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Corrugated Machines and Ancillary Machines

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Aydly Intelligent Packaging Machinery (Guangdong) Co., Ltd. is one of the subsidiary of A.S.I. Group (American Sunflower International Group Co., Ltd.) headquartered in New York USA, Singapore and Hong Kong, China.

 

One-stop solution
We integrate technology research and development, manufacturing and processing, assembly, sales, export, installation and after-sales service, etc. We commit to provide a full range of solutions to the global customers of paper and paperboards related with industries of manufacturing, printing and packaging.

 

High quality
We specialize in carton box printing and packaging machines, corrugated paperboard production lines, laminating machines, flat bed die cutting and creasing machines, EPC with paper making machines, etc.

 

High quality service
Our sales staff visit the customers' plants and discuss requirements, online communication, answer questions and solve difficulties. Technicians on-site installation, regular factory tour to check the machines running and maintenance, repair and fix, global express delivery for the ordered parts, etc.

 

What Is a Corrugator Machine

 

 

A corrugator machine is a large machine composed of a series of smaller machines that combine two different kinds of paper to create cut sheets of corrugated fiberboard. The flat, facing sheets are referred to as liners, while the wave-like, fluted layers are known as the corrugating medium, or simply the medium. The corrugator machine takes large rolls of paper produced on paper machines, flutes the medium, and glues it to the liners, one at a time. It then delivers stacked, cut, and scored sheets of corrugated board to various converting machines. These converting machines turn the sheets of corrugated board into "box blanks," which are ready to be made into boxes and other corrugated board products.


The corrugator combines rolls of linerboard and medium into sheets of corrugated board. A typical corrugator is equipped to run both single-wall and double-wall configurations in a variety of flute heights. Modern machines can also be equipped with innovative enhancements that offer a range of value-added features such as functional coatings, color coatings, tear tape or internal strings, and water-resistant adhesives. Advanced technology, such as razor cutting knives and robotic scoring heads, allows the machine to produce high-quality board with faster setups and shorter cutoffs.

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Why Do You Need a Corrugated Machine

Corrugated boxes are an important part of everyday life. They provide an easy-to-use and renewable packaging resource for almost any product. Corrugated cardboard is something you see every day. Corrugated cardboard containers are widely used in the packaging of both industrial and consumer products.


The demand for corrugated boxes is strong, and their packaging is cost-effective. Main products include cosmetics, soap, auto parts, pottery, glassware, medicine, biscuits, and more. The corrugated box industry plays a crucial role in manufacturing within our economy, affecting everything from food to refrigerators.


Because corrugated boxes cannot be transported economically over long distances, carton factories are often located near production sites. To produce these boxes, a corrugated box-making machine must be equipped with high-quality corrugating equipment and properly maintained.

Automatic Multifunctional Box Folding Machine

 

What Are the Benefits of a Corrugated Machine

If you're in the business of shipping products, you know that corrugated boxes are an essential part of your operations. A corrugated machine can help you create custom corrugated boxes quickly. Here are just a few benefits of using a corrugated machine in your business:

1

Improved Efficiency

Improved Efficiency
A corrugated machine can help you create cartons quickly and efficiently without sacrificing quality. This means you can get your product out faster and with less hassle.

2

Enhanced Quality

When you use a corrugated machine, you will be able to produce strong and durable boxes. This means your product will be better protected during transit and will arrive in better condition.

3

Customization Options

Using a corrugated cardboard-making machine provides many customization options. You can choose the size, shape, and color of your corrugated boxes, ensuring they are the perfect match for your brand and product line.

4

Cost-Effective

Corrugated box-making machines are a cost-effective way to produce custom corrugated boxes. You don't have to outsource your box-making needs; you can create just the boxes you need in-house.

 

Corrugator Machine: Corrugated Cardboard Manufacturing Process
2200 Corrugator Cardboard Lines
Single Gluer Machine for Corrugated Lines
5 Ply Corrugated Cardboard Production Lines
7 Ply Corrugated Cardboard Production Lines

The raw materials for corrugated cardboard are specific grades of paper known as linerboard and corrugating medium (or fluting medium). Linerboard forms the surface of the corrugated cardboard and has strong tear resistance and strength. The corrugating or fluting medium is paper that is corrugated in the single facer; after corrugating, it has increased folding and compression strength. Two sheets of linerboard and one sheet of corrugating medium can be combined to make 3-ply corrugated cardboard, with adhesive applied to the tips of the corrugated flutes. The adhesive is typically made from starch, most commonly maize.


