Process optimization of paper cup bottom-forming using FEM and experimental validation

The extensive use of single-use food and beverage containers continues to raise environmental concerns, particularly due to the limited recyclability of polyolefin-coated paperboards. While polyethylene-coated structures remain prevalent in current manufacturing practices, improving their formability is essential for both optimizing existing processes and enabling the future adoption of more sustainable barrier materials. This study focuses on the bottom-forming stage of paper cup production, a process critical to achieving structural integrity and sealing performance. A finite element modeling approach was employed to simulate deformation behavior and stress distribution during forming, with experimental trials conducted to validate key results. Process parameters such as curling depth and production speed were systematically varied to evaluate their influence on forming outcomes. The results demonstrate that a curling depth of 4.3 mm provides improved seal consistency and structural uniformity, particularly at lower production speeds (80 cups/min), thereby minimizing the risk of defects commonly observed in fast, high-volume manufacturing settings. These findings contribute to a better understanding of process-structure relationships in fiber-based composite forming and offer valuable insights for reducing material waste and enhancing process reliability in sustainable packaging manufacturing.