All our corrugated boxes are made from the best packaging material in the market

One of the keys to our ongoing success is our continued investment in the latest machinery

Manufacturing Process

The corrugator is a series of long linked machines which transforms paper into corrugated board.

 

The corrugating medium, which will become the wavy middle layer in the typical three-layer corrugated board, is pre-heated and steamed so its temperature nearly reaches the boiling point of water, 212ºF. This softens the natural ingredients in the paperboard, making it easier to form into flutes.

 

The web, or long sheet of paper unwinding from the roll, is drawn between a pair of gear-like cylinders called corrugating rolls. This shapes the paper into a series of precise waves. Glue is applied to the tips of these flutes on one side — just the right amount, and at just the right places — and the flute tips are pressed against a fl at liner.

 

This creates a single-face web, a continuous sheet of fl at paper with fluted paper glued to it. To make single wall corrugated board, the exposed flutes of the single face web have glue applied to them, and they’re pressed against a second flat liner.

 

Other parts of the corrugating line press creases into the corrugated board at precise places, so later it will fold on these creases to create a three-dimensional box.

 

The continuous web of corrugated board is now so stiff that it can’t be rolled up. Instead, it’s cut into flat sheets, just the right size for making the boxes that have been ordered. The sheets are then stacked and set aside so the glue can dry properly.

 

How swiftly does all this happen? Modern corrugating lines can move at more than 1,000 feet per minute—more than 11 miles per hour, or three times as fast as a comfortable walk!

 

How does a board become a box?

Converting machines “convert” fl at corrugated boards into boxes. The most common kinds of converting machines are flexo-folder gluers and die cutters.

 

Flexo-folder gluers print, crease, slot, trim, fold and glue the box so that it can be shipped fl at and then be easily formed by the customer and packed.

 

Die-cut machines cut the corrugated board into a pattern the customer will fold and glue into the box shape.

 

A rotary die cutter uses cutting edges called dies, and creasing rules, on a big roller to cut and score the corrugated board as it moves beneath it.

 

A flat die cutter presses knives and creasing rules against a stationary board, the same way you press a cookie cutter into cookie dough.

 

Whichever converting system was used, the corrugated box is now complete, and ready to carry, contain and cushion a product that might be on its way to you!