The Best of Both Worlds Gets Better

Still-smaller flutes and sophisticated print capabilities strengthen microflute's ability to perform double duty.

By Jessica Millward

For the past several years, microflute corrugated's marriage of structural strength and high-quality graphics has proven to be a match made in packagers' heaven. With the development of E- and F-flute boxes in the '90s, the line between folding carton and corrugated converters was blurred, and customers reaped the benefits. Time, and technology, marches on, however, and the microflute industry has kept pace with the evolution of still-smaller calipers and new ideas about printing.

The small flute segment comprises roughly 9 percent of total corrugated shipments in North America, according to Bob Nebeling, product business manager of corrugator equipment at the Bobst Group. He also reports that the annual growth rate of mini-flute applications is between 12 percent and 15 percent. It's clear that microflute is a growth market, but what isn't so clear is precisely what shape that growth will take. While the largest share of production continues to belong to E- and F-flutes, the introduction of N- and G-flutes may change statistics in the years to come.

Under the ‘micro'-scope

N-flute substrates, typically run on Asitrade sheet-to-web machines, possess 90 percent more flutes per foot than E-flute and 42 percent more than F-flute. As Nebeling observes, N-flute's folding, forming, and handling characteristics are much closer to carton board than E- or F-flute. In addition, using N-flute material significantly increases stack density (See chart).

Innovative Packaging Corp. (IPC) introduced the United States' first G-flute material, called GrafXflüt™, in December 1997. Measured at 178 flutes per lineal flute, it is similar in structure to N-flute, but is produced on a wide-web corrugator and uses starch as an adhesive on both sides. Dave Stucker, V.P. of sales and marketing at IPC, asserts with its opportunities for high-end graphics as well as embossing, G-flute "produces … a design breakthrough for the POP and folding carton industries."

Unfortunately, with more flute profiles on the scene, the problem of misidentification arises. Industry-wide standards have not been established, so F-flute = F-flute does not always hold true. The most accurate measure of any stock is its number of flutes per lineal foot.

The general rule of thumb holds that E-flute has approximately 90 flutes; F-flute, about 128 flutes per foot; and G- and N-flutes count 178 per foot.

Print prowess

As the development of microflute continues into its second decade, the question of its optimum printing process remains unanswered. For many printers, litho-laminating is the method of choice. Inland Consumer Packaging's litho-laminate system employs a three-ply process combining a kraft back liner and medium with a solid bleach sulfate top liner. Bruce Grube, Inland's senior V.P. of consumer packaging, maintains, for microflute, "lithography is still the highest-end printing process."

Other converters extol the economic virtues of offset direct. At last April's CMM/PPC Mini-Flute Seminar, Calumet Carton's Ken Roush cited faster turnaround and better registration with offset direct. He further argued Calumet's offset-direct-printed Micro-Corr® packaging requires less expensive printing plates than flexo.

Thinking inside the box

Despite the debate on printing processes, suppliers and converters in the industry readily agree on the vast quantity of successful applications for microflute substrates. The construction accommodates a broad spectrum of box styles, from clamshells to tuck-end cartons. With the ability to serve as both a shipping container and a POP display, Stucker points out, microflute translates into "a package design that incorporates marketing, protection, and shelf display attributes with a single medium."

Tom Grinnan, director of marketing for Mebane Packaging, notices "microflute seems to be catching on primarily in food … and in high-end cosmetics. The graphics and protection which microflute offers cannot be obtained by other packaging materials."

The rapid growth of computer software and hardware bodes well for microflute, believes Bob McQueen, marketing manager at Crown Packaging. Diamond Packaging's Lisa Palvino, director of marketing, remarks that toys are her company's largest growth segment.

With its versatility, microflute corrugated sales representatives aren't hard-pressed to create a pitch. Grube states Inland's sales staff underlines the dual virtues of strength and quality. Diamond Packaging emphasizes the reduced "time to market" involved in using microflute packaging. McQueen stresses the product specificity achieved with microflute stocks.

The rise of the wholesale store has necessitated the creation of shipping items that are as appealing as they are practical. Likewise, even shoppers in more traditional stores have less time for product selection, making graphically enticing packaging a must for viable manufacturers. Microflute corrugated—with a corrugated box's strength and a folding carton's printability—continues to deftly handle the double duty.