Corrugator: The Machine That Makes Corrugated Board

What Is a Corrugator?

A corrugator is the large-scale manufacturing machine that combines flat linerboard sheets with fluted corrugating medium to produce corrugated board — the fundamental material used to make boxes, packaging, and retail displays. The corrugator takes in rolls of paper at one end and produces finished, flat corrugated sheets at the other end, ready for conversion into packaging products through subsequent processes like die-cutting, scoring, slotting, and printing.

The corrugator is the starting point of the corrugated packaging manufacturing process and is among the largest pieces of equipment in any packaging plant. A full corrugator line can extend 300 feet or more in length and processes material at high speed to meet the volume demands of modern packaging operations.

How the Corrugating Process Works

The corrugating process involves several integrated stages that happen in rapid succession as paper moves through the machine:

1. Single facer — the corrugating medium passes between heated, corrugated rollers that form it into the characteristic wave pattern (fluting). Adhesive is applied to the tips of the flutes, and one linerboard sheet is bonded to the fluted medium.
2. Double backer (glue machine) — a second linerboard sheet is glued to the exposed flute tips, creating the sandwich structure of liner-flute-liner that gives corrugated board its strength.
3. Heating and curing — the combined board passes over heated plates that cure the adhesive and remove excess moisture.
4. Slitting and cutting — the continuous web of corrugated board is slit to the required width and cut to the required length using a knife-to-knife measurement, producing individual sheets.

Board Types and Flute Profiles

Corrugators can produce different board constructions by varying the number of layers and flute profiles. Single-wall board (one layer of fluting between two liners) is the most common, but double-wall and triple-wall boards are produced for applications requiring extra strength. Flute profiles — designated as A, B, C, E, and F flute — vary in height and frequency, with each offering different balances of cushioning, stacking strength, and printability.

The flexibility of our two corrugators allows President Container Group to produce the full range of board grades needed across our divisions — from lightweight E-flute for retail ready packaging and POP displays to heavy-duty double-wall board for industrial shipping containers through our PIP division.

PCG’s Corrugating Capabilities

President Container Group operates two corrugators across our Moonachie, NJ, and Middletown, NY, facilities, providing the production capacity to serve customers ranging from local businesses to national brands. Having in-house corrugating capability — rather than purchasing pre-made board from outside suppliers — gives us direct control over board quality, lead times, and cost. This vertical integration is a key advantage for customers who need consistent quality and responsive service for their custom box, display, and industrial packaging programs.