Volumes of
production
Stages of creation
of products
Creating corrugated cardboard
The corrugating unit consists of two corrugating presses with roll-out profiles. After rolling in the corrugating roll, hot steam is supplied through the pipes from the boiler. The corrugating press receives raw materials, and due to the pressure of two layers, corrugated cardboard is created. The inner layer is glued to it in a fraction of a second – the two-layer corrugated cardboard is created, which goes to the heaters and passes through the rolls with starch glue. The front layer of cardboard is fed from below. The felt pad pulls through the web and the final gluing takes place. The cardboard heats up, the machine removes excess moisture. The output is glued and dried cardboard.
Longitudinal and transverse cutting
A solid strip of cardboard moves to the slitting unit, which cuts it lengthwise to the desired dimensions. The waste is cut off and removed using a fan-breaker from the air aspiration system. If necessary, this unit can apply fold lines. Next, the tape is divided into two streams: upper and lower - you can make two different orders at the same time. Here, the web is still endless until it arrives at the cross-cutting section. The sensors automatically determine the length of the cut, preparing the blanks and sending them for transportation along the belt. The operator checks the dimensions, the first visual inspection of the finished sheets takes place.
Transportation on the processing lines
The shuttle picks up the blanks from the upper and lower levels and distributes them to the transport system where they are stored. The blanks cool down at this time, since they are still warm.
Printing, die-cutting and gluing
The blanks arrive at the processing line: it makes print (from one to three colors), makes a die-cut (including a flap die-cut), applies glue to the flap and folds the box.
Formation of batches of finished products
The machine counts a given number of pieces, forms a pack, ties it with tape (so that you can take it and it does not fall apart). Then puts it on a pallet, which is delivered to the packaging line. There, the pallet is wrapped with a stretch film to protect the products from dust and moisture (the paper is very hygroscopic).
Warehousing and shipping
The loader takes the finished packed pallet to the warehouse, where it will be scanned and placed in a temporary storage cell. For strategic clients, we keep safe stocks so that shipment can be made on request. Then we ship by trucks.
Production lines
Corrugator
The Italian corrugator is designed for the production of 3- and 5-layer corrugated cardboard, profiles B, C, E, BC, EB.
In 2023, profile F will be purchased, thus adding the ability to produce profiles F, FB, FC. The corrugator line has high productivity and the ability to simultaneously produce two orders.
In 2023, profile F will be purchased, thus adding the ability to produce profiles F, FB, FC. The corrugator line has high productivity and the ability to simultaneously produce two orders.
Flat and rotary die cutting lines
The company has rotary die cutting and flat die cutting lines available. Due to the variability, we can manufacture products of absolutely any shape. On the lines of rotary and flat die-cutting, products are cut using die-cutting forms.
They are made for us acc. to special order: plywood base, knives and creasing rulers (bending lines).
They are made for us acc. to special order: plywood base, knives and creasing rulers (bending lines).
Inline lines
Inline lines of different formats: miniline and midline. This allows to manufacture products of various sizes with all operations performed at one time — printing, die-cutting, gluing, forming stacks and palletizing. The lines have the ability to use rotary dies, which increases the range that can be produced on this equipment.
Paint mixing station
This is the pre-production site where the paint is prepared according to the Pantone color range. According to the selected color, the program measures the required amount of pigments, mixes, and the finished paint is obtained. Next, the spectrophotometer checks the color sample. The development of individual colors is possible.
Quality Control Laboratory
Provides full quality control. Begins with the input control of raw materials: we check quality of paper for compression, weight, absorbency, moisture content.
We also check the internal dimensions of the box, its compliance with the manufacturing plan, and position of all colors. The ВСТ press shows how many kilograms a box can withstand and how many boxes can be placed in a row. The results are recorded in an electronic quality log, and now we can view any batch for any period of time.
At the end of all tests, the laboratory issues quality certificates.
View the catalog of finished products
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