As for the type of base paper used, it is rarely decided solely by the carton factory. Instead, several factors influence the choice, including the characteristics of the product being packaged (such as the quality of its contents and the duration of use), transportation conditions, the customer’s business philosophy, and their approach to cost control. These elements collectively determine the quality requirements of the selected base paper.
In some cases, low-end or low-margin products only require the use of lower-quality base paper in order to keep production costs down and maintain a small profit margin. However, this can introduce challenges during the production process. For example, if the coating on the white board is poor, printing large areas of blue or green flat tones may result in mottling—where the fibrous structure of the underlying pulp becomes visible due to uneven ink coverage.
To address this issue, one solution is to apply a diluted ink set first on the printing press, which acts as a base layer to cover any uneven spots on the paper surface. This not only helps improve the gloss of the printed image but also reduces the amount of ink needed, making the process more efficient and effective.
Another common problem arises with white paperboards that have weak surface strength. During printing, these materials are prone to dusting, blistering, or delamination, which can negatively impact both efficiency and final print quality.
To mitigate these issues, several strategies can be employed. First, adjust the ink viscosity using a flushing agent to ensure it's suitable for the paper. Second, use the lightest possible printing pressure to minimize damage to the paper's structure. Third, reduce the machine speed slightly to lessen the force that ink exerts on the paper during the printing process. Fourth, arrange the color sequence logically—start with smaller layouts and lighter ink before moving to larger, heavier ones. Fifth, consider air-pressing the sheet or using an over-water technique to help stabilize the print. Finally, for papers with poor surface strength, consider using flexo printing, which typically uses lower-viscosity inks compared to offset or embossing methods. For products with limited printing areas, this adjustment can significantly reduce the risk of dusting, blistering, or delamination.
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