The main cause of Cracking is using the improper process for the material thickness; specifically, employing Scoring instead of Creasing for heavy boards. In these materials, Scoring only creates a superficial cut and fails to displace the thick fibers. Consequently, the fibers break under pressure when the board is Folded along the Die Line. This is particularly common in thick boards with rigid coatings.

To prevent this issue, the production supervisor must ensure the material is prepared with the appropriate process before the Fold. Creasing displaces the fibers of thick board by creating a deep groove, establishing a secure bed for folding, while Scoring, which makes finer cuts, is better suited for lighter materials and prevents the cracking of their printed coating.