Fengchi High-Speed Corrugated Laminating Production Line — Brazil Installation Case Study

Executive summary

On the eve of Christmas 2025, Fengchi’s senior after-sales engineers completed the installation and commissioning of a complete corrugated laminating production line for a Brazilian packaging manufacturer. The turnkey solution — a high-speed automatic litho laminator paired with an automatic flip-flop stacker — delivered reliable, continuous lamination and automated stacking that together improve throughput, product flatness, and downstream die-cutting performance while reducing manual handling and operator fatigue.

Why this solution matters for corrugated packaging manufacturers

Packaging converters face three consistent pressures: higher output demands, tighter quality tolerances for printed boxes, and the need to minimize labor and waste. Integrating a purpose-built high-speed litho laminator with an automated inverting (flip-flop) stacker addresses these pressures by:

• Maintaining precise registration at high speeds so printed face layers align consistently with corrugated boards.
• Delivering uniform adhesive application and strong interlayer bonding for flat, warp-free sheets.
• Automating stacking to prevent scratches/deformation, preserve flatness, and improve die-cutting yield.
• Reducing manual intervention to improve safety and allow operators to manage line performance rather than repetitive tasks.

System components and key capabilities

High-speed litho laminator (core)

• Purpose: Precisely bond printed face sheets to corrugated board at high throughput.
• Performance highlights: Smooth paper feeding, accurate registration control under high speed, continuous and stable lamination, uniform adhesive distribution, and strong interlayer adhesion for flat, warp-free finished sheets.
• Benefits for manufacturers: Improved color box and corrugated packaging quality, fewer rejections, and consistent die-cutting performance downstream.

Automatic flip-flop stacker (downstream)

• Purpose: Receive laminated sheets, invert and stack them automatically to avoid scratches and deformations.
• Performance highlights: Gentle handling, precise stacking alignment, and protection of sheet flatness.
• Operational benefits: Reduction in manual stacking errors, improved safety, and shortened time from lamination to die-cutting.

Line integration and control

• Coordination: Tight mechanical design and mature control system ensure minimal vibration and precise timing between laminator and stacker.
• Stability: Robust construction and control logic make the line suitable for extended production runs and high-consistency industrial environments.

Installation, commissioning, and on-site support

Fengchi’s senior after-sales engineers delivered full on-site support at the Brazilian customer’s facility, including: equipment installation, systems commissioning, and operator training. This hands-on presence enabled rapid full-operational readiness and immediate production start-up — minimizing downtime and accelerating return on investment.

Measurable business outcomes

Manufacturers adopting this combined solution typically observe:

• Higher throughput with fewer stoppages due to precise registration and stable lamination.
• Better product quality — flatter sheets, fewer warps, and improved visual finish.
• Improved downstream efficiency — simpler die-cutting and finishing due to consistent sheet flatness.
• Lower labor costs and better safety thanks to automated stacking and reduced manual handling.

Recommended use cases

This production line is ideal for:

• Large-volume color box and corrugated packaging manufacturers.
• Operations requiring consistent, repeatable lamination quality at high speeds.
• Facilities aiming to modernize finishing lines while reducing manual labor and improving safety.

Talk to our experts

For a detailed specification, ROI estimate, or to schedule a site assessment and demo, contact Fengchi’s sales engineering team. Request a customized line layout and production estimate to match your board types, paper grammages, and daily throughput targets.

FAQ

1. Q: What is a high-speed litho laminator?
   A: A machine engineered to bond printed face layers to corrugated board rapidly while maintaining registration and adhesive uniformity.
2. Q: How does a flip-flop stacker improve die-cutting?
   A: By stacking laminated sheets gently and flat, it reduces scratches and warping, enabling more consistent die-cutting results.
3. Q: What support is provided after installation?
   A: Fengchi provides installation, commissioning, operator training, and ongoing after-sales support to ensure operational readiness and performance.