PerfectFold: the future of liquid creasing for corrugated board

According to Robatech, its PerfectFold system for liquid creasing will revolutionize the folding process for corrugated cardboard by enhancing its efficiency and quality – but how? David Trinkner, Business Development Manager Graphic & Converting, gives us the lowdown in this edition of our ‘In Conversation With…’ series.

First of all, walk us through PerfectFold’s creasing system; how does it enable such precise folding of flat corrugated board?

PerfectFold is a system that creases corrugated cardboard by applying a special creasing liquid onto the two fold lines in a contactless process. The softening of the board allows for very precise folding.

PerfectFold is mainly made up of two jetting heads, a pump, two liquid containers for changeover on the fly, and an I/P converter that controls that the correct amount of liquid is applied according to the production speed.

On that note, what does PerfectFold do that conventional creasing systems can’t? How do they compare?

PerfectFold improves fold precision while simplifying the entire folding process. The system reduces gap variance and fishtailing significantly.

This minimizes process disruptions during box erection. Furthermore, consistency in box dimensions is exceptional. Inserts fit precisely.

Creasing corrugated cardboard with a liquid eliminates the need for mechanical pre-creasing. The flute is simply softened but remains intact. Therefore, the pressure on the creasing tools can be decreased, which results in a noticeable benefit: tool wear time doubles or even triples.

Less pressure on the creasing tool also dramatically reduces the risk of inner line cracking. We are often asked if the creasing liquid reduces box stability, but the box comprehension tests (BCT) we have conducted so far, demonstrated even a 3% to 5% better box stability compared to conventional creasing.

Robatech has designed its SpeedUp creasing fluid for the PerfectFold system. Could you tell us more about this fluid and how it works?

SpeedUp was specially developed for PerfectFold. The creasing liquid penetrates the corrugated board very quickly, enabling high-speed machines to operate at maximum capacity.

SpeedUp leaves no marks after folding and is FDA-approved, making it suitable for cardboard used in food packaging.

How easily can customers integrate PerfectFold into their existing packaging lines, and how might their operations benefit from this solution?

We typically install PerfectFold within a scheduled one-day maintenance period. It’s easy to integrate. Since PerfectFold reduces the cardboard’s stiffness, operators can run the process without pre-creaser and less contact pressure of the creasing tool.

From an environmental standpoint, what can packaging manufacturers expect from this system?

As the folding accuracy is exceptional, especially with double-wall cartons or big boxes, the manufacturing process becomes more stable. That means less production rejects due to consistently sized boxes.

Approximately 90% of all 0201 corrugated boxes are destined to be automatically erected, filled, and sealed by gluing. Packaging manufacturers can anticipate a reduction in customer complaints.

Overall, why would you recommend PerfectFold to customers in the fibre-based packaging sector?

PerfectFold revolutionizes the creasing process, making it more stable, simple, and more sustainable, while also enhancing box quality.

To my knowledge, and what we have experienced so far in the market, no other system can reduce gap variance, fishtailing, and fold cracking to the same extent as PerfectFold.

It’s a true game-changer for packaging manufacturers looking to elevate both efficiency and quality in their production lines.

To learn more on how you can improve the process and quality of corrugated cardboard folding with PerfectFold, click here.