Reliable solutions for cutting corrugated plastic materials

Cutting corrugated plastic

Cutting corrugated plastic is a key part of producing durable, lightweight signage, packaging, and display materials. Corrugated plastic is a twin-wall polypropylene sheet used widely across industries thanks to its weather resistance, rigidity, and cost-effectiveness. While it’s a popular material, especially in retail signage, real estate boards, and reusable packaging, its structure poses specific challenges when it comes to precision cutting, creasing, and folding.

To consistently achieve clean cuts, crisp folds, and production-ready parts, manufacturers and signmakers need the right digital cutting solution. Kongsberg Precision Cutting Systems delivers exactly that: precision, speed, and reliability through advanced technology built for performance.

Common challenges when cutting corrugated plastic

• Delamination and tearing: the fluted structure of corrugated plastic can easily delaminate or tear during cutting, especially if using the wrong tooling or blade settings.
• Inconsistent creasing: without the right pressure and control, creasing lines can become inconsistent or crush the material, affecting the fold quality.
• Material drag and misalignment: lightweight sheets can shift during processing, causing inaccuracies or wasted cuts.
• Tool wear and reduced lifespan: the abrasive nature of corrugated plastic can wear down cutting blades quickly, reducing efficiency and increasing maintenance needs.
• Limited versatility: many cutting systems struggle with switching between cutting, creasing, and V-notching without manual intervention or time-consuming setups.

Why choose Kongsberg PCS for cutting corrugated plastic

Kongsberg PCS understands the demands of modern production environments. Our systems are engineered to overcome the specific challenges of working with corrugated plastic. With over 60 years of experience and a commitment to innovation, we design tools and tables that improve throughput, reduce errors, and maintain the highest cut quality.

• No delamination or tearing: our powerful tooling options, including high-frequency knife tools, are designed for smooth and clean cuts through fluted plastics without damaging the internal structure.
• Perfect creasing, every time: advanced pressure control and precision creasing tools ensure consistent fold lines without crushing or distorting the material.
• Reliable material handling: vacuum zones and intelligent material hold-down systems keep even the lightest corrugated sheets stable throughout the cutting process.
• Longer tool life: our engineered blades and intelligent tool control reduce wear, cutting maintenance costs and downtime.
• Seamless versatility: from cutting to V-notching to creasing, Kongsberg systems support rapid tool changes and automated workflows, maximizing uptime and productivity.

The best Kongsberg tables for cutting corrugated plastic

Whether you're producing high-volume signage or custom packaging, Kongsberg PCS offers cutting tables built to handle corrugated plastic with speed and accuracy. Our modular systems adapt to your production needs and are trusted by converters, signmakers, and display specialists worldwide.

Kongsberg Ultimate

The Kongsberg Ultimate is our flagship digital cutting table, engineered for industrial strength and unmatched throughput. It’s designed to keep pace with the most demanding environments, offering precision and reliability in every cut. 

• Superior motion control: delivers razor-sharp accuracy, even on lightweight or rigid corrugated plastic sheets.
• High cutting speed with no compromise: cuts faster while maintaining quality thanks to its advanced drive system.
• Heavy-duty construction: built to endure continuous use without losing performance, ideal for 24/7 production.

Kongsberg C series

The Kongsberg C series combines versatility and performance in a compact footprint, perfect for businesses needing flexible production without sacrificing speed or quality.

• Multi-zone vacuum hold-down: keeps corrugated plastic sheets firmly in place during cutting to eliminate drift.
• Supports a wide range of tools: switch between cutting, creasing, V-notching, and more with ease.
• High-speed cutting with automation options: scale up as needed with feeder and stacker modules to boost productivity.

Tooling that powers precision cutting of corrugated plastic

• High frequency VibraCut knife tool: ideal for fast, accurate cutting of corrugated plastic; uses a vibrating motion to slice cleanly through tough fluted materials with no tearing.
• V-notch knife: perfect for creating clean 90° folds; removes a small wedge of material for seamless bending without compromising structural integrity.
• VibraCut knife tool: a versatile vibrating blade that cuts a wide range of corrugated substrates, optimized for speed and material control.
• Rigid material knife tool: designed for straight cuts in denser plastic boards; offers minimal deflection for highly accurate results.
• Heavy-duty unit: handles thicker corrugated plastic sheets with ease, applying extra force where needed for deep cuts and strong performance.
• PowerHead: a versatile unit for both cutting and creasing; delivers exceptional precision for packaging applications.
• VariAngle unit: cuts at any angle between 0° and 60° on-the-fly, making it easy to create dynamic display structures from corrugated plastic.
• Dual heavy-duty unit: offers two slots for heavy-duty tools, reducing tool change time and boosting productivity on corrugated jobs.

How Kongsberg PCS helps you master cutting corrugated plastic

Corrugated plastic is a versatile but demanding material. To cut it cleanly and efficiently, you need a system that offers more than just cutting—it needs to handle creasing, V-notching, and high-speed runs without sacrificing quality.

Kongsberg Precision Cutting Systems gives you the edge. With industry-leading hardware, intelligent software, and advanced tooling, our solutions let you move faster, waste less, and deliver better results. Whether you’re a high-volume packaging producer or a sign shop working with diverse materials, we have the cutting table and tools to fit your needs—and grow with your business.

Discover how Kongsberg PCS can help you cut corrugated plastic with confidence. Get in touch with our team today to explore the possibilities.