A Guide to Common Questions About Single Facer Corrugating Machines in Corrugated Cardboard Production Lines

In our daily life, corrugated cartons are everywhere, from express packaging boxes to home appliance packaging boxes. Behind these strong and lightweight boxes lies the core equipment of the corrugated cardboard production line – the Single Facer corrugating machine. For newcomers to corrugated carton production, the Single Facer corrugating machine may still be an unfamiliar device. This article will use easy-to-understand language to answer common questions about Single Facer corrugating machines, helping you quickly understand this key equipment.

What is a Single Facer Corrugating Machine?

Simply put, a Single Facer corrugating machine is a device in the corrugated cardboard production line that presses “corrugating medium” into a wave shape (i.e., “corrugation”) and bonds it with “facing paper” to finally form “Single Facer corrugated cardboard”.

You can imagine Single Facer corrugated cardboard as a “sandwich cookie”: the middle “wave layer” is formed by pressing corrugating medium, and the upper and lower sides (or one of the sides) are attached with flat facing paper. The role of the Single Facer corrugating machine is to complete the two key steps of “pressing out the waves” and “bonding the facing paper”, laying the foundation for the subsequent production of double-layer, three-layer or even five-layer corrugated cardboard.

It is the “main force of the first process” in corrugated cardboard production, directly affecting the strength, flatness and production efficiency of subsequent cardboard.

What Components Make Up a Single Facer Corrugating Machine?

The structure of a Single Facer corrugating machine is not complicated, but each component has its irreplaceable role. We can compare it to a “precision assembly line factory”, where each component performs its own function:

• Corrugating Rolls
  • This is the “core mold” of the Single Facer corrugating machine, consisting of two upper and lower rolls with evenly arranged wave-shaped patterns on the surface. When the corrugating medium passes between the two rolls, it will be pressed into a wave shape consistent with the pattern. The material of corrugating rolls is usually high-strength steel, and the surface is subjected to wear-resistant treatment to ensure that the patterns remain clear after long-term use.

• Pressure Roll
  • Installed on the side of the corrugating rolls, its role is to “apply pressure”. After the corrugating medium is pressed into a wave shape, the facing paper needs to be bonded with the top of the corrugation. The pressure roll will apply appropriate pressure to make the facing paper and corrugating medium fit closely, ensuring a firm bond.

• Heating System
  • Adhesives are used for bonding corrugated paper, and the adhesives need to dry and solidify quickly at a certain temperature. The heating system is usually set around the corrugating rolls and pressure roll, and the temperature of the roll body is controlled within a suitable range (generally 150-180℃) through steam or electric heating to ensure the bonding effect.

• Gluing Device
  • Like an “automatic gluer”, it consists of a gluing roll and a doctor blade. The gluing roll will dip in an appropriate amount of adhesive and evenly apply it to the top of the wave shape of the corrugating medium (that is, the position to be bonded with the facing paper). The doctor blade is responsible for controlling the thickness of the adhesive to avoid excessive or insufficient adhesive.

• Transmission System
  • Composed of motors, gears and chains, it is equivalent to the “power heart” of the equipment, responsible for driving each roll to run synchronously to ensure a stable production rhythm.

• Control System
  • Similar to an “operation panel”, through buttons, displays or touch screens, operators can adjust parameters such as production speed, temperature and adhesive thickness, and can also display the operating status of the equipment in real time for easy adjustment.

How Does a Single Facer Corrugating Machine Work?

The working process of a Single Facer corrugating machine can be divided into 5 simple steps, just like “making a handmade greeting card”, step by step:

• Paper Feeding
  • The corrugating medium (in roll form) enters the corrugating rolls through the guide rolls (the guide rolls are responsible for guiding the base paper flatly to the corrugating rolls to avoid paper skew or wrinkling); at the same time, the facing paper (in roll form) moves towards the pressure roll.

• Corrugation Forming
  • The corrugating medium enters between the upper and lower corrugating rolls and is squeezed by the wave-shaped patterns of the two rolls, instantly becoming a neat wave shape (just like pressing cookies with a mold). At this time, the heating system has heated the corrugating rolls to a suitable temperature, and the corrugated paper is shaped at high temperature, making the wave shape more stable.

• Gluing
  • The pressed corrugated paper continues to move forward. When passing through the gluing device, the gluing roll will evenly apply a layer of adhesive on the top of the wave shape. The doctor blade will scrape off the excess adhesive to ensure that the thickness of the adhesive is just enough to bond the facing paper without overflowing.

