Wasted Energy:

Wasted  Energy:  
The
The  55  Culprits
Culprits  ooff  PPoor
oor  
Tube and Core
Tube   &  CProduction
ore  Production   and
How to Fix Them
and  How  to  Fix  Them  
 The Importance of Preservation in
the Paper Industry
Today,  there’s  no  shortage  of  waste  awareness  and  initiatives  
in  business.  Companies  are  inundated  with  the  concept  of  
“going  green”  and  reducing  their  impact  on  the  environment.  
It’s  no  longer  acceptable  for  businesses  to  over-­‐consume  or  
waste  materials  without  a  legitimate  purpose  and  explanation.  

In  the  paper  industry,  waste  reduction  is  essential.  While  

In  many  cases,  paper   producing  and  converting  paper,  businesses  are  expected  to  
based  products   use  the  most  conservative  practices  to  preserve  natural  
resources  and  prevent  unnecessary  waste.  Large-­‐scale  paper  
already  have  a  slim  
production  means  higher  standards  when  it  comes  to  
profit  margin.  Wasting   preventing  and  managing  waste.  
a  portion  of  that  is  
While  preserving  the  environment  is  essential,  it’s  not  the  only  
simply  not  an  ideal   reason  why  paper  manufacturers  should  be  concerned  about  
outcome  from  a   conserving  paper  and  eliminating  unnecessary  waste.  It’s  also  
business  perspective.   an  economic  issue:  Wasted  paper  has  an  impact  on  cost,  which  
has  an  impact  on  the  price  a  company  charges  its  customer  for  
the  final  product.    

In  this  guide,  we’ll  cover  five  impediments  that  that  the  tube  
and  core  industry  can  correct  to  cut  down  on  waste  and  
improve  manufacturing  over  the  long  term.  

2
 What Challenges Do The Tube
and Core Industry Face?  

Before  we  begin,  it’s  important  to  note  the  differences  

between  the  two  main  components  in  the  tube  and  core  
industry:  
Whatever  the  
• What  is  a  tube?  a  protective  packaging  element purpose,  creating  
primarily  used  for  shipping  and  storing  paper-­‐based
products  that  cannot  be  folded  (such  as  printed tubes  &  cores  
posters  or  artwork,)  often  made  of  cardboard  or  a
requires  that  
similar  material.
• What  is  a  core?  a  central  cylinder  of  cardboard  or paper  serves  its  
similar  material  around  which  another  material  is
wound,  such  as  cellophane,  gift  wrap,  or  adhesive
function  
tape. precisely.  
Tubes  and  cores  serve  a  variety  of  purposes,  primarily  for  
shipping  and  industrial  uses.  Here’s  a  look  at  the  main  
culprits  of  poor  tube  and  core  production  and  how  
manufacturers  can  preserve  material  and  reduce  waste:  

3
 Culprit  #1:  Frequent  roll  changes  

According  to  the  Environmental  Protection  Agency,  every  year  Americans  use  about  90  
million  tons  of  paper  and  paperboard,  or  about  700  pounds  of  paper  for  every  man,  woman,  
and  child  in  the  country.  That’s  a  staggering  figure.    

We  know  that  fewer  roll  changes  mean  less  scrap  from  splices,  as  well  as  fewer  machine  
slow-­‐downs.  Lower  basis  weights  help  reduce  a  manufacturer’s  cost  per  lineal  foot.  Think  
about  changing  out  a  paper  roll  repeatedly  during  the  tube  and  core  production  process.  
Each  time  a  roll  runs  out  and  has  to  be  changed  over,  the  machine  loses  efficiency,  and  time  
is  added  to  the  process.  This  also  generates  waste.  

Tube  and  core  manufacturers  can  begin  reducing  waste  by  using  higher  yield  paper  grades.  
More  lineal  footage  per  pound  on  a  roll  of  paper  can  increase  yield  and  decrease  cost  and  
waste.  

It’s  important  for  tube  and  core  manufacturers  to  look  for  paper  convertors  that  will  
maximize  the  value  of  a  paper  roll.  Using  minimal  splices  during  production  can  significantly  
reduce  tube  waste,  and  save  money  in  the  process.  

Culprit  #2:  Precision  isn’t  priority  

Consider  this  statistic,  according  to  the  World  Resources  Institute,  the  U.S.  is  home  to  just  5%  
of  the  world’s  population,  but  it  uses  about  30%  of  the  world’s  paper  products  every  year.    

Another  way  tube  and  core  manufacturers  can  reduce  waste  is  by  ensuring  their  paper  
converter  is  providing  with  them  with  accurately  slit  paper  rolls.    One  of  the  causes  of  waste  
in  the  tube  and  core  industry  is  from  paper  that  is  incorrectly  slit.    

