You'd Be Surprised How Complicated It Is To Manufacture Cardboard Boxes

cardboard boxCardboard Box

Photo: Science Channel

Whether moving to a new location, carrying your most cherished possessions or delivering important packages, cardboard boxes are always there.Robert Gair invented the cardboard box in 1871 and they’ve been an integral part of our lives ever since. Despite its humble appearance, making a cardboard box is actually really complicated.

The Science Channel documented the manufacturing process as part of its “How Its Made” series (via Explore). 

We’ve broken down the key steps into slides.  

First, this machine rolls out a whole lot of recycled paper to be split up into one wavy sheet of paper called a flute which sits between two flat sheets called liners. They form a corrugated board.

The paper then goes through two rollers called a corrogater. Hot steam is sprayed on the cardboard while another roller glues one side of the flute.

A machine then adheres two liners to hold the box together and strengthen the board.

Next, a razor thin circular saw cuts each side of the cardboard.

The corrogater machine then cuts the board as many as nine times, depending on the size of the box.

The corrogater's final use is to separate the boards into layers using these aluminium tongs.

This next machine stacks the boards in quantities of between 25 and 80 boards. The machine then feeds the next machine at a rapid rate of 8,000 boards per hour.

Next, a trimmer cuts through the cardboard with expert precision to make flaps and handles.

Rubber blades ensure this machine cuts only the parts it's supposed to.

The boxes are processed at an amazing rate of 90 boxes per minute. The unused, cut off paper goes down below, where it is recycled as many as six more times.

A bending machine then folds the boxes along lines already made by the corrogater. Glue is then applied to the places which will come together to form the box. Another machine then folds the glued sections.

The boxes are then put in large piles and then sent off to be shipped away.

To put the proper writing on these boxes, there's an ink kitchen were over 5,000 colours are systematically poured into these containers.

They're then mixed perfectly for just the right colour combinations on the cardboard boxes.

The boxes are finally ready to ship and carry nearly anything you could imagine.

Source: Exp.lore

Processing salt takes up to five years.

NOW WATCH: Briefing videos

Business Insider Emails & Alerts

Site highlights each day to your inbox.

Follow Business Insider Australia on Facebook, Twitter, LinkedIn, and Instagram.