Corrugated Box Machine

Learn About The Corrugated Box Machines Key Features, Uses etc.

Corrugated boxes are used to ship different kinds of items in almost every industry whether you talk about food, automotive, chemical, or pharma. They have multiple layers of cardboard to increase the strength and durability for keeping the products safe during transportation. Corrugated box machines are used to create these boxes at high speed with accuracy. It uses a cardboard sheet to start the manufacturing process and a series of rollers move the cardboard forward to create boxes. Let’s read in detail how these boxes help make shipping products safer. 
 

Origins and Development of Corrugated Boxes

• It all started in England in 1856, when the first corrugated paper got permission for commercial use. 
• The first corrugated box was registered by Albert Jones in 1871 in the United States. 
• Three years later a person named G. Smyth created the first machine to produce corrugated boxes in large quantities.
• Until the 1900s, the technology to create corrugated boxes got better and better to use for shipping products safely. Moreover, corrugated cardboard was even used for insulation in construction projects. 

Key Technological Milestones in Corrugated Box Machinery
 

Corrugated box machines have improved a lot with new technology and features: 

• Smart Production 

Corrugated box machines now have AI features that can automatically detect errors and monitor performance in real-time. Moreover, the system can make decisions on its own to adjust to the new settings. 

• Computerized Printing 

With the help of computer printing the machine can directly print designs onto the boxes. This technology helped the companies to make custom packaging materials. 

• Automatic Machines 

Automatic corrugated box machines were developed for making boxes in large quantities. Many industries require these boxes to ship their products safely. Hence, the companies hire automatic machines for producing and delivering bulk orders on time. 

• Sensors and Chips 

These machines now have advanced sensors and chips for monitoring the movement of goods and sensing the temperature in storage conditions to maintain the product's quality. 

• Adding Bioplastic 

The bioplastic is added to the material used to produce corrugated boxes to make them more durable to hold heavy products. Shipping delicate products becomes very easy with this process. 

• Eco-Friendly Materials

There are new eco-friendly materials introduced for making corrugated boxes. With this, a business can still practice sustainable operations and maintain the same quality of their products. These new materials allow businesses to practice sustainable operations and follow regulatory standards.
 

How Corrugated Box Machines Revolutionized Packaging
 

• Bulk Production For Higher Demand 

With automatic corrugated machines, the companies are able to complete bulk orders in the promised time. The operators can set instructions for the machine and just have to monitor the complete process for smooth operations. Also, they can input different sizes and shapes into the machine to manufacture custom boxes for shipping unique items. Automatic corrugators also help companies cut expenses with fewer labor costs and the waste of cardboard. 

• Maintains Quality Throughout the Process 

With automatic corrugators, the chances of human errors are now gone. These machines only require a few instructions and the size or shape of the boxes required to produce. The rest of the work will be carried out by the machines very easily. The machine offers high accuracy in cutting the exact shapes of the cardboard boxes with quality. Corrugated box machines maintain high quality throughout the batch and every box offers high durability. 

• Eco-Friendly Operations 

Automatic corrugated machines have incredible speed to produce shipping boxes. That’s why they contribute towards eco-friendly business practices by producing boxes on demand. Now, the company won’t have to stock the boxes to ship when the order comes. They can fulfill the demand as the order arrives and produce corrugated boxes faster to deliver on time. This minimizes the wastage of resources and promotes sustainable business. 
 

Core Components and Their Functions
 

• Mill Roll Stand: it holds the paper roll and feeds the machine to produce boxes. 
• Single Facer: this component makes waves to paper to make it strong. 
• Preheated: it is required for heating the paper so it goes into the machine better. 
• Gluing Unit: this part puts the glue on the paper so that they stick multiple layers together.
• Double Facer: it is used to add another layer on top of the glued layers for more durability. 
• Cutter: it is responsible for cutting the cardboard into even pieces to produce equal-sized boxes. 
• Slitter and Scorer: This component draws the lines for the machine to fold the cardboard accurately. 
• Stacker: After the cardboard pieces are cut the stacker carefully collects them. 
• Die Cutter: the die cutting machine cuts out the required shapes from the cardboard. 
• Printer: it is used for printing special designs and logos on the cardboard for brands. 
• Folder Gluer: finally the folder gluer is used to fold the cardboard and glue it to make a box. 

