1. Rethinking Processes, Retrofitting Equipment and
a Better Way to Monitor Board Performance
CONVERTING THE NEW LIGHTWEIGHTS
Sarilee Norton, President
Ralph Young, AICC Technical
Director
Randy Banks, President,
Sharp-International

2. AGENDA
 Consolidation, Economic Metrics, Lightweights—
The New Industry Dynamics
 Quality and Consistency—We Can Do Better
 Crushing the Board--What Do We Really Know
About Where We’re Losing It?
2

3. Same Old, Same Old or Finally a Different Take?
THE NEW INDUSTRY DYNAMICS

4. Consolidation Recap
CONTAINERBOARD’S CHANGING
LANDSCAPE
4

5. 2011—A BANNER YEAR FOR TRANSACTIONS
 RKT/SSCC; IP/TIN
– Long-term positive for the industry
– But a lot has to happen first
 ‘Discipline in the containerboard and corrugated box
markets’
– TIN and SSCC—5th and 6th out of six
– Someone has to do it
– TIN—better cost structure and high integration strategy
 Kapstone and Boise
 What else? What’s next?
5

6. WHAT’S NEXT?
 G-P/PCA?
– Cultural history
– Attractive geography
– But what does Koch want?
– If ain’t it broke…
 Pratt marches to its own tune
 Boise, a buyer or a seller?
 Still a lot of 1-2% players out there
 Multi-plant independents and sheet feeders
6

7. NEW INDY CONTAINERBOARD—THE NEW
NORMAL?
 Oxnard and Ontario CA mills produce 550,000 tons
 Together Schwarz Partners and Rand-Whitney
operate more than 20 converting facilities
 If you can’t beat ‘em, join ‘em—benefits of scale
and supply source ownership
 “This investment represents a generational commitment by
both families to the industry. We have been looking for
opportunities to grow, and these two California mills are
located in what we believe to be a very strategic market for
the future of our industry. They represent two assets that
would be very difficult, if not impossible, to replicate today.”
7

8. CONTAINERBOARD SHARE BY COMPANY
Greif Brothers Longview Fibre
Green Bay All Other
2% 2%
2% 7% International Paper Shown in 3 unlabeled wedges:
Rand Whitney+ 34%
Schwarz Interstate Resources
2%
Boise Atlantic/New Forest 1.0-1.5% each
2%
Kapstone Simpson Paper
2%
Pratt
3% Shown in ‘All Other’:
Norampac Orange County Cont.
3%
Hood Industries
0.5-1.0% each
PCA Sonoco Products
7%
Durango Group
Rock-Tenn
Georgia-Pacific 20%
11%
8

9. Access to New Local Markets, Plant Consolidations,
or Both?
REGIONAL CONVERTING IMPLICATIONS
9

10. SIZE MATTERS
 For the large integrateds, it’s usually about scale and synergies
– IP had 140 plants after Weyco, closed over a dozen
– Smurfit-Stone ~110 in 2008, RKT less than 100 today
– TIN closed several, IP has closed four more already
 Pick the best facility in overlapping local markets or shut down and
start over
 For smaller integrateds and regionals, a good way to enlarge
capabilities and extend geographic reach
 For the independents, a great time reinforce quality, service and
responsiveness you provide
10

11. THE ‘CURRENT’ ROCK TENN
 Even more capacity along the Route 95
corridor—MA, NJ and into the Carolinas
 Legacy Rock Tenn presence in TN, GA, AL
 Mega resources in Chicago-to-Milwaukee
stretch
 Only US based supplier with major position in
Canada
11

12. ALL OVER THE EASTERN US AND CANADA
12

13. THE ‘NEW’ IP—BOX PLANT NETWORK
 Southern CA and Chicagoland ‘thickets’ of box
plants
 Northern CA, upper Midwest, eastern PA, the
Carolinas, northwest GA, TN, central FL and LA-TX
are also capacity pockets.
 Except for the Dakotas, the Rocky Mountain states
and sparse coverage in New England, they are
EVERYWHERE!
 And 10 box plants in Mexico
13

