Box Plant Basics - Corrugators

SKU: C-465Duration: 44 Minutes Certificate Included

Pay-per-view (PPV) format perfect for individual users.

Get immediate access to this interactive eLearning course online. Must be used within 30 days, expires 48 hours after launch.

Great for in-person classroom training or as an alternative to DVD.

Includes printable documents and Convergence Video Player for Windows systems. Content expires after 1 year.

Ideal for corporate licensing and volume users who also need administrative tracking and reporting on training.

Get this interactive eLearning course into your LMS or learn how you can leverage our LMS to deliver training to your workforce.

Need multiple courses or have lots of users? Just let us know a little more about what you need and we’ll get you some great volume pricing.

 Need help deciding? Compare delivery formats.

Course Details


Training Time: 44 minutes

Compatibility: Desktop, Tablet, Phone

Based on: Industry Standards and Best Practices

Languages: English

A corrugator is a large machine, made up of a series of smaller machines, that combines two different kinds of paper to create cut sheets of corrugated fiberboard. The flat, facing sheets are referred to as the liners, and the wave-like, fluted layers are known as the corrugating medium, or simply medium. The corrugator takes large rolls of paper produced on paper machines, flutes the medium and glues it to the liners, one at a time, and delivers stacked, cut, and scored sheets of corrugated board to various converting machines. The converting machines convert the sheets of corrugated board into "box blanks," which are ready to be made into boxes, and other corrugated board products.

At the end of this module, you will be able to:

  • Describe the corrugating process
  • Identify and describe wet end components
  • Define preconditioning and preheating
  • Describe corrugating and pressure rolls
  • Describe how adhesives are applied
  • Describe the function of a double facer glue unit
  • Describe the function of the double facer hot plate section
  • Identify and describe dry end components
  • Describe the function of the stacker
  • Differentiate between double and triple wall corrugators

The following key questions are answered in this module:

How are the flutes in the corrugating medium created?
The medium is heated and conditioned with steam before it travels through the nip created by two corrugating rolls. The corrugating rolls have alternating ridges and grooves which mesh together like gears to form the flutes.

What is the purpose of the "bridge" which carries the single-face board from the single facer to the double facer?
The bridge provides temporary storage for the single-face board to allow for temporary changes in speed at the single facer or double facer.

Why does the double facer need a hot plate section and the single facer does not?
The double facer cannot apply as high a pressure as the single facer because it must preserve the flutes in the medium. So, to fully cure the double face bonds, the sheet must be exposed to high temperatures for a longer period of time.

What is the difference between downstackers and upstackers?
Downstackers have an elevator deck which automatically lowers as the stack builds to maintain the stack height relative to the last conveyor belt. Upstackers have a stationary deck and the last conveyor belt height automatically raises as the stack builds.

Some corrugators can produce double and triple wall board. What is required for each additional wall?
For each additional wall, the corrugator requires an additional single facer unit, bridge level, and glue unit in the double facer glue unit.

Below is a transcript of the video sample provided for this module:

The medium is fluted and glued to one of the liners at the single facer. The preheated and moistened medium travels first through the corrugating nip between the two corrugating rolls. The corrugating rolls have alternating ridges and grooves, which mesh together like gears as they meet in the nip to form the flutes in the medium. After the corrugating nip, the medium is held against the second corrugating roll either by thin metal plates called fingers, vacuums applied to the inside of a perforated corrugating roll, or a pressurized chamber that presses the medium up against a solid corrugating roll. As the fluted medium approaches the nip with the pressure roll, a glue roll applies adhesive to the outer tips of the flutes. The preheated liner enters from the other side of the single facer. It contacts the fluted medium in the single facing nip between the pressure roll and the second corrugating roll. It is the heat and pressure present in this nip that are responsible for the bond that must hold the medium and liner together until the bond can fully cure. The strength of this initial "green bond" depends on the adhesive formula, adhesive application, and time and temperature in the single facing nip.

Use the additional resources and links below to learn more about this topic:

Customer Q&A

Ask a Question

Sorry, we're missing some information

How do I log in to watch a video that I have already paid for?

Easy! Moments after you purchase your pay-per-view (PPV) course, you'll receive an email with login details. Just click the link and log in with your user name and password and you're on your way!

I would like to have some of my employees take 5 of your driving related courses, how can i set this up?

We're in the process of making bulk purchases and purchases for multiple users easier. But for now, you can order multiple courses and just let us know who you'd like to assign courses to. With an email for each user, we can set up their training plans and make sure everyone gets the eLearning assignments they need.

How can I get your paper-making courses for free?

Well, we can't blame you for asking... And while we're a for-profit company, there are situations with students and certain educational organizations where we can help out with a selection of eLearning. However, our online courses are extremely economical. And our paper industry courses are in very high demand. So, without knowing more about your situation, we think you'll get loads of value from the $39 you'll spend on any of our premium courses.

Do you have eLearning in Portuguese?

Yes, we do! And in addition to primary English narration, we produce many courses in a growing number of languages, including Spanish, Chinese, Dutch, German, Italian, Japanese, Korean, Polish, Russian, Tamil, and Thai.

I'm unemployed, but I really like your eLearning. Do I get a certificate when I complete a course?

Yes! All of our courses allow you to print a completion certficate upon successfully passing the integrated test at the end of eLearning. In the future, we'll have badges for you to use in your LinkedIn profiles.
Added to Cart! Click here to view your cart.