Abbey Corrugated Limited

Home > Abbeys products

Products

Abbey produce sheets of corrugated board which are converted by our customers. We do not make boxes or convert sheets. The most common applications for corrugated board are transit boxes, point of sale displays and more general packaging uses. Abbey can produce Single wall, Double wall, Exposed flute and Single face (sheet and rolls)

	Conventional board grades Specialty board grades Claycoat		Barrier liners
			Performance liners
			Exposed flute
			Single face
			PrePrint Flutes Available Flutes and their benefits Machine specifications Average count/stack per pallet Maximum/minimum sizes
	Microflute

CONVENTIONAL BOARD GRADES

A comprehensive range of grades and flutes are available from Single wall Chip/Chip through to Double wall 300Kraft/300Kraft/300Kraft with 175 fluting. We are able to offer virtually any paper combination subject to it meeting minimum order and quality parameters. As part of our Technical Service backup our policy is to recommend an alternative board grade if we believe it offers a more cost effective solution to your requirement. back to menu

SPECIALITY BOARD GRADES

Abbey offers an extensive range of specialised products that are aimed to meet high quality process, rigorous constructional and performance applications. Our range provides an ideal solution to customer requirements and expectations, often being created from materials that are out with traditional grades. Combining these materials with dedicated plant, state of the art equipment, and experienced operators enables Abbey to enhance our customers's product.

CLAYCOAT

Due to the nature of the retail environment, competition to gain the consumer's attention is fierce. Hence in point-of-sale, promotional or display applications the choice of material is critical to ensure your product receives that all-important shelf-shout. To this end we have two material grades marketed under the brands of AbbeyScreen and AbbeyFlex that offer the ultimate finish to differentiate your product. AbbeyScreen is a full clay coated surface, applied to a virgin fibre kraft board. Specifically for use for screen printing due to its bright white finish and smooth coated surface.

AbbeyScreen is a full clay coated surface, applied to a virgin fibre kraft board. Specifically for use for screen printing due to its bright white finish and smooth coated surface AbbeyScreen provides the optimum printing solution for achieving process, fine screen and halftone printing.

click here for the product sheet

AbbeyFlex is a lightly coated clay surface applied to a virgin fibre kraft board that has been specifically formulated to assist the absorption and drying of flexo inks. The clay coating provides an excellent print surface with a bright white, high lustre, smooth finish making AbbeyFlex ideal for multi colour, fine line and halftone graphics.

click here for the product sheet
back to menu

MICROFLUTE

Microflute is a board type that offers an alternative to solid board.

AbbeyLite is a versatile design material being light in weight yet impressively strong and it offers exceptional protection whilst remaining extremely flexible. The small pitch and density of flutes creates a superior surface for printing thus enabling maximum brand exposure.

AbbeyLite also offers the added opportunity to make savings in material reductions, process and labour costs, packaging waste and transportation costs. It is available in both F and N flutes and is an ideal substrate for direct litho, silkscreen of flexo printing process.

click here for the product sheet
back to menu

BARRIER LINERS

Abbey offer bespoke barriers for a variety of protection and performance applications. These barriers are used to prevent such things as: moisture, humidity, grease or oil from effecting the integrity of the corrugated packaging or damaging the products carried or packed within them. In addition, they also enhance the performance of the packaging by adding additional strength and on selected grades can be used in direct contact with food.

These barrier liners combined with the advantages of corrugated packaging (i.e. strength, flexibility, ease of handling and cost efficiency) allow for the packaging to be used in applications where currently more rigorous and expensive materials are used. This provides the opportunity through constructional design and product flexibility to create cost saving solutions to your customers without effecting performance.

Barrier liners are available to special order on kraft, white top kraft and clay coat on various standard grammages. Abbey can assist in identifying the correct material to suit our current specification.
back to menu

PERFORMANCE LINERS

In addition to our barrier range we offer performance liners where their applications are more specialised and user specific. We are currently supplying Ovenable, grease resistant (food applications), silicon release, acid free and microwaveable liners. Many of these liners are of particular benefit in the bakery sector where the versatility of corrugated and the performance of the liner allow raw product to be placed in direct contact and baked in an oven for a specified period. Once ready the finished produce can be sold in the existing packaging or easily released from the liner for customer consumption. This not only provides ideal display packaging but also reduces costs and saves on labour, as no baking trays require cleaning.
back to menu

EXPOSED FLUTE

A double wall product, available in EB and NE, where the outer most liner is excluded thus revealing the top flute profile. This product is ideal for creating unique decorative display packaging, particularly when combined with a preprint flute liner. In addition, exposed flute can also be used as a double wall mounting sheet where the exposed fluting has a litho or screen printed top sheet mounted to it thus creating a strong and rigid product ideal for headers or free standing displays.
back to menu

SINGLE FACE

Abbey offer 3 flute profiles (B, E, F) in either sheet or in roll format. This product is ideally suited for litho laminating display packaging where the thin printed top sheet is mounted onto a corrugated board. The resulting combination adds excellent strength, protection and quality graphics to the overall pack.

