_CB Materials - RI Guide

Guide for Trading and Suppliers Edition: 1 Issued by: Packaging Leader Trading Approved by: Packaging Specialist IoS Date: 2013-02-25, Ed1 Valentin Negru Magnus Johansson

Receiving inspection for converted corrugated cardboard

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Receiving Inspection for CONVERTED CORRUGATED CARDBOARD

Purpose and Scope The purpose of this guide is to secure compliance towards requirement IOS-P-0010 from 2012-10-19, version no: AA-171373-11, appendix B 12.2.5 and ensure a common quality improvement process at Suppliers. Note: the text in black letters is copied from IOS-P-0010, the text in blue letters contains the guideline support to perform a good receiving inspection Overall responsibilities Each incoming delivery of converted corrugated cardboard shall comply with these assessments. Each inspection shall be documented. Note: Passing the inspection does not replace the requirement for the unconverted corrugated board in IOS-P-0010. IKEA supplier is responsible to perform the below described controls. Trading technician needs to agree with IKEA supplier about frequency of inspection (Based on results from previous inspections, evaluation of sub-suppliers, nonconforming materials in production and Customer feedback. ). It is mandatory to control every production batch. IKEA supplier have to secure the proper place to cut the samples from the converted corrugated cardboard sheets and perform all describe control. Optimal is to organize place (similar or use the same as for final control) in normal office conditions and light up the surface with normal light (500 lux, daylight colour). Receiving inspection control 12.2.5.1 Weight assessment The weight in g/m2 shall not be less than 95% of nominal value. This can be measured by comparing dry weight of the samples to the nominal dry weight according to SD or by conditioning the samples and compare with nominal weight according to SD. Dry weight (g/m2) for each quality used for IKEA products is measured within 5 minutes after drying for 6 hours in 103C. CLARIFICATIONS: Nominal value is the value that the supplier states as correct in the Self Declaration, based on test report from approved Test Laboratory. The reference samples weight shall be the nominal value, it should be same as stated in the SD, if the conditioning is done with the same parameters (see ISO-187 conditioning)



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If supplier cannot secure these parameters, conditioning needs to be done in a normal room climate and 24 hour should be enough, supplier should make sure that the air has access to all sides of the board. Supplier shall condition at the same time, both the reference sample and the new shipments to be inspected each time( 5 pieces, each having the same size as reference sample, recommended size min 1 sqdm) due to the humidity variation. For example, if supplier measure the reference sample weight after conditioning and the result is 300 g/sqm, then supplier shall compare the weight of converted cardboard received from CB producer(average weight of the 5 pcs), with this weight. The result of control is positive if the weight is not less than 285 g/sqm: (- 5%) Note: Reference samples shall be refreshed when needed, as a minimum yearly. Equipment: Laboratory balance with controlled weight tolerance +/- 0,001 gram

Picture 1 Laboratory balances examples

Dry weight test should be done in case there are deviations from the nominal value checked as above, or if supplier wants to do the test faster (Note: dry weight method is also more precise) Equipment: Preferred laboratory oven with controlled temperature tolerance +/- 1C

Picture 2 Laboratory ovens examples

CLARIFICATIONS: Nominal value is the value that the supplier states as correct in the Self Declaration, based on test report from Test Laboratory. The reference samples weight shall be the nominal value(Dry weight), same as stated in the SD. For example, if supplier states in SD that the Dry weight nominal value is 300 g/m2, then supplier shall compare the weight of converted cardboard received from CB producer (dry 5 pieces and calculate average), with this weight. The result of control is positive if the weight is not less than 285 g/m2: (-5%)



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12.2.5.2 Compression from conversion Check the compression from conversion. The compression caused by conversion shall be less than 0.3 mm, calculated from nominal value, see Figure 90. To check, cut the board cross flute more than 50 mm from a cut edge or from a fold.

Picture 2 Figure 90 Example of flute deformed by compression

1. Reference flute Shape OK 2. Deformed flute by compression Shape Not OK, flute is leaning.

Picture 3 Corrugated cardboard construction

CLARIFICATIONS: Compare the thickness of reference sample (should be the same as SD, based on Test in laboratory) For example, for IKEA Quality CB30, if the reference sample thickness is 2.92mm, the result is OK if thickness of converted cardboard received from CB producer is 2.62-2.92



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Way of control: It is recommended to measure minimum 5 pcs and take the average result as the figure to compare with the reference sample thickness. Cut the samples minimum 50 mm from the edge or fold. Small size (e.g.10x10mm)

secure that the sample will be perpendicular to the measure tool. It is important to measure thickness on the flat surface of the liners.

Picture 4. Ends of proper tool to measure CB thickness

Equipment: It is important to measure with a proper instrument in order to obtain correct values (make sure the CB is not crushed and apply pressure is correct). Dial gauge micrometer is recommended

Picture 5 OK, Sample shell be perpendicular to the measurement tool Picture 4 Not OK can damage CB

Not OK OK



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Compression on one side of the converted board only, as seen in Figure 91, is not acceptable.

Picture 5 Figure 91 Skewed stack from compression Picture 6 Proper shape of UL with flat sheets of CB

(Not OK) (OK)

CLARIFICATIONS: Figure 91 from specification imitates the unwrapped pallet with components (corrugated cardboard boxes or flat sheets). When controller during the receiving inspection removes the UL packaging shall observe if the sheets of CB are not skewed on one of the UL sides. Often this is the result of the wrong conversion process or ULs handling e.g. pallet overload by stacked second layer of pallets in truck or during free stacking in warehouse. 12.2.5.3 Visual surface test Compare the cardboard in the packaging with the reference sample. There shall be a good resemblance. Examples of what to look for are: Deformations (see Figure 93) Shape of core, and extent of washboard

Picture 70 Reference sample ` Picture 81 Controlled sample - Not OK (washboard surface)

Washboard surface is paper wrinkles on the fluting direction of CB, caused during manufacturing process and are affecting the strength of the CB.



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Picture 92 Deformations on the board

Type and quality of paper Structural differences between reference and sample

Picture 113 Reference sample

Controller can see the structure difference on the 2 pictures. The controlled material shall have the same structure & colour as reference sample. Light up the surface with normal light (500 lux, daylight coloured) from 1 meter with the light source directly above the converted package. The test is passed if the sample has no visible washboard, when observed from 1 meter.

Folding line made by purpose during conversion

Damages made during e.g. handling of sheets

Picture 10 Controlled sample with failed control due to the different colour and structure then reference sample = Not OK



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12.2.5.4 Correctly cut The cut board shall be cut parallel or perpendicular with the flutes. A maximum deviation of 3 mm/m is acceptable, if not the cut pattern states otherwise.

Picture 125 Maximum board cut deviation

Picture 136. Box converted perpendicular to the flute direction

Check if the box shape is converted perpendicular to the flute direction.



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12.2.5.5 Water absorption for corrugated cardboard This is a field test intended to indicate if the corrugated cardboard has good enough quality. To make a complete test, follow the test method according to ISO 535. Add 5 ml water to the surface of the corrugated cardboard, see Figure 94. Wait 90 seconds; Check if the water is still on the surface, or if the liner has absorbed the water, see Figure 95. Remove the water and check if the corrugated board surface has been wetted by the water. Check both the outside and inside of the top liner. Tear the top liner to check the inside. Scratch the surface and control if the top layer comes off. CLARIFICATIONS: Control can only predict whether the sample is close to IKEA requirements; Controller in case of any doubt should judge it as non-compliant control sample. The following diagram and pictures show the pattern of conduct during the control:

Picture 147 Diagram of water absorption control

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_CB Materials - RI Guide