Corrugated Production Line
Double Facer
The Double Facer is the core bonding and finishing unit in a corrugated cardboard production line. It is the stage where single-face corrugated board is permanently bonded with liner paper to form finished multi-ply corrugated board, such as 3-ply, 5-ply, and 7-ply cardboard.
Overview
As a key packages machine in Pakistan, the double facer determines the final strength, flatness, moisture balance, and overall quality of corrugated boards before they move to slitting, scoring, and cutting operations.
At Micro Star Machines, we supply high-performance double facer machines designed for precision bonding, energy efficiency, and consistent quality in continuous production environments.
The double facer converts semi-finished material into fully usable corrugated cardboard through a synchronized process of bonding, heating, and pressing — making it essential for final board quality.
Final Bonding Stage
Creates permanent bonds between single-face board and liner paper
Quality Determination
Establishes final board strength, flatness, and dimensional stability
Production Bridge
Connects forming operations with finishing processes like slitting and cutting
What the Double Facer Does
The double facer performs three essential functions in one continuous process:
1. Bonding
The glued flute tips from the single-face board are pressed together with liner paper to create a strong, permanent bond. This critical step determines the structural integrity of the final corrugated board.
2. Heating & Curing
Heat plates activate and cure the adhesive, ensuring proper penetration and bonding without damaging the paper. Controlled temperature zones optimize adhesive performance across different paper types.
3. Pressing & Flattening
Controlled pressure ensures uniform thickness, smooth surface finish, and dimensional stability of the board. This creates the flat, stable sheets required for high-quality packaging production.
This synchronized three-stage process converts semi-finished material into fully usable corrugated cardboard in a single continuous operation, enabling high-speed production without compromising quality.
How the Double Facer Works
The double facer operates through a carefully orchestrated sequence that ensures consistent bonding and quality:
Production Process Flow
- Material Entry: Single-face corrugated board enters the double facer from the bridge
- Liner Application: Liner paper is applied over the glued flute tips
- Heat Application: The combined layers pass through heated plates
- Pressure Application: Continuous pressure belts or press shoes apply uniform force
- Adhesive Curing: Adhesive cures under controlled temperature and pressure
- Board Exit: Finished corrugated board exits flat, strong, and stable
This synchronized process allows high-speed production without compromising quality, making it ideal for modern packaging machine in Pakistan operations focused on efficiency and output.
Key Advantages of a High-Quality Double Facer
Uniform Bonding Strength
Uniform heat and pressure distribution ensure strong bonding across the full width of the board
Excellent Board Flatness
Controlled pressing reduces warping, curling, and uneven thickness
High-Speed Production
Designed to operate continuously with modern corrugated production lines, supporting large-volume output
Energy Efficiency
Optimized heating systems reduce energy consumption while maintaining curing effectiveness
Reduced Rejects
Stable operation minimizes defects such as delamination, blistering, or weak bonding
Moisture Balance
Controlled heating and pressing maintain optimal moisture levels for board stability
Quality Control & Stability
Our double facer machines are engineered with precision control systems that allow operators to adjust critical parameters for optimal performance:
Temperature Zones
Multiple adjustable zones for optimal adhesive curing
Pressing Pressure
Precise pressure control for uniform board thickness
Production Speed
Variable speed settings for different board types
Board Thickness
Consistent thickness control across production runs
These precision controls ensure reliable performance under varying paper qualities and environmental conditions — a critical requirement for any packaging machine in Pakistan operating in diverse production environments.
Integration with the Corrugated Line
The double facer is designed to integrate seamlessly with all components of modern corrugated production lines, ensuring smooth material flow and consistent board quality from start to finish.
Single Facer Machines
Receives single-face board with optimized moisture and temperature
Bridge Systems
Compatible with overhead and vacuum bridge configurations
Double Gluing Systems
Works with precision glue application for optimal bonding
Slitter Scorer Units
Delivers flat, stable boards ready for precision cutting and scoring
Cut-Off Systems
Provides consistent board quality for accurate sheet cutting
Stacking Equipment
Outputs boards with proper flatness for efficient stacking
Integration ensures synchronized operation across the entire production line, maximizing efficiency and maintaining consistent quality from raw materials to finished boards.
Applications
Corrugated boards produced using a high-performance double facer are suitable for diverse packaging applications across multiple industries:
Shipping Cartons
Strong, flat boards for reliable transportation packaging
Export Cartons
Durable boards meeting international shipping standards
Heavy-Duty Boxes
High-strength boards for industrial packaging
Consumer Goods
Quality boards with excellent printability for retail packaging
Food & Beverage
Clean, stable boards for food-safe packaging applications
Pharmaceutical Packaging
Precise, consistent boards for regulated industries
Why Choose Our Double Facer Machines?
Precision Engineering
Advanced control systems for consistent bonding and quality
Energy Efficient Design
Optimized heating systems reduce operational costs
Robust Construction
Built for continuous industrial operation with minimal downtime
Easy Maintenance
User-friendly design with accessible components
Complete Integration
Seamlessly works with all corrugated line components
Reliable Support
Comprehensive service from trusted packaging machines in Pakistan supplier
Our double facer machines deliver the reliability, efficiency, and quality control needed for modern corrugated production, ensuring your operation meets demanding market requirements while maintaining profitability.
Get Your Double Facer Quote
Contact Micro Star Machines for pricing, technical specifications, and guidance on selecting the right double facer machine for your corrugated production line.
✓ Production line speed and capacity requirements
✓ Board specifications (width, ply configuration, flute types)
✓ Heating system preferences (steam, electric, oil)
✓ Integration with existing equipment
✓ Energy efficiency priorities
✓ Your city in Pakistan + factory layout details
+92 (0) 41 8861153
info@microstarmachines.com