14. SEEING RED?
14

15. WHAT DOES THIS MEAN FOR THE EVERYONE ELSE
IN THE INDUSTRY?
 For converters, not really about reducing capacity
 For consolidators, ‘synergies’ imply fixed cost
reductions—headcount, bricks and mortar, services,
property obligations, inventory baseload
 Where are the two major networks saturated?
 Shutdowns always put some accounts in jeopardy
 For most customers, this is still a local business
 For the containerboard supply, may be fewer mills, but
capacity not likely to shrink
15

16. Please Check the Security of your Seatbelt…
INDUSTRY KEY DRIVERS
16

17. US BOX SHIPMENTS FELL 13% 2007 – 2009
 Steepest decline for the market since the 1970s
 Shipments recovered 3.5% 2010, far more subdued
than the growth in manufacturing
 Since 2010, essentially flat through the third
quarter 2012, continued strong headwinds for the
US economy will prevail before market accelerates
to 3% (?) growth in 2013 and 2014
 Long-term, box shipments may average 1.5%
– Containerboard to grow at a more sedate 1.0% rate
– Shift to lightweight liner takes hold in North America
17

18. CONTAINERBOARD EXPORT MARKETS WERE VOLATILE IN 2009-
2010, BOOMED IN FIRST HALF 2011, STABLE NOW?
 2009-2010 due to numerous factors
– Global credit crisis and economic shocks
– Black liquor credit for US mills
– Shortages that developed following capacity closures
– Fluctuating domestic demand
 By and large, exports supported containerboard prices
at higher levels than the historical norm but growth in
China’s capacity may have a dampening impact going
forward
 Latin America a growing export market, but can it make
enough of a difference
18

19. OPERATING RATES INCREASED DRAMATICALLY IN 2010, EASED IN
2011, STABLE GOING FORWARD?
1.03
1.00
0.97
0.94
0.91
0.88
0.85
0.82
0.79
0.76
90 91 92 93 94 95 96 97 98 99 0 1 2 3 4 5 6 7 8 9 10 11 12 13
19

20. 2011 CONTAINERBOARD INVENTORIES ‘BALANCED’, WEEKS OF
SUPPLY SWELLED, THEN DECLINED IN 2012
Million Short Tons Weeks of Supply
3.2 Million Tons
6.0
Weeks of Supply (R)
3.0 5.5
2.8 5.0
2.6 4.5
2.4 4.0
2.2 3.5
2.0 3.0
1.8 2.5
J99 J00 J01 J02 J03 J04 J05 J06 J07 J08 J09 J10 J11 J12
20

21. When the Economics Shift, So Does the Story
VIRGIN VERSUS RECYCLED
21

22. IF ASIAN DEMAND WEAKENS, SO WILL US OCC
PRICES, OR NOT?
$/Short Tons
250
200
150
100
50
0
90 91 92 93 94 95 96 97 98 99 0 1 2 3 4 5 6 7 8 9 10 11 12
22

23. How Does This All Play Out?
CONTAINERBOARD PRICES
23

24. ARE PRICES ON THE WAY UP, STAGNANT…
…OR UNSUSTAINABLE?
24

25. What’s News?
LIGHTWEIGHT CONTAINERBOARD
UPDATE
25

26. MAJOR LIGHTWEIGHT INITIATIVES SINCE 2006
KapStone is also focused on lightweight kraft linerboard and Longview
markets lower basis weight grades
Company Location Capacity Material Origin
International Pensacola, FL 500,000 Kraft linerboard Conversion from
Paper uncoated free sheet
New Forest Scarborough, ON 250,000 Recycled liner/ Greenfield
medium
Pratt Industries Shreveport, LA 350,000 Recycled liner/ Greenfield
medium
KPAQ St. Francisville, LA 220,000 Kraft linerboard Conversion from fine
paper
Abitibi Bowater Coosa Pines, AL 100,000 Recycled Conversion from
SP Newsprint Dublin, GA ? containerboard/ newsprint
paper
Greenpac Niagara Falls, NY 540,000 Recycled New machine adjacent
linerboard to existing site
26