• Bonding and Pressing
  • The glued corrugated paper meets the facing paper at the pressure roll: the facing paper covers the glued surface of the corrugated paper, and the pressure roll applies a certain pressure to press the two tightly together. At the same time, the heating system continues to heat to allow the adhesive to dry quickly, and the corrugated paper and facing paper are firmly bonded together.

• Cardboard Output
  • The bonded single facer corrugated cardboard (with a wave layer on one side and a flat surface on the other) is sent out from the end of the equipment and enters the next process (such as bonding with another single facer corrugated cardboard to form double-layer corrugated cardboard).

Why Use a Single Facer Corrugating Machine?

Some people may ask: Can’t we make cartons directly with flat paper? Why use a Single Facer corrugating machine to make corrugated cardboard? This starts with the “core value” of the Single Facer corrugating machine:

• Improve Cardboard Strength and Save Materials
  • The wave-shaped corrugated structure is like a “micro-spring”, which can disperse external impact. For paper of the same thickness, when made into a corrugated structure, the pressure resistance and impact resistance can be increased by 3-5 times. This means that less paper can be used to make stronger cartons, saving costs and reducing raw material consumption.

• Flexible Production to Adapt to Diverse Needs
  • Single Facer corrugating machines can produce different types of corrugations (such as A-flute, B-flute, E-flute, etc.) according to needs, meeting the packaging needs of different scenarios. For example, E-flute with fine corrugations is suitable for small packaging boxes of cosmetics and electronic parts; A-flute with tall corrugations is suitable for large packaging boxes of home appliances and furniture.

• Improve Production Efficiency and Reduce Labor Costs
  • The traditional manual production of corrugated cardboard is extremely inefficient, while the Single Facer corrugating machine can realize continuous automatic production, producing tens of meters or even hundreds of meters of cardboard per minute, greatly improving the production speed. At the same time, automatic operation reduces manual intervention and the loss caused by human operation errors.

• Lay the Foundation for Multi-Layer Cardboard
  • A single-faced corrugated cardboard may not be strong enough, but it can be used as a “basic unit” to bond with other single-faced corrugated cardboards or flat papers to form three-layer, five-layer or even seven-layer corrugated cardboards. For example, three-layer corrugated cardboard is a combination of “facing paper + single-faced corrugated cardboard + inner paper”, which has higher strength and a wider range of applications.

What are the Classifications of Single Facer Corrugating Machines?

There are various types of Single Facer corrugating machines on the market. Understanding the classifications can help you find the right equipment faster. We can divide them from the following practical dimensions:

1. Classification by Corrugation Forming Method and Changeover Efficiency

This is the most production-oriented classification, directly related to production flexibility:

1.1 Traditional Single-Flute Type Single Facer Machine

It can only produce one type of corrugation (such as A-flute or B-flute) fixedly. The corrugating rolls are fixedly installed and cannot be replaced. It has the advantages of simple structure and low price, and is suitable for enterprises that produce the same type of cartons for a long time (such as factories specializing in home appliance packaging).

1.2 Multi-Flute Manual Roll Change Single Facer Machine

It can replace corrugating rolls to produce different flutes, but it requires manual disassembly of the old rolls and installation of new rolls, and the whole process usually takes 2-4 hours. It is suitable for small and medium-sized factories that need to change flutes occasionally, such as those that produce both express boxes (C-flute) and food boxes (B-flute), but the two products are not produced at the same time.

1.3 Cassette-Type Single Facer Machine

This is a mainstream upgraded model in recent years, which integrates core components such as corrugating rolls and pressure rolls into a “cassette” (similar to a drawer-type module). When changing flutes, you only need to pull out the old cassette and insert a new one, and the changeover can be completed in 10-15 minutes. It is especially suitable for scenarios that require frequent flute changes, such as producing E-flute small boxes for cosmetics in the morning and A-flute large boxes for furniture in the afternoon, with efficiency improved by more than 80% compared with traditional models.

1.4 Belt-Type Single Facer Machine (High-End Model)

It adopts special “star mesh steel belt” technology, using a steel belt instead of the traditional pressure roll, and presses corrugated paper through surface contact. It has the advantage of flat and indentation-free cardboard surface, suitable for exquisitely printed packaging (such as luxury gift boxes), and the cardboard strength can be increased by 15%-20%, but the price is high, mainly used in high-end packaging fields.

