Fanfold Cardboard Box Making Machine

BOXMAT FANFOLD

Produce short and medium box runs with continuous fanfold cardboard feeding, less material waste, and greater flexibility when changing board width.

Fanfold cardboard box making machine for short and medium runs

Every additional box size kept in stock ties up capital, takes up warehouse space and makes logistics more difficult. And the more variable your production is, the sooner it becomes clear that “standard” packaging no longer fits real orders.

BOXMAT FANFOLD lets you produce boxes on demand. Instead of constantly replenishing stock of ready-made boxes, you can make boxes from z-fold cardboard exactly when they are needed — directly from the pallet. The machine works with a continuous fanfold board web, which reduces manual sheet feeding, shortens format changeovers and helps operators move faster between different box sizes.

It is a solution for companies that want to match the box to a specific product, a specific order and a specific moment in production.

Continuous fanfold cardboard feeding directly into the machine
Less manual material handling during production
Smoother operation in short and medium box runs
Easier changeovers between different fanfold widths
Option to work with sheet cardboard as well
Less waste and shorter downtime during frequent production changes

Choose your machine and feeder setup
for fanfold production

Choose the right BOXMAT FANFOLD variant for your production

1. FANFOLD 1600

Entry-level model designed for producing standard packaging while keeping the investment cost attractive.

Cost-optimized solution
Enables production of basic box styles
One longitudinal tooling axis
Two shafts: creasing and cutting

2. FANFOLD 2400

Designed for companies that need a wider working width and more flexibility when producing boxes from fanfold cardboard.

Wider working version for fanfold cardboard up to 2400 mm
One longitudinal tooling axis
Two shafts: creasing and cutting

3. FANFOLD Advanced 2400

Extends the capabilities of the standard 2400 version with a higher level of automated setup. It is designed for plants that produce many box variants and change formats frequently.

Most advanced version for fanfold cardboard up to 2400 mm
Two working axes with the option to use 12 / 24 formatting tools
Longitudinal tools or independent servo drives enabling simultaneous tool positioning

Available cardboard feeding options

A-FRAME Feeder

Classic frame for one cardboard width
Stable web guidance directly into the machine
Simple, stable solution for continuous production of one format

Side-by-side

Two cardboard webs positioned next to each other
Fast switching between two material widths
Less downtime during production changeovers

X3 / X6

Three cardboard webs arranged one above another
Automatic feeding into the machine
Fast switching between different widths without stopping production
Setup designed to improve output and reduce material waste
Additional side-by-side option

Technical data

FANFOLD 1600

FANFOLD 2400

FANFOLD 2400 ADVANCED

Working width

Up to 1600 mm

Up to 2400 mm

Supported cardboard

3- and 5-ply cardboard, grammage up to 600 g/m².

Positioning accuracy

Positioning accuracy ±2 mm.

Material feeding

A-FRAME

A-FRAME, Side-by-side, X3/X6

Cross formatting

The transport and formatting module feeds the blank, provides stable transport, measures length and performs cross formatting.

Same module type: it feeds the material, provides stable transport, measures length and performs cross formatting.

Longitudinal formatting

The longitudinal formatting module performs creasing and cutting in the longitudinal direction.

The longitudinal formatting module also performs creasing, longitudinal cutting and interrupted cutting lines.

Tool beam

Allows different tool sets to be installed for creasing, longitudinal cutting and making interrupted cutting lines.

The tool beam enables creasing, longitudinal cutting and interrupted cutting lines.

Number of tool axes

One axis for longitudinal tools. From 6 to 12 tools.

Two working axes. 12 or 24 tools, with 6 or 12 tools on each axis.

Tool setting

The sequential manipulator positions the tools one by one, according to an algorithm that optimizes changeover time.

The independent servo drive system enables simultaneous positioning of all tools.

Changeover time

Reduced by the sequential manipulator, with tools positioned one after another.

Shorter thanks to simultaneous tool positioning by independent servo drives.

Setup automation

Automated tool positioning by a sequential manipulator.

Higher level of automation thanks to individual tool servo drives.

Creasing

Pneumatically lowered creasing rollers. Pressure force is selected automatically according to the cardboard type, with manual adjustment available.

Cutting

Pneumatically controlled serrated circular knives, with vertical movement for making interrupted cutting lines.

