Can the machine handle double-wall or triple-wall corrugated boards? | Keshenglong&Shinko Guide

Can the machine handle double-wall or triple-wall corrugated boards?

Printing on double-wall or triple-wall corrugated boards is a common requirement for heavy-duty packaging applications. Professionals often ask: *Can my flexo printer handle these thicker, more robust substrates?* This article explains the technical considerations, industry best practices, and how to ensure your flexo printer is up to the task.

Understanding Double-Wall and Triple-Wall Corrugated Boards

- Double-Wall Boards:

- Consist of two layers of fluted corrugating medium sandwiched between three sheets of linerboard.

- Common thickness: 6-7 mm.

- Triple-Wall Boards:

- Three layers of fluted medium with four linerboards.

- Typical thickness: 10-12 mm or more.

- Application:

- Frequently used for heavy, bulky, or high-strength shipping boxes.

Machine Capability: Key Considerations

Board Thickness & Handling

- Modern flexo printers can process boards up to 12 mm thick, but specifications vary.

- Check your machine’s maximum substrate caliper or thickness rating.

- Feeding mechanisms must support uniform transfer without crushing.

Feeding System Adaptations

- Vacuum Feeders or Lead Edge Feeders are preferred for heavy or multi-wall boards.

- Adjustable feeder roller pressures are vital to prevent skew and jam issues (Manual from FEFCO, European Federation of Corrugated Board Manufacturers).

- Feeder table width should match the increased board rigidity.

Print Quality Maintenance

- Heavier boards may affect print resolution due to surface irregularities.

- Printing plates should be carefully selected for greater compression resistance.

Slotting, Die-Cutting & Folding

- Increased board thickness requires sharper, more robust tooling.

- Slotting knives and die-cutting anvils should be approved for multi-wall operations to reduce wear.

- Enhanced creasing and folding systems may minimize cracking or fiber tear.

Essential Machine Features for Heavy Boards

- High Torque Drive Motors: Prevent feeding failures on thick substrates.

- Reinforced Transport Belts/Rollers: Durable enough for regular multi-wall operations.

- Adjustable Top Pressure Rollers: Precise board holding at every drum.

- Customizable Print Gap Settings: Accommodates increased caliper without print compromise.

- Heavier-Duty Drying Systems: Ensures high ink coverage dries completely.

Best Practices and Optimization

- Conduct regular maintenance checks on feeder and transport systems.

- Use calibrated board guides to maintain registration accuracy (Sourced: TAPPI Standards).

- Optimize ink formulations for dense board surfaces to minimize absorption and smudging.

- Confirm compatibility with board suppliers for consistent board thickness and flatness.

Industry Data and References

- Up to 17% of all flexo-printed cartons use double- or triple-wall boards for shipping goods (Smithers Pira, 2022 Corrugated Board Outlook).

- Machines certified for heavy board handling deliver lower downtime and scrap rates.

Conclusion

Flexo printers can handle double-wall or triple-wall corrugated boards when equipped with appropriate feeding, printing, and cutting systems. Always check your machine’s technical specifications. For tailored advice or to see compatible machines, consult Keshenglong&Shinko’s technical team.

References:

- FEFCO Technical Handbook, European Federation of Corrugated Board Manufacturers

- TAPPI Test Methods on Corrugated Board

- Smithers Pira – The Future of Corrugated Packaging to 2027

For more tailored solutions, reach out to Keshenglong&Shinko, your partner in advanced flexographic printing technology.