27. GREENPAC BASICS
 Partnership which includes
– Norampac (60%): Canadian based, 6 machines, primarily
recycled, ~3% share of North America
– Jamestown Container, Containerboard Partners and affiliated
box plants
– Integration of newly purchased Bird Packaging
 328-inch multi-fourdrinier recycled linerboard machine;
540,000 tons capacity; will represent almost 2% of N.A.
linerboard capacity in 2013.
 Basis weight range 20-35#; will trim 3-out to meet
modern corrugator requirements
27

28. WHY WOULD THEY DO IT?
 Separate what’s good for the industry from what’s
good for the company
 3% of the market, will be 6th, after PCA and Pratt
 5 mills; 1.1 million tons, mainly recycled (inc. Trenton)
– No virgin liner capabilities
– Machines are narrower, slower, older
– Will trim only 2 or on some just 1 roll for 98- and 110-inch
corrugators
– Highest cash costs of the top six
28

29. LIGHTWEIGHTS—SOME MIGRATION, NO
INFLUX…YET
 The Norampac machine is 12 months away—not too soon
for them to be developing customer opportunities and
marketing strategy
 Pratt is producing lightweight recycled liner and medium at
three mills, day in, day out
 Kapstone, Longview, Atlantic and others are marketing
lightweight grades
 Reports that additional companies are quietly running
lighter weights for specific customers
 Some Europeans would love to find a way to serve the US
market.
29

30. LIGHTWEIGHTS–TAKEAWAYS
 The case for lightweighting
 Technological considerations
 Lightweights are mainstream in Europe
 The pull of global CPGs and retailers
 Virgin versus recycled—who wins?
 Will Norampac be the first or the only?
30

31. We Can Do It Better!
QUALITY AND CONSISTENCY

32. WHY SHOULD I BE INTERESTED?
 Continued consolidation-reduced supply
 Containerboard price fluctuations coming
 International companies buying in Europe
 Elevated combining and converting technologies
new flutes M, R, S, and T
 Methods to evaluate sheet suppliers
 New packaging designs
 Prepare for shelf and retail ready packaging
 Financial savings could be substantial
32

33. QUOTE FROM GENERAL MILLS
 “…We realized that most of that innovation that
was happening was coming from small
companies.”
 “Most of the innovation is also happening
outside the U.S”
 “We want to drive cost savings through a focus
on performance needs.”
Joe Piton , Buyer, FBA 2012 Annual Meeting
33

34. WHY ULTRA LIGHTWEIGHTS?
 Europe linerboards tons <35# at 45% +
 US linerboard tons below 35# at 17%
 European paper making and combining highly
sophisticated
 Australians are here, Europeans are coming—
fifteen years ahead of us
 Cost effectiveness and sustainability
34

35. RECENT INDUSTRY HEADLINES--USA
 Converting plants energy self-sufficient
 Solar panel fields at RFC and Maxco
 OCC prices still high, wood unchanged
 Collection of OCC at 91%-an all time high
 Export of US OCC now over 40%
 Recovered fibre inclusion in containerboard
at 46%- all time high in US, Europe 85%
 Mills reduce fresh water usage, burn biofuels
35

36. WHERE ARE LIGHTWEIGHTS PRODUCED?
 Atlantic Packaging and Rock-Tenn Solvay
 IP Pensacola (all export) UFS machine
 SP Newsprint-GA
 Kapstone-NC and SC
 Converted SBS machines- KPAQ-LA
 Norampac (GreenPac) Niagara Falls
 Grupo Unipak Mexico?
 Longview Fibre: Port Townsend-WA
 On the drawing board-newsprint
 Imports?
36

