Welcome to HIC Machinery CO. corrugated, where we manufacture and sell corrugated Automatic plants For 3 PLY & 5 PLY Corrugated boards and a wide range of specialty packaging Corrugated Machines. Today, we’d like to demonstrate how we make our products. The main material of the corrugated board is the containerboard grades of the paper liner which becomes the flat facings of the board is primarily made from the long fibers of softwood trees media format which becomes the fluted middle layer of corrugated board is primarily made from the shorter fibers of hardwood trees. In this Article, We Know The Complete Overview process of Corrugated board-making plant machinery from start to finish HOW IS CORRUGATED CARDBOARD MADE?
HOW IS CORRUGATED CARDBOARD MADE? | The first step in making a corrugated board
The first step in the production of a corrugated board takes place in a machine known as a single phase. A single phaser combines a liner and a medium to make a single face web. To do this, the medium is passed through a set of corrugating rolls at high heat and pressure to form the flutes that give the corrugated board.
The performance attributes needed for the finished packaging item.
Its tensile strength and cushioning capacity Each pair of corrugating rolls is manufactured in a specified flute and profile to provide the performance characteristics required for the finished packaging item. After a cornstarch-based adhesive is applied to the flute tips by the glue roll, the liner is brought into contact with the fluted medium by a pressure roll, which turns against a metering roll to control the proper quantity of adhesive that is provided to the flute tips.
It is critical that the correct pressure is applied to the corrugating rolls and also that the adhesive reaches the ideal temperature and reliability to form a strong bond between the liner and fluted medium; this combination is known as the single-facer web. The web then leaves the single phaser and is elevated to a bridge that transports the web to the double glue unit.
Double backer : Corrugated liner and corrugated medium
The backer on both sides The liner and corrugated medium are fed into the single phaser from opposite sides via a pair of roll stands that are connected by a device known as a splicer.
The splicer allows the machine to change from one roll to another without stopping when the roll is consumed or when a change in paper grade or width is required as roll stock is unwound and heads to the single phaser.
The paper is wrapped around heated rolls or pre-heaters, which heat the paper to the right temperature for the corrugating process. Wrap arms govern the amount of time the paper is exposed to heat, allowing for some control over raising or decreasing heat to the paper.
Single Facer Web : Corrugated Sheets Exporter And supplier | HOW IS CORRUGATED CARDBOARD MADE?
The single face web is tried to carry up and away from the single phaser by incline belts. The web folds up in festoons for the length of the bridge until it enters the end section of the bridge that relates to the triple stack.
This exists to allow the single-face web to cure with a firm bond so the integrity of the flute structure is not interrupted if double wallboard is being made Both single phasers on the corrugator are operational, supplying two single face webs to the bridge for assembly at the double glue unit.
The double glue unit
The single-face web is threaded through heated rolls and into a machine known as the double glue unit, which applies cornstarch-based adhesive to the flute tips. The liner, which will become the corrugated board’s outside facing, is threaded through the heated rolls at the bottom of the triple stack.
The outside or double-faced liner for facades and roofs
As the board is dragged into the double backer, the outside or double-faced liner is bonded to the single face web. The top and bottom belts in the double backer pull the board through the machine, and the double backer has a series of heated plates that continue to transfer heat into the board to cure the adhesive bond. The belts in the double backer pull the board through the wet end of the corrugator and force it to the dry end.
The Role of Slitter score | HOW IS CORRUGATED CARDBOARD MADE?
After passing through the double backer, the combined board is scored, slit, and cut to finishing specifications. It next passes via a shear, which cuts the board in half to allow for order adjustments, and then into a slitter score, which slits the board to the right width and, if necessary, places the scores into the board to the required dimensions. Two independent slitter score portions are shown in this state-of-the-art slitter score. While one portion is preparing for the next order, the other is operating.
When it’s time to change orders, the shear cuts the board in half to produce a small space that allows the slitter score sections to drop in or rise from the board path, allowing the board to align between the top and bottom shafts where the scoring and slitting heads are affixed speed after the board is slipped and scored.
The Section Of the cut-off knife
It keeps going till it reaches the cut-off knife. The cutoff knife cuts the final corrugated sheet to the exact size required. An upper and lower knife is found on most corrugators. So that two distinct orders can be joined to print on the same paper width and grade. There are exit wheels that expel cut sheets onto single-belt conveyors.
