The corrugated rollers are made from high-quality 50CrMoA alloy steel.

The coatings include chrome plating and tungsten carbide. The coating thickness ranges from 0.06 to 0.08mm. We can process the largest corrugated rollers in the world, with a maximum width of 3600mm and a diameter of 600mm.

Heating methods include peripheral heating, siphon pipe steam heating, electric heating, and oil heating.

We offer both external and internal vacuum systems (for cutting slanted grooves, straight grooves, and small hole cutting).

The rollers undergo a composite heat treatment process including nitriding, high-frequency quenching, tempering, and cryogenic cooling (-190°C). The hardness can reach HRC >60.

After polishing, the surface roughness can reach Ra ≤0.4.

The lifespan of peripheral heated tungsten carbide corrugated rollers can exceed 100 million meters. For siphon heated tungsten carbide rollers, the lifespan ranges from 50 to 80 million meters. The actual lifespan depends on the flute profile, diameter, equipment stability, paper sand content, customer-specific orders, and maintenance practices.

The body of new corrugated rollers is made from high-quality forged alloy steel, which is expensive, leading to high manufacturing costs. However, worn rollers can be re-ground and re-coated, allowing them to be reused. Tungsten carbide rollers can be repaired 2-3 times, and the lifespan of repaired tungsten carbide rollers is slightly shorter than that of new rollers, but the cost is only half. Chrome-plated rollers can also be repaired, and if the hardness is high enough, they can even be re-coated with tungsten carbide.

We can design multiple flute profiles based on your requirements for flute height and sheet caliper. This optimization ensures the best performance and maximum efficiency. Our flute profiles, under the same flute height and pitch conditions, offer a lower sheet caliper compared to other manufacturers, which helps reduce raw paper costs. We design the UV-shaped flute profile, which not only increases the flat crush strength of the board but also saves on raw materials, reduces glue consumption, and ensures a smooth board and optimal printing results.

Yes, we can process any flute profile. We have already produced N, G, and F flutes with heights ranging from 0.4mm to 0.9mm, which are applied in industries such as tobacco packaging, cosmetics packaging, and food packaging (e.g., pizza boxes).

Corrugated roller resonance is a complex issue caused by multiple factors. Resonance can be either inherent or acquired. Inherent resonance is caused by quality issues with the roller itself and can only be mitigated but not fully eliminated. Acquired resonance is primarily due to roller installation and equipment issues, and it can be resolved by adjusting the equipment. To avoid inherent resonance, our solution is as follows:

• Optimize the flute profile: We research existing flute profiles and make informed decisions about parameters, then redesign the flute profile accordingly.
• Improve roller processing precision: Roller processing precision issues can also contribute to resonance. We ensure high precision in every step of the process, including raw material inspection, dynamic balancing, roundness, parallelism, tooth profile inspection, sidewall inspection, hardness, and surface finish. High-precision rollers effectively prevent resonance.

We require complete drawings and confirmation of the custom flute profile for your specific needs.

We can process corrugated rollers for any brand of single facer, including popular international brands and Chinese brands such as JingShan, XieXu, XiangYi, TCY, Champion, and more. We are also a supplier of corrugated rollers for well-known domestic and international corrugated packaging equipment manufacturers like Fosber, BHS, Marquip, Mitsubishi, and Peters.

Please refer to the attached maintenance manual for detailed instructions.

Backed by over 20 years of experience in corrugator roll processing and design, we offer optimized flute profiles that help customers reduce costs. Our proprietary combined heat treatment ensures high roller hardness, and the use of imported Praxair hard tungsten carbide coating results in high wear resistance. Our rollers have low noise, long lifespans, and fast operating speeds.