The Project Gutenberg eBook, How Paper Boxes Are Made, by Robert Francis Salade

How Paper Boxes
are Made

A PRACTICAL AND INSTRUCTIVE BOOK TELLING
HOW THE BEGINNER MAY MANUFACTURE ALL
KINDS OF PAPER BOXES, WITH SPECIAL
CHAPTERS ON THE PRINTING DE-
PARTMENT FOR PAPER BOX
PLANTS, EMBOSSING, GOLD-
LEAFING, LABEL
WORK, ETC.

WITH 100 ILLUSTRATIONS

By ROBERT F. SALADE

Author of “Plate Printing and Die Stamping,” “How to Make Cutouts,” “Newspaper Men of the Night,” etc.

PUBLISHED BY
The Shears Publishing Company
LAFAYETTE, INDIANA
1920

Copyright, 1920
SHEARS PUBLISHING COMPANY
LaFayette, Indiana

LIST OF CONTENTS

HOW PAPER BOXES ARE MADE

CHAPTER I

WITHIN the last few decades the paper box manufacturing industry of the United States has grown to tremendous proportions, due of course to the ever-increasing demand for paper boxes of every kind imaginable. The manufacturers have kept in steady progress with the times, and so efficiently have they organized and managed the industry that today it ranks among the largest and most important in the country. The business is rapidly developing on every side. New uses for paper boxes are constantly being discovered. In many instances, paper boxes, on account of their neatness, lighter weight and economy, are taking the places of those made of wood or tin.

Comparatively few people outside the industry ever stop to consider the fact that the paper box business has been responsible for the success of many another business. Manufacturers of the many different varieties of packaged-goods which are sold over the counters of retail stores, advertising experts and salesmen, know well that attractive, graceful paper boxes help wonderfully in selling the goods. But, the buying public in general gives little thought to this truth. With the exception of advertising and first class printed matter, handsome paper boxes today are one of the greatest selling forces in business.

It has been only during recent years that manufacturers, advertising men and salesmen have been giving closer attention to the selling power of high grade paper boxes. In days gone by the quality and appearance of paper boxes received little consideration. Some years ago, a plain, commonly-made box was considered good enough for the purpose, but not so in these days. In this age the average buyer would not be interested in a nationally-advertised product if it were packed in a mean-looking box, no matter how excellent the product may be. This explains why we see such a large number of display advertisements on bill-boards, in the street cars, and in newspapers and magazines, including the statement, “Packed in a Neat Box.”

In the present time, after a large manufacturing concern has perfected all arrangements for making perhaps, a new breakfast food, a new perfume, toilet soap, candy, tooth paste, or some other desirable article, the next step that is taken to market the product is in organizing a good sales force. Then, the manufacturers consult with one of the big advertising agencies for the purpose of launching a national advertising campaign. Among the first features of the campaign to receive close study by the advertising experts is the style and appearance of the paper boxes which are to contain the product in question. Often, many different shapes and colors for the containers are planned and tested before the right design and color scheme are decided upon. The broad-minded manufacturer will not object to paying substantial prices for attractive paper boxes any more than he would object to paying high prices for advertising in newspapers and magazines, as the advertising men can easily prove to him the fact that beautiful paper boxes will help in selling the goods.

QUALITY IS ESSENTIAL.

This does not mean that any manufacturer could succeed with the aid of attractive paper boxes in selling anything that is not of good quality. He would possibly sell an inferior article, by means of advertising and appealing paper boxes, for a limited time, but the public would soon learn whether the article was good or not. But, the manufacturer of a high grade product may always depend on good advertising and attractive paper boxes to help him in making a success of his business, and this is the point that the writer wants to make clear to the reader. The psychology of a handsome paper box is something wonderful. Women, particularly, delight in buying candy, perfumes, and many other things packed in beautiful paper boxes and tied with colored ribbons. Men, too, derive pleasure through buying goods packed in attractive boxes. All of us like dainty packages, whether we admit the truth or not.

When paper boxes are made and used for the purpose of carrying goods to retail dealers, in cases where the dealers unpack the merchandise and sell it in loose form to the public, it is not necessary, of course, to have such fine boxes as those which go into the possession of the buying public. Large size shirt and hosiery boxes, for example, seldom pass into the hands of customers of retail stores. Boxes of this class should be neat, strong and of good appearance, but there is no reason for having them expensively finished. The larger-size boxes which are to be found upon the shelves of retail shops are usually covered with glazed paper, in colors such as buff, red, light blue, pink, etc. Store-keepers prefer boxes covered with glazed, colored paper for the reason that colors, and the high gloss of the paper help in making their sales-room look attractive.

These are very important facts that every paper box manufacturer must keep in mind, and the more attention that is given to the aesthetic side of paper box making, the better for the business in general. The field for fine and fancy paper boxes, as well as for plain boxes, is without limitations. It is a rich, fertile field, and the manufacturer with new ideas and good business management can “plant and grow” all the orders for paper boxes that he may care to handle.

The box-maker with ideas does not have to wait for orders to come to him. Hundreds of manufacturers in various lines of business are willing and ready to consider suggestions in the way of unique and handsome paper boxes which may mean increased sales of the goods or articles that they are marketing. The demand for “dust-proof,” “germ-proof,” “damp-proof,” and the trade-marked folding paper boxes is without end. Box-makers who are in a position to offer new-style containers of this character will have no reason for complaining about “slack seasons.” The fiber container field also offers unlimited possibilities to the manufacturer of fiber products.

This is the age of progress. Creative salesmanship is now needed in every line of business. The box manufacturer in these days must give more of his time and thought than in the past to the subject of creative salesmanship. He should work hand-in-hand with merchants, sales managers and advertising experts when big selling campaigns are being planned. The United States is just entering the greatest period of prosperity in the history of the country, and without question the paper box industry is to enjoy its proper share of this prosperity, but the box-maker who fails in keeping abreast with the times will be in danger of “falling by the wayside.”

IMPORTANT QUESTIONS.

Creative salesmanship, standard cost systems, efficient plant management, and the matter of procuring a sufficient supply of skilled labor are among the most important questions of today which must receive deep study from the box manufacturers in general. With these serious questions in mind, the writer has prepared this text book on the subject of Paper Box Making for the purpose of helping the progress of the industry in every way possible. Before attempting this work, the writer spent considerable time in several of the modern paper box factories, studying the mechanical equipment, labor-saving methods, ordinary working operations, etc. Several of the larger plants where paper box machinery is designed and made, were also visited. In this manner, valuable data for this book were secured.

The main purpose of this book is to teach beginners, or apprentices, the practical work of paper box making. We are not so egotistical as to believe that we can make a trained paper box maker with the aid of printed matter, but at least we can try to offer simple, practical information which we hope will be helpful to beginners. We shall try to do our very best in making the technical facts plain and understandable, and if we succeed in giving the reader a clear, general idea of how paper boxes are made, we will be well satisfied.

May we suggest to employers, superintendents and foremen in the paper box industry to place this book in the hands of apprentices for study? It may even be possible to present copies of the book to young men and young women who are not working in the industry, but who may desire, after reading this volume, to engage in the interesting work of paper box making. This is merely a suggestion, but it may be of some value in gaining new apprentices.

This book will include information on Plain Paper Boxes, Fancy Paper Boxes, Round, Oval and Odd-shaped Boxes, Cutting and Creasing for Cartons, The Label Printing Department, Fiber Containers, and on other subjects of this character. It would be almost impossible for anyone to describe all of the many different kinds of plain, fancy and folding boxes that are being made at the present time, so we will merely describe the regular line of paper boxes that are considered as standard in the trade.

PLAIN “SET-UP” PAPER BOXES.

The term “set-up,” applies to paper boxes which are covered with separate lids. Folding boxes do not come under this term for the reason that they are glued together at one side, and remain in flat form until the time when they are used as containers, cut out sections of the sheet then being folded to serve as “lids.” In other words, a folding box is complete in one piece, while a set-up box (a shoe box, for example), is of two parts, the box and the lid.

A set-up box must be cut, creased, folded, stayed and covered before it is complete. The lid also must be cut, creased, folded, stayed and covered.

Various kinds of boxboard are used for the making of plain paper boxes, but the three principal kinds used are called “Chip-board,” “News-board” and “Straw-board.” Chip-board is made from pulp formed of all kinds of waste paper. News-board is made from pulp formed of old newspapers. Straw-board is made from straw. These three different kinds of boxboard come from the paper dealers, or from the mills, in various sizes and thicknesses to meet all of the requirements of the box factory.

Chip-board is more generally used for all kinds of plain paper boxes. It is of gray color, and it has rather a rough surface. When the boxes are to be of good quality, like a candy box for instance, the chip-board is lined on one side with white news paper, or white book paper. This lining is done before the boxboard is cut and creased in shape for making the boxes. Many of the larger box-makers do their own lining on a special machine called the Parry Liner, which has been designed especially for the purpose. Other box-makers send the boxboard to outside concerns who make a specialty of lining board for the trade.

