Production line and factory setup overview
A medium industrial paper-converting line producing two-ply single-face corrugated board from one fluting-paper web and one liner web through roll receiving, reel stands, web tension control, preheating, corrugating-roll forming, starch preparation and application, pressure bonding, bridge or take-off control, rotary or NC sheet cutting, stacking, moisture conditioning and quality release. Two-ply board is an intermediate sheet or wrapping product, not a rigid shipping carton by itself.
Recommended lowest-entry line configuration Enter only with confirmed buyers for single-face sheets or rolls. Screen an 1,400-1,800 mm, 30-60 m/min line with two hydraulic or shaftless roll stands, preheaters, one supported single facer for a selected flute, starch kitchen, pressure/vacuum system, NC cut-off and stacker. Include paper-roll handling, steam or electric thermal system, moisture control and laboratory instruments.
Production process and implementation sequence
- Paper-roll receiving, conditioning and release
- Liner and fluting reel mounting
- Web tension control and preheating
- Fluting through heated corrugating rolls
- Starch preparation, metering and application
- Pressure bonding and controlled take-off
- NC cutting or rewinding and stacking
- Moisture, bond and dimensional release
Products, capacity and market fit
- Single-face board serves protective wrapping, furniture, glass, food separators and lamination markets.
- Local conversion shortens lead time for Afghan packaging users.
- One flute and controlled width reduce roll and tooling complexity.
- Paper price, steam efficiency and waste determine economics more than rated line speed.
- Two-ply single-face corrugated sheet - Approved width, flute, cut length, moisture, bond and warp - Protective packaging, separators and downstream laminators
- Single-face corrugated roll - Approved roll width, diameter, tension, flute and moisture - Flexible wrapping and converters with roll-fed processes
Core production machinery and line specifications
| Machine / stage | Function / value | Production note |
|---|---|---|
| Two reel stands and roll handling | Feeds liner and fluting paper safely | Width and roll-mass rated |
| Preheaters and web-tension controls | Conditions moisture and stabilises webs | Paper-specific settings |
| Single facer and corrugating rolls | Forms one flute and bonds liner | One launch flute profile |
| Starch kitchen and glue unit | Prepares and meters corrugating adhesive | Controlled solids and viscosity |
| Steam or electric thermal system | Supplies stable forming heat | Site energy study |
| NC cut-off and stacker or rewinder | Forms ordered sheets or rolls | Buyer format |
| Paper laboratory | Tests basis weight, moisture, bond and compression | Incoming and finished release |
Raw materials, utilities and factory requirements
- Specified fluting medium and liner paper rolls
- Corrugating starch, approved additives and water
- Cores, wrap, straps, pallets and labels
- Corrugating-roll, bearing, knife and glue-system spares
- Stable three-phase power and line control supply
- Steam boiler with treated water or approved electric heating
- Humidity-controlled paper-roll and product warehouse
- Roll-handling truck, hoist and safe reel-change area
- Starch preparation water, drainage and ventilation
Indicative low-entry investment and implementation plan
These planning ranges prioritize economical machinery, local labor and local civil works. Final pricing follows confirmed capacity, product specification, delivery terms and site conditions.
| Scope | Indicative range | Entry-plan note |
|---|---|---|
| Roll stands, preheaters and single facer | US$55k-135k | 1,400-1,800 mm entry line |
| Starch, thermal, cut-off and stacker systems | US$35k-95k | One sheet or roll route |
| Roll handling, laboratory and utilities | US$22k-65k | Paper and steam controls |
| Freight, installation, commissioning and spares | US$30k-85k | Specialist alignment required |
| Indicative installed project total | US$142k-380k | Building, boiler fuel and paper stock excluded |
Detailed proposal and next step
The proposal contains the complete line flow, machinery scope, raw-material and utility requirements, implementation stages and indicative entry planning. Final configuration follows confirmed products, capacity, site and budget.