37. Engineering Parameters for 20# Linerboard-a working document
Unit BEST TEST TAPPI
of IN LINER TEST Longview KPAQ SP KapStone Greenpac Rock-Tenn
Measurement CLASS 2 PROCEDURE Newprint Solvay
PHYSICAL PROPERTIES
Moisture Content Percent T-412
target 8 8 7 7 8 7
CD variation +/- 1.5 +/- 2.0 +/- 1.5 +1.75/-2.6 nr
moisture streak
Internal Bond (Z tensile) 0.001 ft lbs/in2 138 100
Cobb (sizing) T-441
Top 2 minute min/max g/m2 32 28 50 and 105 30 and 65 50 25 and 70
Bottom 2 minute min/max g/m2 TBD 112 50 and 105 30 and 65 50 35 and 75
Smoothness- Sheffield units 280 TBD T-538 360 target 390 365
Porosity-Gurley sec/100 cc 50 36 T-460 50-200 18 20
Burst- Mullen lb-f/in2 67 31 T-807 60 55 45 60
RC lb-f/6 in or units T-822 36 25
STFI 11.4 6.9 T-826 11.5 12.5 9.5 12.6
MD Slide Angle degrees 18 min TBD T-815 26 target 20 25
MD Tensile Strength ft-lbs/in 58 TBD T-494
CD Tensile Strength ft-lbs/in 29 TBD T-494
MD Stiffness ft-lbs/in 5543 TBD T-494
CD Stiffness ft-lbs/in 2229 TBD T-494
MD Tear gf TBD 1.61 T-494
CD Tear gf TBD 2.26 T-414
Luminous Reflectance L value TBD TBD T-414
Hard Caliper 0.001 inches 5.1 7.6 T-411 6.5 6.2
Basis Weight #/msf 20 T-410 20 +/- 1# 20.5 20.5 20
Scuff # strokes TBD TBD target 30
Wax Pick Dennison # 16 TBD T459
Dirt mm2/m2 TBD TBD T-563
Date of document 2/18/2011 RAY RAY 1/1/2012 1/14/2011 5/11/2012 6/15/2012 TBD TBD
© 2012 Association of Independent Still In
Corrugated Convertors develop-ment
37

38. Single Stream Waste Headed Where?
38

39. NEW FIBRES TO NORTH AMERICAN CONTAINERBOARDS
 Sugar Cane
 Ground wood (newsprint)
 Eucalyptus
 Hemp
 Northern European hardwoods
 Mixed office waste with coatings
Challenges to waste paper dealers,
 papermakers, combiners, converters, and
corrugated users
39

40. LEADING EDGE CORRUGATOR TECHNOLOGY
 Automatic web tension controls
 IR temperature sensors at six locations
 Crews, quality personnel, or lab technicians that
conduct temperature audits every shift.
 Moisture sensors at two locations and a
manual moisture analyzer for combined board
at the dry end of the machine
 Speed sensitive warp arm adjusters on the
preheaters and preconditioners.
40

41. LEADING EDGE CORRUGATOR TECHNOLOGY
 Precise glue applicator gravure rolls.
 Containerboard from only two paper machines
with specific fibre length and sheet formation.
 Automatic load controls on the double facer
 Concise recipes (machine settings) for each
board combination
 Controls to monitor and adjust adhesive
temperature and viscosity
41

42. STATE OF ART: CONVERTING
 Three minute change anilox rolls
 Ink control systems: now temperature
 Bobst PolyJoiner, AMS’s Tri-Feeder
 New prefeeder systems
 Lighter weight back anvil covers
42

43. STATE OF ART: CONVERTING
 Flexos 15,000-20,000 blanks/hour
 Continuous run, set up while running
 Non-crush converting-Emba and others
 Robotic bundle handling-Automatän
 Optical scanners: adhesion and slots
43