Chip-board, news-board or straw-board, when used for the making of ordinary boxes—shoe boxes, for example—is not lined. Better-class boxes, such as are used for holding collars and cuffs, silk shirts, handkerchiefs, neckwear, writing paper, and “white goods” of many varieties, should be lined with white book paper.

The first step toward the making of a paper box is in deciding on the proper measurements. The specifications must indicate the length, width and depth of the box, as well as the length, width and depth of the lid. The length and width of a lid, for a plain set-up box, must of course be slightly larger than the length and width of the box. To ascertain the correct sizes of both the box and its lid, the box-maker first makes models, and after these have been approved, the regular work of making quantities of the boxes is commenced.

Robinson Double Rotary Cutter and Creaser.

The full-size sheets of boxboard are fed into a scoring machine which cuts and creases the sheets to the proper dimensions. Several pieces of board, of the size required for the boxes, or lids, are cut from the sheet with one operation. The machine is equipped with a series of rotary knives and rotary scorers, which can be moved and adjusted to the positions desired. The rotary scorers are like dull knives, and are set up a little higher than the cutting knives; thus they score the sheet instead of cutting completely through it.

Single scoring machines, which score and cut the sheets of boxboard in only one direction, are used in some of the box-making plants. In other plants double scoring machines, which score and cut the sheets in both directions, are in service. The double scoring machine is naturally a big time-saver on large orders for the simple reason that it cuts and scores, both ways, on the sheet without it being necessary for the operator to feed the sheets through the machine a second time.

The cut and scored blanks, when in flat form ready for cornering and folding, appear like this:

Figure 1. Showing blank for paper box, cut to proper size, scored,
but with corner-pieces not yet removed.

The next operation is in removing the corner pieces from the blanks. This work is performed with the aid of a cornering machine. There are single, double and quadruple cornering machines in some of the larger plants, but the single and double cornering machines seem to be the most popular. The single cornering machine removes only one corner from the blank with one operation; the double cornering machine cuts out two corners with a single operation and the quadruple machine removes all four corners with one operation.

Power Double Cornering Machine.

The cornering devices are equipped with cutting knives, arranged so that they may easily be adjusted. The guides may be adjusted so that many different sizes of corners may be cut out of the blank stock. As many as twenty or more blanks may be placed under the knives at one time. The double cornering machine has two sets of knives and guides which are adjustable to provide for the various sizes of blanks. In the same manner the knives and guides of the quadruple machine are adjustable to provide for many different sizes of stock and also various sizes of corners.

When feeding the blanks into the single cornering machine, it is necessary, of course, for the operator to feed the sheet four times before all of the corner pieces have been removed.

When the four corner-pieces have been removed from a sheet of stock, the blank has the following appearance:

Figure 2. Showing blank for paper box, cut to proper size, scored
for folding, and with corner-pieces removed.

Some of the box-makers who make a specialty of fine, small-size set-up boxes for the drug trade, jewelers, etc., have machines which score the blanks, and cut out the corner-pieces simultaneously. This device is for small work only, and its principal advantage is accuracy. When scoring and cornering small-size blanks separately, it is often difficult to have this scoring line in perfect alignment with the corners. On this special type of scoring and cutting machine it is necessary for the operator to feed one blank at a time. Cutting and creasing of this kind can also be done on cutting and creasing presses, with dies formed of steel cutting and creasing rules. This process will be explained in another article.

After the blanks have been cut, scored and the four corner-pieces removed, the blanks are then bent upwards on all four sides so as to put them in form for the staying machine operation. Several of the blanks can be bent partly into shape with one operation. The operator of the staying machine then takes each blank and properly shapes it into the form of a box as the stay paper is applied to each corner. The staying machine is equipped with a roll of narrow Kraft paper which is gummed on one side. The machine is also equipped with a water-pan and a roller which moistens the gummed paper as it passes along. The operator places one corner of the box in position on the machine; the head of the machine descends and affixes a strip of the stay paper on the outside corner of the box. The operator then turns the box in rapid succession while the machine “stays” the other three corners of the box. The cutting of the stay paper to the proper size is an automatic operation, and the device can be adjusted to cut off any length of stay paper. The stay paper placed on the outside corners of the box, holds the box together.

Power Corner-Staying Machine.

In the case of very small boxes and lids, the stay paper is attached by hand, although the machine is adapted to small-size as well as large-size boxes.

CHAPTER II

PLAIN “SET-UP” BOXES (Continued)

AFTER the work of staying the corners of a plain set-up paper box, and its lid, has been completed, the next operations are to cover the sides of the box, and the sides of the lid, with paper of the desired weight, color and finish. The kinds of paper which are generally used for covering plain paper boxes are, white glazed, cheviot, and colored glazed. This stock may be bought from the manufacturers in either the form of large rolls, or in the form of flat sheets. When the ordinary power covering machine is used, the paper is applied to the sides of the boxes from rolls of the proper width.

The slitting and rewinding machine is used for the purpose of cutting the large rolls of paper into rolls of various sizes. The cutting wheels on the slitting and rewinding machine can be “spaced apart” to any width required. They may be set as close together as ½ inch apart. Conveniently located on the machine is a steel bar containing a scale, marked off into inches and fractional parts of inches. This scale makes it an easy matter for the operator to fix the slitting wheels in the positions wanted for cutting the large roll of paper into smaller rolls. As the wide sheet of paper unrolls and passes the slitters, the smaller strips of paper are rewound on spindles.

There are several good slitting and rewinding machines on the market which may be operated by hand or power, as desired.

Cameron Cutting and Rewinding Machine.

When the sides of paper boxes are to be covered with the aid of a covering machine, a roll of paper of the necessary size and kind is first placed on the machine. The width of the roll of paper is about an inch wider than that of the surface of the box which is to be covered, for the reason that about one-half inch of the paper is turned in and over on the inside of the box, and about one-half inch of the paper is turned in over the bottom of the box. One operator attends to the covering operation, while another performs the work of “turning-in.”

Knowlton Power Covering Machine.

SOME OPERATORS CARELESS.

The standard covering machine is equipped with a glue-pan, heating apparatus, gluing roller, glue scraper, a table, and a cut-off device. The gluing roller revolves in the glue pot, in such a manner as to apply the glue to one side of the paper as the paper passes over the surface of the roller. The glue pan may be heated by steam, gas or electricity. The scraping device regulates the amount of glue applied to the paper. When the machine is in action the operator simply wraps the strip of paper around the four sides of the box, allowing a “lap-over” of the paper, at one corner of the box, of about one inch. Some operators are careless, and they often allow “lap-overs” of several inches of paper, which of course results in considerable wastage of paper during the course of a day. The carefully-trained operator will try to save as much paper as possible. Another important point which the efficient operator will consider is in having the “lap-over” occur at one corner of the box, and not in the center of one side of the box. When the “lap-over” is made at one corner of the box, the work looks neat and finished, but when the seam is made on one side of the box, the work presents a poor appearance.

Long, narrow set-up paper box. Size, 3¹⁰⁄₁₆ × ⁴⁄₁₆ in. Used by
the medical profession for holding hypodermic needles.

It is also very important that the work of “turning-in” should be done as neatly as possible. The “turner-in” works on a table near the covering machine. As the operator of the covering machine finishes wrapping a box, it is passed to the second operator who turns in the corners and edges of the paper. A wad of cheese-cloth, or a soft, clean cloth of any kind, is useful in the work of turning-in, the corners and edges of the paper being rubbed down firmly and smoothly. Some operators of covering machines also use a cloth in smoothing the paper as it is applied to the sides of the box. Others use merely the palm of the hand. Attached to the machine is a receptacle for holding tallow which many workers make use of for keeping their hands free from glue. On the new model covering machines the cut-off device is adjustable, up and down, by means of screws, and it can be moved to and from the box-spindle in any desired position, without it being necessary for the operator to leave his or her seat. The cut-off device may be operated by hand by means of a lever.

TIME SAVING SYSTEM.

In a large number of paper box making plants tables are placed near the covering machines, and the work of “turning-in” is done on these tables. Near the covering machines are the topping machines. The work is handled in such a manner, that one operator passes the boxes on to another, until finally the boxes and the lids are completed and assembled. The boxes are then packed in cases ready for immediate shipment. This system is the means of saving time, labor and expense, as it makes it unnecessary for the operators of the various machines to leave their seats. One operator does the covering of boxes, the second operator covers the sides of the lids; the third attends to the work of “turning-in”; the fourth is in charge of the topping machine. Girls or boys then assemble the boxes and lids, and pack them in the cases.

Many set-up paper boxes, in addition to being covered with white glazed, cheviot, or colored glazed paper, are finished with gold-paper edges. Some have a gold edge at the top of the lid, and a gold edge at the bottom of the box; others have four gold edges; still others are covered with colored glazed paper, and have four edges of white glazed paper. Paper boxes of this variety may properly be placed under the heading, “fancy,” but we want to mention them here on account of the edging-work being done on covering machines in about the same way as plain covering work.