Industries That Use Corrugated Box Machines
 

• E-commerce

The E-commerce industry uses a lot of corrugated boxes to keep their products safe while shipping. Actually, they use two types of packaging to avoid any sort of damage to the product. First is interior packaging and the second is exterior packaging. The corrugated boxes are used as exterior packaging for shipping products all over the country. Many different types of boxes are used in e-commerce that have different shapes and sizes to have a perfect fit for products. 

• Marketing and Printing 

Now that the printing industry has so many ways to decorate corrugated boxes they serve as promotional tools for many brands. Marketing professionals are using these boxes to advertise their products and services. High-quality designs on the boxes make them highly attractive and appealing. They capture the eyes of everyone when delivered to houses. 

• Food & Beverage 

The Food & Beverage industry is using corrugated boxes in a large quantity. They use these boxes for both shipping their products and promoting the brand name. As these boxes are durable they can carry heavy food and beverage products. Moreover, the companies get their brand’s logo and design printed on the boxes for advertisement. 

• Supply and Stationery 

Stationery products like paper are also shipped using corrugated boxes as they can easily be damaged without protection. These boxes keep the items secure with their durability that comes from multiple layers of cardboard. Moreover, these boxes are used for displaying the stationery products so that it does not get damaged in the process.  

• Textile and Luxury Goods

Online purchased textile products are shipped in corrugated boxes to prevent any kind of damage. Customers expect their products to be in the best condition when they order online. Companies make sure they receive it with double protection using both interior and exterior packaging.  Moreover, the companies also print their brand logo and design for free advertisement as they know that people do unboxing videos on different platforms. 

• Electronics 

Corrugated boxes are created with multiple layers of cardboard and they provide excellent protection to the packages. The electronic industry gets the most benefits from their durability as they ship every product in corrugated boxes. Whether you have purchased the product online or offline the company only uses these boxes for packaging and shipping. For extra protection layers, they add custom-shaped thermocol around the product and then pack it in the boxes.  

• Healthcare

The healthcare industry also uses corrugated boxes for keeping their medical instruments and devices safe. These equipment are very delicate so even a little damage can disturb their functioning. Corrugated boxes are made from multiple layers of cardboard for protection of the product inside. Moreover, the companies use different shapes of thermocol for packaging the devices inside these boxes safely. 

• Batteries and hazardous materials

The companies have followed strict guidelines and regulations when they have to transport batteries and different types of hazardous materials. These types of products can be damaged very easily and temperature changes can affect their working efficiency. For this problem, the companies use corrugated boxes to pack these items and keep them safe from damage because of falling, vibrations, and temperature changes. 

• Logistics and Shipping 

Corrugated boxes are used in large quantities in fields like logistics and shipping for the safety of the products. When you place an order online it is wrapped with multiple layers of protection including bubble wrap, interior packaging, and exterior packaging. Out of these, the most durable are exterior packages which are corrugated boxes that protect the products from any kind of damage. 

• Military 

Shipping military items is a difficult job that requires extra paperwork and following a set of regulations. Some of the items that the military uses are very delicate and require extra care. To solve this problem multiple layers of protection are used while shipping them which also includes using corrugated boxes. These boxes keep the items safe from damage, temperature changes, humidity, and more problems. 
 

Major Advantages of Corrugated Box Machines 
 

• Save Expenses 

With automatic corrugated box machines, the making of corrugated boxes becomes less expensive. The company doesn’t require manual labor for completing the job and the machine can work automatically from feeding materials to the finished product. Also, the machine uses materials in limit and prevents the wastage of resources. Because of these two reasons, a company saves both time and money. 