The corrugator machine, also known as the corrugated cardboard production line, is a set of machines arranged in a line that can handle three, five, or seven sheets of paper to produce single, double, or triple-wall cardboard. The corrugated cardboard manufacturing process can be achieved continuously.


The reels of paper are fed into the single facer and conditioned with steam heat. The corrugating medium is formed into flutes between the corrugating rollers in the single facer. Next, starch is applied to the tips of the flutes, and the inner liner is glued to them. The corrugated medium and liner then exit the single facer together, forming what is known as the single face web. After leaving the single facer, the single face web enters the double facer, where it meets the outer liner and forms 3-ply corrugated cardboard. After the double facer, the cardboard goes through the slitter scorer and cutting-off machine and is stacked at the end.


We have developed an advanced single facer with two pairs of corrugated rollers for different flutes, which can change the flute type without stopping the machine. This changeover takes 15-30 seconds, and production can resume within 2-3 minutes.

 

Difference Between Finger and Fingerless Corrugation Machines

 

★Single Facer:

The single facer is a machine that converts craft paper into 2-ply corrugated board. There are two types of single facer machines used in the corrugation industry:

Finger type single facer

Fingerless type single facer

 

★Both types of machines have different characteristics and specifications

●Finger Type Single Facer: In a finger type corrugation machine, the flute paper is guided by brass adaptors. Due to the slots in the glue applicator roll, there is no gum application in a gap of 3 mm at every 50 mm interval. Finger type corrugation machines are available in different sizes, from 32 inches to 80 inches. The size of the machine depends on the box type and size.
●Fingerless Corrugation Machine: In a fingerless corrugation machine, the fluted paper is guided by suction. Thus, there are no slots in the gum applicator roll, so the gum applicator roll applies gum continuously and uniformly from one end to the other. Fingerless corrugation machines can have different sizes according to the size of the corrugated board.


★Advantages of Fingerless Corrugation Machines

●No Adaptor Marks on the Board: Since there are no brass adaptors in fingerless machines, there are no brass adaptor marks on the board.
●Increased Compression Strength of the Board: With a fixed flute height and fixed radius, the compression strength of the board increases in fingerless corrugation machines.
●Increased BF (Bursting Factor) of the Board: Due to the increased compression strength, the BF of the board also increases.

 

Paper Tube Making Machine

Common Functions of Corrugated Machines

Control Panel

Pneumatic and electric control buttons, along with an indicator panel, are operated from a control panel and are easy to use.

 

Adjustable Adhesive Chink

The adhesive chink is adjusted and displayed via a motorized system, allowing precise control of the upper glue amount.

 

Glue Roll Stop Function

The glue roll has a stopping function to prevent glue from drying up and sticking to the roll, which can cause flute misalignment and increased paper waste.

Chrome-Plated Components

The pressure roll, glue roll, and cool-glue roll are finished with chrome plating.

Motorized Adhesive Pan Dam

The adhesive pan dam is motorized for width adjustment during use.

Glue Circulation System

Glue circulation prevents drying and viscosity changes that could affect adhesion.

Fingerless Single Facer

Designed for lightweight and flexible production, suitable for producing light products.

 

Applications of Corrugated Machines in Different Industries

Corrugated machines are essential equipment in the manufacturing process of corrugated cardboard, a versatile and widely used packaging material. These machines play a crucial role in shaping the corrugated board's structure, strength, and overall quality, catering to diverse applications across multiple industries.

 

Packaging
The primary application of corrugated machines is in the production of corrugated cardboard packaging. This type of packaging is renowned for its strength, durability, and cost-effectiveness, making it ideal for a wide range of products, including food and beverages, electronics, furniture, and machinery. Corrugated cardboard boxes provide ample protection during transportation and storage, minimizing damage and preserving product integrity.