Let us take the case of a gold-edged paper box for example: The narrow roll of gold paper is placed on the covering machine, along with the wider roll of glazed, or cheviot paper. Both the gold strip and the other strip are applied to the box, or lid, simultaneously, the gold strip being placed underneath the main strip. The main strip of paper is a size that when applied to the box, or lid, (over the gold strip) it allows the gold edging to show. Only the gold strip is “turned in,” either over the top or bottom of the box, or over the top and edge of the lid. With work of this character the operator must be careful to have the two strips of paper run straight and even as one is glued over the other.

The topping machine operates much on the same principle as the covering machine, and it is used for applying paper to the tops of box-lids, after the sides of the lids have been covered. The better class of set-up boxes are covered on the bottom in addition to having the tops of their lids covered, but ordinary, plain set-up boxes are not covered on the bottom. The writer has before him a set-up box which had been used for holding a dozen linen collars. The board for this box has been lined with newspaper, making it neat and clean on the inside. The lid is covered and topped with pale yellow glazed paper. The sides of the box are covered with glazed paper of the same color as the lid, but at the top the edges are trimmed with white glazed paper. The bottom of the box is covered with white book paper. This is that kind of box which should have the bottom covered, although the bottom piece of paper is not absolutely necessary. Writing paper boxes should also be covered on the bottom. The question of covering the bottoms of set-up boxes should be determined by considering the general qualities of the box, and the purpose for which it is to be used. There is no reason for covering the bottoms of common set-up boxes.

One of the smallest set-up paper boxes manufactured. Size 1⁷⁄₁₆ × ⁷⁄₁₆ in. Sides ³⁄₁₆ in. Used by the medical profession.

One of the best power topping machines on the market is that made by the Hobbs Manufacturing Company, of Worcester, Mass. This machine has an automatic cut-off device, and it is equipped, of course, with a work table, glue pan, gluing roller, etc. A roll of paper, nearly the same width of the lid, or box-bottom, which is to be covered, is placed on the machine. Glue is applied to one side of the paper as it is drawn over the surface of the gluing roller. When the strip of paper has been stretched across the top of the lid, or the bottom of the box, the operator depresses the adjustable lever at one side of the machine, and the paper is cut off to the required size. On top of the work-table is a locating projection which holds the box in place. A locating gauge is also provided so that the vertical adjustment of the table can easily be made.

It is only fair to state that there are other efficient topping machines in general use, some being operated by hand, others by power.

Many set-up paper boxes, which are made for heavy usage, such as for holding hardware, tools, toys, glassware, etc., are wire stapled at the corners instead of having the corners strengthened with Kraft paper, or stay paper. Some box manufacturers are making all of their set-up boxes with wire-stapled corners. There are several wire stitching machines now being made by well-known concerns which have been especially built for use in the paper box industry, and they have proved very satisfactory. The boxes and their lids, after having been fastened at the corners with copper, or wire devices, are covered and topped with paper in the usual manner. The wire stitching machine is operated in much the same way as the staying machine, each corner of the box, and of the lid, being “stitched” with wire in rapid succession. For an exceptionally strong paper box which is to have rough usage, the wire-staying will be found more practical than paper-staying.

Figure 3. Diagram shows shape of wrapper used on Stokes & Smith Wrapping Machine.

Perhaps the most remarkable machine ever invented for use in the paper box industry is the Stokes & Smith Wrapping Machine which automatically places glued paper on all kinds of paper boxes. One of the great advantages of this device is that it completely wraps the box, or its lid, with a single sheet of paper. In other words, it “covers” and “tops” at the one operation. Flat sheets of paper, cut out at the corners like the diagram shown on page 29 are necessary when using this machine.

Stokes and Smith Wrapping Machine.

For cutting the sheets of paper to this special shape, a Stokes & Smith Double Cornering Machine is essential. The sheets are first cut square, or oblong, to the size desired, and the odd-shaped corners are cut out afterwards. The Double Corner Cutter will cut two corners from a pile of the sheets simultaneously. In about an hour’s time a sufficient quantity of the wrappers can be cut to provide for a day’s run of work on the Stokes & Smith Wrapping Machine.

Extension bottom boxes, or to use the old term, boxes with “French edges,” may also be wrapped on the Stokes & Smith device, but for this class of work wrappers of still another shape than that shown by Figure 3 are necessary. Again, for work of this character, the machine must be equipped with an Extension Bottom Covering Attachment. The change in the shape of the wrappers is made by equipping the Double Corner Cutter with the proper sub-presses, knives, and dies.

Another advantage of the Stokes & Smith Wrapping Machine is that it will apply printed or lithographed wrappers to the paper boxes, therefore making it unnecessary to have printed labels pasted on the boxes after they have been covered. These facts are not presented for advertising the Stokes & Smith Company. In offering these facts we merely desire to acquaint the reader with all that is new in the way of paper box machinery, and were we to omit mention of the Stokes & Smith Wrapping machine, we would feel that this series of articles would not be complete.

HOW WORK IS HANDLED.

In plants where this machine is in operation, the work is handled as follows: First, the sheets are cut square or oblong to the required size. Second, the corners for regular paper boxes, or the corners for extension bottom work, are cut from the paper. Third, the wrappers are fed through a gluing machine, which by means of rollers, places a thin coating of glue on one side of the paper. Fourth, the sheets, with the glue-side up, are placed on a revolving table which is really a part of the wrapping machine. Fifth, from the revolving table the operator of the wrapping machine lifts up a wrapper with one hand, and with the other hand takes an uncovered box, placing it bottom down on the glued paper, being careful to see that the bottom of the box is accurately centered between the cut out corners of the wrapper. Sixth, the box and wrapper are then placed on a form on the wrapping machine. The action of the machine thereafter is “almost human.” The box and its wrapper pass down through a series of brushes and rollers which draw the wrapper closely to the sides of the box, neatly folding the paper at the corners and ends, and turning in the edges of the wrapper on the inside of the box. At the end of a complete revolution of the machine the box emerges from the machine in a finished condition.

In some of the larger paper box manufacturing plants, where Stokes & Smith machines are being used, a great deal of time is being saved by grouping the machines, and by working the operators in teams. For example, two wrapping machines and two gluing machines are so arranged that the boxes and the lids are finished, inspected and assembled with all of the work being done in one small “department.” In not a few shops the boxes and lids are covered on machines which are located a considerable distance apart, resulting in a waste of time when the boxes and lids are assembled. The accompanying illustration will give the reader an idea of how the machines may be properly grouped so as to eliminate unnecessary handling:

Figure 4. Illustrating how time and labor may be saved in the plant
by grouping the machines properly, and by working
the operators in teams.

SHOULD STUDY FLOOR PLANS.

Paper box manufacturers should devote time and study to floor plans of this character. With the shorter work-day being adopted in all parts of the country, and with skilled labor becoming more scarce every day, it behooves the manufacturer to work out plans by which time and labor may be saved, and which will make an increased amount of output possible. This may be accomplished through following plans that will effect real efficiency in the factory. No matter what kinds of machines the manufacturer may be using, they may be grouped in such a way as to make it possible for the various operators to work closely together in teams.

Within the last few months the writer visited a paper box making plant where the staying machines were located at one end of a spacious room, and where the covering machines were located at the other end of the room. In about the center of the room the topping machines were placed. Think of the great number of unnecessary foot-steps which are made by the workers in this shop during the course of a day! Consider the large amount of time that is being wasted every day in carrying the material from one machine to another! The reader can readily understand that by grouping the staying machines, the covering machines, and the topping machines in small “departments,” so to speak, the boxes and lids could be finished, inspected and assembled simply by passing the work from one operator to another as the different processes are completed.

The larger sizes of plain paper boxes, such as those used for holding envelopes, shoes, etc., are not made from the same shapes of blanks as are used for the making of the smaller sizes of boxes. In the majority of cases the board used for the larger-size boxes consists of three separate pieces. The main piece contains flanges with mitered corners. After the main piece of box-board has been cut to the required size, and after it has been scored and the corners mitered, the board is folded or bent to form the bottom and two sides of a box, having flanges at either end. Separate side pieces are then glued to these flanges, making the box complete as to form. The principal reason why the larger-size boxes are made in this fashion is because it prevents wastage of box-board.

CHAPTER III

SIDE-SET PAPER BOXES.

IF a single piece of box-board were to be used for the making of a large-size set-up paper box, (a hat box, for example) it would necessitate the cutting out of four corner pieces which would be as large in size as the two side walls of the box, therefore the reader can readily understand that it would not be economical to cut out corners of stock which is to be used for the larger-sized boxes. Another advantage of the side-set paper box is in the ends being stronger than the ends of a one-piece box. While this strong feature of construction would not been needed in a small-size box—a pound size candy box, for instance—it is an advantage for a larger size box such as is used for holding 500 No. 10 envelopes.