The corrugator’s stacker beds accumulate the sheets to the stacker bays. The sheets are stacked and then unloaded on moving belts for stacker operators to do quality checks and prepare for strapping and shipment conversion machines transform corrugated sheets into boxes.
Print design and branding machines | Rotary die cutters and flexo folder gluers
These machines print designs and logos on the boxes and cut them to the right size for their purpose. Machines are divided into two categories. flexo folder gluers and rotary die cutters When the box is finished, the flexo machine glues and folds it, while the rotary die cutter departs.
Unglued and flat rotary die-cut boxes, like pizza boxes, are often molded by hand or wrapped around a product and attached to a customer’s equipment. A rotary die cutter may also manufacture numerous boxes from each sheet, whereas a flexo machine yields.
The lasers and optical sensors | HOW IS CORRUGATED CARDBOARD MADE?
Material is transferred to each machine center onto an in-feed conveyor via a series of lasers and optical sensors called photo eyes, as well as communication between an inventory management system and real-time production scheduling. Automatic transfer carts keep each machine fed with corrugated sheet stock. Each stack is broken down into smaller sections called blocks and shingled individually to a feed table.
The sheets are fed through a series of feed wheels that act in tandem with feed rolls to insert the sheet into the machine. The feed rolls are composed of a soft durometer material to avoid crushing the board. Maintaining board caliper or thickness is critical for total board strength in the end box carried by a vacuum transfer system.
The designs and branding are printed
The sheet through the machine across multiple print sections on a rotary die cutter machine the designs and branding are printed on the bottom of the corrugated sheet stock after the stock moves through the print section it reaches the rotary die cutters there are different cutters for every box type that the factory produces.
The cutters Section
The cutters are made up of two half-cylinders with metal blades embedded in them, as well as foam rubber sections to eject the cut board scrap pieces. The scrap is captured and recycled back to a paper mill for future roll stock production. The scrubber is the next section, and it removes any remaining loose cutouts and rough edges on the cut sheets. The sheets are then shingled once again to slow them down as they approach the stacker.
If the sliced sheets collide with the stacker too forcefully. The stacker beds collect the sheets into stacks, which are then discharged on moving belts for the stacker operators to do quality inspections and prepare the sheets for strapping and shipment. The flexo process begins similarly to that of a rotary die cutter, with stock being put onto the conveyor by an automatic transfer system cart each stack is broken down into blocks in this flexo machine. The printing is done on the top of the sheet.
The stock is transferred to a pre-feeder
As a result, the stock must be inverted and transferred to a pre-feeder. This automation eliminates the need for human inversion where the stacks are inverted. The sheets are then shingled and fed into a feed bed, where feed rolls feed the sheet into the machine. The print plates are positioned on a cylinder, and ink is applied to the print plate via an ink system.
This machine also uses rotary die cuts to transfer the ink to the board as it travels through the machine. However, unlike the rotary only cutter, which may manufacture ma18ny boxes per sheet, it only produces one box per sheet. The scrap is caught and recycled for future roll material on a flexo, and machine glue is applied in preparation for folding.
A high-speed detection system called clear vision
Every box is monitored for glue placement and gap measurements using a high-speed detection technique called clear vision. A high-speed camera is plac18ed at the point of glue application to detect the amount and thickness of glue lines, as well as the measurements of the slots in the front and back of each box. These measurements are compared to a developed standard to predict whether a bad box will be produced as it travels through the machine.
Any out-of-spec box will be coated with UV coating, and the bottom of the bundle will be sprayed as well as the bundle moves down.
The UV coating is detected by a black light on the conveyor system, which causes it to expel. The whole package. So that an operator can find and remove the low-quality box.
The speed of production a doubler | HOW IS CORRUGATED CARDBOARD MADE?
It prior to reaching the customer to account for the speed of production a doubler is used to assist crew members in combining each bundle in preparation for load forming the doubler stacks bundles on top of each other these combined bundles are then assembled into a specific stacking pattern to meet customer needs load tags are inserted into each unit to uniquely identify each load as it is sent to shipping to be made ready for delivery to the customer at the end of another workday you can rest easy knowing that you have the very best corrugated supplier in the industry whether you need corrugated sheets standard corrugated containers or specialty packaging products We hope you’ll read to HOW IS CORRUGATED CARDBOARD MADE? and understand the Complete making process Cardboard Boxes by HIC Machinery Co. ( Top 3/5Ply Corrugated Plant Manufacturer) as your supplier of choice safety sustainability innovation quality customer focus and value creation it’s in our DNA in everything we do.