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The corrugated industry has always cooperated with the truck and rail committees to help develope package requirements for the safe shipment of goods on common carriers. The original Rule 41 and Item 222 are examples of this joint effort. They became the systems we've known for years in which one of the elements of package performance and carrier compliance was measured by using the widely recognized "mullen" or burst test. In recent year's changes in unit loads, truck size and warehouse heights have caused an increased awareness of and an emphasis on, the stacking strength of corrugated boxes. A better, more efficient way of measuring box performance was needed-not because boxes were failing excessively, but because the shipping environment had changed extensively. To meet this need for a better performance measure, the corrugated industry trade associations worked with representatives of the rail and truck committees to develop alternate Rule 41 and Item 222. Because the alternate proposals included an optional use of different containerboard properties, the American paper Institute also provided some very important input. Everyone agreed that the compression strength of combined corrugated board, as determined by the "short-column" or "edge-crush" test, was a way to more accurately determine the performance of corrugated containers in the real-world shipping environment. HOW ARE ALTERNATES RULES DIFFERENT As the mullen test established a minimum burst strength for containers accepted under the original carrier rules, ECT testing established a minimum edge crush value for corrugated containers under the alternate carrier rules. The fundamental difference is that, under the original rules, a minimum combination of liner basis weights was required. Both the original rules stipulated this through a requirement for "minimum combined weight of facings." Under the alternate carrier rules, the requirement of "minimum combined weight of facings." Has been eliminated. Basis weight still exists, but it is not a requirement for compliance using the alternate rules. The alternates determine compliance in part by the minimum "edge crush" (ECT) value certified on the box stamp in pounds per inch width versus the original carrier requirements for burst strength or "mullen" in pounds per square inch. HOW WERE THE EDGE CRUSH VALUE DETERMINED? Two separate test were conducted by the Institute of paper Science and Technology -- the first in 1982, the second 1989. These tests established average edge crush of most upgrages of conventional corrugated board. They were conducted nationwide using sample containers submitted by independent and integrated corrugator and sheet plant. In both 1982 and 1989, the average test values reported were virtually the same. Additionally, to assure mathematical accuracy, the industry had the 1989 figures analyzed and extrapolated by professional statisticians at New York University. The results are as shown below:
DO I HAVE TO USE THE ALTERNATE? No. First and foremost, the alternate rules are just that. They are available for the use at the boxmaker's or box customer's option. Converters can continue to manufacture, test and certify corrugated containers using conventional raw materials which meet the requirements for box and content weight, united inches, combined minimum weight of facings and mullen test complying with the original carrier regulations. If you or your customer make this choice, then nothing changes. WHY WOULD I WANT TO USE THE ALTERNATE? Use of the alternate rules can benefit the customer, the converter, the corrugated industry and the environment. Edge-crush compliance allows for greater flexibility in liner and medium combinations, which achieve more efficient package design and still attain the desired performance. Boxmakers and their customers can thus comply with shipping regulations and use lighter-weight materials. HOW WILL USING THE ALTERNATE RULES HELP THE ENVIRONMENT? There is considerable public interest in the environmental issue concerning reclamation, recycling, recycled materials and solid waste source reduction. Stricter landfill regulations exist or are being developed in many states. Federal, state and local governments are genuinely concerned about the need for an improved environment. The corrugated industry can be proud that for years it reclaimed and recycled its product long before it became environmentally fashionable. The alternate carrier rules enhance this further by allowing the use of lighter-weight materials that still provide box performance. Also lighter materials with an increased content of recycled material mean corrugated packaging becomes even more environmentally friendly. Less new wood fiber and less solid waste. WHAT ARE HIGH PERFORMANCE LINERS? Simply stated-"High Performance Liner" has a ring crush value equal or greater that twice its own basis weight. Ring crush is a measure of "liner stiffer" obtained by compressing a circular sample of linerboard to point of failure. High ring crush liners used to manufacture combined board give higher ECT values and produce lighter material. MUST I USE HIGH PERFORMANCE MATERIAL TO COMPLY WITH THE ALTERNATIVES? No. All tests run in 1982 and 1989 to determine average ECT values were performed on ordinary commercially produced boxes comprised of conventional raw material. In other words, boxes which had met carrier requirements for bursting strength were used to determine average edge crush values. WHY WOULD I WANT TO USE HIGH PERFORMANCE LINERS? You and your customer may determine that packages you've designed can provide satisfactory product protection and offer possible economic advantage using high performance material. WHAT IF THE ALTERNATE RULES DON'T WORK? We believe they will work because of the positive results of the test run in 1982 & 1989. Boxmakers, in cooperation with their customers, will determine through proper design and testing which rules will apply to a given product's packaging and shipping needs. Remember: use the alternate carrier rules in optional. INDUSTRY MONITORING The corrugated industry has formed an ad hoc committee composed of representatives from both carrier and committees, the American paper Institute (API), the association of Independent Corrugated Converters (AICC), the Fibre Box Association (FBA) and the institute of Packaging professionals (IOPP) which can, if needed, monitor the shipping performance of containers using the alternate rules. SUMMARY Much thought, time, effort and money has been invested in the development of the alternate carrier regulations. Their use can offer opportunities for innovative package design. They will result in more efficient corrugated packaging without sacrificing safe transit. Additionally, the use of "lighter" high performance material or lighter regular grades containing a higher percentage of recycled material will result in the industry helping fulfill an important civic responsibility. |
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