44. SHELF-READY AND RETAIL-READY PACKAGING
Courtesy of Mid-Atlantic Packaging
44

45. REQUIRES INNOVATION AND REDESIGN
 Doublewall: E/B, B/B, E/E, E/F
 Design for smaller boxes, boxes with master
pack, RRP, SRP, counter displays, headers
 Faster merging of small flute and folding carton
applications
 Greater opportunities for small flute now that
emerging containerboards are available.
 Carton within a carton
45

46. CHALMERS TORSION TESTER
46

47. AICC EDUCATIONAL RESOURCES
47

48. THIRD EDITION: END USER NEEDS
48

49. STAYING INFORMED
49

50. EDUCATIONAL RESOURCES
50

51. RESOURCE: 2ND SCIENCE OF PAPER SCHOOL
51

52. EVEN MORE RESOURCES
52

53. It’s All About Crushing the Board
MD TORSIONAL STIFFNESS AND BOX
PERFORMANCE

54. WHAT DOES THIS RAILWAY BRIDGE…
…AND A PIECE OF CORRUGATED BOARD HAVE IN COMMON?
54

55. CORRUGATED BOARD
Caliper
Bending Stiffness = Tensile Stiffness of the
Liners x Board Caliper²
55

56. MD TORSIONAL STIFFNESS
Why is MD Torsional Stiffness Important?
1. MD Torsional Stiffness is a measure of the
“Structure” of the whole board but especially
the flutes
2. MD Torsional Stiffness failure leads to Bending
Stiffness Failure
3. Bending Stiffness Failure leads to Compression
Failure
4. Compression Failure leads to Box Failure
5. Box Failure leads to very unhappy clients
6. If you don’t measure it you can not control it
56

57. WHAT PROPERTY BEST DEFINES ‘STRUCTURE’
MD Torsional Stiffness
Unstrained board flute profile
Liner movement indicated by arrows
57

58. MD TORSIONAL STIFFNESS
There are three important times when you need
to know about MD Torsional Stiffness
1. When you are making it
2. When you are destroying it
3. When you are guaranteeing your box
performance
58

59. MD Torsional Stiffness Testing
An easy and accurate way to measure MD Torsional
Stiffness using a natural resonance technique
59

60. BUILDING IN TORSIONAL STIFFNESS:
CORRUGATOR INFLUENCES
 Selection of liners and mediums – type, quality, basis weight
 Corrugating temperature, moisture, friction, drag
 Corrugating rolls – profile, size, wear
 Glue application – film thickness, evenness, quality
 Adhesion – pressure roll, tack development, temperature
 Pressure rolls during drying
 Slitting
 Feed rolls anywhere
60

61. CORRUGATOR LABYRINTH – THE CONVERTOR’S INPUT
61

62. FLUTE PROFILE
 C4 more triangular than C2
 C4 better bracing, higher MDTS
 Lower ECT and takeup factor (TUF)
62

63. FLUTE SHAPE EFFECTS
--------------MDTS bpi----------------
Construction, #s Construction, grammes Model est. C2 C4 ECT C2 ECT C4
36/31/36 K175(D150)K175 14.4 12.2 16.1 6.1 6.2
42/31/39 K205(D150)K190 15.6 13.3 17.9 7.0 6.1
42/31/42 K205(D150)K205 16.1 13.3 19.3 6.9 5.7
42/39/39 K205(M190HP)K190 21.2 17.7 23.2 8.1 8.0
42/39/39 K205(M190HP)K205 21.6 17.8 23.4 8.6 8.2
Averages 17.8 14.9 20.0 7.3 6.8
% Differences -16.4 12.4 -6.8
C4 is 34% Stiffer than C2
63

64. CORRUGATING ROLL WEAR – C FLUTE
14
13
12
New module BPI
11
BPI and ECT
10
9
8
Worn module
7
6
5 ECT
4
9-Nov 19-Nov 29-Nov 9-Dec 19-Dec 29-Dec 8-Jan 18-Jan
64