In  addition,  tubes  or  cores  with  printed  images  or  logos  also  require  precision  in  printing  and  
layout.  If  the  image  on  a  tube  or  core  is  printed  with  incorrect  measurements,  the  paper  
used  to  wind  the  tube  or  core  will  form  an  image  that  doesn’t  match  up  and  will  often  be  
thrown  away,  or  look  unprofessional.  Avoid  this  issue  by  seeking  out  paper  for  tube  and  core  
manufacturing  from  a  trusted  paper  converting  company  and  by  providing  detailed  
measurements  for  your  products.  

4
 Culprit  #3.  There’s  no  commitment  to  consistency  
Repetition  breeds  familiarity.  Having  a  consistent  product  will  cut  down  on  mistakes  and  
keep  the  production  process  moving  more  efficiently.    

One  of  the  signs  manufacturers  will  often  notice  is  flagging,  or  dog-­‐ears,  peeling  from  the  
edge  of  a  tube  or  core.  This  is  an  indication  that  the  material  around  a  core  is  incompatible  or  
that  inaccurate  measuring  has  led  to  a  discrepancy  in  alignment.  Choosing  compatible  paper  
and  working  with  it  the  right  way  are  key  to  creating  a  quality  tube  or  core  product.  

One  way  to  achieve  a  consistent  paper  product  is  through  consistent  paper  characteristics.  
This  makes  achieving  the  right  fit  and  maintaining  accurate  measurements  easier.    

Qualities  such  as  water  hold  out,  smoothness  of  sheet,  finish  of  sheet,  and  moisture  are  
important  factors  for  the  paper  used  in  tube  and  core  manufacturing.  The  ideal  consistent  
tube  or  core  paper  should  align  evenly  together  when  the  slit  width  is  correct.  Tight  
registration  and  a  consistent  product  help  reduce  overall  waste.  

Culprit  #4.  There’s  no  recycling  plan  in  place  

This  is  the  easiest  solution  for  paper  waste.  The  bad  news:  paper  and  paperboard  products  
represent  the  largest  portion  of  our  municipal  solid  waste  stream  (i.e.,  trash).  The  good  
news:  in  2013,  we  recycled  over  67  percent  (or  nearly  5.4  million  tons)  of  all  the  paper  that  
Americans  used,  according  to  the  EPA.    

Recycling  is  the  ultimate  key  that  tube  and  core  manufacturers  can  use  to  manage  the  waste  
incurred  during  the  production  process  in  a  sustainable  way.  Partnering  up  with  a  local  
recycling  facility  or  using  machinery  to  collect  and  compact  your  paper  waste  can  keep  the  
process  easy  and  ongoing  for  your  business.    

Tip:  Avoid  throwing  away  board  and  cores  that  you  don’t  have  to  in  the  production  process.  
Instead,  look  for  ways  to  repurpose  paper  or  discarded  cores.    

5
 Culprit  #5.  Branding  opportunities  are  lost  
Another  opportunity  tube  and  core  manufacturers  often  overlook  or  underutilize  is  custom  
branding  on  their  products.  By  printing  your  logo  or  contact  information  on  tubes  and  cores,  
you  can  create  a  marketing  impact  on  the  items  customers  see  every  day.    
A  versatile  paper  converter  can  print  on  paper  and  cardboard  prior  to  tube  and  core  
manufacturing  for  a  cleaner  and  more  precise  process.  Simpler  printing  jobs  can  be  
accomplished  on  completed  tubes  and  cores  as  well.  In  either  case,  the  added  value  for  your  
brand  makes  having  the  logo  or  branding  message  printed  on  your  product  an  easy  step  to  
make.  In  fact,  it  could  only  cost  pennies  more  to  add  custom  printing  to  a  tube  and  core  
paper  order.    

When  you  use  simple  steps  like  these,  not  only  do  you  cut  down  on  waste,  you  reduce  costs  
and  downtime,  and  improve  production.    As  a  tube  and  core  manufacturer,  look  for  a  paper  
converting  company  that  offers  overall  and  customization  for  your  paper  needs.  Having  
precise  measurements,  using  a  consistent  product,  recycling  left  over  material,  and  adding  
your  logo  are  all  ways  you  can  overcome  the  top  5  culprits  to  tube  and  core  production.    

To  learn  more  about  finding  the  right  tube  and  core  paper  components,  contact  us  today.  If  
you’d  like  more  information  on  paper’s  impact  on  the  environment,  download  our  guide  –  
The  Paper  Trail:  Environmental  Myths  and  Facts  

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