 

Building and Construction
Corrugated board also has significant applications in the building and construction industry. It is used as a lightweight and insulating material in wall panels, roofing systems, and temporary structures. Its ability to withstand humidity and temperature variations makes it suitable for use in various climate conditions. Additionally, corrugated board is commonly employed as protective packaging for building materials, such as drywall, tiles, and flooring.

 

Agriculture
Corrugated board finds extensive use in the agricultural sector. It is employed as packaging for produce, such as fruits and vegetables, providing protection during transportation and extending shelf life. Corrugated boxes are also utilized in greenhouse applications to regulate temperature and humidity, promoting optimal plant growth. Additionally, corrugated board is used as a barrier to prevent growth and suppress soil erosion.

 

Medical and Pharmaceutical
In the medical and pharmaceutical industries, corrugated board serves as a protective packaging solution for sensitive equipment, medical supplies, and pharmaceuticals. Its ability to maintain a sterile environment is essential for preventing contamination and ensuring product integrity. Additionally, corrugated board is used in the manufacturing of disposable medical supplies, such as gowns, drapes, and bandages.

 

Automotive
The automotive industry utilizes corrugated board for the packaging and protection of automotive parts and components. The durable nature of corrugated cardboard ensures that parts are safeguarded during transportation and handling. It is also used as a cushioning material to prevent damage from vibration and impact. Additionally, corrugated board is employed in the production of temporary displays and signage for automotive showrooms.

 

Our Factory

 

Aydly Intelligent Packaging Machinery (Guangdong) Co., Ltd. is one of the subsidiary of A.S.I. Group (American Sunflower International Group Co., Ltd.) headquartered in New York USA, Singapore and Hong Kong, China. We specialize in carton box printing and packaging machines, corrugated paperboard production lines, laminating machines, flat bed die cutting and creasing machines, EPC with paper making machines, etc.
We integrate technology research and development, manufacturing and processing, assembly, sales, export, installation and after-sales service, etc. We commit to provide a full range of solutions to the global customers of paper and paperboards related with industries of manufacturing, printing and packaging.

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Products Equipments
 

Our machines are used in paper mills, corrugated paperboard factories, carton box makers, printing and packaging factories, etc.

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FAQ
 

Q: How long is a corrugated machine?

A: Total length of the corrugator: approx. 110 m. Actual working width: 2300 mm limited by working width of the preheaters and single facers.

Q: Why need a corrugated machine?

A: The operating process of the single facer machine includes the following: creating conditions for unwinding and manipulating the face paper and core paper; pre-processing and preheating the core paper and the face paper; preparing for corrugating and bonding processes; forming a straight core paper specific corrugation; applying adhesive to the newly formed corrugation tip; bonding core paper and facial paper together; transporting the single-faced paper web to the conveyer bridge. If the single-facer paper web delivered to other processes has quality problems, the other processes cannot be repaired or compensated at all. Therefore, the single facer machine is very important for carton production.
The quality of the corrugated board produced by the single facer corrugated machine directly affects the production cost of the carton. The base paper is the main material for the production of cartons. About 75% of the cost of carton production comes from raw materials. If the corrugated board produced by the single facer is unqualified or defective, it means the waste of raw paper and other materials, an increase in production costs, and a decrease in production profits.

Q: What are the structural features of a corrugated machine?

A: The paper guiding adopts wind adsorption, keeping the stability of flutes under the condition of high speed.
The corrugated paper is adsorbed to the middle corrugated roller to form a negative pressure zone of 180°and then to finish the rolling of corrugation through the vacuum box by a fan.
The width of the suction slot of the lower corrugated roller is not more than 2mm, able to reduce the stripe mark on the single side of corrugated cardboard.
The transmission part adopts universal joint transmission and separates the vibration source, which makes the maintainability higher, the transmission more stable, and the operation more reliable.
The reducer casing adopts oil bath lubrication and closed gear transmission, reducing the vibration of the machine.
This machine adopts an auto-cycle glue supply and pneumatic control glue supply and returns, making it characterized by buffering effect.
The glue roller surface is treated with special mesh nicking and chrome plating. Get a quote about the single facer corrugation machine.

