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How to innovate the manufacturing process of corrugated box production equipment parts
Corrugated rolls are essential components in the production of corrugated cardboard, serving as the molds that shape the flutes. As one of the most expensive and critical parts on single-faced corrugating machines, their performance directly impacts the quality and durability of the final product. The height of the corrugated teeth determines both the thickness and structural strength of the cardboard. Therefore, it is crucial for these rolls to maintain high wear resistance and dimensional stability over time, ensuring consistent and reliable production.
In the past, when the surface of a corrugated roll became worn, the common repair method was to apply hard chromium plating. However, this traditional technique often resulted in poor wear resistance, leading to frequent maintenance and reduced service life. To address these limitations, an innovative solution has been developed: a silicon carbide-chromium nano-ceramic coating applied to the working surface of the corrugated roll. This advanced coating has a thickness of 0.08–0.10 mm and consists of three distinct layers. The first layer forms a strong ion diffusion bond with the base material, while the second layer acts as a supportive base. The outermost layer is a highly wear-resistant nano-ceramic coating. This technology makes the corrugated roll approximately three times more durable than conventional hard chrome-plated versions, significantly extending its lifespan and reducing downtime and maintenance costs.
Similarly, the anilox roller plays a vital role in flexographic printing, where its performance directly affects print quality. Traditionally, metal anilox rollers made from low-carbon steel or copper were engraved with a 45° pyramid structure and then chrome-plated. However, due to the thinness of the coating, these rollers tend to wear quickly, especially under high-speed operation. This wear reduces the volume of the ink cells, which can lead to uneven ink distribution and lower print quality.
To overcome these challenges, laser-engraved ceramic anilox rollers have emerged as a superior alternative. Made from nano-ceramic materials, they offer enhanced hardness, toughness, and wear resistance. These properties allow them to maintain consistent performance over extended periods, making them ideal for high-volume and high-quality printing applications. As a result, ceramic anilox rollers are increasingly replacing traditional metal ones in flexographic presses. Their ability to meet the demanding requirements of modern printing processes ensures better print quality and greater operational efficiency. This technological advancement not only improves the reliability of the printing system but also supports the production of higher-quality packaging solutions.