Mastering Corrugated Cardboard Production: The Key Points of Quality Control

At first glance, the process of producing corrugated cardboard may seem relatively simple. However, achieving high-quality corrugated cardboard is no easy task. To truly excel in corrugated cardboard production, you must focus on mastering one critical concept: "One Glue, Two Tensions, Three Temperatures." By paying attention to these three factors, you can significantly improve the quality of your cardboard.

So, what does One Glue, Two Tensions, Three Temperatures mean? This concept highlights the three core aspects of corrugated cardboard production that need to be closely monitored and controlled:

1. One Glue: The Lifeblood of the Cardboard

In corrugated cardboard production, glue (or adhesive) is like the lifeblood of the material. It holds the layers together and directly impacts the cardboard's strength and integrity. Managing glue effectively requires focus on two key elements:

• Glue Temperature: The glue needs to reach a specific temperature to ensure proper bonding. Unfortunately, many operators misunderstand this aspect. Some believe the optimal glue temperature is 30°C, others say 80°C. In reality, the glue's ideal gelling temperature should be maintained around 58°C ± 2°C to achieve maximum adhesive strength.
• Glue Viscosity: Glue viscosity also plays a crucial role. When making glue, you can consider varying viscosity based on the machine. For instance, single-facer machines can operate with lower viscosity, while gluing machines need higher viscosity for stronger bonding. A general rule for effective gluing is high concentration, low viscosity.

2. Two Tensions: Tension Control for Stability

Controlling tension throughout the production process has a major impact on the quality of the corrugated cardboard. Improper tension can lead to warping and other defects:

• Brake Tension: Adjusting brake tension is critical. For example, if the tension from the paper roll brake is inconsistent, the board may develop an "S-curve" or bend. Inconsistent feed tension to the single-facer machine can also lead to poor flute formation. A properly balanced tension system ensures the paper enters the next stage of production smoothly, improving overall stability and quality. Tension rollers and correction systems can be used to balance this tension.
• Gravity and Pressure Rollers: These rollers can significantly affect the cardboard's physical properties. Excessive pressure can flatten the board, reducing its edge crush and box compression strength. Conversely, if the pressure is too low, the corrugations may not form properly. Ensuring that roller gaps and alignment are properly set will help maintain the cardboard's physical integrity.

3. Three Temperatures: Steam, Moisture, and Speed Control

Temperature, moisture, and speed control are the final pieces of the puzzle in producing high-quality corrugated cardboard. These three factors are interconnected, and optimizing each is crucial to ensuring the cardboard's consistency:

• Steam Temperature: Steam provides the necessary heat to bond the layers of the corrugated cardboard. A properly regulated steam temperature directly impacts cardboard adhesion and production speed. If the corrugator roll temperature falls below 150°C, flute formation and bonding will suffer. If the hot plate temperature is too low, high-speed production becomes impossible as the glue won’t gel properly, resulting in poor bonding. The solution is to adjust the production speed to match the available heat to maintain product quality.
• Moisture and Humidity Control: The pre-heater temperature must be carefully controlled. If it’s too high, the paper will lose excessive moisture, causing the board to crack or burst. The goal is to maintain appropriate moisture levels in the paper throughout the production process.
• Production Speed: Faster speeds demand higher heat levels. If production is running too fast without enough heat, the glue won’t activate properly, leading to weak bonding. If necessary, reduce the production speed to ensure the cardboard's quality is maintained.

Conclusion: Elevating Production Quality and Reducing Costs

In summary, controlling these three key factors—glue, tension, and temperature/speed—throughout the entire corrugated cardboard production line is essential for improving quality and reducing costs. Proper management of glue viscosity, tension adjustments, and heat ensures that the board produced will meet the highest standards, while also allowing for more efficient production.

By mastering One Glue, Two Tensions, and Three Temperatures, you can significantly enhance the quality of your corrugated cardboard and create a more cost-effective, streamlined production process.

A few videos of machine running in box factory, so you can know us more ;))

Giant, Korea-owned company, manufacturing factories in both Korea and China.

Machine running in box factory, Flexo Printer Slotter Die-cutter Folder Gluer + Strapper + Robot Arm Palletizer (+ pre-feeder):

https://youtu.be/BAA0WbZfLPM?si=muN535Ubko_jSS8r