Q: How to operate a corrugated machine?

A: The single facer Machine process is a critical component to the manufacturer of the high-quality combined board.
The basic Single facer operation must do the following.
Allow for unwinding and controlling the single face liner and medium.
Preheat/Precondition the liner and medium to prepare them for the flute forming and bonding process.
From the flat medium web into its characteristic fluted shape.
Apply adhesive to the tip of the newly formed flute.
Join the medium with the single face liner.
Transport the single-face web into the bridge.

Q: What are the main components of a corrugated machine?

A: The main components of the corrugated machine are a paper mill roll stand, corrugating roller, pressure roller, preheating roller, gluing device, pneumatic device, paper guide, vacuum adsorption device, etc.
First, the corrugated core paper is heated, and then the corrugated roll is used to make the required corrugated shape. The corrugated paper is bonded to form a single facer corrugated board. The heating methods of the core paper include steam heating, electric heating, and oil heating. corrugated machined flutes can be customized or customized.

Q: Do corrugated machines require preheating and pre-treatment?

A: Preheating and preconditioning are the processes of preparing the medium and liner, respectively for the fluting and the bonding by adding heat. Heat and moisture are added to the corrugating medium in the preconditioning process to soften the fiber and make the fiber more pliable. This enables the flutes to form without fracturing or losing there shape. The heat was added to the liner to begin the gelatinization process of the adhesive.

Q: How to bond corrugated machine?

A: Flute formation and bonding of the fluted medium to the single face liner occur in the single facer corrugation machine. The basic components of the single face process have remained essentially the same since the beginning of the corrugating industry. The corrugating rolls are a set of grooved heated rolls that mesh together under pressure and impart a fluted shape to the medium as it passes through the nip. A hold-down mechanism keep the fluted medium in contact with the corrugating roll while an applicator roll applies a starch-based adhesive to the flute tip. A pressure roll secures the bond between the corrugation medium and the single facer liner.

Q: Do corrugated machine require heating and drying?

A: The heating and drying mechanism is the maestro behind the scenes, arranging the corrugated materials' transformation from malleable forms to sturdy constructions, in the complex symphony of corrugation equipment. In order to ensure that the glue between the corrugated medium and liner sheets cures as well it can and gives strength and stability to the finished product, this important aspect is critical to the corrugation process.
Fundamentally, the heating and drying mechanism is an example of fine engineering. It carefully controls the humidity and temperature, protecting against problems like delamination, warping, and uneven drying. This guarantees that the desired structural integrity and dimensional stability will be there when the corrugated board comes out of the process.

Q: What are the key functions of the corrugated machine?

A: The crucial function of precision cutting and stacking is highlighted in the complex world of corrugation technology. This dual-functionality mechanism, the last movement in the corrugation symphony, raises the production process to the level of an art form, guaranteeing that every corrugated board is produced with perfect precision and elegance.
This system's precision cutting feature embodies technological precision. Fractions of millimetres of precision are measured in the precise trimming of the corrugated board by automated cutting mechanisms controlled by sophisticated controls. This accuracy is essential for ensuring consistent measurements as well as for designing packaging solutions that are specifically suited to the requirements of different industries.

Q: What are the maintenance techniques for corrugated machine?

A: If you want your corrugator to last, you need to take care of it. The following is an overview of the maintenance tips for the corrugated cardboard-making machine:
1) Keep it clean
Your corrugated box-making machine will work best if it is kept clean. Be sure to wipe down the machine after each use to remove any debris that may be clogging the gears.
2) Lubricate moving parts
Lubricating the moving parts of a corrugator is essential to keep them in good condition. Make sure to apply a light coat of lubricant to all moving parts every few months.
3) Check the alignment
Failure to align can result in reduced machine efficiency and possible premature wear. Check the alignment of the corrugator and adjust as necessary.
4) Check the blades
The blades on corrugator machines need to be kept sharp. Blunt blades will cause the machine to work harder, resulting in poor-quality cardboard. Check your blades regularly and sharpen them if necessary.
5) Proper storage
When you are not using your corrugator-making machine, make sure to store it in a dry, dust-free environment. Covering the machine will help keep it clean and protect it from the elements.
6) Regular maintenance
Just like any other machine, your premium corrugator will require regular maintenance. You'd better be sure to have it serviced by a qualified technician at least twice a year.