2. Classification by Degree of Automation

This classification directly affects the difficulty of operation and production efficiency:

2.1 Manual Single Facer Machine

All parameters (temperature, speed, adhesive thickness) need to be adjusted manually, and the machine must be stopped when changing paper. It is suitable for small workshops with a daily output of less than 500 meters, such as small factories making simple cartons in rural areas, and the operation of the equipment requires high skills of operators.

2.2 Semi-Automatic Single Facer Machine

Core parameters (such as heating temperature, production speed) can be preset through the panel, and the equipment will automatically maintain stability, but paper change and cleaning still need to be done manually. The speed is generally 30-80 meters per minute, suitable for small and medium-sized carton factories (such as enterprises making packaging for local e-commerce), balancing cost and efficiency.

2.3 Fully Automatic Intelligent Single Facer Machine

Equipped with a computer control system and sensors, it can automatically adjust temperature, pressure and adhesive dosage, and can also detect cardboard quality through cameras (such as whether there is missing adhesive or wrinkling), and automatically adjust when problems are found. High-end models also support remote monitoring and data statistics, with a production speed of 100-300 meters per minute, suitable for large packaging enterprises or factories that need continuous production.

3. Classification by Heating Method

Heating is the key to corrugation bonding, and different heating methods affect energy consumption and applicable scenarios:

3.1 Steam-Heated Type

It heats the corrugating rolls through steam generated by a boiler, with uniform and stable temperature, suitable for high-speed production (over 80 meters per minute). However, it needs supporting boilers and pipelines, with high initial investment, and is subject to environmental protection policies (some areas have controls on boilers), so it is more suitable for large factories.

3.2 Electric-Heated Type

It directly heats the roll body with electric heating tubes, with fast heating (reaching the working temperature within 10 minutes), no need for additional equipment, and convenient installation. The disadvantage is high energy consumption (electricity fee is more expensive than steam), suitable for small and medium-sized factories or scenarios with slow production speed (30-60 meters per minute).

3.3 Oil-Electric Heat Exchange Type

It uses heat-conducting oil for circular heating, combined with electric heating tubes and a temperature control system, with good temperature stability (temperature difference does not exceed ±2℃), and no need for a boiler, with strong environmental protection. The energy consumption is between steam and electric heating, and it is a popular choice for small and medium-sized factories in recent years.

4. Classification by Pressure Method

Pressure determines the bonding effect, and different pressure designs are suitable for different papers:

4.1 Positive Pressure Type Single Facer Machine

It directly presses and bonds corrugated paper and facing paper with a pressure roll, with a simple structure, and the pressure is usually 0.3-0.5MPa. However, the pressure is concentrated at the contact point, which is easy to leave indentations on the cardboard surface, affecting the printing effect. It is suitable for producing packaging with low appearance requirements (such as moving cartons). (Note: MPa is a pressure unit, and novice users can ignore the specific value and just understand the pressure characteristics)

4.2 Negative Pressure Side Suction Type Single Facer Machine

It relies on vacuum suction to make the paper fit the corrugating rolls, with a vacuum degree of about -0.04 to -0.06MPa, reducing mechanical pressure, making the cardboard surface flatter, and can handle thinner paper (30-50 grams of low-weight paper). It is suitable for cartons that need printing, such as outer boxes for food packaging. (Note: Vacuum degree is a negative pressure unit, and novice users can ignore the specific value and just understand the pressure characteristics)

Selection Quick Reference Table

How to Choose a Single Facer Corrugating Machine?

When choosing a Single Facer corrugating machine, newcomers are prone to the misunderstanding of “only looking at the price”. In fact, the applicability, stability and after-sales service of the equipment are more important. Here are some key points:

1. Clarify Production Needs

First, figure out what you want to do:

• Production scale: How many meters of cardboard need to be produced per day? For small-batch production, medium and low-speed equipment is sufficient; for large-scale production, high-speed equipment must be selected.
• Corrugation type: What type of corrugated cardboard is mainly produced? If only one type is produced, a single-flute equipment is more cost-effective; if multiple types are needed, a switchable multi-flute equipment is selected, especially the cassette-type model, which can save a lot of changeover time.
• Facing paper type: Is thick paper or thin paper used? Thin paper (such as 30-50 grams) requires negative pressure equipment to avoid damage; thick paper can choose the traditional positive pressure type.

