Box Plate Making Machine

A box plate making machine is an essential equipment for manufacturers who need to produce large quantities of boxes, crates, pallets and other protective packaging products made of cardboard, corrugated sheets, plastic corrugated boards, aluminum plates or steel plates. This guide provides a comprehensive overview of box plate making machine technology, working process, components, suppliers, prices and more.

How Does a Box Plate Making Machine Work?

The working process of a typical box plate making machine involves roll forming methodology to convert flat sheets into shaped plates through consecutive bending and forming stations. The key processes are:

Material Feeding – Sheet materials are loaded onto an uncoiler and fed into the machine through automated rollers. Materials used include cardboard, corrugated boards, plastic boards, aluminum sheets, steel sheets etc.

Pre-cutting – The sheets may be pre-cut to required widths by built-in slitter scorer machines or shearing machines before forming.

Forming Mechanism – The sheets pass through a series of roll forming stations which applies pressure to progressively bend them into desired plate profiles through bespoke roller dies. Common profiles produced are channels, angles and complex structural shapes.

Design & Customization – Machines utilize CAD systems and CNC precision for forming personalized profiles, logos, text, perforations, slots, holes etc. as per custom design needs.

Automated Fabrication – Formed profiles are automatically sorted, stacked, bundled by robotic arms and output systems ready for downstream packaging processes. Modern machines enable quick changeovers between plate designs.

Waste Collection – Excess materials trimmed by slitters and leftover pieces during forming are automatically collected and discharged aside by conveyors for recycling or disposal.

Therefore, through coordinated feeding, pre-treatment and multi-stage bending mechanisms box plate fabricators can mass produce protective structural packaging components just-in-time.

Box Plate Making Machine
3 Waves Highway Guardrail Roll Forming Machine

Types of Box Plate Making Machines

There are several equipment varieties used which differ in production rate, automation capabilities, theoretical flexibilities and overall technological sophistications:

Machine TypeDescriptions
Manual and Mechanical MachinesBasic lever operated bending equipment with manual loading/unloading of plates. Low accuracy and productivity.
Hydraulic Type Bending MachinesBetter force control and stroke movement allows precision forming. Moderate production rates. Semi automated models available.
Pneumatic Type Bending MachinesUtilizes pneumatic cylinder and valve control for force application on sheets. Higher degree of movement flexibility possible.
CNC Bending MachinesMost advanced computerized numeric control for multi-axis movement of forming dies. Interactive touchscreens allow easy order changes and precision execution.
All Electric/Servo Motor MachinesHighly responsive AC servo motors coordinates all mechanical motions. Saves energy and enables most accurate positioning.

[Insert Image of Different Types of Box Plate Making Machines]

Caption: Different varieties of plate bending machines for structural packaging component fabrication

Therefore, while basic manual and hydraulic presses may suffice for small scale applications, automated CNC integrated and all-electric box plate lines offer highest productivity and day-to-day flexibility crucial for industrial producers.

Main Components of Box Plate Machines

Though design variations exist across box plate equipment models, core constituent elements which enables the forming functionality remains similar:

ComponentFunction
Roller FeederFeeds sheet metal stock into machine from uncoiler/stack
Roll Forming StationsApplies calculated pressure for bending sheets into shape progressively
Plate Cutoff PressTrims formed profiles to customized lengths
CNC Control ConsoleEnables flexible order programming and monitoring on touchscreen
Servo Motor SystemProvides coordinated movements between components
Robotic StackerAutomatically stacks finished pieces for easy collection
Conveyor BeltsTransports waste pieces out to collector/recycler

[Insert Illustrative Diagram Showing Key Parts of a Box Plate Making Machine]

Caption: Core components of a typical box plate fabrication equipment and their roles

While numerous auxiliary tools like loopers, straighteners and deburrers may be integrated in higher end lines, above elements enable the fundamental fabrication functions universally.

