There are various terms for the standard case, 0201, RSC, OPT etc., see the Notes on Case Code Terminology for further details. This design is the most popular because it is the most board efficient and cost effective. Again, see Most Economic Size Ratios for various Designs for further details.

The required Internal sizes of a pack should normally be what is specified to a supplier. The supplier will add allowances relating to the board's caliper to give a bend-to-bend, manufacturing size. The internal dimensions of a case should always be shown in the following way:

Length x Width x Depth.

is the longest side in the opening, usually in the flat plain.
is the shortest side in the opening, usually in the flat plain. (sometimes also termed Breadth)
is the measurement from the top of the opening to the base, usually in the vertical plain. (sometimes also termed Height)

1ST WAY SIZE: The size of a piece of board that relates to its flute direction.

2ND WAY SIZE: The size of a piece of board that relates to its cross flute direction.

C.A.D.: Computer Aided Design

Canners flaps: 0204 with gapping inner flaps missing 50% of can diameter. This is permissable in some exort regulations.

CHOP: This is the second way size of a board, that the manufacturer's Corrugator produces. It is also sometimes used as another term for 2ND WAY SIZE.

CORRUGATOR ADHESIVE Corrugator adhesive is made from a corn based starch formula.

CRASH LOCK- 0711 type glued base flaps.

DEAD LAY: This term relates to die-cut packs. Dead-lay means that the pack's Gross size does not have machine trim. Usually this will be in the 1st way, since it is the 1st way that will have the most accuracy. The advantages of running dead lay, on a specification, are that it reduces the board area used, so reducing cost. It also reduces the amount of waste going through the factory, so lowering our waste levels. The disadvantages of running dead-lay are that the edges of the blank are less accurately cut and so make-up problems can result. Also either the "bird beak" on the a rotary die-cutter or the gripper bars on a flat-bed die-cutter can cause damage to the lead edge of the pack.

DECKLE: This is the first way size measurement, across the manufacturer's Corrugator. It is also sometimes used as another term for 1ST WAY SIZE.

Die-Cut: A production process whereby packs are produced with the aid of a cutting-die, using a stamping process. This can be either flat-bed or rotary. This is usually used to produce either the more complex shaped designs, such as a FEFCO 0427, or to provide greater accuracy. There is normally tooling costs and greater running costs involved with die-cut designs.

ECT: Edge Crush Test. One of the standard test methods for finding the column crush strength of a grade of board. Please see ECT Testing for further details.

FLANGE: The flange is the area of board attached to panel 1, which is joined to panel 4 in manufacture. It is also known as the manufacturers joint. The standard case flange size should be a minimum of 30 mm.

cutting-die: The word cutting-die usually relates to the cutting tool used on a die-cutter. However, the cutting-die usually consists of more than one part. They are usually made from plywood and have steel cutting and creasing rule, fixed into a cut into the wood.

GLUE LAP EXTENSIONS: The purpose of glue lap extensions is to strengthen the joint of a glued case. They are typically used for all glued cases, particularly those with a depth less than 300mm. Glue lap extensions should not normally be used in any case, in the following instances:

  1. It has an outside glue flange.
  2. It has fully overlapping flaps (0203 style).
  3. An 0214 style top flap is used, in which case use extensions on the bottom only.

  4. Most die-cut cases do not have extensions.

GROSS SIZE: This is the size produced by the manufacturer on their Corrugator and includes all of their machine trims.

KRAFT (usually shortened to "K") Kraft liner represents the top grade material in terms of appearance and physical properties used in the corrugated industry. These liners are in general made almost entirely from softwood pulp. Kraft liner is available in various forms i.e. unbleached kraft, bleached kraft, mottled kraft and white top kraft. Fully bleached kraft is rarely used these days. In the recent past the specification for kraft have also been loosened, so that a small percentage of recycled material can also now be included. This usually takes the form of re-pulped kraft liner or corrugated box waste. This waste is applied to the base ply of the liner. There are two advantages to this, namely it conserves fibre and closes up the sheet, decreasing it's perosity, which is an aid when used on any machines which pick up the board via vacuum suction cups.

Mottled Kraft and white lined kraft usually contain less waste, which is added for the same reasons as it is in the brown kraft liners. It is not possible to add larger percentages of waste, as this could affect the whiteness of the sheet. Bleaching of the top ply for these materials is often of the oxygen type, mainly for environmental reasons. Normal pH levels - 5.5 to 7. Generally the pH level of board itself is neutral, since we use a slightly alkerline starch.

NETT SIZE: This is the overall size of the opened, flat, finished pack. The first of the two sizes always denotes the flute direction and the second size denotes the cross flute direction. Hence, "first" and "second" way sizes, above. e.g. NETT SIZE - 400 x 1000 indicates that the flutes will run in the 400 mm direction.

NUMBER UP: The number of individual jobs contained within the board size. Typically this will be shown as one figure against the production machine e.g. Bobst - 6 Up, or as two individual figures related to the board size e.g.
NETT SIZE: 300 X 300

GROSS SIZE: (2 Up) 625 X (3 Up) 917
n.b. Obviously this includes machine trims.

PANELS: A standard case has four panels, which are numbered away from the flange. Panel 1 being the one nearest the flange.

Push Lock or Press Lock - 0216 type base.

Reverse Flute Feed: The flute direction of the board fed into the machine is perpendicular to the machine's direction of operation..

SEMI CHEMICAL FLUING MEDIUMS (usually shortened to "SC") Semi chemical fluting is manufactured from hardwood pulp, with the inclusion of up to 35% of waste or other fibre. The waste material is added to allow a greater choice of types of wood sources to be used, plus conserve wood fibre.

STEREO: These are the printing "plates" used on many machines for the flexographic printing process, which is a relief type printing process; that is it uses a raised printing area. The stereo is flexible and is mounted around a "drum" on the machine.

Swift slots: Swift slots are angled on one side and have a corner cut out on the other, rather than being straight. This means that the inner flaps still hold the pack square, during filling, but the waste material is easily stripped on the die-cutter.

TEST (usually shortened to "T") The most common type of Test liner is a homogeneous material manufactured from 100% chosen grades of waste, e.g. from box plant off cuts and supermarket empty boxes. Obviously, the higher the proportions of kraft in the waste, the higher grade of test liner that is produced.

Although the surface finish of this type of Test liner can be good it is not quite up to the high standard of Kraft liner. Test liner is sized (with cooked corn starch) to a level similar to Kraft, but it is more prone to cracking. The compression component of Test liner approaches that for kraft, but the Burst level is considerably lower. Test liner is widely used as an alternative to Kraft for the inner lining of corrugated board but it can also be used as an outer liner when appropriate. Care should be used in using Test on both facings of a case, if the pack is likely to be subjected to a high or continually changing moisture environment. Generally the pH level of board itself is neutral, since we use a slightly alkerline starch.

A special Test liner with an identical surface finish to Kraft is also made, this incorporates a Kraft outer layer and is used when a similar appearance to Kraft liner is desired. This is known as duplex Test. The outer surface of the Test liner can also be produced in a range of colours (White, Mottled etc. Bleaching of the top ply for these materials is often of the oxygen type, mainly for environmental reasons). Normal pH levels - 5.5 to 6.

WASTE BASED FLUTING MEDIUMS (usually shortened to "WB") 100% waste based materials, chemically reinforced with corn starch. Normal pH levels - 6.5.

Additional information can be found on the TalkPkg website, amoungest others