For this kind of a box, the chip-board, news-board, or straw-board is cut and scored to the size required on either a single or double scoring and cutting machine. This refers to the body-piece of the box. The side pieces may be cut to the desired size, in stacks of fifty or more sheets at a time, on an ordinary power paper cutter, or of course, the side pieces may be cut from large-size sheets of box-board on a scoring and cutting machine, or on a rotary board cutter. In many of the big paper box plants the rotary board cutter is being used for neck-pieces, side-pieces for side-set boxes, and for other plain cutting where no scoring is to be done in connection with it. The main advantage of the rotary board cutter is in the smooth, clean edges left on the box-board after it has been cut into the various sizes. The smooth, clean edges could not be procured on an ordinary paper cutting machine, but in the case of common paper boxes, the rough edges of end-pieces would not be a serious matter. For the better grade of boxes the edges of the end-pieces should be smooth and free from small particles of the board, especially when the box is to be covered, as the rough edges would show plainly from under the covering.

Fig. 5. Showing the construction of the flange style of paper box.
Note the mitered corners of the flanges.
Fig. 6. Shows the end-pieces glued to the flanges.

Mitering for stock that is to form the body-pieces for side-set boxes is done on a machine such as the Hobbs Duplex Corner Cutting and Mitering Machine which is also used for cutting the corners for one-piece set-up boxes. The Hobbs machine is so constructed that two corners may be cut from box-board on one side, and two miters cut from box-board on the other side. In other words, it is a quadruple machine which will permit two operators to work upon it at the same time, the operator on one side doing corner cutting, and the operator on the other side doing mitering. Either side of the machine may be used independently of the other, and all sizes of corners up to 3 inches, and all sizes of miters up to 1 inch in depth, can be done by making the necessary adjustments of the dies, sub-presses, and gages. The two miters may be spaced as wide apart as 22 inches, and the two corners as wide as 20 inches.

Some of the paper box manufacturers are making the side-set boxes by hand, but the majority of box-makers are using Ending Machines for this kind of work. The hand method of construction is very simple: The operators are seated on each side of a long table; one operator “turns in” the flanges of the body-pieces, and shapes them ready for receiving the end-pieces; another operator applies glue to the end-pieces and keeps a supply of the glued end-pieces, arranged in rows, ready for the next operator who places the body of each box on a form, and then applies the end-pieces. It requires care for the operator to place the end-pieces in true register with the bottom and sides of the box. The scoring lines made for the flanges are followed as guides for putting on the end-pieces squarely. The form is simply a smooth block of wood, the size of the interior of the box that is being fashioned. The amount of work which a force of skilled hand-workers can turn out during the course of a day is really surprising.

HOW EFFICIENCY IS ACCOMPLISHED.

Efficiency in the production of hand-made paper boxes, as well as efficiency in the production of machine-made boxes, is accomplished by keeping the workers, or the machines, abundantly supplied with material, and by having boys or girls carry the material to and from the tables or machines, instead of having experienced operators attend to such work. When a force of operators start work at a table, or at a group of machines, there should be a steady flow of material to keep them constantly employed. This is the system now being followed in the leading box-making factories, and it is a system which should be adopted by every box manufacturer, no matter how small his shop may be. Keep your skilled help plentifully supplied with material. Do not allow your best operators to waste time in carrying stock from place to place when boys or girls, with the aid of light trucks, can do this class of work just as well.

This leads up to still another important suggestion which we will offer to the manufacturers in general: Do not keep your apprentices working for long periods at menial tasks, such as carrying stock, sweeping floors, running errands, etc. Push the apprentices ahead as rapidly as possible. Train them to become first-class box-makers.

A brief description of the Hobbs Automatic Ending Machine will doubtless give the reader an idea of how end-pieces are attached to the flanges of boxes mechanically: This machine is equipped with a form, pasters, a hopper and a feeder, all being adjustable to provide for paper boxes of various sizes. The machine is designed to apply end-pieces to the bottom and sides of a box, causing the ends to adhere to the in-turned flanges at either end of the box. The body of the box is placed upon the form by the operator with the flanges lying flat upon the surface. The end-pieces are placed in a hopper, and the machine automatically feeds the undermost end-piece forward, applies paste to three edges as it is being fed, registers the end accurately with the box-body upon the form, and then presses the end-piece firmly to the flanges. This completes the ending operation.

VARIOUS KINDS OF ADHESIVES.

Various kinds of paste and glue are used for ending work. White Dextrine is recommended for this purpose by many box-makers. Stein, Hall & Company, of New York City, make a Dry Ending Gum, as well as Dry Gums for all classes of paper box work. The “Mikah Cold Glues,” manufactured by the National Glue and Gelatine Works, of New York City, are also well recommended. There are other good glues and pastes on the market.

In addition to the Hobbs Automatic Ending Machines there are several other ending machines in general use which are rendering first class service. The Kingsbury & Davis Double Ending and Quadruple Staying Machine is another “wonder-worker” which is worthy of special mention. It is said that one of these machines will do the same amount of work that can be done on five single enders or stayers.

Some of the larger-size paper boxes which are constructed with flanges and end-pieces, have a strong linen thread running around the sides of the box, near the top, for the purpose of strengthening the corners, the paper covering of the box concealing the thread. Other paper boxes with flanges and end-pieces, have the corners stayed on the outside with Kraft paper in the same way as the smaller-size set-up boxes. Others still have the four top edges and the four corners of the lid stayed with Kraft paper, also the four bottom edges and the four corners of the box stayed with the same material. This makes a box and lid of very strong construction, and as a rule, a box and lid of this kind are not covered with glazed paper, or in fact, paper of any kind, the box-board being allowed to show in its natural color. Many of the larger-size envelope boxes are made in this manner, the corners and edges stayed, but no covering paper applied to either the inside or the outside of the box or lid.

Shoe boxes, in nearly all instances, are stayed at the corners, and afterwards are covered with white glazed paper of an inexpensive grade.

MANY TWO-PIECE BOXES.

Although the great majority of paper boxes of the larger sizes seem to be made on the plan of the flange construction with separate end-pieces, there are also many boxes made from two pieces of box-board—one continuous side-piece, folded and joined at one corner, and a “set-in” bottom-piece. A square-shaped box containing a “neck”, such as is used by manufacturing chemists for magnesia, etc., is often made on this pattern. Writing paper boxes, and other boxes which are high and square in form, are also made in this way.

When a paper box is made on this plan—with one continuous side-piece and a set-in bottom-piece—there is practically no wastage of box-board, for the reason that no corner-pieces are cut out of the stock as would be the case with a one-piece set-up box. The continuous side-piece is scored at three corners, and is joined and stayed at one corner. The body is then set on a form, of the same size as the interior of the box, and while the body remains on the form, the bottom-piece is set in. Strips of stay paper are then pasted to the four edges of the bottom-piece, and to the four bottom edges of the box, so as to hold the body and bottom-piece together. When an extra strong box of this design is wanted, gummed linen tape is used instead of stay paper for holding the body and bottom-piece together. Sometimes the stay paper, or linen tape, is pasted on both the inside and the outside of the box, along the edges of the bottom-piece and body, for the purpose of making an exceptionally strong box.

Paper boxes of the kind which have been described in the last few paragraphs are usually covered, after the staying material has been applied to the corner and at the bottom of the box, with cheviot paper, or with glazed paper in white or color. A large-size, high and square box of this type looks particularly handsome when covered with light gray cheviot paper. The high, oblong box also makes a nice appearance when covered with the cheviot. Trimming of white glazed paper, at the top edges of the lid, and at the bottom edges of the box, forms a good “color scheme” with the cheviot paper, and the trimming enhances the general appearance of the box.

When large-size paper boxes are made with either flanges and side-pieces, or with continuous side-pieces and set-in bottoms, the lid is made on the same pattern as a lid for a plain set-up box, that is with cut-out corners, and with the corners joined together with staying material. In the case of a large-size “telescope” box, however, the lid is made in the same way as the box, the size of the lid being large enough, of course, for the lid to fit over the sides of the box. A “telescope” box is the kind generally used for holding suits, coats, shirt waists, men’s underwear, etc. Boxes of this class are usually low in depth, say about three inches, and are therefore made with cut-out corners, or with folding corners. Some telescope boxes, in the larger sizes, are made as high as 12 inches, both the box and the lid being formed of two separate pieces. We shall endeavor to explain how folding suit boxes are made in another chapter.

EQUIPMENT REQUIRED FOR SMALL PLANT.