2. Inspect Equipment Quality

• Core component materials: The materials of corrugating rolls and pressure rolls directly affect their service life. Priority is given to high-strength steel with quenching treatment. The higher the surface hardness, the slower the wear.
• Operational stability: On-site testing can be carried out to observe whether the equipment has abnormal noise and vibration during operation, whether the cardboard output is flat, and whether the bonding is firm. For high-speed models, attention should be paid to synchronization to avoid “paper jams” or “skewed corrugations”.
• Energy consumption: In long-term production, energy consumption costs may exceed the equipment itself. If the local electricity fee is cheap, electric heating can be selected; in areas where steam is convenient, steam heating is more cost-effective; in places with high environmental protection requirements, priority is given to oil-electric heat exchange type.

3. Pay Attention to After-Sales Service

Corrugating machines are precision equipment and are prone to failures. When purchasing, you should ask clearly:

Choosing a manufacturer with a sound after-sales system can avoid shutdown losses caused by equipment failures in subsequent production.

• Is installation and commissioning service provided? (Professional personnel are required for the installation of complex models)
• How long is the warranty period? (Generally 1-2 years, and core components such as corrugating rolls should have a longer period)
• Are vulnerable parts (such as doctor blades, bearings) easy to purchase?
• Can the manufacturer respond within 24 hours when a failure occurs?

4. Compare Cost-Effectiveness

Don’t blindly choose the most expensive one, nor buy low-quality ones for cheap. For example:

• Small workshops: Choose manual single-flute type + electric heating to meet basic needs.
• Medium-sized factories: Choose semi-automatic cassette-type + oil-electric heat exchange, balancing changeover efficiency and energy consumption.
• Large enterprises: Choose fully automatic intelligent type + steam heating, suitable for high-speed continuous production.

Common Faults and Solutions of Single Facer Corrugating Machines

Even if the right equipment is selected, some small problems may occur in daily use. Mastering the solutions to the following common faults can reduce downtime:

1. Irregular Corrugation Formation (Uneven Wave Sizes)
   • Possible causes: Wear of corrugating rolls, unstable base paper tension, insufficient temperature of corrugating rolls, abnormal humidity of base paper (too dry or too wet, normal moisture content should be controlled at 8%-12%).
   • Solutions: Check whether the surface of the corrugating rolls is worn, and replace if necessary; adjust the tension controller to allow the paper to enter smoothly; increase the temperature of the corrugating rolls to ensure sufficient shaping of the paper; detect the humidity of the base paper, properly humidify if too dry, and pre-dry if too wet.
2. Insufficient Bonding Between Facing Paper and Corrugated Paper
   • Possible causes: Too little or too much adhesive applied, insufficient heating temperature, insufficient pressure of the pressure roll.
   • Solutions: Adjust the gluing device to make the adhesive thickness uniform (usually 0.1-0.2mm); increase the heating temperature to 160-180℃; appropriately increase the pressure of the pressure roll.
3. Wrinkles on Cardboard
   • Possible causes: Uneven base paper tension, offset position of guide rolls, excessive production speed.
   • Solutions: Readjust the tension; check whether the guide rolls are parallel and adjust their positions; appropriately reduce the production speed and observe whether the wrinkles disappear.
4. Abnormal Noise During Equipment Operation
   • Possible causes: Loose components, worn bearings, insufficient lubrication.
   • Solutions: Stop the machine to check all connecting parts and tighten loose screws; replace worn bearings; add lubricating oil according to the instructions.

Daily Maintenance of Single Facer Corrugating Machines

Doing a good job in daily maintenance can extend the service life of the equipment and reduce failures. In short, it is “frequent inspection, frequent cleaning, and frequent lubrication”:

1. Daily Inspection
   • Before starting up: Check whether the base paper is installed firmly, whether the adhesive is sufficient, and whether all buttons and displays are normal.
   • During operation: Observe whether the equipment has abnormal noise and vibration, and whether the cardboard quality is stable.
   • After shutdown: Clean the residual adhesive on the corrugating rolls and pressure roll (special cleaning agents can be used), and turn off the power supply and heating system.
2. Weekly Maintenance
   • Check whether all transmission components (gears, chains) are loose and tighten them in time.
   • Add lubricating oil to moving parts such as bearings and gears to reduce wear.
   • Clean the dust and paper scraps on the surface and inside of the equipment to keep the environment clean.
3. Monthly Maintenance
   • Check whether the patterns on the surface of the corrugating rolls are clear, and report for repair in time if there is wear.
   • Calibrate the temperature sensor of the heating system to ensure accurate temperature.
   • Test whether the safety devices (such as emergency stop buttons) are sensitive.

