ZRAY Launches Eco-Friendly Packaging Line Compatible with 100% Recycled Corrugated Board (350–900 g/m², ≤30 CPM) | ZRAY
Recycled corrugated is now a procurement mandate, not a niche request: EU PPWR targets and retailer scorecards push buyers toward 100% recycled board, yet the same board fights the erector at every station. Shorter fibres mean lower stiffness, dust sheds from cut edges, and moisture swings make blanks warp. ZRAY’s eco-friendly line runs 100% recycled board from 350–900 g/m² by re-tuning the vacuum, speed and pre-creasing — without a second machine. The base platform still seals virgin board, so a plant can switch feedstock by recipe, not by capital spend.
Recycled Board Characteristics and ZRAY Adaptation
| Property of recycled board | Effect on erecting | ZRAY countermeasure |
|---|---|---|
| Short fibre, lower stiffness | Panel buckles in platen | Enlarged vacuum suction cups, de-rated speed |
| Basis weight 350–900 g/m² | Heavier blanks | Same magazine range, 150 NL/min air |
| Moisture 8–10% | Warp > 5 mm | Humidity-controlled infeed, re-squared magazine |
| High dust, edge shedding | Filter clog, AL-01 | Integrated dust extraction at pickup |
| Weak score lines | Crack on fold | Upgraded pre-creasing (предбиговка) quality |
Running recycled board, line speed is set to 30 CPM (down from 40 on virgin) and suction cups are upsized so the vacuum decay stays above the −55 kPa trip point. Better pre-creasing is the single biggest fix for edge cracks on 5-layer recycled BC.
Sealing Method: Tape vs Hot-Melt vs Water-Based
| Method | Adhesive per box | Recyclability | VOC | Unit cost |
|---|---|---|---|---|
| Pressure tape (50/75 mm) | 0 g glue | Fully recyclable | None | Low |
| Hot-melt | 1.2–2.4 g | Recyclable with board | Low | Medium |
| Water-based (PVA) | 1.0–2.0 g | Recyclable, low VOC | Very low | Medium |
For a plastic-reduction programme, pressure-sensitive tape and water-based glue are the cleanest: both separate from the fibre stream in repulping. Hot-melt stays at 1.2–2.4 g per case and is the choice when a tamper line is required.
Energy and Air Consumption
| Item | No-heat model | Hot-melt model |
|---|---|---|
| Main drive power | 3.0 kW | 3.0 kW |
| Glue tank heater | — | 1.5 kW (standby 0.4 kW) |
| Air consumption | 95–150 NL/min | 95–150 NL/min |
| Supply | 380 V/50 Hz 3-ph (220 V/60 Hz option) | same |
The no-heat tape model adds zero heating load, so a recycled-board line on tape saves the 1.5 kW melt-tank draw versus a hot-melt cell — meaningful on a three-shift, 8,000-hour year.
Compliance and Circularity
The line supports FSC-recycled claims and meets EU PPWR plastic-reduction points when paired with tape or water-based glue. Reducing hot-melt use and dropping plastic strapping directly lowers the packaged-product recyclability fee in several member states. ZRAY supplies a material-declaration sheet per machine for your EPR filing.
PLC Alarm Codes — Recycled Board Tuning
| Code | Description | Typical cause on recycled | Field tuning |
|---|---|---|---|
| AL-01 | Vacuum below −55 kPa | Dust-clogged filter, short-fibre leak | Clean filter, upsize cups, raise supply to 0.6 MPa |
| AL-03 | Pickup miss | Warped, low-stiffness blank | Re-square magazine, lower speed to 30 CPM |
| AL-04 | Forming jam | Edge crack, weak score | Engage pre-creasing, raise platen + 0.5 mm |
Step-by-step: (1) blow down dust at the pickup head; (2) swap to the larger suction-cup set; (3) set speed 30 CPM; (4) enable pre-creasing; (5) re-zero the forming platen. Most recycled-board jams clear after step 3.
Preventive Maintenance Schedule
| Interval | Tasks |
|---|---|
| Daily | Drain FRL bowl; clean vacuum filter; check dust bin; inspect cups; verify tape/glue |
| Weekly | Wash dust-extraction screen; lubricate guides; check belt tension; test E-stop |
| Monthly | Replace vacuum filter element; empty dust collector; calibrate platen; torque frame bolts |
| Quarterly | Replace suction cups; descale (if hot-melt); grease gearbox; verify PLC I/O |
| Annually | Change gearbox oil; replace bearings; insulation-test panel; re-level frame |
Dust removal is the extra load: the extraction screen is washed weekly and the collector emptied monthly, because recycled board sheds far more fines than virgin.
Model Selection for Recycled Board Lines
Browse the full ZRAY product range to match CPM and board grade across our erector families. For single-wall recycled runs at moderate volume, the Single-Piece Case Erector delivers the same 0.5–0.6 MPa air architecture and shares the enlarged-cup kit.
Get a Quotation for Your Packaging Line
Send us your carton size range, board grade and required CPM — our engineers will return a model recommendation, layout drawing and quotation within 24 hours.
Contact ZRAY: [email protected] · WhatsApp +86 13681839278
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