Working Process of Box Plate Machines

Understanding the step-by-step flow of sheet materials as they are converted into profiled plates allow appreciation of the forming methodology:

1. Loading – Steel, aluminum or cardboard sheets/reels loaded onto rear feeder rack enters uniformly through powered rollers

2. Feeding – Stock sheets engages with feed rollers which moves and guides it towards first forming section

3. Center Guiding – Additional guides centers the strips accurately as per width

4. Shearing – Hydraulically powered shearing blade levels leading sheet edge

5. Slitting (Optional) – Preset slitting saws slices sheets vertically into multiple strips

6. First Bending – First set of calibrated vertical rolls initiates primary bend

7. Second Bending – Sequential bending stations forms metal gradually into “U” channels through alternate roller stations

8. Final Bending – Last stands concludes profile shaping with small adjustments/flattening

9. Cutoff Press – End presses cuts finished bent shapes into set lengths by numeric control

10. Sorting – Separator gates divide custom and stock plates onto designated conveyors

11. Stacker – Robotic pickers collects and palletizes finished pieces for easy handling

12. Scrap Collection – Leftover scraps automatically ejects into collectors for recycling

Therefore, through coordinated feeding, multi-stage bending and sorting functionalities box plate making machines can transform raw sheets into finished structural packaging components rapidly.

What Materials can be Formed by Box Plate Machines?

A wide range of sheet materials with suitable mechanical properties can be progressively roll formed into profiled box plates:

Sheet MaterialKey PropertiesTypical Thickness Range
Mild SteelHigh strength, Durability, Reusability0.5 mm – 2 mm
Stainless SteelCorrosion Resistance, Longer Life0.6 mm – 1 mm
Aluminum MetalLightweight, Strong, Conductivity0.8 mm – 1.5 mm
Galvanized SteelZinc Coating, Good Weatherability0.3 mm – 1.2 mm
Cardboard SheetsLightness, Printability, Recyclability2 mm – 7 mm
Corrugated BoardsHigh Cushioning, Stiffness, Low Cost5 mm – 15 mm
Plastic Corrugated BoardsWater/Moisture Resistance, Chemical stability4 mm – 10 mm

[Insert Image Showing Different Materials Being Used in Box Plate Making]

Caption: Wide range of metallic and paper materials can be structurally profiled into box plates

Therefore steel and aluminum allows durable heavy load bearing plates while paper/cardboards suit consumer packaging purposes. Overall wide material flexibility ensures applicability across all major industries.

What are the Application Areas of Box Plate Machines?

The profiled channels, angles and custom plates produced find extremely diverse usage across sectors:

IndustryApplication Areas
Consumer ProductsProtective Packaging for White Goods, Electronics etc.
FurnitureKnockdown Crates, Pallets
AutomobilesCar/Bike Bodywork, Components Casing
AviationContainer Boxes for Aero Structures Transport
Logisticsdexion Shelving, Warehouse Racking, Chemical Drums
InfrastructureScaffolding, Construction Shuttering
AgricultureGrain Storage Silo, Greenhouse Framing

[Insert Infographic Map Showing Major Application Sectors of Box Plate Fabrication Equipment]

Caption: Formed box plates caters to extremely wide ranging usage across essential industries

From delicate electronics to heavy machine structures, appropriately designed structural plates can provide secure and sometimes reusable transportation support. Custom plate capability also enables niche producers to fabricate application specific enclosures in-house through rapid reconfiguration.

How to Choose Right Box Plate Making Machine?

Selecting optimal box plate line for production needs depends on balancing key performance factors:

Machine ParametersConsiderations
Production SpeedPlate sizes, volumes, time targets
Material CompatibilitySteel, aluminum, cardboard compatibility
Plate SizesMax/min widths, lengths to manufacture
Precision RatingTolerances as per design needs
Automation GradeManual, semi or fully automated features
Customization FlexibilityQuick design/dimension changes needed?
Budget RangeAvailable investment capital for equipment

How to Choose Right Box Plate Making Machine?

