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How is corrugated made?

1/ From paper to corrugated board

the papers used in the production of corrugated are specific grades called «Linerboard» and «Fluting Medium».

the adhesive which is applied to the tips of the flutes is starch usually originating from products of natural origin the most common being maize (corn).

The corrugator machine

A corrugator is a set of machines in line, designed to bring together three, five or seven sheets of paper to form single, double or triple wall board. This operation is achieved in a continuous process.

The reels of paper are fed into the corrugator, the paper is conditioned with heat and steam and fed between large corrugating rolls which give the paper its fluted shape in the Single Facer. Starch is applied to the tips of the flutes on one side and the inner liner is glued to the fluting. The corrugated fluting medium with one liner attached to it is called single face web and travels along the machine towards Double Backer where the single face web meets the outer liner and forms corrugated board. The corrugated board is then cut and stacked.


The main parts of a corrugator are the splicer and reelstand:

These are the machines which feed the paper rolls into the corrugator and enable rolls to be changed without interrupting the production of corrugated board.

The single facer:

This machine transforms the paper into a series of connected arches called « flutes » thanks to the corrugating rolls that are large cylinders with a corrugated profile. If the flute profile has to be changed, then the corrugating rolls need to be changed.

The double backer:

It glues the outer liner to the fluting to obtain single, double or triple wallboard. The single face web is pre heated, starch is applied to the tips of the flutes. The outer liner is then bonded to the single face web to form corrugated board. It is a complex operation that requires great expertise in the pre-heating, moisture control and gluing processes.

The bridge:

This enables the Double Backer to run at different speeds from the Single Facer especially when reel or order changes take place. This is achieved by the single face web forming festoons that are controlled at the Single Facer station.

Bridge festoons



The glue unit and double backer:

Here, the single face web is prepared for glueing to the outer liner.

It is roughly the same process as the single facer unit with some variations of the pre-heating and gluing processes.

The hot plate section:

It is at this stage that the single face web is combined with the outer liner. The heating section ensures that the bond is strong by gelling the glue and removing moisture.

The rotary shear:

After the board emerges from the Double Backer it passes under a rotary shear that cuts across the whole width of the web. This is used to chop out damaged lengths of board or to effect a change over from one grade of board to another.

The slitter / scorer:

This operation slits and scores the board in the machine direction, with the scoring which determines the style of the finished box.

The cut-off knives:

These cut the board to the exact required lengths to obtain the corrugated sheet used in the making of corrugated packaging.

The stacker:

Finally, corrugated sheets are automatically stacked. Then they are moved directly to the conversion machine or sent to a converting plant.

2/ The Conversion process: the line convertor

This is the final stage of the process that consists in printing and then slotting, folding and gluing the corrugated board to manufacture a corrugated container.

Different operations are carried out according to the customer’s specification and according to the type of packaging.

The three main categories are the "regular slotted case", the flat bed "die-cut" container and the rotary "die-cut" container. Die-cutting concerns packaging which requires very precise cutting and which can have a complex design.

The converting process varies according to the type of packaging:

Whatever the type of packaging, printing on corrugated sheets is always possible.

The flexographic print process is commonly used for printing on corrugated.

This process uses the relief printing technique and is characterised by:

high processing speed

high level of quality

and an excellent quality/price ratio

Printing can be done « in-line » or « off-line ».

The regular slotted cases (RSC):

Most of them are produced with an in-line flexographic Printer/ Slotter Folder Gluer which, in one operation, prints, cuts, folds and glues the blank into its final shape.

The packaging is then palletised and ready to be shipped flat to the customer.

The die-cut packaging:

Rotary Die-cutting



The die-cut containers are manufactured on a die-cutter that cuts and creases the board. It is usually reserved for a more sophisticated pack style.

This process requires a « form » that can be mounted around a cylinder, in which case the machine is called a rotary die-cutter, the other variant is called a flatbed die-cutter. As indicated by its name its form is flat.

Once the converting process is over, the corrugated packaging is put on a pallet and can be delivered to the customer. 

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3/5 Ply Automatic Board Plant

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Fingerless Single Facer Paper Corrugating Machine
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Fingerless Single Facer with two Profiles
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Single Facer Corrugating Machine
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Single Facer Corrugating Machine (Vertical Type)
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Flexo Printer Sloter Creaser Cum Rotary Die Cutter
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Automatic Sheet Laminating Machines
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Automatic Floder Gluer
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Flexo Board Printer
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Auto Reel to Sheet Cutter
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Sheet Pasting (Glueing) Machine
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Sheet Pressing Machine
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Board Cutter
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Auto Partition Slotter
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Automatic Assembly of corrugated Board Partitions
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4-Bar Rotary Siltter Creaser
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Overhung Eccentric Slotter
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Combined Creaser Slotter
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Box Stitching Machine
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Semi Sheet Laminating Machines
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Heavy Duty Punching, Creasing & Embossing Press
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Corrugator Rolls & Pressure Rolls
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Chain Feeding Rotary
Die Cutting Machine

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Printing Slotting and Die Cutting Machine
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Per-Heater & Pre-Conditioner
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3 no. of Pre-Heater for Paper and 2 Ply
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Mill Roll Stand
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Hydraulic Mill Roll Stand
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Single Facer Fingerless
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Single Facer Fingerless (PLC Controlled)
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Hot & Cold System
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Over Bridge Conveyor
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Pasting Machine
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Graduate
Pasting Machine

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Semi Automatic Lamination Machine
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Heavy Duty Flatbed Die Cutting Machine
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Single Facer With Sheeter
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Reel to Reel Slitting Machine
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Gum Making Plant
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Auto Stacker
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Fully Automatic Stiching Machine
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Speeding Semi-Auto Stitcher
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Single Face Paper Corrugating Machine
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Corrugating Problems Solutions
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Paper Testing
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How is corrugated made?
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Why Corrugated?
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Our Exports
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PAPER BOARD MACHINERY COMPANY
Regd. Office :
115, D.L.F. INDUSTRIAL AREA PHASE - 1, FARIDABAD - 121003, HARYANA (INDIA)

Contact Numbers :

Telefax : + (91) - (129) + 4113117  
Mobile : 0091 - 9811071540, 9818056789

E-mail :

paperboard@gmail.com corrugatingmachinery@gmail.com nagpalgroup@gmail.com

URL :

www.corrugatingmachinery.com  
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