Aopack BM2800-Max box making machine for film-faced 7-ply corrugated cardboard

The challenge: Producing film-faced multi-wall corrugated boxes in small volumes

Many corrugated box manufacturers receive orders requiring film-faced corrugated cardboard for improved surface protection and moisture resistance. While the board structure may be standard multi-wall corrugated material, the laminated surface and increased thickness create additional production challenges — especially for small and medium batch orders.

Traditional converting equipment is typically optimized for large production runs. When handling small quantities of 7-ply corrugated cardboard with film lamination, manufacturers often face:

• Long setup times
• Die manufacturing costs
• Inefficient short-run production
• Feeding challenges caused by laminated surfaces
• Limited flexibility for oversized box designs

These issues make small batch production inefficient and costly.

The solution: On-demand box making machine for film-faced corrugated board

A modern box making machine must be capable of processing laminated corrugated materials while maintaining flexibility for customized orders. The Aopack BM2800-Max box making machine is designed for on-demand box production, enabling efficient manufacturing of film-faced corrugated cardboard boxes without dedicated dies.

Key production advantages include:

• Digital single-pass box production
• Die-free manufacturing process
• Fast size changeover
• Efficient short-run production
• Flexible customization for diverse packaging requirements

This allows manufacturers to process specialized materials without disrupting standard production workflows.

Designed for multi-wall corrugated material – supporting up to 7-ply board

The Aopack BM2800-Max cardboard box maker supports processing of multi-wall corrugated structures, including up to 7-ply corrugated cardboard.

• Material processing capability includes:
• Double-sided film-faced corrugated board
• Standard multi-wall corrugated cardboard
• Laminated corrugated sheets
• Thick corrugated materials used for large packaging

The machine maintains stable feeding and cutting accuracy even when processing laminated surfaces, ensuring consistent production results.

Flexible production for jumbo and oversized box designs

Large-size corrugated boxes often require flexible manufacturing approaches due to sheet dimensions and structural requirements. The BM2800-Max enables efficient production of oversized box designs using on-demand digital manufacturing.

Manufacturers can produce:

• Jumbo FEFCO 0201 boxes
• Multi-piece oversized cartons
• Custom large-format packaging
• Small batch customized box orders

All without changing tooling or producing dies.

Ideal box making machine for low to medium volume production

The BM2800-Max is specifically designed for flexible production environments where order quantities vary. Typical applications include:

• Short-run box production
• Custom-sized packaging
• On-demand manufacturing
• Laminated corrugated box production
• Oversized box manufacturing

By reducing setup time and eliminating die costs, manufacturers can improve operational efficiency for small and medium volume orders.

A flexible box making machine for modern corrugated packaging production

As packaging demand shifts toward customization and shorter production cycles, corrugated plants require equipment capable of handling diverse materials and order sizes.

The Aopack BM2800-Max box making machine provides:

• Film-faced corrugated board processing capability
• Support for up to 7-ply corrugated cardboard
• Flexible on-demand production
• Efficient manufacturing for customized and oversized boxes

This enables manufacturers to expand production capability while maintaining flexibility and efficiency.

About Aopack box making machines

Aopack specializes in on-demand box making machines designed for low to medium volume corrugated box production. The BM series supports flexible manufacturing across a wide range of packaging applications and material types.

This article was originally published by Aopack.