Analyzing above technology factors against business expectations allows suitable equipment matching. Additional pointers while purchasing:

  • Prioritize essential functionality needed rather than unnecessary features
  • Consider potential production growth over 5-10 years lifespan
  • Get machine directly from manufacturer than intermediaries
  • Evaluate after-sales support and maintenance ecosystem
  • Cross compare multiple box plate machine suppliers on parameters
  • Prefer suppliers with proven experience record over new entrants
  • Visit facilities to inspect machine quality firsthand before ordering

Therefore, carefully projecting operational needs and matching with ideal box plate equipment capabilities ensures profitable manufacturing.

Who are the Leading Box Plate Making Machine Manufacturers?

With box pallet fabrication demands growing globally, companies worldwide provide technologically advanced solutions:

CompanyCountryTypical Price RangeMax Plate Width
Rollmech MachinesIndia$100,000 – $250,0001650 mm
IMTEK Machine BuildersTurkey$150,000 – $300,0002100 mm
Erdal Makina LtdTurkey$80,000 – $220,0001800 mm
Hebei Linhui Plate MachineryChina$60,000 – $180,0001300 mm
ASHOK IRON WORKSIndia$50,000 – $120,0001500 mm

[Insert Company Logos and Images]

Caption: Leading global companies providing advanced box plate making equipment solutions

In addition, many regional level manufacturers worldwide also provide cost effective models catering to local demands.

How Much Does a Box Plate Making Machine Cost?

Investment costs depends on multiple aspects like speed, scale, level of automation and customization needs:

Cost Influencing Factors
Automation GradeManual & Mechanical Machines$50,000 – $100,000
Hydraulic Presses$80,000 – $150,000
CNC Touchscreen Controlled$150,000 – $350,000
Maximum Plate Width1000 mm – 1600 mm$100,000 – $250,000
1800 mm – 2200 mm$200,000 – $350,000
Production Speed10-30 plates/min$100,000 – $200,000
40-60 plates/min$250,000 – $500,000
Customization FlexibilityLow-MediumStandard Base Price
High Flexibility50% Price Premium

In general, automated CNC controlled box plate machines with wider production volumes, larger part processing capabilities and high changeover flexibilities costs over $300,000. However high production scale benefits over long-term pays off the premium price.

Installation & Commissioning of Box Plate Machines

Proper machine installation ensures smooth production commencement:

  • Prepare level concrete foundation as per floor plan needs with provisions for machine anchoring
  • Unload machine components carefully by crane/forklift without damages
  • Assemble frame, houses, stations as per manual using proper tools
  • Connect hydraulic, pneumatic and electric power/control cables
  • Install safety guards, sensors and accessory tools like loopers
  • Check lubrication levels of all moving parts
  • Initialize machine control system and set working parameters
  • Feed test materials and run trial bending operations
  • Fine tune roller positions till achieving target plate accuracy
  • Integrate post-forming conveyors if automating transfers

[Insert Image Showing Factors to Consider During Installation]

Caption: Systematic assembly, precise positioning and meticulous testing enables smooth box plate machine commissioning

While producers can self install smaller capacity machines, complex high end lines are setup by supplier engineers ensuring operational readiness from day one.

Operation of Box Plate Making Machines

Despite wide configurational variations, core fabrication sequence remains consistent:

Pre-Operation:

  • Select product bending recipe from machine library or input fresh using CAD
  • Position roller dies, cutting press as per plate design
  • Set feed length, conveyor sorting logic electronically
  • Load sheet reels, stack onto rear feeder

Production:

  • Start cycle to feed sheets automatically into process flow
  • Monitor forming sequence through consecutive bending stands
  • Formed pieces gets sorted, stacked by exit automation
  • Continuous operation while raw material stock lasts
  • Finished products unloaded to pallets/containers

Post-Operation:

  • Power down, clean excess oils, material scraps
  • Clear residual sheets by overriding rollers manually
  • Apply rust prevention oils on exposed machine parts
  • Analyze plate quality, adjust paramters if needed
  • Schedule maintenance checks based on machine usage

Therefore, beneficial pre-operation preparations coupled with attentive production monitoring allows extracting optimal functioning.