• Customizations

Corrugators have a lot of customization options that increase their usage and benefit the companies. These machines can be customized to produce various shapes and sizes of corrugated boxes. Different types of products require packaging boxes of their own shape and size to prevent the damage from moving inside. Tightly packed products with thermocol sheets as additional layers of protection are much safer while shipping. 

• Durability 

Corrugated boxes are made using multiple layers of cardboard that offer them such high durability. Moreover, for absorbing any kind of shock from a fall, these layers have a wave-like pattern between them. Moreover, with a little bit of customization, these boxes can be produced in various shapes and sizes for a perfect fit to the products. This prevents extra movement of products inside the box that can damage them. 

• Eco-Friendly 

Corrugated boxes are designed from cardboard material which is easily recyclable and also decomposable. So it does not harm the environment and easily decomposes over time. Also, the automatic machines that produce these boxes use a limited amount of materials as per the system introductions. This reduces the wastage of resources and saves the company from unnecessary expenses.  

• Higher Production

Automatic corrugated box machines can produce a large number of boxes in less time. They are designed for working at peak performance for long hours. Having low downtime and no requirement for frequent maintenance these machines increase the overall productivity of a business. Moreover, in case a business receives a large number of orders then these machines can provide an upper hand to produce the order within promised time. 

• Quality Control 

Unlike the manual methods of producing corrugated boxes, the automatic machines maintain consistent quality. These machines can sort out the defective pieces which go through the process once again. Moreover, the chances of human error are also eliminated from the automatic operations. Repetitive tasks take a toll on humans but not on the machines they maintain quality throughout the process. 

• Versatility

There are various types of corrugated boxes that are created using single--, double, and triple-wall corrugated sheets. Automatic corrugated machines are highly versatile and support all these materials for producing the boxes. Every type of box has its own application in different industries. 

• Reduction of Shipping Costs

Shipping cost of a product depends on its weight and packaging materials can increase this cost by adding their own weight. Unlike the others, the corrugated boxes are very light in weight but highly durable and help reduce the shipping cost. 

Key Considerations When Choosing a Corrugated Box Machine
 

There are many factors you should carefully consider while choosing a corrugated box machine for your facility: 

• Production Capacity 

The very first thing to identify about corrugators is their production capacity and compare it with your requirements. Every machine has its own capacity to produce corrugated boxes of various shapes and sizes. Miscalculating it can cause you a lot of profit which can be earned through large orders. You must choose a machine that has greater production capacity than you require for bulk orders. 

• Box Type

There are many different types of corrugated boxes with multiple layers of cardboard. So, if you want to choose the right automatic corrugated machine you must know how many types of boxes it can produce. Also, make sure to match that with the type of market you are serving and their demands. 

• Automation 

You can choose from different types of automatic corrugated box machines available in the market. For that, you will need to identify the product capacity and overall requirements of the market. With this, you can exactly find out the level of automation you will need. For example, there are manual machines for producing boxes in low quantity, semi-automatic for medium size operations and then there are fully automatic machines for producing corrugated boxes in bulk. 

• Available Space 

Another important thing you must be careful about is the available space in your facility for installing the machine. Corrugated box machines are available in various sizes and shapes. You should compare the floor space of your facility with the requirement of installing the machine. The right thing would be to choose a machine that leaves some extra space even after the installation to move around. 

• Budget and Returns 

The corrugator can be expensive but it can be a great investment which can offer large profits in the long run. For this, you must identify your budget and spend on the machine that offers the best value under that budget. After a few orders or months, you may see your revenue increasing greatly. 

• Maintenance and Service

High-quality machines used in different fields require regular maintenance and service to perform perfectly. Without the maintenance sessions, the system in the machines can fail. However, frequent maintenance requirements are not good for a business as they increase expenses. So, it will be best to check the machine's specifications and select the one that is made of premium quality material and components. For example, machines made from stainless steel can last up to many years without corrosion or wearing out. 

• Safety Features 

Make sure your new corrugated box machine has required safety features for your operator's safety and the workers around it. Modern machines are coming with advanced features like emergency stops, new sensors to detect errors or any system failures, and many more.