• Case Studies
Case Studies
  • Corrugating Roll Optimization for a Russian Packaging Plant
  • Corrugating Roll Optimization for a Russian Packaging Plant
Corrugating Roll Optimization for a Russian Packaging Plant

A corrugated packaging plant in Russia, specializing in the production of 5-ply corrugated board and cartons, was experiencing limitations in production speed. Their maximum machine speed was capped at 180 m/min. Any attempt to exceed this speed led to machine resonance, paper breakage, and poor board quality.

Yonghui conducted a comprehensive assessment of the client’s order structure and analyzed the existing flute profiles in use. Based on these insights, we re-engineered the flute profile and applied precise control over the corrugating roll’s raw material selection and machining accuracy. After installing the optimized corrugating rolls, the plant’s average running speed increased to 300 m/min. This significant improvement not only boosted overall production efficiency but also ensured that the quality of the corrugated board fully met the client’s performance requirements.
Tungsten Carbide Corrugating Rolls for a Thai Packaging Plant
Tungsten Carbide Corrugating Rolls for a Thai Packaging Plant

A corrugated packaging plant in Thailand adopted our tungsten carbide corrugating rolls for their E-flute production line. The corrugating roll packaging plant experienced notable improvements in production reliability and material efficiency:

  • Consistent and controllable coating thickness, ensuring high roll precision and reliable performance.
  • Advanced polishing process following the coating treatment resulted in a surface roughness of Ra 0.2–0.4, fully meeting the demands of high-speed corrugators with reduced wear.
  • When paired with UV and UVV flute profiles, the rolls enhanced board hardness, reduced adhesive consumption, and minimized core paper waste.
Micro-Flute Corrugating Rolls for an Indian Cigarette Packaging Plant
Micro-Flute Corrugating Rolls for an Indian Cigarette Packaging Plant

Currently, with the rapid development of the packaging industry, micro-corrugated boards are being applied more and more widely. Our company produces micro-flute corrugating rolls for micro-corrugated boards of F, G, and N types, which can be used in the packaging of cigarettes, pizzas, cosmetics, and other products. We are the only manufacturer in China that can perform tungsten carbide spraying on corrugating rolls used for making N-type corrugated boards. The tungsten carbide coating can ensure the stability of the tooth height of corrugating rolls, meet the requirements of high-quality printing, and guarantee the exquisite appearance of the cartons. The tungsten carbide coating can achieve a relatively long service life, reduce the number of times of replacing corrugating rolls, and improve production efficiency.
  • Peripheral Heating Corrugating Rolls for a Russian Packaging Plant
  • Peripheral Heating Corrugating Rolls for a Russian Packaging Plant
Peripheral Heating Corrugating Rolls for a Russian Packaging Plant

A corrugated packaging plant in Russia installed our peripheral heating corrugating rolls on their Fosber corrugator. The rolls we supplied, delivered significant performance advantages, such as:

  • Rapid heat-up time, reaching optimal operating temperature within five minutes, reducing machine downtime during startup.
  • Minimized thermal deformation, extending roll service life by approximately 20% compared to conventional corrugating rolls.
  • Achieved over 10% energy savings, contributing to more sustainable and cost-efficient production.
Tungsten Carbide Roll Refurbishment for a South African Packaging Plant
Tungsten Carbide Roll Refurbishment for a South African Packaging Plant

A corrugated packaging plant in South Africa entrusted Yonghui with the refurbishment of tungsten carbide corrugating rolls used on their BHS equipment. The repair process was carried out with precision and full traceability, following a standardized multi-step workflow:

  • Disassembly of returned rolls and removal of accessories
  • Comprehensive inspection and issuance of a detailed diagnostic report
  • Repair proposal and confirmation of restoration parameters
  • Sequential restoration steps including: • Cleaning and tungsten carbide removal
    • Welding of bearing seats and worn gear sections
    • Precision grinding and post-grinding quality inspection
    • Sandblasting and reapplication of the tungsten carbide coating
    • Final grinding, polishing, and surface testing
  • Final inspection and packaging for return shipment

Through this meticulous refurbishment process, the client successfully extended the service life of their rolls while restoring full performance and reducing replacement costs.
Customized Corrugating Rolls for a Taizhou-Based Packaging Manufacturer
Customized Corrugating Rolls for a Taizhou-Based Packaging Manufacturer

A packaging company in Taizhou, China, specializing in corrugated board production, operates a 2500 mm BHS corrugator. Based on the client’s specific production needs and equipment configuration, Yonghui supplied custom-engineered corrugating rolls optimized for high-speed operation. The upgraded rolls enabled the production line to maintain a stable running speed exceeding 320 m/min, helping the client achieve higher throughput while ensuring consistent board quality.

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