The Corrugator machine pairs the various papers then cuts the ribbon to the desired size in order to obtain sheets of corrugated cardboard. 

BHS Corrugator

The latest-generation line installed at Ghelfi Ondulati is prepared for industry 4.0.

Automation and self-learning

Multi-level automation and innovative parameter self-learning systems minimise the set-up times and the need for human intervention, whilst also minimising waste generation.

Zero Defect System

Any product defects are detected online by an ultrasonic control system, called ZDS (Zero Defect System). Such imperfections are automatically discarded, minimising product waste and guaranteeing the end customer a product that complies with the utmost modern quality standards.

Cutting via image detection

In perfect synergy with the pre-print department, a sophisticated image detection system ensures the perfect centring of the cut in respect of the printing, meaning that product customisation reaches a new and elevated level.

Before being processing in the cardboard box factory, the corrugated cardboard panels are stored in the semi-finished warehouse. It is here that the cardboard cools and “matures”, involving the evaporation of the water contained within and the polymerisation of any resins.

Robotic transport system

The system works as an intermediate buffer between the box factory and corrugator, able to unload the cardboard from the corrugator to then render it available for transformation when required, all in a totally automatic manner.

Laser guided vehicles

Automatic warehouse with 3 laser-guided trolleys.

In “Post-print” printing, flexo printing machines are normally used, availing of water-based inks to stamp engravings on very soft polymers (known as “clichés”). Each cliché transfers a certain colour to the cardboard sheet. The cliché is kept inked by a mesh roller (an anilox) and transfers its image to the sheet of cardboard for “stamping”. For quality printing results, the line of the anilox must be coordinated with the type of media on which to print (paper and wave) and with the image to be represented.

Bobst Masterflex HD

The latest generation flexographic printing machine, with 7 printing groups, is equipped with a Registron system to automatically maintain the registration between the printing groups.

Bobst Masterflex 203 A-Matic

A flexographic printing machine with 6 printing groups. Over time, our Masterflex has been retrofitted with all available options, to maintain performance but above all so as to offer a product of the highest quality to every customer.

High-speed, large-size simplex colour coil inkjet printer for corrugated cardboard packaging.

• Use of a cover from 80 to 400 g/m²
• HP A50 water-pigmented inks, suitable for the food industry
• 183 m/min. line speed to reach 300
• Native resolution of 1200 DPI
• 4 colours + BA, totalling 7
• Coil width up to 2,800 mm

The die is the matrix on which the blades and cables are mounted to reproduce the packaging, starting from the printed sheet. There are rotary and flat die cutters. The former are faster and more productive, whilst the latter are more dimensionally precise. A rubber component in the rotary die-cutter takes care of any die-cutting scrap, whilst a specific tool handles clean up in the flat die-cutter.

Bobst Mastercut 2.1

A flat die cutting machine of the latest generation, it is equipped with the Power Register system for automatic re-registration during die-cutting.

Power Register

With this system, the machine is able to guarantee the perfect registration of the die-cutting due to automatically making corrections based on marks printed on the sheet.

It produces standard cardboard boxes, starting from a sheet of unprinted cardboard passed through a single machine, composed of several simplified printing units, a die-cutting unit, a slotter and a folding machine.

Casemaker Martin FFG 924 NT

Casemaker bearing 6 printing groups, equipped for HD flexographic printing, having the latest generation systems for the automatic retention of the registration between the press groups.

This device is able to glue even complex boxes that have already been printed and die-cut.

Fold-paste Bobst Pacific 3.0

BOBST folder-gluer, specific for corrugated cardboard, with a maximum folding speed of 250 m/min.
Equipped with poly joiner for the realisation of boxes composed of several die-cuts.