Packaging Converters & Box Plants
In-house corrugated board production lines that give independent box plants full control over board quality, cost, and lead time — the foundation of a vertically integrated converting operation.
Independent box plants that previously bought board from outside suppliers are increasingly investing in their own corrugator lines to capture margin, guarantee board availability, and control flute quality and moisture. A BOSON corrugated board production line turns kraft paper reels into single-wall, double-wall, or triple-wall board on one continuous line — the raw material that feeds every downstream converting machine.
Challenges We Solve in This Market
Board supply dependency
Buying board from third-party corrugators means waiting on their schedule, absorbing their margins, and risking stock-outs during peak season. An in-house corrugator line eliminates the middleman and secures your board supply on your terms.
Inconsistent board quality
When board arrives warped, delaminated, or off-spec, your converting machines jam, print registration drifts, and waste piles up. Producing board in-house with controlled preheating and starch application ensures flat, well-bonded board every time.
Margin compression from outsourcing
Every square meter of board bought externally carries a supplier's profit. Vertically integrating corrugation captures that margin inside your own plant, turning board cost from an expense into a controlled production variable.
The Dedicated Machine Combination
A complete BOSON corrugator line feeds kraft paper reels through preheating, single-facer corrugation, glue application, double-backer bonding, slitting, scoring, cutting, and stacking — producing flat corrugated board sheets ready for the converting floor.
Hydraulic Mill Roll Stand HS-B
Holds kraft paper reels up to 5 tons and feeds liner and fluting medium into the line with controlled tension and braking.
View DetailsPreheater PH
Conditions paper fibers with heat so they bend without cracking during flute formation — critical for flat, warp-free board.
View DetailsCassette Single Facer BS-MW25
Shapes the fluting medium into arches and bonds it to the first liner with starch adhesive — the heart of the corrugator.
View DetailsOverbridge Conveyor TO
Carries the single-face web to the glue station while electric correcting maintains alignment and tension.
View DetailsNC Glue Machine PM-D
Applies starch adhesive evenly to flute tips before the outer liner is bonded by the double facer.
View DetailsDouble Facer DF-D
Bonds the outer liner to the fluted medium under heat and pressure, curing the complete board structure.
View DetailsNC Slitter Scorer CS-A
Slits the continuous board to width and scores fold lines, with order changes in 2 seconds and 999-order storage.
View DetailsNC Cut-off PC-25
Cuts the board to sheet length with ±0.5–1mm precision at up to 250 m/min for consistent blank sizes.
View DetailsAuto Stacker HM-30A
Counts, stacks, and discharges finished board sheets for transfer to the converting floor.
View DetailsGlue Making System BS
Automatically prepares and controls starch adhesive viscosity for consistent bonding across the line.
View DetailsThe Right Cardboard for This Market
An in-house corrugator lets box plants produce the exact board grade each converting job needs — from lightweight single-wall for standard RSCs to heavy double-wall for export cartons — without compromise or supplier minimums.
Material Specifications
- Single-wall (3-ply): 2 liners + 1 flute — standard RSCs and retail cartons
- Double-wall (5-ply): 3 liners + 2 flutes — heavy-duty and export cartons
- Configurable flute profiles: A, B, C, E, BC for any converting requirement
Corrugated Boards in This Market
Not sure which flute or machine combination fits your product?
Our engineers will recommend the ideal setup based on your product weight, transit conditions, and branding needs.
Frequently Asked Questions
Why should a box plant invest in its own corrugator line?
An in-house corrugator eliminates third-party board margins, guarantees board availability and quality, and lets you produce the exact flute and ply structure each job requires — turning board from an outsourced cost into a controlled production variable.
Can one corrugator line produce both single-wall and double-wall board?
Yes. A 5-ply corrugator line uses two single facers and can produce single-wall board (using one single facer) or double-wall board (using both), giving a box plant full flexibility to match board structure to each order.
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