What Is Corrugator Equipment?

These machines transform kraft paper into fluted board, bonding it with liner corrugator equipment papers to form single-wall (2-ply or 3-ply) or multi-wall (5-ply or 7-ply) sheets. This process is at the heart of the corrugated packaging industry, which is rapidly expanding due to the e-commerce, logistics, food, and FMCG sectors.

From paper feeding systems to automatic stackers, corrugator equipment is essential for efficient, high-volume packaging production.

Key Components of Corrugator Equipment

1. Reel Stand

The reel stand holds the kraft paper rolls and ensures smooth unwinding for feeding into the corrugator line.

• Hydraulic or shaftless options

• Equipped with brakes for tension control

• Supports multiple reels for high-speed lines

2. Preheater

Preheats the kraft paper to enhance bonding strength and moisture control.

• Single, double, or triple roll systems

• Thermic fluid, electric, or steam-based

• Ensures uniform temperature distribution

3. Single Facer

The core unit where fluting is created. Corrugated medium is passed through flute rollers and bonded to a liner.

• Available in finger-type or fingerless models

• Uses suction systems for better contact and reduced damage

• Determines the flute profile (A, B, C, E, F)

4. Glue Unit (Gluing Machine)

Applies adhesive (starch-based glue) between layers to create the corrugated board.

• Equipped with auto glue gap adjustment

• Stainless steel rollers for durability

• Variable glue application system

5. Double Facer

Adheres the second liner to form a complete 3-ply board and ensures flatness through controlled pressure and heating.

• Belt-type or roller-type

• Adjustable pressure settings

• Crucial for board strength and smoothness

6. Slitter Scorer

Cuts and scores the board to the desired width and fold lines for easy box forming.

• Manual, semi-auto, or servo-controlled

• High precision blade positioning

• Multi-knife options for speed

7. Cut-off Knife

Used to cut the corrugated sheets to the required length.

• Rotary or shear-type systems

• Servo-controlled for length accuracy

• High-speed and vibration-free cutting

8. Conveyor and Stacker

Moves finished sheets for stacking and bundling. Ensures efficient sheet handling and minimizes labor effort.

• Manual or automatic stackers

• Adjustable stack height and sheet alignment

• Integrates with packaging lines

Types of Corrugated Board Produced with Corrugator Equipment

• Single Face Board (2-ply) – Liner + Flute

• Single Wall Board (3-ply) – Liner + Flute + Liner

• Double Wall Board (5-ply) – Two flute mediums with three liners

• Triple Wall Board (7-ply) – For heavy-duty packaging

Advanced Corrugator Equipment Features

1. PLC/HMI Control Systems

Modern machines come with programmable logic controllers (PLC) and human-machine interfaces (HMI) for easy operation and monitoring.

2. Automatic Splicing and Reel Change

Uninterrupted production with auto reel splicers, reducing downtime and operator involvement.

3. Flute Change Technology

Quick-change flute rollers help in flute profile switching (e.g., B to E flute) without stopping production.

4. Moisture Control and Energy Efficiency

Integrated systems monitor moisture, temperature, and energy use for consistent board quality and lower production costs.

Applications of Corrugated Board Made by Corrugator Equipment

1. E-Commerce Packaging

Lightweight and durable boxes for product shipping, especially for apparel, electronics, and consumer goods.

2. Food & Beverage Industry

Corrugated trays, pizza boxes, and produce packaging that meet hygiene and structural standards.

3. Retail & Display Packaging

Printed corrugated boards for point-of-sale displays, shelf-ready packaging, and branded cartons.

4. Industrial Packaging

Heavy-duty corrugated sheets for machinery parts, automotive components, and electronics.

Top Corrugator Equipment Manufacturers (India & Global)

1. Champion Corrugated Pvt. Ltd. (India)

Offers high-speed automatic corrugation lines with energy-efficient design and CE certification.

2. Surjeet Industries (India)

A trusted name in vertical and fingerless corrugator machines, suitable for small to mid-scale operations.

3. Hebei Xinguang Carton Machinery (China)

Global supplier with complete corrugated production lines at affordable pricing.

4. BHS Corrugated (Germany)

World leader in high-speed corrugators with advanced automation and diagnostics.

5. Fosber Group (Italy)

Specializes in fully integrated corrugator lines with IoT and predictive maintenance tools.

Price Range of Corrugator Equipment

Corrugator machine prices depend on the level of automation, size, speed, and configuration:

• Basic single facer machines: ₹5,00,000 – ₹15,00,000

• Semi-automatic lines: ₹20,00,000 – ₹50,00,000

• Fully automatic corrugator lines: ₹60,00,000 – ₹3,00,00,000+

• High-speed servo-controlled lines (international brands): ₹3 Cr – ₹15 Cr+

Benefits of Investing in High-Quality Corrugator Equipment

• Superior Box Strength and Uniformity

• Increased Production Speed and Accuracy

• Reduced Labor Costs through Automation

• Energy Efficiency and Waste Minimization

• Compliance with Global Packaging Standards

• Faster ROI in Growing E-commerce and Retail Markets

Things to Consider Before Buying Corrugator Equipment

1. Type of Corrugated Board Needed (3-ply, 5-ply, 7-ply)

2. Daily Production Capacity

3. Availability of Spare Parts and Service Support

4. Power Consumption and Energy Saving Features

5. Floor Space Requirements

6. Manufacturer Reputation and Certifications

Conclusion: Corrugator Equipment – The Backbone of Modern Packaging

Whether you’re launching a new packaging plant or expanding an existing operation, investing in the right corrugator equipment is crucial for achieving speed, precision, and cost-efficiency. India offers a wide variety of reliable, customizable, and export-quality corrugation machinery that competes with global brands while being budget-friendly.

The future of packaging lies in automation, sustainability, and versatility, and Indian corrugator equipment manufacturers are rising to meet that demand.

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