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PRODUCTION LINES

Corrugated boxes
production lines

INTEGRATED MODULAR SOLUTIONS FOR AUTOMATIC PRODUCTION OF CORRUGATED BOXES

Automatic production lines for making of corrugated cardboard boxes made by Zemat Technology Group are designed and built as highly advanced systems with a wide range of automation and flexibility of configuration to provide the custom boxes manufacturing solution. Complete line may include synchronized lift, automatic feeder, flexographic printer, boxmaker machine with the gluing option, box folding unit and stacker.

All variants can be modified according to customer needs. The technical specification of each production line varies depending on the custom modifications.

From simple feed and cut, to much more complex feed - print - cut and crease - glue - fold and stack...

The whole box production process can be automated thanks to unique solutions provided by Boxmat series of machines.

THE BOXMAT AUTOMATIC PRODUCTION LINES ARE THE PERFECT SOLUTION FOR THE MOST DEMANDING CUSTOM BOX MANUFACTURING FACILITIES.

They can be implemented with shipping boxes or custom full color pre-printed boards for specialty packaging boxes.

Automatic BOXMAT systems save time and production cost, increase productivity in the boxmaking process

Industry 4.0 implementation with JQS Job Queue System

Smart scheduling of boxes production flow process Synchronized with any internal MRP, MES, ERP, MOM production control software

PRODUCTION LINE COMPONENTS:

1. HYDRAULIC SCISSOR LIFT WITH CONVEYOR

The LIFT design is adapted to the corrugated board stacks used by the customer.
Available stack parameters:

Length: 1500 – 5000 mm.
Width: up to 2400 mm.
Height: up to 1600 mm as standard. Individual configuration up to 1900 mm available.
The lift platform is built with a roller conveyor, positioning the stack of boards in the transverse axis and ensuring precise feed of boards into the machine.
There is an option to install the lift in the special trench/channel below the floor to work more conveniently with high stacks, or at the floor level on special rises and platforms.

2. AUTOMATIC BOARD FEEDER

Corrugated board FEEDER picks the boards from the stack using special manipulator and pneumatic suction cups and moved by swivel no-crash rolls. The boards are aligned by an automatic bumper to ensure a smooth transition to the next component of the production line. Technical parameters of the feeder are set according to the size of a stack of boards. Feeder is controlled by the HMI with a touch screen panel and synchronized with the full production line.

3. FLEXOGRAPHIC PRINTER

Single or double printing cylinders
1 or 2 color printing (SIDE BY SIDE)
Ceramic Anilox cylinder
Print width: up to 760 mm (30”) – single cylinder
Working print area width: 2400 mm (94”)
Independent drives and motion control of each cylinder
Repeat Rotation of flexo print cylinders
Repeat Rotation of flexo print cylinders
Special design steel/AL profile structure for vibration free printing
No need for special tooling or dies
Easy access for clean up and quick changeover of polymer plates
Intuitive touch screen HMI for easy setup and control

4. BOARD CONVEYOR SYSTEM

Conveyor enables the transport of boards between the components of the production line and it is also a time buffer ensuring optimal and fast operation of the entire line.
The size of the conveyors depends on the size of used corrugated boards. The system is usually installed in the two places of the production line:
– between the printer and the boxmaker
– between the boxmaker and the automatic box folding system

5. BOXMAKER: BOXMAT HD / BOXMAT PROi

FEATURES:

One pass operation to make a perfect box
Several dozens of preprogrammed FFECO styles
Switchover time – less than 60 seconds
Large 19” touch screen HMI + INTELIGO System
External board length control
10 sectional slotting knives
Built-in VPN secure connection for HMI allowing remote diagnostics and updates
No need for special tooling or dies
Additional modules or equipment available

ONLY IN BOXMAT HD:

Independent drive for each tool nest provides very fast position setup
Integrated double die cutting system
Counter-knife and counter scoring/creasing system
Automatic recognition of the specific tool in the nest
Conveyor waste/scrap REMOVAL system
Cardboard density up to 1250g/m2

6. BOXES FOLDING SYSTEM

The cut boxes are folded with the use of carriers placed on pneumatic actuators. It is most often used to make boxes from the FEFCO 2xx and 5xx series with glue already applied at the previous stage of production. The length of the supported formats can be up to 4200 mm and the width up to 2400 mm.

7. STACKER

Optional boxes stacking unit.

No LONG TERM corrugated board contracts!

With Boxmat machines, you have a freedom to choose your own
corrugated supplier and make your own BOXES ON DEMAND