New Technology for Corrugated
This fall, the corrugated industry heads to Savannah, GA, to explore what’s possible and build what’s next. CorrExpo 25 will taking place October 20-22, 2025, and is expected to bring together 1,500 corrugated industry professionals from more than 300+ companies.
Program planning is underway, led by working professionals within TAPPI’s Corrugated Packaging Division (CPD). New this year: the TAPPI Women’s Summit will be co-located with CorrExpo on Monday, October 20, adding even more value (see page 48). Pro tip: book hotel accommodations early to take advantage of special rates (learn more at CorrExpo.org.)
A high point of the event is the show floor, hosting exhibitors displaying working machinery and live demonstrations of new and proven technologies. For this article, we’re spotlighting more than 20 of the latest offerings from vendors throughout the corrugated packaging industry. If you see something perfect for your plant, note the booth number at the end of each write-up and come to Savannah to talk to an SME live on the exhibit floor.
I also check in with three members of TAPPI’s Corrugated Packaging Division Council who share their expert insights: Keith Hamilton, VP, Operations for Georgia-Pacific Packaging LLC; Bert Hurler, manager, engineering and capital purchasing, Packaging Systems, North America, at International Paper; and Michael D. Martin, VP engineering, Corrugated-US/Canada for Smurfit Westrock. All three companies are world-leading corrugated manufacturers.
NEW TECH SPOTLIGHT
A.G. Stacker’s DUO digital twin technology offers an HMI-driven experience for three of its patented systems: the eXT front end system, eBREAK bundle breaker, and the new eZFa automatic load former. These custom digital blueprints of your A.G. equipment allow your team to train, plan, and collaborate in a risk-free virtual environment. The company’s SIMCORRA planning software lets users create and test custom factory layouts, production runs, and more. Booth 407.
Albany International offers a belt for every application in corrugated plants, from single-facers to double-backers, OEMs to retrofits. The newest member of the company’s “DURA” family of corrugator belts, DURAGUARD is constructed of a 4-layer woven base and 100 percent polyester fibers and yarns. Its surface is treated with Albany’s specially formulated coating, designed to virtually eliminate starch build-up while providing excellent durability against edge wear. Booth 442.
The UltraFEED from Alliance Machine Systems International is a new electric platform designed to bring corrugators all the benefits of the company’s legacy prefeeders with smoother, quieter operation and excellent reliability. Alliance’s line of prefeeders includes innovative features and can match the size, speed, and printing capabilities of any mill’s flexo folder gluer or rotary die cutter finishing machine. Booth 613.
Amtech’s completely integrated suite of ERP and MES systems provide tailored solutions to help corrugated, folding carton, and label manufacturers remain competitive. Flagship software solutions include EnCore ERP, with features including advanced planning tools for corrugated and folding carton manufacturing; Label Traxx, to manage label printing businesses from order entry to invoice; and Axiom, a sheet feeders-focused tool that provides integrated scheduling to help plants reduce operational costs. Booth 332.
BW Papersystems is advancing one of its most trusted machines with the introduction of the Vanguard SFG Singlefacer. This next-generation singlefacer integrates the latest automation and process control technologies and is designed to improve board quality, productivity, and operational efficiency. Advanced moisture control systems condition both the liner and medium webs, for optimal bonding across all paper weights and types. The machine’s automated diagnostics and monitoring capabilities provide real-time insights. Booth 201.
Engineered Recycling Systems’ new Continuous Cleaning Modular (CCM®) OCT Filter is an innovative system that finally addresses the limitations of conventional baghouse filters, offering enhanced safety, efficiency, and ease of maintenance. By operating under positive pressure and using fabric walls, the system prevents pressure buildup, reducing explosion hazards and allowing for safe indoor installation. Its modular design allows for scalability to meet varying air volume demands. Booth 743.
Global Boxmachine’s K1X Jumbo Flexo Folder Gluer recently set a new square footage production record when the team at Rusken Packaging in Fort Worth, TX, hit 2.75 million square feet in 16 hours. The K1X pairs new folding technology with proven flexo capability to cater to the demands of modern boxmakers; it runs non-stop with a synchronized system and features heavy duty components. Booth 413.
Haire Group’s Apstar line of flexo folder gluers and rotary die cutters have features that set a new standard of performance for companies that need versatility. For more than 45 years, Haire Group has partnered with customers to understand their unique needs and provide tier-one service and support. Other solutions include EDF Europe’s Encore line of FFGs and RDCs, the Engico Jumbo flexo folder gluer, and much more. Booth 213.
HarperLove Adhesives provides high-quality corrugator additives including wet-strength resins, corrugator and starch cleaning products, specialty carriers, and more. Boxmakers will also be interested in the company’s Corrugator Performance Audit, a week-long, deep-dive evaluation into plant operations to identify corrugator and control system issues and insure everything is working as designed; at the end of the process, technicians will quantify the ROI that can be realized. Booth 533.