While holding an interview with a manufacturer of paper box making machinery who has furnished complete plants for many box-makers during the last two decades, the writer asked the manufacturer to mention the equipment that would be required for a small paper box factory just starting in business. The manufacturer answered that it would be difficult for him to specify the kinds and sizes of the machines necessary for a small new plant, without knowing exactly the class of work which was to be produced. The manufacturer explained, however, that for an ordinary plant where a general line of plain set-up paper boxes were to be made, the following equipment would probably be sufficient in the beginning of the venture:

One Single Scoring and Cutting Machine.
One Staying Machine.
Two 9-inch Covering Machines.
One 12-inch Covering Machine.
One 16-inch Covering Machine.
One 16-inch Topping Machine.
One Ending Machine.
One Single Corner Cutting Machine.
One Paper Slitter.
One 34-inch Paper Cutter.
Supplies of box-board, staying material, white and colored glazed paper in 25-inch rolls, cheviot paper in 25-inch rolls, paste, glue, etc.

The corner cutting machine may be equipped with interchangeable dies for cutting round corners, miters for box-bodies with flanges, and odd shapes of many kinds, such as for example, corners for wrappers used on Stokes & Smith machines. All of this work may be done on the single cornering machine in addition to the plain corner cutting for set-up boxes, but it would be necessary to order the special dies as “extras,” as they are not furnished with the regular equipment.

ECONOMY IN POWER EQUIPMENT.

The machines mentioned may be operated by either hand or foot power, or they may be equipped for power fixtures. Power machines are recommended as always being the most economical, as the amount of work produced on power machines is far greater than the amount of work produced by hand or foot power. In many of the big paper box making factories practically all of the machines are driven by individual electric motors, which means that there is no wastage of electric current when all of the machines are not in motion. When individual motors are being used in a plant, no overhead shafting or belting is necessary. Overhead shafting and belting is often responsible for dirt, dust or oil being thrown on expensive material. When steam power, or a single large motor, is used in a plant, it costs money for shafting and belting, and it also costs something to operate the shafting and belting before the power reaches the machines. Belts often break and must be repaired while the machines are standing idle. All of this expense is eliminated by the individual motor system; it helps in maintaining clean work-rooms, and it saves the manufacturer a considerable sum of money on account of the electric current being consumed only at points where the machines are in operation. On occasions when all of the machines are not running, there is a certain reduction in the amount of current used. This is not the case when a single large motor is in service. It spends its power in driving shafting and belting even when only one of the machines is in operation.

With the mechanical equipment which has been suggested for the establishment of a small paper box-making plant, and with a force of experienced operators, the manufacturer would be in a position to produce all kinds of plain set-up paper boxes such as are used for confectionery, shoes, writing paper, collars, envelopes, and so forth. As the business grows other machines of greater capacity may be added to the plant. In due course of time the manufacturer could have a double scoring machine, and perhaps an automatic wrapping machine, installed, but it would not be advisable for the box-maker to invest money in such machines unless he controlled enough business to keep them constantly busy. It would be a mistake for the manufacturer to buy an automatic wrapping machine, or other extraordinary equipment, when he is not sure of having sufficient work to provide for such equipment.

Practically all of the large and successful box-making concerns are specializing in some particular line. For example, one large company is specializing on druggists’ pill and powder boxes. Another firm is making fine candy boxes of all kinds. Still another concern is making nothing except folding boxes. The specialty line seems to be “the thing” in these days, and one can easily understand why it would not pay a manufacturer in attempting to make every variety of paper boxes and folding boxes. It would be almost impossible for him to properly equip his plant with the machinery which would be necessary to handle all classes of work. The folding box business is one branch of the industry; the set-up box business is another branch. Nevertheless, there are some cases where the manufacturer of set-up boxes could add a cutting and creasing department to his plant with advantage, and there are also some instances where the maker of folding boxes could enter the set-up paper box field. But, in no case would it pay the manufacturer to make all kinds of folding and set-up boxes. As a general rule the box-maker should specialize in some particular line.

CHAPTER IV

DRUGGISTS’ PILL AND POWDER BOXES.

ONE of the most important branches of the paper box industry is that which is devoted to the manufacture of druggists’ pill and powder boxes. Only a comparatively few concerns are engaged in the production of these specialties, and at the present time these firms are practically in control of this class of business, for the reason that their plants have been especially equipped for the production of this line. In some instances these manufacturers have had special machinery built for the particular needs of their factories.

While it is true that a great many of the small pill and powder boxes are made by hand, by skilled workers who have had long experience on this kind of work, it is also a fact that large numbers of small pill and powder boxes are being made on machines. In one large plant, of Philadelphia, there are several specially-built machines which are being used for the making of round pill boxes of various sizes. The owners of this plant will not allow strangers to see these machines in operation; in fact, only certain loyal employes of the firm are permitted to enter the department where these machines are located.

Another concern, who for the last sixty years has been making a specialty of druggists’ pill and powder boxes, will not allow visitors in the mechanical departments of the plant under any circumstances. All “secrets” in the processes of manufacture are carefully guarded, and only certain employes have admittance to the work-rooms where round pill and face powder boxes are put together. The manufacturers of pill and powder boxes in general seem to have erected a “Chinese Wall” around their industry, and they should not be blamed for this, as in some instances the manufacturers have spent thousands of dollars in perfecting machines and processes, and these of course are their own private property.

Nevertheless, the writer is of the opinion that no manufacturer will lose anything by allowing visitors to walk through all departments of his factory. Personality in business and quality of product are things which cannot be stolen. You cannot steal a man’s ideas, or rather his brains. Consider the business methods of the Curtis Publishing Company, of Philadelphia, for example. This company is said to have the best-equipped printing plant in the world. Doubtless the reader knows about the superior quality of The Ladies’ Home Journal, The Saturday Evening Post, and The Country Gentleman—the three famous magazines produced by the Curtis Publishing Company. This company invites the public to go through all departments of its wonderful plant. This great $25,000,000 concern is not afraid of anybody stealing its “secrets.”

“Competition is the life of trade.”

ROUND PILL AND POWDER BOXES.

Through the courtesy of one manufacturer of druggists’ pill and powder boxes, the writer was permitted to see how this line of work is produced, so far as the plant in question is concerned, and the writer will attempt to explain the practical side of this work in the following paragraphs. The reader will be particularly interested in this subject, no doubt, when it is mentioned that some of the facts presented have never before appeared in print, to the writer’s knowledge. This is a bold statement, but we believe that it is well supported.

Round and oval paper boxes, especially the smaller sizes such as are used for face powders, pills, capsules, etc., are made by highly-skilled labor and this class of work is considered to be the most difficult in the paper box industry. Round work is far more intricate than square-box work of any kind. It requires years of practical experience for one to become a first class round or oval box maker. Round work is an art, and many of the fine pill and face powder boxes which are seen in drug stores are beautiful works of art. The greater portion of round and oval work is done by hand, although as stated, some round pill boxes are made on machines.

Round pill and powder boxes are made in a considerable number of sizes and in a great variety of colors and trims. Round pill boxes are made as small as three-fourths of an inch in diameter and with a depth as low as eight-sixteenths of an inch. Then there is a full range of sizes all the way up to three and five-sixteenths inches in diameter, and even larger.

Plain, round, shouldered pill boxes are made from two round pieces of box-board, two “rings” of equal size, made from paper, and one larger “ring” which forms the shoulder or neck.

Round Shouldered Pill Box—Covered with colored glazed
paper, leaving four white edges.

Note that a round box of this type does not have projecting edges at the top of the lid and at the bottom of the box. The round top and bottom pieces set within the rings. The ring is first placed over a form; glue is applied to the edge of the round piece of box-board, and this is then set inside the ring. A strip of thin trim paper—gold, white or colored—is then pasted around the side of the ring, the strip of trim paper being wide enough to extend slightly over the top of the lid, or over the bottom of the box. This extension of the trim paper helps in holding the round piece of box-board to the edge of the ring and produces a smoothly-covered edge.

THE FINISHED BOX.

Both the lid and the bottom of the box are made in the same manner as described. After the trim-paper has been applied to the sides and edges of the rings, strips of white or colored glazed paper are then pasted around the sides of the rings (over the trim-paper), these strips not being as wide as the strips of trim paper. The finished box shows four edges of the trim, one at the top of the lid, one at the bottom of the lid, one at the top of the box and one at the bottom.

The shoulder ring, or neck, is nearly double the height of the ring which forms either the box or the lid. Paste is applied to one edge of the neck-ring and the neck-ring is then placed inside one of the box-rings, the end containing the paste adhering to the bottom of the box. It is well also to put a small portion of the paste on the side of the shoulder-ring which goes down inside the box. The lid, of course, fits snugly over the neck.

Some round, shouldered boxes of this type are covered on the inside with colored glazed paper, others have merely the tops and bottoms lined with white paper. In the latter case, the box-board used for the round top and bottom pieces is lined on one side before being cut into circles.

The rings for the lids, boxes and shoulders, when made of white paper, are naturally white on the inside. We will explain how the tubes for the rings and shoulders are made later on.

Round, Shouldered Projecting Edge Pill Box—Covered with colored enameled paper, leaving four gold edges.

