Single Facer
THE HEART OF THE CORRUGATOR LINE
It’s the first major section where the corrugated medium (fluting) is formed and glued to a liner to produce single‑face board.
Form
Flutes are formed between heated corrugating rolls.
GLUE
Adhesive is
applied evenly to the flute tips.
BOND
Fluted medium is bonded to liner under heat and pressure.
Single Facer
Construction Features
Corrugating Rolls
Precision ground, heated rolls with flute profiles.
Pressure Roll
Presses liner to fluted medium for bonding
Preheaters & Preconditioners
Control paper temperature and moisture for proper forming
Glue Unit
Applies starch based adhesive evenly to flute tips
Drive & Control System
Synchronizes roll speeds, tension, and heat
Cassette System
Allows fast flute roll swaps.
Steam System
Supplies heat to corrugating rolls for flute formation
Frame & Bearings
Heavy duty construction for stability at high speeds
Common Types
- Fixed‑Roll Single Facers – Traditional design; flute roll changes require downtime.
- Cassette‑Type Single Facers – Quick‑change flute roll cassettes; minimal downtime for flute changes.
- Fingerless Single Facers – Use vacuum transfer instead of fingers; reduce flute damage and improve printability.
- Finger‑Type Single Facers – Traditional design with fingers guiding the medium; robust and proven.
- High‑Speed Single Facers – Designed for >300 m/min with advanced controls and heat systems.
Common Types
- Fixed‑Roll Single Facers – Traditional design; flute roll changes require downtime.
- Cassette‑Type Single Facers – Quick‑change flute roll cassettes; minimal downtime for flute changes.
- Fingerless Single Facers – Use vacuum transfer instead of fingers; reduce flute damage and improve printability.
- Finger‑Type Single Facers – Traditional design with fingers guiding the medium; robust and proven.
- High‑Speed Single Facers – Designed for >300 m/min with advanced controls and heat systems.
Key Selection Factors
When specifying or upgrading a single facer:
Flute Profiles Needed
– A/B/C/E/F or combinations
Production Speed
– Match to line speed requirements
Paper Grades
– Range of liner and medium weights; recycled vs. virgin fiber
Changeover Frequency
– Cassette type for frequent flute changes.
Heating System
– Steam capacity and temperature control.
Adhesive System
– Starch type, application precision, and control.
Vacuum vs. Finger Transfer
– For quality and maintenance preferences.
Machine Width
– Must match corrugator width.
Operator Ergonomics & Safety
– Accessibility, guarding, and automation
Maintenance & Care
To ensure consistent quality and long life:- Daily Cleaning – Remove starch build‑up from rolls and glue unit.
- Roll Surface Care – Avoid scratches; inspect flute profile regularly.
- Bearing & Gear Lubrication – Follow OEM schedules.
- Steam System Checks – Maintain correct pressure and dryness.
- Glue Gap Calibration – Ensure even adhesive application.
- Alignment & Tension Control – Prevent warp and mis‑tracking.
- Scheduled Overhauls – Replace worn rolls, bearings, and seals as per OEM intervals.
Key Parameters to Order
| Parameter | Why It Matters | Typical Range / Note |
|---|---|---|
| Machine Width | Must match corrugator | e.g., 1800–2500 mm |
| Flute Profile(s) | Determines board caliper & strength | A, B, C, E, F, etc. |
| Corrugating Roll Diameter | Affects flute formation & speed | 280–380 mm typical |
| Heating Source & Capacity | Ensures proper flute forming | Steam at 170–200 °C |
| Max Speed | Matches line capacity | 150–350 m/min |
| Transfer Type | Influences flute quality | Finger or vacuum |
| Glue Unit Type | Adhesive control | Single or dual doctor roll |
| Cassette Change Time | Impacts downtime | <15 min for modern units |
| Drive Type | Precision & maintenance | Gear or belt drive |
| Paper Range | Flexibility | e.g., 90–440 gsm |
Latest Technology Trends
- Cassette‑Type Quick Change – Flute roll swaps in 3–15 minutes.
- RFID‑Enabled Roll Modules – Store flute‑specific settings for automatic parameter adjustment.
- SoftTouch Glue Application – Constant contact pressure for uniform adhesive film.
- High‑Speed Capability – Up to 480–500 m/min with precise temperature and tension control.
- Vacuum Transfer Systems – Reduce flute deformation, improve print surface.
- Servo‑Driven Adjustments – Automated pressure, gap, and alignment control.
- Energy Efficiency – Optimized steam usage, heat recovery, and insulated covers.
- Integrated Quality Monitoring – Sensors for flute geometry, bond strength, and warp control.
- Modular Design – Easy upgrades and maintenance without full machine replacement.
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