Overview of cartonboard
We supply many of Australia and New Zealand’s most loved consumer brands with high-quality recycled cartonboard.
With over 50 years of experience in providing prompt, reliable service and delivering responsive cartonboard supply, Amcor works tirelessly to deliver the best cartonboard product to support the brand and packaging requirements of our customers.
Amcor supports a diverse range of markets, including:
- Frozen Food
- Dry Grocery Products
- Convenience Food
- Fast, Predictable & Reliable Supply
Amcor’s integrated systems and processes enable flexibility to meet changing consumer demands. The Jumbo reel storage facility at our Petrie site in Queensland provides a high security of supply to the Australian market. Product stockholdings are readily available to satisfy urgent demands and customer orders are despatched around Australia seven days a week.
When combined with our high Delivery in Full on Time and in Specification (DIFOTIS) record, Amcor’s cartonboard customers recognise real bottom-line benefits to their business, including:
- Lower inventories
- Improved supply chain integration
- No stock-outs
- Improved use of storage space
- Increased processing efficiencies
- Reduced waste
Amcor Cartonboard - What We Do
Amcor is committed to enhancing Australian and New Zealand consumer brands and delivering sustainable recycled cartonboard that supports the environment. With a wide range of cartonboard varieties to suit specific Folding Carton requirements, Amcor’s teams of dedicated Account Managers ensure our customers are not only provided with the best cartonboard possible, but with reliable, on-time supply.
Amcor’s range of cartonboard products includes:
- Artcote Grey Cartonboard
- Artcote White Cartonboard
- Artcote Kraft Cartonboard
- Starcote Laminating Cartonboard
- Unlined Boxboard
- Beverage Carrier Board
Key Account Management
Maintaining a commitment to the Australian market is of key importance – this is why we have a dedicated team of Key Account Managers to service the major Australian commercial centres. Our Key Account Management (KAM) process ensures we identify our customers’ needs, provide solutions and monitor outcomes.
We focus on adding value to our customers’ business through:
- Being the industry leader in gaining Environmental Accreditation to ISO 14001
- Supporting sustainable business practices including water, waste and energy reduction, as well as building an on-site Material Recycling Facility (MRF) at Petrie Mill
- Ongoing support of the Australian Recycled Cartonboard (ARC) program – which helps our customers to satisfy two of five compliance obligations under the National Packaging Covenant
- Maintaining a strong commitment to environmental sustainability by ensuring all wood fibre used for the manufacture of some cartonboard products is sourced from environmentally responsible sources
Customer Service Excellence
Amcor Cartonboard is committed to delivering excellent customer service. Our friendly, dedicated and experienced team is supported by sophisticated systems that enable customers to get immediate order confirmation and despatch information, as well as order progress tracking - from processing through to final delivery.
About Amcor’s Cartonboard History
Amcor’s Petrie Cartonboard Mill has been an important part of the Petrie community for over 60 years. With construction beginning in 1951, the mill was officially opened by Australian Prime Minister Rt Hon R G Menzies in December 1957.
Since that time, Amcor’s Petrie Mill has evolved thanks to many investments in state-of-the-art technology to ensure the Mill continues to produce world-class recycled cartonboard.
Cartonboard Production Process
The cartonboard manufacturing process has remained largely unchanged for many decades. Amcor’s recycled cartonboard production at the Petrie Mill adheres to world-class standards, which means our customers are supplied with a high-quality, premium cartonboard to suit the final folding carton format and application.
The cartonboard manufacturing process follows a series of steps, including:
The Wet End
This is the beginning of the cartonboard manufacturing process. Recycled and/or responsibly sourced virgin fibre is blended with water and then flows out evenly onto four separate continuous moving plastic fabrics to form the four plies of the cartonboard base sheet. Water is drained by gravity from the fibre slurry, through the moving fabric.
After all the free water has been drained from the fibre, the fabric passes over vacuum boxes to further remove water. The individual sheets (plies) are brought together one by one while still moist. A starch solution is sprayed uniformly between each ply to assist with ply bonding, to form the ‘web’.
The four layers of fibre are pressed together to promote consolidation of the sheet via a series of roll presses. The web is squeezed between synthetic felts, which transfer excess water by absorption from the web to the felt, further reducing the moisture content of the web from 80% to 50%. Water is removed from the continuous felt before it re-enters the press for another cycle.
The web (which is still very moist) then winds over 72 polished, steam heated cast iron cylinders - the surface temperature of which reaches 140 degrees Celsius. An open weave synthetic fabric presses the web against the cylinders which evaporates the remaining moisture. The dried web is now recognisable as carton board. Prior to coating, the board passes through a computer controlled calender to ensure uniform thickness across the web.
The board continues on from the dryers through three coating processes whereby pigmented liquid, similar to water based paint, is applied to improve the surface properties of the board for both visual appearance and print reproduction quality.
The coating process comprises three stages:
- Pre-coat - Similar to an undercoat, the Pre-coat is used to improve smoothness and prepare the board for subsequent coating
- Second coat - Delivers consistency in cartonboard opacity and brightness
- Final coat - Last coat of colour, which then passes through another soft calender to deliver extra gloss and smoothness
The cartonboard is then wound to form a jumbo machine roll. The Petrie Mill operates 24 hours a day, seven days a week, producing one 15 tonne jumbo roll every 40 minutes.
There are no standard sizes for cartonboard reels or sheets, as both carton design and the type of printing press used can vary for each finished carton. We process every order exactly to the nominated specifications of our customers.
Our large jumbo roll storage facility, which stores around 11 000 tonnes of cartonboard, enables the supply of all cartonboard products on either a weekly or fortnightly basis. This guarantees prompt and regular supply, as the buffer it provides allows the board making and finishing schedules to operate independent of each other.
Cartonboard can be delivered in two ways – either as sheets or in reels. The sheeters cut the cartonboard down from jumbo reel into the sheet size required. To ensure the cartonboard Amcor supplies is as specified and of the highest quality, the duplex sheeter has an in-built fault detection and ejection unit. The sheets are then palletised and shrink-wrapped for delivery.
The rewinder slits larger rolls into reels for customers who utilise cartonboard in this format. Each reel is stretch-wrapped for storage and transport.