65. PERFORMANCE – BASIS WEIGHT VS. TORSIONAL
STIFFNESS MEASURE
180
160
140
120
100
80
60
40
20
0
Combined Basis Box Performance
Weight (#s/MSF) Index (BPI)
Lightweight B/C DW
96.3 14.2
(24.6/16.4M/16.4M/18.4M/20.5)
Standard B/C DW
159 15.3
(42.0/23.0M/29.0/23.0M/42.0)

66. B/C DW – PITCH RATIOS
BC flute with conventional pitch ratio of 11/9
BC flute with adapted pitch ratio of 4/3
BC flute with adapted pitch ratio of 3/2

67. TYPICAL IMPROVEMENTS ON CORRUGATOR USING
MD TORSIONAL STIFFNESS
Kiwi Fruit Board Grade BPI Comparisons
# Paper Make up Comments BPI
1 DCK170(M190HP)K175(D115)K230-BE 2011 Grade 31.6 CONTROL ML's MB's
2011 Exisiting B SC adds 9.2% BPI ambient even
2 DCK170(SC180)K135(D115)K230-BE 34.8 9.2%
flute Rolls after reduction of middle liner.
New B fresh rolls (no flank or
New B flute Rolls 6.6%
3 DCK170(SC180)K135(D115)K230-BE 37.1 profile change) adds a further
13.3.12 (14.8%)
6.6%
4 DCK170(M190HP)K175(D115)K275-BE 2011 Grade 31.4 CONTROL I T's
2011 Exisiting B SC adds 9.2% BPI ambient even
5 DCK170(SC180)K135(D115)K275-BE 34.8 9.8%
flute Rolls after reduction of middle liner.
New B fresh rolls (no flank or
New B flute Rolls 14.3%
6 DCK170(SC180)K135(D115)K275-BE 40.6 profile change) adds a further
13.3.12 (29.3%)
14.3%
Ian, i'm sending this to you in confidence. F.Y.I. and you may find interesting. The calipers have also
increased & ECT only marginally. M
The xls is pretty self explanatory but we have 3 sets of figures from numerous tests Dec '11 though to last
week in 4'12 comparing old 2011 CONTROL & failing Kiwi Fruit Trays to new Semi Chem data & recently
new B flute rolls installed 13.3.12 ..NOTE the new B flute is not a new flank clearance/profile/T//Up its just
a straight replacement.
Without knowing the MDTS, these impressive
improvements would not be identified
67

68. BOARD PROPERTIES VS CRUSH
68

69. C FLUTE CRUSH VS MDTS AND CALIPER
100
90
Caliper 2
R = 0.9627
80
70
60
Vaule (%)
50
DST
40
30
20
R2 = 0.9903
10
0
0 5 10 15 20 25 30
Crush (% )
69

70. MDTS BEFORE & AFTER CONVERTING - USA
16
14
12
10
DST (bpi)
8
6
4
2
0
C1 C2 C3 C4 C5 C6 C7 C8 C9 C10
Sample Number
100
80
DST % Retained
60
40
20
0
C1 C2 C3 C4 C5 C6 C7 C8 C9 C10
Sample Number
70

71. USA DATA
DST (bpi) Caliper ECT % Change board to box
Sample Flute Board Box Board mm Box mm Board Box DST Caliper ECT
1 C 11.02 6.96 4.34 4.06 66.84 51.03 -36.8 -6.4 -23.7
2 C 5.74 3.32 3.89 3.63 36.32 33.65 -42.2 -6.5 -7.4
3 C 14.28 11.58 4.17 4.19 50.14 50.42 -18.9 0.6 0.6
4 C 9.16 1.5 4.04 3.73 40.86 37.81 -83.6 -7.5 -7.5
5 C 8.52 7.52 3.96 3.99 37.8 34.52 -11.7 0.6 -8.7
6 C 8.28 5.52 4.14 4.09 48.48 49.69 -33.3 -1.2 2.5
7 C 6.86 6 3.81 3.78 33.84 33.99 -12.5 -0.7 0.4
8 C 11.68 7.24 4.11 3.97 45.1 42.7 -38.0 -3.5 -5.3
9 C 10.52 7.62 4.11 3.99 48.81 43.76 -27.6 -3.1 -10.3
10 C 10.06 4.84 4.16 3.86 47.3 41.4 -51.9 -7.2 -12.5
Ave 9.6 6.2 4.1 3.9 45.5 41.9 -35.7 -3.5 -7.2
Min 5.7 1.5 3.8 3.6 33.8 33.7 -83.6 -7.5 -23.7
Max 14.3 11.6 4.3 4.2 66.8 51.0 -11.7 0.6 2.5
71