Abbey offer a preprint (chop to register not available), barrier and performance liners on all its single face flute profiles.
back to menu

PREPRINT

The method of adding up to 6 colours and varnish, in one pass, onto a liner prior to corrugating. The advantage of this application is that due to having no flute profile to contend with an excellent print reproduction can be achieved as print registration and colour balance are more readily controlled.

In addition, preprint is of particular use in laying down base colours that are difficult to maintain or shade critical for "branded" applications. It can also add colour to the inside liner of the board thus reducing the number of passes on press and lessen the risk of damage to the outer liner - this is of particularly relevance to clay coated point of sale products. Abbey offer preprint in chop to register, random repeat and full colour tint and recommend the following liner grades for achieving the maximum print result; clay coat, white top kraft and fully bleached kraft liners.
back to menu

FLUTES AVAILABLE

PROFILES AVAILABLE
Flute Profile	Flute heights (mm)	Take up factor
B	2.2	1.37
C	3.7	1.44
E	1.1	1.28
F	0.7	1.19
N	0.46	1.15
BC	2.2/3.7	1.3/1.44
EB	1.1/2.2	1.37/1.44
NE	0.46/1.1	1.15/1.28

FLUTES AND THEIR BENEFITS

C FLUTE
A larger flute than 'B', offering greater compression strength, but it may be crushed more easily. It also takes up more storage space than 'B' flute.

B FLUTE
By far the most widely specified flute profile thanks to its superb robustness (difficult to crush), good compression strength and compactness which minimises storage space.

E FLUTE
A fine flute used for corrugated 'cartons'. It gives excellent crush resistance and a compression strength better than solid fibreboard. Excellent printability.

F FLUTE
This material offers an exceptional surface for printing and is impressively strong thus creating a versatile decorative packaging material. It is suitable for printing by screen, flexo and can be processed by new generation litho machines.

N FLUTE
The finest flute that Abbey manufacture and has been specifically engineered to allow for direct litho printing. It is light in weight, offers exceptional protection and has a superior surface for printing thus making it ideal for decorative packaging applications.

BC DOUBLE WALL
A combination of 'B' and 'C' flute is normally specified when compression and stacking strength is important.

EB DOUBLE WALL
If strength and good printability are required then EB Double wall should be considered. Other benefits are that the performance of EB to BC is not that different but EB uses much less storage space. Conversion speeds are similar to C flutes.

NE FLUTE
Abbey have created a superior double wall combination that maximises the graphical benefits that can be obtained from claycoat liners. NE flute provides the optimum print surface for both screen printing and post print flexo applications, by having the outer liner fully supported by the N flute profile - this results in the complete elimination of flute shadow. It prevents unwanted density and tone changes during printing. This not only speeds up the printing process, through more control and less waste, but also produces a superb reproduction of your graphics. NE flute is an outstanding versatile design product. It is thin in caliper, light in weight, yet exceptionally strong. It is easily formed and enables tighter constructional tolerances thus permitting the creation of more elegant display packaging.

Roll your mouse onto the image below to see the difference NE flute makes

MACHINE SPECIFICATIONS
Flute form	Site	Slit Min*	Slit Max**	Chop Min***	Chop Max**
C	Blunham	250mm	2460mm	575mm	4600mm
B	Blunham	250mm	2460mm	575mm	4600mm
E	Kettering	250mm	1760mm	550mm	3700mm
BC	Blunham	250mm	2460mm	575mm	4600mm
EB	Kettering	250mm	1760mm	550mm	3700mm
F	Kettering	300mm	1350mm	550mm	1650mm
Claycoat (B,E,EB,NE)	Kettering	250mm	1760mm	550mm	3700mm
Single Face (B,E,F)	Kettering	325mm	1560mm	550mm	1650mm
Abbeylite (F,N)	Blunham	300mm	1050mm	500mm	1550mm
Notes	*	First way sizes between 200mm and 249mm will be subject to a surcharge and dependant on flute profile. (Please contact customer services for details).
	**	For sheet sizes where the width is greater than 1760mm or the chop is greater than 4000mm the minimum order quantity will range from 500 m2 or 3000 m2 depending on the grade being ordered:
	***	Minimum chop length for widths greater than 1760mm is 600mm. Chop lengths below 575mm and 550mm may be available on certain flutes. Please contact customer services to discuss profiles and costs.

The approximate sheets per pallet are as detailed in the table below - please note that these quantities may vary due to the grade and size of sheet ordered.

Average count/pallet
Flute Profile	Double Face	Single Face
B	400	900
C	270	400
E	600	1070
F	900
N	1100
BC	180
EB	270
NE	350

back to menu

WELCOME I MISSION I PROFILE I NEWS I PRODUCTS I PRODUCT SEARCH I SERVICES I ORDERING I TECHNICAL SERVICES I EDI I CONTACT