EM Project automates corrugated sheet feeding

EM Project has introduced a new Automatic In-Feed Vacuum Table for its BOXmaker ULTRA, expanding the level of automation available for short-run and on-demand corrugated box production.

The new module is designed to automatically lift, align and feed sheets directly into the machine, reducing the need for operators to handle each board manually before production.

System handles three- and five-layer board

The automatic in-feed can process three- and five-layer corrugated board up to 10 mm thick, giving converters flexibility across a broad range of packaging applications.

Automated alignment before the sheet enters the machine is intended to improve consistency and reduce the physical workload associated with feeding larger or heavier corrugated sheets.

BOXmaker ULTRA reaches 1,600 boxes per hour

The BOXmaker ULTRA can produce up to 1,600 boxes per hour, depending on format and configuration. Combining this throughput with automated sheet feeding can help reduce interruptions between individual production cycles.

The system is particularly aimed at converters handling customised and shorter production runs, where frequent format changes can make conventional high-volume boxmaking equipment less efficient.

Rapid changeovers support multiple FEFCO designs

EM Project says the machine can switch between different FEFCO codes and box styles in approximately 30 seconds.

Fast changeovers allow packaging producers to move between orders with limited downtime, an increasingly important capability as customers request more SKUs, customised dimensions and smaller batch sizes.

Printing and gluing integrated in a single pass

The BOXmaker ULTRA can also combine gluing and flexographic printing within the same production process.

Integrating multiple converting steps reduces the need to move work between separate machines and can simplify production planning for corrugated boxes requiring basic graphics, branding or product information.

Automation reduces manual handling

The Automatic In-Feed Vacuum Table is intended to improve workplace ergonomics by removing repetitive lifting and positioning tasks from operators.

This can be particularly relevant when larger corrugated sheets are being processed continuously, where manual handling can create both productivity limitations and occupational safety concerns.

On-demand boxmaking gains importance

Demand for on-demand packaging systems is increasing as manufacturers and fulfilment operations seek to produce box sizes more closely matched to individual products and orders.

Producing packaging in shorter runs can reduce inventories of pre-made boxes while allowing companies to respond more quickly to changing dimensions, product launches or customer-specific requirements.

Automation supports more flexible corrugated production

The new in-feed system reflects a wider shift towards more automated but flexible corrugated converting environments. Rather than focusing only on maximum long-run speeds, machinery suppliers are increasingly developing systems that combine rapid changeovers, integrated processes and lower operator intervention.

By automating the first stage of sheet handling, EM Project is extending this approach across the BOXmaker ULTRA workflow, allowing converters to increase productivity while maintaining the flexibility required for customised box production.