A system and method for producing a board product characterized by having two corrugated mediums and at least one embossed medium in the board product. The board product may further include one or more facings that are adhesively coupled to either the corrugated medium, the embossed medium, or both. Generally speaking, a corrugated medium may be characterized as a paper product that exhibits flutes induced by a cross-corrugating process such that the induced flutes are perpendicular (or at least not congruent) with the machine direction of the paper product. An embossed medium may be characterized as a paper product that exhibits flutes induced by a linear-embossing process such that the induced flutes are aligned with the machine direction of the paper product. A resultant board product is stronger and more efficiently produced because of the linearly-embossed medium harnessing the natural strength of the paper in the machine direction.

A system and method for producing a board product characterized by having two corrugated mediums and at least one embossed medium in the board product. The board product may further include one or more facings that are adhesively coupled to either the corrugated medium, the embossed medium, or both. Generally speaking, a corrugated medium may be characterized as a paper product that exhibits flutes induced by a cross-corrugating process such that the induced flutes are perpendicular (or at least not congruent) with the machine direction of the paper product. An embossed medium may be characterized as a paper product that exhibits flutes induced by a linear-embossing process such that the induced flutes are aligned with the machine direction of the paper product. A resultant board product is stronger and more efficiently produced because of the linearly-embossed medium harnessing the natural strength of the paper in the machine direction.

A system and method for producing a board product made from paper products that have embossed medium that features an improved structural profile. The improved structural profile may include a triangular flute pattern wherein each flute may exhibit a first linear leg support and a second linear leg support that each support a center apex structure. The apex may have a substantially flat portion that is configured to engage a facing. As such, the board product may further include one or more facings that are adhesively coupled to the embossed medium. Further, the apex of each “triangle” may also have a groove or channel for receiving an adhesive in a continuous and uniform manner.

The method includes the step of pulling the corrugated board along hot plates by means of an upper flexible member and a lower flexible member driven by two electric motors. By at least one electric parameter of the drive motor of the lower flexible member, the correct operation of the traction device and in particular the correct ratio of the linear feeding speeds of the two flexible members is checked. The method provides an iterative check of the controlled electric parameter and a possible correction of the speed of the flexible members to maintain the desired speed ratio.

The methods provide for detecting at least one operational parameter of a functional unit of the plant and calculating a current value of at least a first statistical function of the operational parameter in a current temporal window, the current value of the first statistical function defining a first coordinate of a point of current operation of the functional unit. A step is also provided of verifying whether the point of current operation is within a range of allowable values of the first statistical function, the values contained in the range of allowable values corresponding to a correct operation of the functional unit. In case the point of current operation is outside the range of allowable values, the position is determined of the point of current operation with respect to the range of allowable values and a statistical diagnosis is provided of the cause of the deviation of the current value from the range of allowable values based on the position.

Systems for providing efficient manufacturing of paper, sheet, and/or box products of varying size and structure, often with pre-applied print (“pre-print”), are provided herein. One or more controllers can be used to aggregate orders and information to prepare one or more control plans (e.g., reel maps, reel plans, etc.) for processing a roll of web product through the manufacturing process. The control plan may include a set of instructions for operating one or more systems within the manufacturing process to form the desired finished paper-based product. In such a regard, efficient manufacturing of various paper-based products, including corrugated boxes, folded carton, labels, flexible paper, industrial bags, plates, cups, décor, and many others, can be achieved. Further, efficient customer ordering/tracking, job aggregation, print imposition, corrugator planning, and tracking and adjustments throughout the manufacturing process are contemplated.

The method includes the step of pulling the corrugated board along hot plates by means of an upper flexible member and a lower flexible member driven by two electric motors. By at least one electric parameter of the drive motor of the lower flexible member, the correct operation of the traction device and in particular the correct ratio of the linear feeding speeds of the two flexible members is checked. The method provides an iterative check of the controlled electric parameter and a possible correction of the speed of the flexible members to maintain the desired speed ratio.

One or more implementations of a multi-layer film include a first layer non-continuously bonded to a second pigmented layer. The multi-layer film includes an unexpected appearance differing from the appearance of the pigmented layer. In one or more embodiments, the multi-layer film includes a metallic appearance despite the pigmented layer being devoid of metallic pigment. The multi-layer film also includes areas that are visually distinct from areas of the film with the unexpected appearance. The visually-distinct areas comprise areas in which the first layer non-continuously is in intimate contact with the second pigmented layer. The visually-distinct areas have the appearance of the pigmented layer or another appearance. One or more implementations also include methods of making multi-layer films and bags with an unexpected appearance and visually-distinct areas.

A system comprises a corrugator single facer configured to receive a first web and a second web, to corrugate the first web and adhere the first web in a corrugated state to the second web in an uncorrugated state to form a single face corrugated web as output. The system also includes a folder gluer operatively connected to receive the single face corrugated web from the corrugated single facer. The folder gluer is configured to fold and adhere the single-face corrugated web into a tube.

Systems and methods for forming corrugated boards are disclosed. The system includes a single face unit configured to form a single face board having a fluted layer and an outer liner. The system also includes a single face buffer configured to store or hold a length of the single face board. The system has a glue station configured to attach a second outer liner to the single face board to form a single wall board. The system also has an ultrasonic unit configured to apply ultrasonic vibrations to the single wall board. The ultrasonic vibrations are configured to remove moisture from the single wall board, activate, heat, and/or dry an adhesive used to attach the fluted layer and the outer liners, and/or cause the fibers of the fluted layer and the outer liners to weave, intertwine, or otherwise stick together.