate

Customer dissatisfaction

Imposing an additional fee for replacing packaging

In today’s competitive world, a simple packaging mistake can cost you customers.

Solutions to prevent carton breakage

✅ Choosing a reputable factory specializing in cardboard production

Choosing a manufacturer who oversees all stages of production, from raw material procurement, machinery settings, adhesive formulation, environmental conditions, and quality testing, is key to preventing carton breakage.

✅ Multi-stage quality control

At Raviya Cartoning, quality control is carried out not only at the end of the production line, but also during production. This process helps to correct the smallest defects before they become a major problem.

✅ Use standard glue

The adhesive formulation in Ravya is adjusted to provide both high adhesive strength and the necessary flexibility to prevent the carton from breaking.

✅ Standard printing and die cutting

All die-cut molds at Raviya are designed according to standards and with high precision so that unnecessary pressure is not applied to the cardboard and the fold lines are regular and precise.

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Why should we buy from Raviya Carton Manufacturing?

With over a decade of experience in producing three-layer, five-layer, laminated and die-cut cardboard, Raviya Carton Manufacturing is known as one of the pioneers in this industry. This factory, using state-of-the-art machinery and a team of experts, has been able to produce export-quality products.

Features that have led Raviya to have large national and international companies on its client list:

Description feature

Multi-layer quality control Quality check at all stages
Variety in producing all types of cartons in all dimensions and models
Free technical advice Help in choosing the best type of packaging
Competitive price Cost management without reducing quality
Fast delivery to all over the country in the shortest time
Anti-fracture guarantee with specialized resistance tests

Conclusion: The end of carton breakage with Raviya carton making

If you are also facing the problem of cardboard breakage, it is time to choose a reliable, professional and committed manufacturer to supply your packaging. With experience, expertise and up-to-date technology, Raviya Carton Manufacturing guarantees to produce cartons that are resistant to pressure, folding, transportation and humidity.

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📞 Contact us for orders and advice:

Website: www.packseh.com

contact: 09991867837

WhatsApp: 09991867837

Raviya Cartoning, your reliable companion for high-quality packaging

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