With a highly automated production line behind them, corrugated cardboard boxes have evolved from rolls of raw paper into the cardboard boxes we use on a daily basis. The creation of corrugated cardboard and the shaping and processing of cardboard boxes comprise the two phases of the complete production process.
Phase 1: Corrugated cardboard production line
The majority of the production line's length is devoted to this fundamental step, which turns raw paper into rigid, flat corrugated cardboard. "Wet part" and "drying part" are further divisions.
Wet part: Corrugated material formation and bonding
This section's main task is to press the base paper into a corrugated shape and adhere it to the facing paper.
The core of the production line is a single-sided corrugated machine. In order to create a single-sided corrugated board, two heated corrugated rollers are used to press the core paper into a wavy shape and instantly bind it with the inner paper.
Important point: Corrugated roller quality is very important. Alloy steel rollers with a diameter of at least 375 mm are typically used in high-speed production lines, which must maintain a high temperature of 160–180 °C. To satisfy various order requirements, the sophisticated single-sided machine allows for the rapid substitution of rib kinds (such as A, B, C, and E ribs).
Pasting machine and double-sided machine: To create the final multi-layer cardboard, glue the ridges of single-sided corrugated board and then cover them with paper.
Key point: Pressure rods, which can apply pressure more evenly, prevent edge flattening, and guarantee the thickness and strength of the cardboard, take the place of conventional gravity rollers in modern machinery.
Preheating presetter: A crucial step in guaranteeing the cardboard's flatness and avoiding warping is heating and regulating the base paper's moisture level prior to bonding.
Wet pat: Precise stacking and cutting
Here, the continuous cardboard made from the wet end is carefully sliced and stacked in accordance with the specifications of the order.
A machine that cuts wide cardboard longitudinally and presses out the vertical creasing lines needed for later folding into boxes is called a longitudinal cutting and creasing machine.
Crucial point: The productivity of order replacement is significantly increased by the completely automated computer-controlled slitting machine, which can automatically switch specifications in less than a minute.
The production line's efficiency bottleneck is the cross-cutting machine. It is in charge of cutting the cardboard horizontally into flat, predetermined-length plates.
Important point: The production line's maximum speed is directly determined by its performance. With a cutting speed of 250 meters per minute, the high-speed machine, powered by a servo motor and spiral blade, can still control the cutting precision within ± 0.5mm.
Stacker: To be ready for the next step, automatically count and arrange the cut cardboard in a tidy stack.
Phase 2: The Process of Forming Cartons
The resulting corrugated cardboard is merely a "semi-finished product" and must undergo the subsequent procedures in order to be used as a cardboard box.
Printing slotting machine: effectively transforms flat plates into foldable box blanks by combining printing, slitting, creasing, slotting, and chamfering into a single instrument.
Die cutting machines are used to create cardboard boxes with intricate designs or those that call for unique shapes (such irregular boxes or display boxes) with far greater accuracy than standard slotting.
Glue/Nail Box Machine: The final step of forming a cardboard box is to bond or nail the overlapping tongues of the box blank together to form a complete empty cardboard box.
Important aspects of selection and procurement
It is advised that you pay attention to these three factors while thinking about purchasing these devices:
Matching: The production line is a system, and in order to prevent "small horses pulling big cars," each machine's speed must be matched. The slowest link—typically the cross-cutting machine—determines the line's total pace.
Automation and Intelligence: Investing in production management systems, fully automated paper feeding machines, etc. can significantly save labor costs and boost productivity.
Key elements: Pay attention to the material, diameter, and mid-height design of corrugated rollers, as well as the cross-cutting machine's drive mode and control system, which are essential for guaranteeing cardboard's quality and production efficiency.
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