BOXmaker ULTRA features fully automated setup of all modules, allowing the machine to be setup quickly. The time needed for switching between box models is less than 30 seconds. Machine is equipped with a wide variety of modules allowing it to perform slotting, slitting, creasing/scoring, lengthwise and cross cutting, printing, and gluing – all in a single pass! Created with Industry 4.0 paradigm guidelines the ULTRA is a statement of dominance and technological advantage in the world of corrugated cardboard converting industry.
The control unit of the BOXmaker ULTRA is consisted of 21 inch touch sensitive HD widescreen color display with user friendly UI. The unit itself comes with predefined FEFCO standard models in memory. Free mode offers the possibility of creating a box of any style and measure, greatly increasing flexibility. The memory itself can hold up to 3000 models. Intuitive and user friendly HMI comes with in-house created software diligently created in accordance with years of R&D and user feedback.
The slotting knives are setup automatically via the control unit. The knives are made of high density steel alloy which allows for heavy duty reliability and extended use even with processing 1400GSM, high grade corrugated cardboard. The machine has 2 slotting knives that are positioned automatically via threaded spindles and servo motors. The transversal creasing tool is integrated in the knife subframe. The knives are segmented and can be positioned independently from one another.
The creasing wheels are automatically setup via the control unit. The machine has four creasing wheels and it is possible to use only the selected wheels, i.e. not crease the full length of the cardboard, by retracting the wheels at a desired point. The wheels can be quickly, tool free changed, thus making switching from different diameters and formats a simple task. The machine has 4 creasing wheels, with a possibility of placing auxiliary creasing wheels on the longitudinal cutting line.
The circular blades serve the purpose of cutting cardboard along the length. As seen with the cross cut and longitudinal creasing this unit can perform work selectively and anywhere along the length of the corrugated sheet. The unit is utilized when producing FEFCO 0204, FEFCO 0403, glue flap or material reformatting. Also, in combination with cross cut, windows and similar square/rectangular shapes can be cut. There’s six creasing wheels in total.
The cross cutting tool serves the purpose of cutting off excess material thus enabling for multiple boxes to be made from single panel of cardboard. The blade runs across the width and cuts in the direction of the flute. The module is also utilized for production of pallet boxes with loading flap. The unit can produce transversal cuts anywhere on the sheet, which enables it to create box locking mechanisms, loading flaps and windows on the box. In combination with longitudinal cutting knives, square and rectangular shapes can be cut out in the sheet, effectively replacing die cutting for those forms.
The printing unit is capable of outputting single color prints of up to 1000mm of width and 870mm in length, making it the perfect choice for standard transportation box markings as well as high detail complicated multi raster graphics. The imprint can be placed anywhere on the box, including creased areas. Printer setup and fine tuning is entrusted to a sophisticated system of servo actuators that are governed by setup from the control unit. This, in turn, means that the print position both transversally and longitudinally is defined via control unit. The same goes for the amount of color applied. Flexo printing being a craft after all, there is some manual labor to be done, in the form of polymer printer plate placement and fixture as well as unit cleaning. The ink utilized is eco friendly water based, non-poisonous flexo print ink.
The gluing unit is a glue application nozzle and the supporting actuators. Developed with single pass functionality in mind, the gluing module rounds up the box production process and allows for a more flexible production cycle. The unit is servo powered and moves at speeds up to 1m/s. The glue can be dispersed in lines, double lines or dots anywhere on the cardboard sheet. This module allows gluing across the width or height of the box. The glue application components are sourced from Nordson USA, while the actuators, as all other actuators come from Lenze.
The die cut module, as its name suggests, creates die cuts, commonly used to produce boxes with handles or ventilation openings. It is a moveable die cut press. The unit is positioned automatically and the distribution of cuts is also setup digitally via control unit. The total force the die cut can exert is 5200 Newton.
BOXmaker ULTRA-PVF reconciles a high level of flexibility and automation with reliance on only one operator in production. It brings a new dimension of automation that is especially applicable in systems with standard job repetition. It does not only feed, but also correct the position of the board. With the option to send work orders from a remote location, it enables true machine operation by a single operator. It is most widely used in the production of boxes for furniture and the automotive industry, but also in systems that want to reduce the impact of the human factor in their production.
The high flexibility of adjustment of the feeding system allows for utilization of corrugated cardboard of all qualities, which is also reflected in the systems’ capability to process deformed/bent material. ULTRA-PVF stands raised on a pedestal made according to the highest safety standards, but with the advantage of easy access to the inside of the machine for simple manipulation of modules and servicing. Spheres are integrated on the lifting platform, which allows the operator to easily place the stack of cardboard in place. The automatic feeder is modular and can be subsequently installed on the existing BOXmaker ULTRA.