Tool stabilization

Pneumatic brakes hold the tools in position.

Pneumatic brakes also ensure stable tool positioning.

Material transport

Driven steel shaft coated with polyurethane, six double no-crush rollers, pneumatically raised and lowered rollers.

Driven steel shaft coated with polyurethane, six double no-crush rollers, pneumatic roller lifting and adjustable pressure force.

Measuring system

Measuring encoder and measuring wheel with a dedicated profile.

Measuring encoder and measuring wheel with a special profile.

Operator panel

21-inch HMI touchscreen

Printing option

JETBOX or miniFLEXO

Gluing option

✓

Choose the right BOXMAT FANFOLD for your production

A fanfold cardboard box making machine can work in different machine and feeder setups, so the choice should not be based only on the machine’s working width. What also matters is how your daily production actually runs. Before selecting a specific variant, it is worth looking at the whole process: the types of boxes you produce, the way fanfold cardboard is fed into the machine, and how often orders and formats change. This helps you use fanfold board more effectively and avoid investing in a setup that is either too limited or unnecessarily extensive.

Contact us and we will help you choose the right BOXMAT FANFOLD setup for your production.

Request a quote

BOXMAT FANFOLD – consulting, configuration and service

The Zemat Technology Group team supports customers at the stage of selecting the right BOXMAT FANFOLD variant, choosing the cardboard feeding system and configuring the entire process for real production conditions.

We also provide global technical support, including remote diagnostics, service assistance and access to spare parts, to help maintain system continuity and reduce the risk of unplanned downtime.

Installation and commissioning

Adjustment of operating parameters to the production environment.

Training and operation

Preparing the team to work with the system and configure print projects.

Technical support

Remote diagnostics, service assistance, and access to spare parts and consumables.

What is fanfold cardboard and how does it work?

Fanfold cardboard, also known as continuous cardboard, endless board, z-fold board or accordion-folded corrugated board, is multi-ply corrugated cardboard folded alternately and supplied on pallets. Unlike traditional sheets with fixed dimensions, fanfold cardboard forms a continuous web of raw material. Box making machines automatically feed it from the pallet, crease it and cut it to the exact length required for a specific package. This enables on-demand box production and helps reduce production waste.

What are the differences between the BOXMAT FANFOLD machine models?

The series includes three versions for different production needs. FANFOLD 1600 and FANFOLD 2400 differ in working width, up to 1600 mm and 2400 mm respectively, and operate with one tool axis and a sequential manipulator that positions knives and rollers one after another. FANFOLD 2400 ADVANCED is the most advanced version: it has two working axes, up to 24 tools, and can be equipped with independent servo drives for simultaneous positioning of all tools, which significantly shortens changeover time.

What cardboard does the BOXMAT FANFOLD system process and how is the pressure force selected?

The machines are designed to process 3- and 5-ply cardboard with grammage up to 600 g/m². All models have pneumatically lowered creasing rollers. The pressure force is selected automatically by the control system according to the selected type and thickness of the material. The operator can also make manual adjustments from the 21-inch HMI touchscreen.

Can the machine produce boxes, print and apply glue in one process?

Yes. The BOXMAT FANFOLD series is designed as a modular production platform. Each model can be integrated with additional modules. This means the machine can be equipped with marking and printing systems, such as the JETBOX digital module or miniFLEXO flexographic module, as well as an automatic glue application system. As a result, you can produce a finished, customized package in one technological pass.

When does a fanfold or z-fold cardboard system make sense?

A continuous fanfold cardboard system makes the most sense in plants where packed products vary significantly in size, such as e-commerce and fulfillment operations, as well as when packing long or oversized items, including furniture, profiles and joinery products. It is worth considering if you want to reduce high stock levels of ready-made boxes, limit the use of void fill and reduce shipping costs caused by sending empty space inside parcels. For mass production of one fixed box format, buying traditional ready-made boxes may still be the more economical option.

Why is z-fold technology a good choice for e-commerce boxes and short-run production?

In e-commerce and short-run production, flexibility is critical. Traditional box production often requires purchasing and changing dies for each box size. With BOXMAT machines, including BOXMAT FANFOLD, additional dies are not required for standard box format changes. The knives are positioned automatically by servo drives. You can produce one regular slotted box and then switch to a different box style with completely different dimensions, without the cost of an additional die.