BOXES WITH PROJECTING EDGES.

Round, shouldered pill boxes with projecting edges are made in about the same way as the plain, round boxes, with the exception that greater care must be taken by the operator in wrapping the trim paper around the projecting edges of the lids and boxes. Particular care must also be taken in placing the round pieces of box-board accurately in position over the edges of the rings.

For trimming the edges of boxes with projecting edges, light-weight paper having special stretching qualities should be used. In the trade this stock is known as “Round-work Glazed.” A. Hartung & Company, of 506 Race street, Philadelphia, are in a position to furnish this paper on special order. It can be supplied in white, gold and in various colors. It comes in rolls 24 inches wide.

Many expert operators on round box work are capable of making boxes with projecting edges without using forms for placing the tops and bottoms of the boxes accurately into position. Some operators make use of metal rings which are placed over the box-rings after the round pieces of box-board have been attached to the glued edges of the box-rings. According to the size of the boxes being made, the metal ring’s outside dimensions are the same as the diameter of the round pieces of box-board. The inside of the metal ring fits closely around the outside of the box-ring. By careful manipulation with the fingers, the operator with the aid of the metal ring, obtains an even margin on the projecting edge all around.

Other operators do not use glue in applying the edges of the rings to the round pieces of box-board, the strips of trimming paper serving to hold the material together firmly. The strip of trimming paper, with paste applied to one side of it, is neatly wrapped around the outside of a box-ring and around the edge of the round piece of box-board. One edge of the trim paper is then turned over the edge of the round piece of box-board, and the other edge of the trim paper is then turned over the edge of the ring. It requires experienced fingers indeed to accomplish this tedious work without causing the turned edges of the trimming paper to wrinkle. “Practice makes perfect.” The skilled operator can produce a surprising amount of this class of work during the course of a day. The finished product shows the trimming paper smoothly wrapped around the boxes and lids, and where the paper passes over the projecting edges of the boxes and lids, not the smallest wrinkle in the paper is to be seen. The turned-in edges of the trimming paper are even and smooth.

EDGES LEFT EXPOSED.

The operator holds in proper position one of the box-rings, and one of the round pieces of box-board, as the trimming paper is applied. After the trimming paper has been put on, strips of glazed paper, of the color desired, are pasted to the sides of the boxes and lids, leaving the edges of the trimming paper exposed.

Round, shouldered pill boxes with projecting edges are made in many different sizes, some as small as one and one-sixteenth inches in diameter, and with a depth as low as one-half of an inch. These boxes are trimmed and covered with papers of various colors, and beautiful effects are obtained when correct color schemes are chosen. White or gold trimming paper harmonizes well with all other colors of paper. A box covered with white trimming paper and bronze enameled paper, leaving four white edges, forms a pleasing color combination. Bronze and gold, light blue and white, red and gold, light blue and gold, are only a few of the many good color schemes which are being used.

Some of the fine, round, shouldered pill boxes with projecting edges are lined inside with silver, gold, colored or tin foil paper. Some of these boxes are covered entirely with gold paper, others are covered entirely with white or colored paper. Others again are covered with fancy embossed, or watered paper, after gold or silver trimming paper has been applied.

The tops of the lids for these boxes are not covered by the box-maker as a general rule. Druggists who buy these boxes paste their own printed round labels to the lids of the boxes as physicians’ prescriptions for pills, capsules, etc., are filled.

One can form some idea of the large number of round pill boxes which are being consumed in this country when considering the number of drug stores that are located in all sections of the United States. The demand for high grade round pill boxes is constantly increasing. At the present time, the supply of fine, hand-made pill and powder boxes is not equal to the demand, as only a few manufacturers are specializing in this class of product.

SHOULDERED MAGNESIA BOXES.

Among the other kinds of small paper boxes which are used extensively by pharmacists are plain, round, shouldered magnesia boxes, as they are termed in the trade. Round boxes of this variety are higher in form than the pill boxes which have been described, and they are used for holding other powders in addition to magnesia. (Insect powder, for example). Some boxes of this model have a depth of three inches, while the diameter of the lid is one and fifteen-sixteenths inches.

Round Shouldered Magnesia Box—Covered with
colored glazed paper.

Round, shouldered boxes of this class are made in about the same way as plain, round pill boxes, the round pieces of box-board being glued to the inside edges of the rings. In some instances, the sizes of the rings for the lid and box are both the same. In other cases the depth of the ring for the box is considerably larger than the depth of the ring used for the lid.

The shoulder, or neck, for this kind of box consists of a tube which is almost the same height as the interior of the box. One edge of this tube is glued to the bottom of the box. Some glue is also applied to the side of the tube, so that it will hold firmly to the inside of the box. On account of the neck on this style of box being higher than the neck on a pill box, some slight difficulty would be experienced in placing the lid of the box over the neck. To overcome this, a slit, running slightly on an angle, is cut into the neck with a sharp knife. This slit causes a lap-over of the neck, at the edge, making it an easy matter to slide the lid on.

PURPOSE OF HOLES

Before cutting the slits in the necks, some operators punch small holes, with a bodkin or an awl, in the sides of the necks, at a point where the length of the slit is to be determined. The hole serves two purposes: First, it acts as a guiding mark when the operator cuts the slit; second, it has an influence on the lap-over, allowing it to be moved freely as the lid is placed over it.

Round, shouldered magnesia boxes are covered with glazed or enameled paper, white or colored. Trimming paper is seldom applied. When tubes, or rings of white paper have been used in the construction of these boxes, the covering paper for the side of the box and side of the lid may be cut to widths that will permit four white edges of the box to show. These white edges make the box and lid appear as though they had been trimmed with white paper. The reader is to understand, however, that in the case of a round box with projecting edges, it would be necessary to apply trimming paper, before pasting on the regular covering paper, as the trimming paper serves to hold the round piece of box-board to the edge of the ring.

In the case where the tops and bottoms of plain, round boxes are to be covered with glazed or enameled paper, there are two methods of covering: One method is in having one side of the box-board (which is to be used for the tops and bottoms of the boxes) covered with glazed or enameled paper before the box-board is cut into round pieces. The other method is in having round pieces of the paper, of desired size and color, cut out with a die, and the round pieces of paper are then pasted to the tops and bottoms of the boxes.

Labels for round magnesia boxes are usually pasted to the sides of the boxes, and for this reason the tops and bottoms of these boxes are frequently covered with glazed or enameled paper, the same color as that applied to the sides of the boxes.

As mentioned in a previous paragraph, some plain, round boxes, not having projecting edges, are trimmed on all four edges with “Round-Work Glazed Paper” before regular glazed or enameled paper is applied to the sides, but as a general rule, only round boxes with projecting edges are treated in this manner.

HOW THE “BARRELS” ARE MADE.

To a person not familiar with the process of manufacturing round and oval paper boxes, it would appear that the sides of the boxes are formed of light-weight cardboard, rolled to the required shape. Such is not the case. The tubes, or “barrels” from which the rings for the boxes are cut, are made of paper. The tubes from which the shoulders or necks are cut, are also made of paper. Manila stock is used for tubes of the cheaper grade. Machine finished book paper is used for tubes of good quality, and the tubes which are used for the making of the finest face powder boxes are constructed of white coated or enameled paper. This will explain the beautiful gloss-white surface which may be seen on the inside of expensive face powder boxes.

Knowlton Tube Cutting Machine.

The various kinds of paper used for the making of tubes comes in rolls, and can be supplied by any of the well known paper dealers in rolls of standard widths. What is known in the printing trade as 50-pound manila, 50-pound machine finished book, and 80-pound enameled or coated-one-side, are the kinds of paper generally used for making the different varieties of tubes. These papers can be furnished in all of the standard weights or thicknesses.

Parallel tube rolling machines are necessary for this class of work. James Brown, Jr., & Sons, Manayunk, Philadelphia, Pa., have invented a tube rolling machine which is capable of turning out twenty-two “barrels,” sixteen inches long, per minute. This machine is equipped with a paste tank, a steel mandrel of the desired size, a cut-off device, and a roll of the paper, say sixteen inches wide. Adjustments can be made so as to roll the tube to any required thickness. Three or four complete revolutions of the mandrel are all that are necessary for a tube which is to be used for small pill boxes. Flour paste is recommended in making tubes of the kind in question, but dextrine or any of the patented cold glues on the market may be used for the purpose.

CHAPTER V

DRUGGISTS’ PILL AND POWDER BOXES (Continued)

IN addition to manufacturing tube rolling machines for the box-makers, James Brown, Jr. & Sons, Manayunk, Philadelphia, are also making tubes for the trade. Instead of manufacturing the tubes, or “barrels,” for round boxes in their own plants, some of the box-makers order the tubes made by concerns like James Brown, Jr., & Sons. Afterwards, the box-makers have the finished tubes cut into rings of the required sizes, and assembled into boxes in their own plants. There is an advantage, of course, in the box-maker having his own tube rolling machines.

