The corrugated cardboard production line is a continuous automated system that creates three-, five-, or seven-layer corrugated cardboard by putting raw paper (roll paper) through a number of intricate processing steps. The basic idea is as follows: flat core paper is heated, pressured, and fused into wavy corrugations. It is then securely bonded with face and inner paper and cut to the required length to create the appropriate cardboard.
The complete workflow is broken down into the following sections, which correspond to each section of the production line:
1. Holder for raw paper
Function: To move and haul bulky rolls of unprocessed paper. Face paper, inner paper, and core paper are typically represented by different raw paper racks in a production line.
Principle of operation: Using a hydraulic system, raise and secure the roll paper in place. Using the brake mechanism, regulate the paper's tension to guarantee that it enters the subsequent step consistently and smoothly, avoiding breakage or wrinkling.
2. One-sided device
Making single-sided corrugated structures is the primary function of this corrugated cardboard production technique.
Roller preheating: In order to make the paper flexible and simple to form, the core paper will first go through the preheating roller, which will evaporate some of the moisture.
A single-sided machine's "heart" is the corrugated roller. It is made up of two big metal rollers that mesh together; the lower roller is a toothed corrugated roller, while the upper roller is a pressure roller.
Between these two rollers, the core paper travels.
Flat core paper is pressed into continuous, permanent wavy corrugations at high pressure and temperature (typically 160–180 °C).
Gluing tool: Evenly cover the corrugated surface with adhesive, most often starch paste.
Bonding: After being pressed and glued, the core paper instantly comes into contact with a surface paper, also known as an inner paper, and is securely bonded to it by the pressure roller.
This produces single-sided corrugated cardboard, with one side being flat and the other corrugated.
3. Conveyor frame overpass
Connecting single- and double-sided devices is its function. Several single-sided machines are needed to produce multi-layer cardboard. For instance, two single-sided machines are needed to make two single-sided cardboard sheets: "face paper+B corrugated" and "C corrugated+inner paper" when making five layer cardboard (BC or BE corrugated, etc.).
Working principle: This inclined conveyor frame lifts and moves the single-sided cardboard made by the first single-sided machine above the second single-sided machine. In order to guarantee continuous production, the pedestrian bridge is outfitted with tension adjustment devices and guide rollers that can store a specific length of cardboard and regulate the speed differential between the front and back parts.
4. A machine with two sides (and several preheaters)
Function: To create the final double-sided or three-layer structured corrugated cardboard, single-sided corrugated cardboard is bonded to another flat piece of paper, such as inner paper or another layer of single-sided cardboard.
Preheater: To ensure ideal bonding conditions, the paper will be reheated once more before going into the double-sided machine.
Glue machine: Another layer of single-sided cardboard that needs to be glued has a corrugated top. Apply adhesive to this layer.
Heating plate: A collection of enormous heating plates, often known as the "hot bed," form the center of the double-sided machine. Under the conveyor belt's motor, the bonded cardboard travels over the hot plate. The glue rapidly gelatinizes and solidifies when exposed to high temperatures and pressures, securely joining the paper layers into one cohesive piece.
5. The compartment for drying and cooling
Function: The freshly produced cardboard from the double-sided machine has a soft texture, a high moisture content, and a high temperature. To form it and get the appropriate hardness and flatness, it must be cooled and any excess moisture removed.
Working principle: The cardboard enters the cooling zone after first going through the drying zone, which is typically done with hot air drying. Fans or the natural breeze are typically used for cooling. A conveyor belt pulls the cardboard through a massive "S"-shaped channel, which aids in initial shaping and traction.
6. A machine that cuts and presses longitudinally
Function: Press out crease lines (also known as pressure lines) so that the cardboard box manufacturer may fold the continually produced, extremely wide base cardboard into future boxes while also cutting the cardboard to the width specified by the order.
Working principle: A wire pressing wheel with a flange is used for wire pressing, and a circular knife that spins up and down is used for cutting. All of the wire rollers and knives have computer-controlled settings that may be rapidly changed to accommodate varying order sizes.
7. A cross-cutting device
Function: Cut continuous cardboard to the order's specified length.
Principle of operation: This massive "guillotine" completes cutting while in motion. Based on the predetermined length, the computer system precisely determines the cross-cutting knife's speed so that it coincides with the cardboard's forward motion, cutting the cardboard cleanly and guaranteeing that the cut is rectangular rather than trapezoidal.
8. Stacker Function:
This feature makes it easy to package and carry by automatically stacking the cut single cardboard neatly and counting the output.
Working principle: Cardboard is stacked one at a time into a predefined number of stacks utilizing lifting platforms, baffles, and conveyor belts before being moved away by forklifts.
The central control and driver system
A central computer control system (PLC) is used to operate modern tile lines. The system will automatically adjust all parameters, including the temperature and pressure of each raw paper rack and single-sided machine corrugated roller, the amount of glue applied, the cutting distance of the longitudinal cutting line machine, and the cutting speed of the transverse cutting machine, to achieve fully automated production. The operator only needs to enter the material, corrugated type, length, width, and order quantity of the cardboard in the control room.
In brief
The corrugated cardboard production line operates on the basis of a continuous, multi-process integrated automated process:
The following steps are involved: unwinding, preheating, corrugated forming, single-sided bonding, skybridge conveying, gluing, multi-layer bonding, heating, bonding, drying, and cooling, shaping, longitudinal cutting, pressing, transverse cutting, fixed length, stacking, and output.
The entire procedure is accurate and efficient, demonstrating the potent potential of contemporary industrial automation technology.
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