Maintenance of Box Plate Making Machines

Despite sturdy designs, periodic upkeep necessary for longevity:

Maintenance ActivityFrequencyBenefits
General CleaningDailyRemove sheet dusts, excess oils
Inspection of Bearings/GearsWeeklyIdentify wearing signs early
Hydraulic Oil Replacement6 MonthsClean internal contaminations
Greasing of Moving Joints3 MonthsEnsure smooth movements
Machine CalibrationYearlyCorrect forming alignments overtime
Electrical Connections CheckYearlyAvoid loose wiring faults

[Insert Image Showing Maintenance Activities Being Carried Out]

Caption: Systematic lubrications, inspections, recalibrations prevents unexpected downtimes

Therefore, following disciplined maintenance schedules through proper manual keeping enables realizing full machine lifespans.

Advantages of Box Plate Making Machines:

  • High production speeds up to 60 plates/min enables mass fabrication
  • Automated robotic stacking completely eliminates manual labor needs
  • Save inventory space with just-in-time custom plate production
  • Computerized metric control offers high repeatability within ±0.2mm
  • Quick roller changovers facilitates easy order variety production
  • Comprehensive safety mechanisms prevents workplace hazards
  • Sturdy designs built for 24×7 heavy industrial loads over decades
  • Key functional modules remains consistent across machine sizes

Limitations of Box Plate Making Machines:

  • High initial capital investment of over $100,000
  • Large factories spaces needed for machine installation
  • Skilled manpower necessary for operations and maintenance
  • Limited flexibility in plate width sizes due to roller constraints
  • Customized plate capabilities involves additional process complexities
  • Significant material wastages from sheet edge trims
  • Risk of unplanned downtimes from wear/tear of components

Box Plate Machine Failure Analysis, Troubleshooting & Solutions

Failure ModePossible CausesFixes
Uneven Plate BendsMisaligned Rollers, Improper GapsRecalibrate roller positions
Worn out Roller SurfacesReplace aging rollers
Excess Component WearLack of LubricationIncrease greasing frequency
Bearing/Gear IssuesInspect and replace damaged parts
Hydraulic LeaksBroken Seals or HosesIdentify and patch leaks
Blockages in Valves/PumpsFlush and overhaul hydraulics
Inaccurate Length CutsWorn out Press BladesResharpen or replace aging blades
Incorrect Measurement LogicReview and adjust machine parameters

[Insert Images Depicting Common Defects and Solutions]

Caption: Identifying root causes of failures accurately guides appropriate fixing measures

In addition to above maintenance fixes, having annual service contracts with suppliers provides additional support for troubleshooting and spare parts supply.

Box Plate Making Machine
Box Plate Making Machine 12

FAQs

Q: What sheet metal thickness can be formed into box plates?

A: Typically 0.5 mm to 2 mm for steel and 0.8 mm to 1.5 mm for aluminum materials can be profiled. Install appropriate roller dies to suit target thickness. Reduce speeds for thicker sheets.

Q: Does the machine require special foundation?

A: A level concrete flooring of atleast 200 mm thickness having suitable anchoring provisions for machine is recommended.

Q: Can cardboard sheets be formed into box plates?

A: Yes, corrugated boards and plastic corrugated boards within 2 mm to 15 mm thickness can be progressively bent using pressure rollers into structural plates. However ensure adhesives can withstand process heating.

Q: What auxiliary equipment helps improve production efficiency?

A: Integration of deburring stations, automatic bundling straps, plate sorting conveyors, custom printing systems helps improve automation flow.

Q: What safety mechanisms are present?

A: Standard features include emergency stop buttons, two-hand operation switches, safety mats, light curtains, door interlocks and overload protections.

Q: What is the typical production capacity?

A: Output speeds range 10-60 plates/min based on width, thickness and profile complexity. Automatic stackers with pallet dispensers helps maximize productivity.

Q: Does the machine require skilled labor?

A: Mechanical proficiencies helps but modern computerized models are simple to operate through menu driven touchscreens without special skill needs.

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