Not sure where to begin on your plant’s automation journey? Kaska Robotics is a sales consultancy matching client needs for robot, vision, and logistics technology with proven partners. With more than 40 years of industrial manufacturing automation experience, Bob Kaska works for his clients and is paid by Kaska Robotics partners, which include 20/20 Robotics, Iris Factory Automation, Quicktron Robotics, and others. Booth 823.
Kiwiplan supplies integrated packaging ERP & MES solutions for sheet and box plants, display makers, and specialty packaging manufacturers. The company’s digital capabilities can help customers maximize throughput and daily square footage with enhanced visibility and automated tracking and scheduling; increase efficiency by integrating shipping and production planning; and keep the entire plant floor connected. Booth 539.
The latest tech from Kolbus is its RD 115G Rotary Die Cutter with flexoprint. With its innovative gear drive and many automatic adjustments, this machine features additional drives in the die-cutting area and the creasing and slitting unit so that these processes do not affect the printed image. The modular machine concept allows print modules for inside and outside printing in one pass, with extended print module frames for optimum drying capability.
LLumin Inc.’s CMMS+ maintenance software empowers packaging companies to optimize maintenance processes, reduce downtime, and ensure seamless operations. With tools designed to shrink mean-time-to-repair and deliver lightning-fast uptime, LLumin keeps your equipment running to meet customer demands on time. CMMS+ enables you to track maintenance histories, manage tasks from start to finish, and handle repairs, inspections, and preventive maintenance effortlessly. Booth 129.
Mistubishi Heavy Industries’ EVOL line of boxmaking machinery is tailor-made to handle different carton styles at maximum capacity. Combined with EVOL’s characteristic shortest setup time, Mitsubishi hopes to help customers generate more business and greater profits. Features include Mitsubishi’s Lead Edge Feeder with overlapping wheels in a zigzag arrangement; patented independent drives for the anilox rolls; EVOL’s exclusive preventive maintenance feature, and a patented Ink Circulation Recovery and Washing System. Booth 701.
Oxytech Systems provides innovative and reliable infrared drying systems and ultraviolet curing systems. For corrugated box makers, infrared drying systems can help reduce energy consumption by optimizing components critical to drying flexo inks; they can also improve the efficiency and speed capabilities of corrugators. Booth 343.
Providing top-tier manufacturing and supply solutions for the corrugated box industry, Stafford Corrugated Products specializes in die cut anvils and rotary die bolt products. As of March, 2025, Stafford’s new partnership with Policart (leading manufacturer of red anvil covers) has elevated Stafford to become the industry’s premiere supplier of anvil covers. Booth 107.
Sun Automation Group offers Helios, an innovative Industrial Internet of Things (IIoT) solution designed to provide unprecedented data and control to customers throughout the corrugated converting industry. With its failure prediction capabilities, Helios predicts and prevents machine failures through real-time monitoring and intelligent analysis. Using a new machine learning algorithm, it detects subtle anomalies that might be imperceptible to human operators and takes corrective actions or alerts the maintenance team. Booth 101.
From T-Buck, the Easi-Set™ Folder Arm Upgrade brings a new world of efficiency, precision and quality to any plant’s flexo folder-gluer. The durable, fully adjustable, dual pivot folding arms eliminate the guess work and positioning limitations of conventional OEM folding arms. Super slick folding rods virtually eliminate friction and drag. The dual pivot points allow operators to quickly put the folding arms and rods right where they need to be. Booth 122.
Doctor blade friction represents 62 percent of the electricity consumption in the drying section—so Valmet’s doctoring team has developed new blade materials and conducted numerous friction tests to create innovative new low-friction doctor blades. The new doctor blades are carbon and glass-reinforced composite blades with low-friction fillers, for lower CO2 emissions and reduced operation costs. They also contribute to cleaner dryer cylinders and offer increased blade lifetime. Booth 708.
WSA USA designs and commissions some of the most advanced and automated plants in the corrugated industry. The company’s new WSA Automatic Robotic Top Pad Inserter & Label Applicator, designed for finished goods lines and sheet lines, features an ABB Robot with special vacuum gripper head. Its measures each unit, automatically places customizable dunnage patterns on top of each stack, folds the dunnage down and has an option to automatically apply a load tag. Booth 324.
YoungShin USA Ltd. has just introduced its fully-automatic SuperFeed series of pre-feeders, designed to seamlessly integrate with the Zenith and Meridian series of YoungShin’s diecutters as well as standard flatbed diecutters and a variety of digital printers. The SuperFeed can process up to 7,000 sheets per hour and requires minimum production floor space yet expedites the staging and feeding of sheets one-by-one automatically. Booth 118.
Paper360°: As a manufacturer, what is your biggest challenge when adopting new technology: cost? Service? Training? Integrating into your existing system?
