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BOXmaker ULTRA-PVF
Fully automated boxmaking production system with integrated feeder, position correction, and single-operator capability.
Low Power Consumption
Automatic Loading of Cardboard
Industry 4.0 Compatibility
Key features
- Automatic feeding system with position correction
- True single-operator production capability
- Job orders transferable and controlled remotely
- Changeover between box types in under 30 seconds
- Industry 4.0 interface for smart monitoring and control
- Handles single, double and triple-wall boards up to 14 mm
- Processes deformed or bent material with high stability
- Reinforced frame on elevated pedestal for easy access and safety
- Modular feeder – retrofit available for existing ULTRA machines
- High-speed performance with energy-efficient servo drives
BOXmaker ULTRA-PVF Features and Modules
Control unit
The 21-inch touchscreen offers intuitive operation with pre-loaded FEFCO standards and storage for up to 3000 models. It supports remote job transfer, manual and automatic modes, and real-time diagnostics through Industry 4.0 connectivity. Integrated automatic feeder with vacuum alignment ensures precise sheet loading and stable operation on a 1400 kg platform, even with deformed materials.
Slotting knives
Two 500 mm segmented knives automatically adjust via the control panel. Made from hardened steel alloy for long-term precision and durability. An integrated transversal creasing tool allows slotting and scoring in one step.
Circular Knives and Creasing Wheels
Six circular blades and four creasing wheels are individually controlled for accurate cutting and folding. Optional perforation tools allow further adaptability and faster switching between formats.
Cross-Cut Module
Servo-driven unit that creates precise transversal cuts and flaps anywhere on the sheet. It enables production of pallet boxes, windows, and locking mechanisms without separate die-cut operations.
Printing module
Single-color flexo printing unit (up to 1000 × 870 mm) for logistics and branding markings. Controlled digitally via the main unit with automatic setup and dual clichés for quick switching.
Nordson Gluing Module
Servo-controlled cold-gluing system with one or two nozzles. Applies lines or dots at up to 1 m/s anywhere on the sheet. Ensures clean, reliable bonding within a single pass.
Die-Cut Module
Digitally positioned press (120 × 160 mm) for custom shapes and handholes. Automatic setup simplifies alignment; force of 5200 N delivers precision without manual adjustment.
More than 80 box styles
Technical Specification
| Corrugated Board Type | single, double, and triple wall |
| Cardboar Thickness | up to 14mm |
| Cardboard Density Range | up to 1400g/m2 |
| Max. Board Size | 2400mm width x 7000mm lenght |
| Min. Board Size | 300mm width x 650mm length |
| Production Capacity | up to 1600 boxes per hour (FEFCO 200) |
| Slotting Knife | 2 x 500mm segmented slotting knives |
| Distance between slotting knives | 50mm - 2200mm |
| Width Slotting Knife | 8mm |
| Vertical Cutting Knife | 6 x circular knives |
| Soring/Creasing Wheel | 4 |
| Cross Cutting Knife | 1 |
| Power supply | 16.5kw |
| Air Pressure | 6-8bar |
| Dimension | 7270mm x 8005mm x 2000mm |
| Gross Weight | 10780kg |
| Automatic Paper Feeding | YES |
| Handhole on Box Sides | YES 120mm x 160mm |
| Platform Capacity | 1400kg of active load |
| Maximum Board Size | 2400mm x 3000mm, stack height 1100mm |
| Speed | 1600 pcs per hour. |
| Vacuum fingers - ejectors | YES 8 |
| Can be retrofitted to BOXmaker ULTRA | YES |
| Correction of the position of the cardboard board | YES |
| Number of operators needed | 1 |
Options
| Nozzles | as per your choice 1 or 2 |
| Printing unit | with or without |
| Die-cut | as per your choice 1 or 2 |
| Slotting knife | 600mm |
Engineered for Maximum Automation
BOXmaker ULTRA-PVF takes automation beyond setup adjustment — integrating automatic feeding, sheet alignment, and remote job control into a single system. As a fully automated boxmaking machine, it delivers precision and reliability through advanced servo drives and vacuum fingers, ensuring accurate board placement and error-free operation by one operator.
Built for continuous production, the PVF handles all board qualities including deformed materials with ease. This combination of autonomy and reliability sets a new benchmark for modern automated lines focused on efficiency and safety.
Automation Built on Experience
With over 200 machines installed worldwide, EMproject89 applies decades of engineering experience to deliver machines that combine flexibility, speed, and precision. The ULTRA-PVF is the culmination of that expertise — designed for industries where repeatability and operator efficiency are critical.
Built on EMproject89’s engineering heritage, ULTRA-PVF ensures long-term stability, adaptability, and low operating costs. Each unit includes professional installation, operator training, and reliable after-sales support to keep production running at peak performance.
Equipped with online connectivity for fast troubleshooting and service support, the system allows custom tooling configuration for diverse production needs and handles corrugated cardboard through flute and counter-flute processing across E, B, C, A, D, EB, EC, BC, AB, and AC profiles.
Frequently asked questions
How does the automatic feeder work?
The integrated feeder uses vacuum fingers and alignment sensors to load and correct board position automatically before processing.
Can the machine be operated by one person?
Yes. ULTRA-PVF is designed for true one-operator control thanks to its automatic feeding and remote job management system.
What materials can it handle?
It processes single, double and triple-wall boards up to 14 mm thick, including deformed and low-quality sheets.
How is maintenance handled?
Only routine cleaning and checks of blades and rollers are needed. The control system provides self-diagnostics and remote assistance for fast service.
Is training included with installation?
Yes — operators receive full training covering automatic feeding, control interface, and safety procedures during installation.
Is the feeder available as an upgrade for existing ULTRA machines?
Yes. The feeder module can be retrofitted to existing ULTRA units for enhanced automation and feeding precision.
