Corrugated Production
Keep corrugated production moving, even with rising demands
Corrugated packaging producers face increasing job variation, tighter deadlines, and higher customer expectations. Shorter runs and complex board types put pressure on every step of your workflow.
Reduce manual handling, minimise bottlenecks, and increase output. Without adding operators or complexity.
The challenge
More variation. More pressure. Less margin for error.
The corrugated packaging market is shifting toward shorter runs and more customised jobs. Material complexity and frequent job changeovers increase setup time and interrupt production flow.
- Rising demand for diverse box formats
- Frequent material and job changes
- Tighter turnaround expectations
- Quality standards that leave no room for rework
Bottlenecks
Where you lose time and capacity
Inefficiencies in corrugated workflows often come from predictable points. These make throughput unpredictable and workforce costs higher than they need to be.
- Manual handling between cutting, creasing, and finishing
- Waiting time between job changeovers
- Material handling interruptions
- Quality variations that cause rework
A better workflow
A smoother, more predictable corrugated workflow
Imagine a production environment where jobs flow from loading to output with fewer interruptions. Manual steps are reduced, transitions are seamless, and output remains consistent, even with frequent job changes.
This is the reality for corrugated producers who optimise their workflow Less firefighting, more throughput.
Key outcomes
What this approach delivers
Higher throughput per shift
Keep orders moving through the line without manual bottlenecks slowing the queue.
Reduced manual handling
Minimise time spent moving boards between stations and reduce operator involvement.
Consistent quality across jobs
Produce repeatable results that reduce rework and waste, regardless of board type.
How it works
Corrugated production, step by step
Each stage in your corrugated workflow should reduce delays, simplify transitions, and ensure consistency. No matter the job size or board type.
01
Load and prepare jobs
Boards and files are organised quickly, reducing setup time and minimising operator involvement between jobs.
02
Run continuous production
Jobs are processed across multiple board types without stopping or slowing the workflow. One operator monitors; the machine runs the queue.
03
Deliver finished output
Boards move to finishing with repeatable quality and fewer errors regardless of job mix or complexity.
Applications
Corrugated use cases
Stacked boxes
Efficiently handle frequent job changes and varying box sizes without interrupting the line.
Complex board designs
Deliver precise results across intricate cuts and creases, consistently and at speed.
Short- to medium-run jobs
Maintain throughput speed without sacrificing quality across changing job specifications.
Proof
Proven in corrugated production
"Increased daily output by up to 30% while reducing manual handling between workflow steps."
Head of Production, Corrugated packaging manufacturer, Europe
Talk to an expertCorrugated producers adopting this approach see measurable improvements in both efficiency and throughput.
Jobs flow faster, quality becomes more predictable, and manual work is reduced. Processes become more consistent across board types, job sizes, and production volumes.
Used by corrugated packaging manufacturers running continuous, high-volume production across Europe.
FAQ
Questions corrugated buyers ask us most.
Yes. Kongsberg tables are built to handle single, double, and triple wall corrugated board. The Feeder and Stacker supports board thickness up to 50 mm and rigid board weights up to 30 kg per sheet. Tooling is available for all board types and flute structures.
Kongsberg corrugated creasing tools are purpose-built to maintain correct crease depth and pressure regardless of board thickness variation or flute type. Combined with software-driven pressure control, the system adapts automatically, eliminating the manual trial-and-error typically needed when switching board stock.
The Feeder and Stacker feeds at up to 2 boards per minute and eliminates idle time between sheets. Combined with the optional underside camera, which removes the need for manual registration checks, customers typically report saving 20 to 30 minutes per job and significant increases in overall daily output, depending on job mix.
Yes. With automated board feeding and software-driven job queuing, one operator can manage multiple tables simultaneously. The Feeder and Stacker handles repetitive loading and unloading, freeing the operator to focus on job setup, quality checking, and downstream tasks.
The Feeder and Stacker is available as an upgrade to existing compatible Kongsberg tables as well as a new purchase. If you want to start with manual feed and automate later, the table platform is designed to support that upgrade path. Contact us to confirm compatibility with your current machine.
Payback period depends on your current production volume, labour costs, and job mix. Key drivers include reduced labour cost per unit, higher throughput from the same floor space, reduced material waste through better nesting, and lower cost of rework. We recommend speaking to a Kongsberg specialist for a production-specific ROI assessment.
Get started
See how this approach fits your corrugated production
This workflow delivers results when your production is under pressure and you need to increase throughput without adding operators.
- You run short- to medium-run corrugated jobs
- You handle diverse board types
- You need consistent quality with minimal rework
Get your recommendation
Tell us about your corrugated workflow and we'll recommend the right configuration for your production needs.
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Get a quote
Know what you need? Get a detailed quotation including configuration options, installation, and support.
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Talk to a specialist
Speak directly with a production specialist about your board types, volume, and workflow goals.
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