Application Fields of Single Facer Corrugating Machines

As the core equipment of corrugated cardboard production, the application value of Single Facer corrugating machines is reflected in the production chains of many industries, which can be specifically divided into the following scenarios:

1. Express and Logistics Packaging Industry
   • Provide basic cardboard for e-commerce express boxes and logistics turnover boxes. For example, Single Facer corrugated cardboard used in the production of 3-layer express boxes is quickly pressed into C-flute or B-flute through Single Facer corrugating machines to meet the needs of light weight and shock resistance in express transportation.

2. Food and Daily Necessities Packaging Industry
   • Adapt to the production of exquisite packaging such as food gift boxes and cosmetic boxes. The indentation-free cardboard produced by belt-type Single Facer machines can be directly printed with exquisite patterns, used in chocolate boxes, skin care product packaging boxes, etc., balancing beauty and protection.

3. Electronics and Industrial Parts Packaging Industry
   • Provide buffer packaging for small electronic components (such as chips, resistors) and mechanical parts. The fine corrugated cardboard produced by E-flute Single Facer corrugating machines can accurately fit the shape of small products, preventing collision damage during transportation.

4. Display and Marketing Materials Industry
   • Used to make supermarket shelf displays, promotion platforms, etc. The high-stiffness cardboard produced by negative pressure side suction Single Facer corrugating machines can be cut and folded into various display structures, with both environmental protection and cost advantages.

5. Special Packaging Fields
   • In medical packaging and frozen food packaging, special Single Facer corrugating machines can adapt to oil-proof and moisture-proof base paper, produce functional cardboard that meets industry standards, and meet special requirements such as hygiene and low temperature resistance.

Why Choose Jeytop’s Single Facer Corrugating Machines?

As an enterprise rooted in the core industrial cluster of corrugated carton machinery, Jeytop Carton Machinery relies on the whole industry chain resources to achieve localized efficient collaboration, with a production cycle 15%-20% shorter than the industry average, allowing cost-effective equipment to reach the production line faster. A medium-sized carton factory adopted Jeytop’s cassette-type Single Facer machine solution, and the equipment delivery cycle was compressed from the industry’s conventional 40 days to 32 days, quickly responding to the production capacity demand during the e-commerce peak season.

Jeytop’s Single Facer corrugating machine series covers all scenario needs:

• After a home appliance packaging enterprise adopted the belt-type Single Facer machine, the edge pressure strength of the cardboard increased by 18%, the rejection rate caused by indentation problems dropped from 5.2% to 1.5%, and the production speed was stable at 280 meters per minute;
• A food packaging factory selected the negative pressure side suction type model, combined with anti-condensation design, solved the problem of facing paper wrinkling in high-humidity environment, and the rejection rate decreased by 4.3%;
• The electric-heated single-flute equipment of a small and medium-sized customer, through precise temperature control design, saves about 200 US dollars in electricity fees per month compared with similar products.

All series of models are equipped with a stable operation system, and high-end models are equipped with intelligent functions:

• Intelligent humidity sensing (automatically adjust the temperature of corrugating rolls by ±3℃ when detecting fluctuations in base paper moisture);
• Multi-stage pressure control (automatically match 0.3-0.5MPa pressure range for facing papers of different weights);
• Optional remote diagnosis module, with fault response time shortened to within 2 hours. A chain packaging enterprise used this to reduce downtime by 12 hours per month.

For special needs, Jeytop provides customized solutions: adding preheating components for customers in low-temperature areas to solve the problem of base paper embrittlement; optimizing the heating system for high-altitude areas to ensure stable working temperature of 150-180℃.

Having been deeply involved in the industry for 15 years, we are a national high-tech enterprise. Our equipment has passed CE and ISO9001 certifications, serving more than 3,000 carton factories worldwide, covering more than 20 fields such as home appliances, food and electronics. We provide full-process butler-style services from selection consultation, installation and commissioning to operator training.

If you need to match a highly adaptable Single Facer corrugating machine solution for your production line, please contact our technical team. Jeytop will customize an exclusive solution according to your production capacity, base paper type and regional environment, making every meter of cardboard both efficient and high-quality.

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