72. HOW PRINTING AFFECTS CRUSH
72

73. TCY40 PRINTER
After gap adjustments
16 Corri
Increase in MDTS = 35.6% Caliper
mm
14 13.5 13.6 13.6 13.6
Corri BPI
12.2
BPI
Log—Conv. Print Caliper 11.9
12
11.2
10.8
10 Conv
Exponential—Conv. Print BPI Plain
Caliper
7.9 mm
8 7.6
Conv
Plain BPI
6
Caliper
4.01
3.98
3.95
4.12
4.12
4.08
4.08
4.02
4.1
3.9
4.1 Conv
4 Print
Caliper
Exponential--Conv.
mm
Plain BPI
2
Conv
Print BPI
0
Feed ex Corrugator TCY 40 no setting 1st TRIAL increased 2nd TRIAL increased 3rd TRIAL decreased # 4th TRIAL decreased #
changes as we found it. Infeed rollers 0.75 to 1.7 stacker infeed from 7.5 1 print station Green 2.7 2 print station Blue 2.8 to
(not calibrated) BPI not to 9.0 to 3.5 3.2
recorded. Estimate
between 7.6 to 7.9
Trial Action
73

74. MDTS AND STACKING PERFORMANCE
74

75. EFFECT OF CRUSH
75

76. COST SAVINGS MODEL
Medium Offset
Actual = tested DST ALTER board grades & prices Use -5.057
lbs to gsm x = 4.882 RF -5.057
SC -2.057
USA Board Grade - C Flute
Cost/1000ft² DB Medium SF Actual Theory DST
Old Board $ 27.44 Now 35 23 35 9 11.0
New Board $ 25.20 New 31 23 31 10.0
Cost Savings $ 2.24
Cost % savings 8%
Weight savings (lbs) 8
Wgt % savings 8%

77. WHO IS TESTING MD TORSIONAL STIFFNESS?
Australia Estonia Hungary Poland
Austria England Ireland Scotland
Belgium Fiji Italy Spain
Chile France Lithuania Sweden
Czech Republic Germany New Zealand Thailand
Denmark Holland Papua New Guinea USA
26
Australasia/Pacific
88 Europe
USA - ?
77

78. MD TORSIONAL STIFFNESS IS:
 The missing major strength property of corrugated board
 The property that tells you how well you make your board
 The property that tells you how badly you crushed your board
 The property that tells you how well your board will perform in
the service environment
 The property that leads to box failures in a stack
 The major property you need for quality control
 The property that allows you to optimize board grade
performance
78

79. IMPLEMENTING AN MD TORSIONAL STIFFNESS
PROGRAM WILL ALLOW YOU TO:
 Improve the quality of corrugated board off the corrugator.
 Improve the quality of finished boxes off the RDC/FFG.
 Reduce damage during conversion
 Setup a QC system to guarantee optimal performance
 Reduce board weight
 Shift money from raw material cost to the bottom line
 Reduce customer complaints
 Keep an eye on your competition
79

80. Rethinking Processes, Retrofitting Equipment
and a Better Way to Monitor Board
Performance
CONVERTING THE NEW
LIGHTWEIGHTS Sarilee Norton, President
Ralph Young, AICC Technical
Director
Randy Banks, President,
Sharp-International