The finished “barrels” for round paper boxes are cut into rings of various lengths on a rotary tube-cutting machine which works somewhat on the principle of a lathe. Some of the larger manufacturers of round pill boxes have had special cutting machines built for this purpose. Tube-cutting machines of this kind are supplied by some of the larger manufacturers of paper box machinery.

In some paper box factories, where small, round and oval pill boxes are produced as a specialty, the tubes are rolled by hand on forms of the required sizes. After a tube has been rolled, it is placed on another form to dry for about twenty-four hours before being cut into small sections on a lathe. The machine-made tubes are said to be just as satisfactory as the hand-made tubes. All of the tubes are allowed to dry thoroughly before cutting them into rings.

COVERING FOR ROUND AND OVAL BOXES.

As previously mentioned, small round and oval boxes are first covered with Round-work Glazed Paper, having special stretching qualities. This stock comes in rolls, 24 inches wide. A rotary slitting machine is used for cutting the paper into widths of the necessary sizes. The slitting and rewinding machine cuts the large roll into strips, and these are rewound into small rolls. The operators on the round and oval boxes make use of the smaller rolls when covering the boxes.

The glazed white or colored paper used for finishing the boxes also comes in rolls, and the large rolls are cut into sections, or different widths, on the slitting and rewinding machine, in exactly the same way as the Round-work Glazed Paper.

In some plants, small covering machines, of special model, are used by the operators in applying the paper to the sides of round and oval boxes. In other plants, all of the covering work is done entirely by hand, the operators working with paste, scissors, and the small, narrow rolls of glazed paper. This is artistic work, indeed, and it can be done only by experienced operators.

The hand-operators work on spacious tables, and these are provided with the tools, gluing-boards, paste-containers, and all of the material necessary for the making of the round and oval paper boxes. The operators at intervals rub their fingers on small cakes of bees’ wax to keep the fingers clear of paste or glue. One operator continually works at covering the boxes and lids; another works exclusively at finishing, or rather, covering the sides of the boxes and lids with strips of colored glazed paper; still another operator inserts the necks in the boxes. The boxes and lids are then assembled together, and the completed product is afterwards packed in large-size paper boxes, usually holding one gross each.

CUTTING ROUND AND OVAL PIECES.

The round and oval pieces of box-board for the tops and bottoms of the round and oval paper boxes are cut to the proper sizes and shapes by means of steel dies and a press. A steel die of the required size and shape is placed over about a dozen pieces of box-board. The die and stock are then placed under the head of the press; powerful pressure is applied, and the steel die cuts through the dozen or more pieces of box-board, cleanly cutting out the disks or ovals as the case may be. It is necessary, of course, to have a steel die for each size and shape desired. The manufacturers of small round and oval boxes have complete sets of steel dies, suitable to all the standard sizes of work, and these dies are kept in first-class condition so that they are always capable of doing sharp, clean cutting. Several different dies may be put under a large press at one time. The square or oblong pieces of box-board are cut to sizes to conform with the various sizes of dies so as to prevent as much wastage of stock as possible. A margin of about one-half of an inch, all-round, will do for the average die. Steel dies and die-presses can be furnished by any of the large manufacturers of paper box machinery.

OVAL SHOULDERED PILL BOXES WITH PROJECTING EDGES.

Oval shouldered pill boxes with projecting edges are made much in the same manner as round shouldered pill boxes with projecting edges, with the exception that oval forms are used for properly shaping the boxes and their lids.

The forms for the oval boxes are usually made of hard-wood, and they are accurately cut and smoothly finished so that the box and lid will fit nicely together. The covering is done while the box, or the lid, remains on the form. The regular rings, cut from the round tubes are used, and these round rings are easily placed over the oval forms. Extreme care must be exercised by the operator when applying the Round-work Glazed paper to the sides and projecting edges of the oval boxes and lids. The work of setting in the necks is comparatively simple.

Oval Shouldered Pill Box with Projecting Edge—Covered
with enameled paper, leaving four gold edges.

A particularly beautiful effect is obtained by first covering an oval shouldered pill box (projecting edges) with gold Round-work Glazed paper, and by then covering the sides with white, buff, pink or blue glazed paper. This leaves four gold edges. A striking color effect is obtained by first covering the box and lid with black paper, and then covering the sides with lavender glazed paper. Purple and gold make another pretty color scheme.

ROUND FACE POWDER BOXES WITH DOME TOPS.

Among the most popular face powder boxes are the round ones having domed tops. Boxes of this design also have projecting edges. Some are covered with fine, colored and embossed paper, leaving four gold edges; others are entirely covered with gold paper; others still have four white or gold edges and are finished with colored glazed paper.

Face Powder Box with dome top—Covered with colored
enameled paper, leaving four gold edges.

Beck Doming or Embossing Machine.

The Charles Beck Company, of 609 Chestnut street, Philadelphia, make a duplex embossing press which has been designed especially for the “doming” of tops for round or oval face powder boxes. It is a hot press, and by means of brass male and female dies, it shapes round or oval pieces of box-board into convex forms for the tops of the boxes. The Beck Duplex Embossing Press consists of two complete presses which operate alternatingly. A set of dies is placed in proper position in each press. The operator places a box-top over the female die of one press, and as that box-top is being embossed, the operator places another box-top over the female die of the other press. In this way there is always a box-top being embossed, either on one press or the other. The box-top remains between the heated dies long enough to be firmly molded into a dome.

The printed labels for dome-topped face powder boxes are pasted on the round or oval pieces of box-board before the embossing is done, so that the labels will have the same convex form as the box-board. The covering is done the same as with flat-topped round boxes with projecting edges.

ODD-SHAPED FACE POWDER BOXES.

Fancy face powder boxes are made in many different sizes and shapes. Some have mirrors set in on the inside of the lids, so that the lady using the powder, when traveling, may see her face. Novelty boxes of this kind are “irresistible” to the fair sex. They are in great demand, and they bring high prices. Some face powder boxes are square with round corners; others have shapes like hearts, diamonds, etc. The odd-shaped boxes usually have wide flanges, or French edges, top and bottom, sometimes projecting as much as one-quarter of an inch. The tops are embossed, or are padded with cotton wadding before the covering is applied. The covering often consists of fine embossed paper, in rich colors like deep red, royal blue, purple, gold, pink, and warm brown.

All of these boxes are made entirely by hand from fine grades of cardboard, although the tops and bottoms are usually of the ordinary box-board, covered on both sides with glazed paper. Forms are used in making the odd-shaped boxes, and the work is done by highly-skilled operators who have had long experience on the one line of product.

PLAIN OBLONG POWDER BOXES.

Small paper boxes of this variety are used extensively by the drug trade for physicians’ prescriptions calling for powders wrapped in papers.

Oblong Plain Powder Box—Covered with colored
glazed paper.

Boxes of this type are made from light-weight Manila, news, chip or straw-board, and they are cut, scored and folded in practically the same way as the larger-size set-up boxes. There is a machine on the market especially designed for cutting corners and scoring blanks for small boxes of this variety. The corner-cutting and scoring are done simultaneously, so that the corners and scoring-lines will register accurately. In fine hand-work, pieces of the glazed covering paper are cut to the sizes needed. The strips of paper are pasted around the sides of the boxes and lids, and the edges of the paper are turned in, top and bottom.

Many small-size, square and oblong pill and powder boxes are now being made by machines. The Improved Brightwood Automatic Box Machine, manufactured by the U. S. Automatic Box Machinery company, of Boston, Mass., will make paper boxes as small as 1 and ½ inches as well as boxes of larger sizes. Another wonderful device is the Automatic Box Making Machine, Model 33, manufactured by the New Jersey Machine Corporation, of New York City. This machine will automatically make a wide range of small set-up boxes such as are used for cigarettes, cigars, needles, pins, buttons, clips, pills, powders, jewelry, garters, etc.

SLIDING BOXES FOR POWDERS AND LOZENGES.

The small-size sliding boxes are also used liberally by the drug trade, for powders, pills, lozenges, etc.

Sliding Box—Covered with gold embossed paper.

These boxes are made from light-weight manila, news, chip or straw-board, both the box and the sliding holder being covered with glazed paper, or fancy embossed paper. In some instances, the edges of the slide and box are trimmed, but in most cases plain covering is done. The box proper is made the same as a small set-up box. The sliding tops are made the same as the necks for square or oblong boxes. Nearly all sliding boxes are made by hand.

The sliding tops for this kind of boxes are first made in long sections, being cut and creased on a regular cutting and scoring machine to the desired widths. The long sections are then cut into smaller pieces on a machine like the Robinson Chopper, made by John T. Robinson Company, of Hyde Park, Boston, Mass. Necks for other styles of boxes are cut, scored and “chopped” in the same manner.

