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PRODUCTIVE PROCESS

THE CORRUGATOR

The corrugator is a machine that couples the various papers and cuts the tape in order to achieve the desired format to obtain corrugated cardboard sheets.

Corrugator BHS

The latest generation line installed in Ghelfi Ondulati is designed for industry 4.0.

Automation and self-learning
Multi-level automation and innovative parameter self-learning systems minimize set-up time and the need for human intervention, minimizing waste generation.
Zero Defect System
Any product defects are detected on-line by an ultrasonic control system, called ZDS (Zero Defect System). These imperfections are automatically discarded, minimizing product waste and guaranteeing to the end customer a product that conforms to the highest modern quality standards.
Cutting by image detection
In perfect synergy with the pre-print department, a sophisticated image detection system ensures perfect centering of the cut with respect to printing, allowing you to bring the personalization of the product to a new, very high level.
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SEMI-STORED WAREHOUSE

The sheets of corrugated cardboard before being processed in the box factory are stored in the semi-finished warehouse; it is here that the cardboard cools and “ripens”, i.e the process of evaporation of the contained water and of the polymerization of any resins is completed.

ROBOTIC TRANSPORT SYSTEM

The system works as an intermediate buffer between the box factory and the corrugator, and in a totally automatic way is able to manage the unloading of the cardboard from the corrugator and then make it available for processing when required.

Laser guided vehicles
Automatic warehouse with 3 laser-guided carts.
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THE PRINTER

Flexo printers are normally used in “post-print”: this is a type of print that uses water-based inks and stamps engraved on very soft polymers (clichés). Each cliché transfers a certain color to the cardboard sheet. The plate is held inked by a rolled roller (anilox) and transfers its image to the cardboard sheet for “stamping”. For a good print result, the anilox line should be coordinated with the type of media on which the printing (paper and wave) and with the image to be represented takes place.

BOBST MASTERFLEX HD

Latest generation flexographic printing machine, with 7 printing groups, equipped with the Registron system to automatically keep the register among the printing groups.

System IQ300
This system is able to identify printing defects and expel them in a totally automatic way, ensuring a very high quality of the product.

BOBST MASTERFLEX 203 A-MATIC

Flexographic printing machine with 6 printing groups. Over time our Masterflex has been retrofitted with all available options, to maintain the performance, but above all the possibility of offering a product of the highest quality to the customer.

System IQ300
This system is able to identify printing defects and expel them in a totally automatic way, ensuring a very high quality of the product.
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THE DIE CUTTER

The die is the matrix on which blades and cords are mounted to reproduce the packaging starting from the printed sheet. There are rotary and flat die-cutting machines. The former are faster and more productive, the latter are more precise in terms of size. The cleaning of the punching waste is entrusted to the gumming in the rotary die-cutting and to a special tool in the flat die-cutting.

BOBST MASTERCUT 2.1

Flat die-cutting machine of the latest generation, equipped with the Power Register system for automatic rewinding during the punching phase.

Power Register
With this system the machine is able to guarantee a perfect die-cutting register because it automatically makes corrections based on the mark printed on the sheet.
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IL CASEMAKER

It produces the American boxes starting from an unprinted cardboard sheet in a single machine passage: it is made up of several simplified printing units, a die-cutting unit, a slotter and a folder.

CASEMAKER MARTIN FFG 924 NT

Casemaker equipped with 6 printing groups, equipped for HD flexographic printing, equipped with the latest generation systems for the automatic maintenance of the register between the printing groups.

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THE FOLDING-MOLD

It also glues even complex boxes that have already been previously printed and die-cut.

FOLDPASTE BOBST PACIFIC 3.0

Bobst folding machine, specific for corrugated cardboard, with maximum bending speed of 250 m / min.
Equipped with poly joiner for the realization of boxes made up of several blanks.