Q: How many types of corrugated machines are there?

A: There are two main types of corrugation machines, namely vertical corrugation machines and inclined corrugation machines.

Q: What is corrugated machine?

A: A corrugator machine is a large machine, made up of a series of smaller machines, that combines two different kinds of paper to create cut sheets of corrugated fiberboard. The flat, facing sheets are referred to as the liners, and the wave-like, fluted layers are known as the corrugating medium, or simply medium. The corrugator machine takes large rolls of paper produced on paper machines, flutes the medium and glues it to the liners, one at a time, and delivers stacked, cut, and scored sheets of corrugated board to various converting machines. The converting machines convert the sheets of corrugated board into "box blanks," which are ready to be made into boxes, and other corrugated board products.

Q: How about unwinding and tension control of corrugated machine?

A: At the single facer corrugation machine, a roll of the liner is positioned on one side of the station. A roll of the medium is positioned on the opposite side. Each roll is supported by a roll stand that enables the paper to unwind freely as it is pulled into the single-facer corrugation machine. Typically two roll stands exist for the liner and two roll stands for the medium. This makes it possible to prepare one roll for use while another roll is unwinding. When a running roll is completed or an order requires a change in the paper the standby roll can be spliced in without stopping the machine.
Tension must be maintained on the paper as it unwinds to keep it tracking straight into the single facer corrugation machine and prevent wrinkling. Constant tension is maintained by applying pressure to the brake mounted on the rotating core chuck that holds the roll in position. The brake pressure requirement change as the diameter of the roll is decreased.
A full-diameter roll requires greater brake pressure than necessary toward the end of the roll. Early roll stands required the operator to make periodic manual adjustments to the brake tension. The roll stand used today automatically lessen the pressure as the roll diameter decrease.

Q: What is the difference between vertical and oblique corrugation machine?

A: Vertical type corrugation machine is steam heated, while oblique type corrugation machine has automatic lubrication pump with pipeline. Vertical type corrugation machine has motorized loading reel stand, whereas oblique corrugation machine has reel stand self-loading hydraulic.

Q: What is the function of a corrugated machineunit?

A: The single-facer unit is a crucial component of all state-of-the-art corrugation machines, marking the beginning of corrugated magic with its technological miracle. This unit acts as the pivot point in the corrugation process, coordinating the corrugated medium and liner sheets to create the sturdy and long-lasting corrugated board.

Q: What is the speed of a corrugated machine?

A: Product Introduction : Design Speed 60m min Effective width 1400mm. Product Introduction : Design Speed 60m min.

Q: What is the function of the adhesive coating system for corrugated machines?

A: The glue application system is a silent virtuoso in the complex dance of corrugation machinery, using dexterity and grace to forge the strong bonds that characterise corrugated perfection. The skilful application of adhesive, a critical stage in the corrugation process that guarantees the flawless union of corrugated medium and liner sheets, is at the core of this technology.
A prime example of innovation is the glue application system, which provides a precise, customisation, and controlled method for applying adhesive. Because of this feature, corrugation machines can accommodate different thicknesses and flute profiles of paper, making them suitable for a range of paper grades. As a result, the corrugated board exhibits a consistent and uniform bonding strength, which is a sign of dependable packaging.

Q: What is the purpose of the corrugated machine?

A: Simple paper sheets are fundamentally transformed into strong corrugated boards—also called cardboard—by a corrugated machine. To give the paper its distinctive wavy pattern and give it strength and durability, the paper is fed through a series of rollers during the process.

Q: How does a corrugated machine work?

A: A corrugated machine works by using a series of rollers to create corrugated cardboard. The machine starts with a large sheet of cardboard. The raw cardboard is fed into the machine, where it passes through a series of rollers.

Q: What is the function of the corrugated machine?

A: The corrugated machine takes large rolls of paper produced on paper machines, flutes the medium and glues it to the liners, one at a time, and delivers stacked, cut, and scored sheets of corrugated board to various converting machines.

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