Burt Hurler, IP: The biggest challenge is training a diverse workforce that comes with varying levels of experience, technical skills, and learning styles. Introducing new technology means we need to bring everyone—management, frontline operators, and maintenance technicians—up to speed on complex systems, often within existing, tight production schedules. Some team members adapt quickly, while others require more time and hands-on support, which impacts overall adoption.
Training must also be ongoing to keep pace with system updates and ensure knowledge retention, especially as employee turnover and shift work create gaps. Maintenance teams face a particular challenge, since they must master new, advanced diagnostics and repair techniques while maintaining legacy equipment. Coordinating a comprehensive, effective training program that addresses these varied needs without disrupting plant operations requires significant planning, resources, and most importantly, investment. Without investing in workforce development alongside the technology, we risk not realizing the full potential of new systems—leading to waste, increased downtime and ultimately skepticism of the technology.
Michael Martin, SW: The biggest challenge when adopting new technology in this industry is the lack of experience. Over the past several years an exodus of talent and experience has occurred, accelerated by the COVID-19 pandemic. New hires often seek better working conditions, making attracting and retaining new talent with skills and abilities for the next generation of technology adoption more challenging.
New technology should make things easier, more accurate, and take decisions away from humans. The goal is to make safety, processes, quality, and maximum throughput more repeatable. Unfortunately, new technology often comes with abrupt change, confusion, and complication, delaying its adoption.
To further complicate things, manufacturers often release new products too early, leaving the end users to deal with gaps and request help to polish the designs in a live production environment. Startup curves are often delayed; spare parts availability is often lacking; and troubleshooting inefficiencies delay returning equipment to operational status after a downtime event. When successful adoption is delayed and trust/buy-in is hard to get, leadership becomes reluctant to make further investments in new technology due to the failed return on initial investment promises.
Paper360°: Where has new technology (machinery, monitoring, system integration) made the biggest difference in your operations?
Keith Hamilton, GP: New machinery with enhanced data collection capabilities, coupled with GP’s monitoring capabilities, has made the biggest difference in our operations. One is not helpful without the other. We rely on equipment to give us real-time insights of all critical data points, and we rely on advanced modeling techniques to alert us when that data presents an opportunity for a facility.
The biggest impact is seen when we can collaborate openly with our vendors and utilize both of our companies’ equipment expertise and analytics capabilities in tandem to arrive at the most value-added solution.
Paper360°: What’s one area in a corrugated plant that you think is overdue for a technology breakthrough?
Burt Hurler, IP: One area ripe for a technology breakthrough is the converting department, particularly die cutting and flexo folder-gluers. Despite significant advances in upstream and downstream automation, these machines still rely heavily on manual setups and adjustments, resulting in downtime and variability. Smart automation and HMIs; AI-driven setup; and real-time diagnostics, machine adjustments, and operator guidance could drastically improve changeover speed, consistency, and reduce waste—ultimately boosting overall plant efficiency and product quality.
Another key area that is overdue—and is now undergoing a technology breakthrough—is maintenance and asset management. Many corrugated plants still rely on reactive or simplistic time-based maintenance schedules, which often result in unplanned downtime and costly repairs. The continued integration of predictive maintenance technologies—using IoT sensors, machine learning, and leveraging AI with real-time data analytics—will allow for earlier detection of wear and enable planned interventions before failures occur. This not only ensures higher uptime and more reliable operations, but should result in extending overall equipment life and reducing new capital needs.
Paper360°: Is there something you wish technology suppliers really understood about the corrugated process that they seem to overlook?
Keith Hamilton, GP: Data integration still has a long way to go. In the current state, each technology has a separate user interface for individual assets or vendors. If this was integrated, operations leaders would have all the information they need to make quick decisions at their fingertips. This could also help prevent training burnout and allow team members to cover for absences and time off without having to learn a new interface or operating system.
There is also a gap to close with monetizing technology and the failure to develop people at the same pace tools are developed. This gap in creating more value is rarely from a lack of advancement in technology, but from failing to effectively train and build capability in the facilities to be able to leverage the applications.
Michael Martin, SW: Equipment manufacturers have the same goal as the rest of us: To make the most money in the shortest time possible. This goal drives cost-cutting measures at all levels including designing and building products that are compact, easier to ship, quick to install, and quick to start up. These are all good things but often come with collateral damage in terms of ease of use once installed.
Unless the manufacturer is sensitive to this, new equipment with the latest technology design is often “half-baked.” It is often difficult to service, difficult to operate efficiently, and hard to train for—and therefore perceived as more complicated. I believe genius lies in simplicity in this space. My goal is for new equipment with automated processes to make as many decisions for our associates as possible, to minimize the impact of a lack of experience on the plant floor.
Often, manufacturers and solutions providers don’t make the connection between machine design and the operator, the maintenance personnel, or our front-line leadership. That connection drives maximum safety, quality, and productivity. I often tell manufacturers that, if they knew more about how a human thinks, what they need, and how they interact with equipment through intuitive controls, they would produce a more perfect machine.