After the long sections for the sliding tops have been cut into the proper lengths, the covering is then done. The pieces of cover paper are cut on a paper cutter to the necessary sizes. The operator first pastes a sheet of the cover paper around the sides of the slide, leaving the edges of the paper projecting at each end of the slide. Then, with scissors, the operator cuts the projecting paper, at each corner, on an angle. The edges of the cover paper are then turned in on the inside of the slide. The box is covered the same as a large-size set-up box, the edges of the paper being turned in at the top and bottom. The corners of small sliding boxes are not always stayed, the covering paper being sufficient to hold the corners together.

Some sliding boxes are covered with white “watered” paper; others are covered with glazed plaid paper of various colors. Others, still, are covered with calico paper, or with gold star paper.

OBLONG SHOULDERED POWDER BOXES.

Paper boxes of this model are generally used by druggists for holding physicians’ prescriptions of powders, but these boxes are also used for holding capsules, tablets, etc.

Oblong Shouldered Powder Box—Covered with white
enameled paper, and having four gold edges.

These boxes are made from Manila, news, chip or straw-board, of the lighter weights, and the side of the stock which will appear on the inside of the boxes and lids is first lined with white paper. Some of these boxes are made the same as regular set-up boxes (with the exception of the neck). Others are made with set-in top and bottom pieces. The box-board for the inner tops and bottoms of the best quality boxes are lined with white enameled paper, the stock used for the sides of the boxes is lined with plain white paper.

In the case of an oblong shouldered box having set-in top and bottom pieces, forms, or blocks, are used by the operators for holding the tops and bottoms into position as the trimming paper and covering paper are applied. The trimming paper is applied first, then the covering paper is put on, leaving four edges of the trimming paper exposed.

The necks, or shoulders, are first made in long sections with the aid of a rotary cutting and scoring machine. The long sections are then cut into the desired lengths on a machine like the Robinson Chopper. The outer sides of the necks are now covered with white enameled paper, and after the paper has been turned in over the inner sides of the necks, the necks are then inserted in the boxes, held with glue at the sides.

Small boxes of this style usually are covered on the bottoms with white enameled paper. The tops of the lids are not covered, the printed labels used by the druggists serving as coverings. The boxes and lids of shouldered boxes of this kind are both of the same size. The trimming and covering is done in various colors of paper.

The greater number of square and oblong shouldered boxes have the tops and bottoms set in, instead of the box and lid being formed of solid pieces of box-board, for this reason: The sides for shouldered boxes are made in long sections, and after the long sections have been folded to the proper shape, and stayed at one corner, (on the inside) the long sections are cut into the necessary widths on a chopping machine. Naturally, by this method, the “frames” for the boxes and lids are all of the same square or oblong size, on account of having been cut from the one size material. This means that the lid and box register accurately.

SQUARE SHOULDERED BOXES.

Square shouldered boxes, for physicians’ prescriptions of powders and pills, are almost as popular in the drug trade as round boxes.

Square Shouldered Pill and Powder Box—Covered with buff
glazed paper, trimmed with four gold edges.

Practically all square shouldered pill and powder boxes are made with set-in tops and bottoms. The sides are first made in long sections. The long sections are then cut on a chopping machine to the smaller sizes necessary for the sides of the boxes. The small “frames” are put on forms; the square blanks are set in, and the trimming paper is applied which holds the square pieces to the sides. The strips of covering paper are then pasted around the sides. The necks are made in long sections, afterwards being cut into the required lengths. The stock used for the necks is lined on the inner side with white paper. After the long sections have been cut into smaller lengths, each small section is covered on the outer sides with white enameled paper, the paper being turned in over the edges which will appear at the top of the neck. The necks are then inserted in the boxes, held with glue at the sides. The lids and boxes are both the same size, and they register accurately over the neck.

An attractive color effect for a square shouldered pill and powder box is obtained by first covering the box and lid with red glazed paper, and then covering the sides of the box and lid with green imitation wood paper. This leaves four red edges showing.

Some square shouldered pill and powder boxes have hinged lids, so that in the homes of sick people the covers of different boxes cannot become interchanged, and wrong directions on the labels of the covers followed.

SQUARE TELESCOPE BOXES.

The telescope pill and powder box is also popular in the drug field. The lid and box are both of the same depth, and the lid fits down over the sides of the box. A box of this type may be over-filled with capsules or powder papers, the deep lid allowing for the extra capacity.

Square Telescope Powder or Pill Box—Projecting edges at
bottom—Trimmed with gold paper, and covered
with colored glazed paper.

Telescopic boxes of this class are made the same as small set-up boxes in cases where the box does not possess an extension bottom. When the box has projecting, or French edges, the sides are made in the same way as the square shouldered boxes, with the exception that the bottom piece of blank is not set within the sides. In this case, the square blank is placed against the edges of the body, in proper position, and the operator wraps the paper in such a manner as to hold the bottom-piece firmly to the edges of the sides. Some telescope boxes have projecting edges trimmed with gold paper, and the sides covered with white enameled, or colored glazed paper. The inner sides of the box and lid are usually lined with white glazed paper.

SUPPOSITORY BOXES WITH PARTITIONS.

Suppository Box—Covered with white enameled paper,
four bronze edges—Lined with tin foil.

Suppository boxes with partitions are made much the same as square or oblong shouldered pill and powder boxes, with the exception of the lids being deeper, and the addition of the partitions. Some boxes of this variety are hinged.

The stock used for the partitions is usually lined on both sides with white enameled paper, or with tin foil. The interior of the box and lid is also lined either with white enameled paper, or with tin foil, to correspond with the partitions.

The Charles Beck company, of Philadelphia, supply a paper box-maker’s saw which is particularly adapted to the work of sawing slots for partitions of paper boxes. The E. G. Staude Manufacturing company, of St. Paul, Minn., furnish the Junior and Standard Slotters which are adapted to all kinds of slotting work for paper box partitions. The Staude slotting machines are equipped with automatic feeders, and they are capable of turning out a great amount of finished product very rapidly.

The edges of the partitions are glued to the sides and bottoms of the boxes.

CHAPTER VI

CANDY BOXES

ON account of the greatly increasing demand for candy boxes of all kinds in every section of the country, the writer thought it well to devote a chapter to this important subject, and an attempt will be made to explain the styles and construction of the most popular models of candy boxes which are on the market at the present time. It would be almost impossible for one to describe all of the many different kinds of candy boxes which are being made today, so it is the writer’s intention to mention merely those boxes that may be considered as standard in the trade.

Standardization of the styles and sizes of candy boxes is something that is seriously needed in the paper box industry, but standardization cannot always be followed by the manufacturers of candy boxes for the reason that the confectioners often want odd-shaped and special sizes of boxes to make their product more attractive to the public. It is a fact that a beautiful, odd-shaped paper box helps greatly in selling expensive candies, and even a “freak” box that is attractive without being beautiful is nevertheless a powerful selling agent. When the confectioner wants an out-of-the-ordinary box, and is willing to pay the necessary cost, the box-maker should give the confectioner what he wants, but whenever possible to talk the confectioner into using boxes of standard sizes, the box-maker should do so, as the standard styles and sizes of candy boxes will serve well for every practical purpose.

DEMAND FOR SWEETMEATS

With the passing of strong drinks in this country came a greater demand for sweetmeats from every direction. Confectionery and ice cream parlors are taking the places of liquor saloons in many instances. New candy factories are being erected in almost every town and city. American men and women are consuming larger quantities of chocolates, chewing gum and candies than ever before—they are paying high prices for the best sweetmeats, and expensive grades of confections are selling more rapidly than the cheaper grades. All of this means more business for the box-makers, and the box manufacturer who is in a position to make fine candy boxes as a specialty may have all of this class of work that he may care to produce.

Many box-makers are specializing in fancy candy boxes. Their plants are equipped to handle this one line of product to the best advantage. By making a specialty of this line, a great deal of the work can be standardized in such a way that the blanks, wrappers, neck-strips, trimming paper, covering paper, extension bottoms, etc., can be cut to standard sizes. The operators, through working continually on the same styles and sizes of boxes, soon become very efficient, and are capable of producing a larger output than would be the case in a plant that is not specializing on candy boxes. All successful box-makers are specializing in some particular kind of work, and this is a custom which should be more generally followed in the trade.

SYSTEMATIC ARRANGEMENT OF MACHINES

On the next page is a diagram which shows a systematic arrangement of machines for staying and wrapping extension bottom boxes and lids, affixing two laces in each box, and closing the boxes.

The extension bottoms are registered and attached to the box and lid blanks by means of a Stokes & Smith Extension Bottom Gauge, Model W.

The blanks are glued with a hand stencil and are placed in the gauge with the extension bottoms, after which they are delivered to the staying machine, which is elevated on a portable platform.

After the staying operation the boxes and lids are passed through a hopper to the operator of a Stokes & Smith Wrapping Machine.

The operator of the gluing machine places the glued wrappers upon a revolving table within convenient reach of the wrapping machine operator.