Optimising Cardboard Production:

Why UK Manufacturers Are Upgrading Their Corrugating and Laminating Equipment in 2025

An Insider’s Perspective on the Evolution of Packaging Machinery

As I walked through our production floor last week, watching our decade-old corrugator struggle to keep pace with increasing demand, I couldn’t help but think about the conversation I’d had with James or was it Keith? from Martins Corrugator Engineering. “Your single facer is the bottleneck,” he’d said, pointing to efficiency charts on his tablet. “With the right equipment upgrade, you could increase your throughput by 30% while reducing energy consumption.” That conversation changed my perspective on what modern corrugating machinery could achieve in today’s competitive packaging market.

For those of us managing medium to large cardboard manufacturing operations across the UK, the pressure to optimise production while meeting sustainability targets has never been greater. E-commerce demand continues to surge, requiring faster turnaround times and more customised packaging solutions. Meanwhile, energy costs remain stubbornly high, making efficiency improvements a priority for every production manager.

The Hidden Costs of Outdated Corrugating Equipment

When was the last time you calculated the true cost of running your current corrugating line? Most of us track the obvious metrics—units per hour, downtime, reject rates—but often miss the cumulative impact of inefficiencies that modern equipment has already solved.

Consider this comparison based on data from recent installations across similar UK operations:

“We were honestly shocked when we calculated the payback period,” admitted Thomas, a production director at a midlands-based packaging company I met at last month’s industry conference. “The fingerless single facer alone paid for itself in just 11 months, purely on material savings and reduced maintenance costs.”

The Technological Evolution You Might Have Missed

If you haven’t closely examined the corrugating machinery market in the past three years, you’ve missed a significant technological evolution. Suppliers like Martins Corrugator Engineering have transformed what was once primarily mechanical equipment, with automation have made them into sophisticated, digitally controlled production systems.

Today’s high-speed corrugating equipment incorporates:

• Advanced flute forming systems that maintain precise paper tension, dramatically reducing warp and dimensional variation
• Intelligent glue application systems that adjust in real-time based on paper moisture content and line speed
• IoT-enabled components that predict maintenance needs before failures occur
• Energy recovery systems that capture and repurpose thermal energy
• Integrated quality control that continuously monitors board quality and automatically adjusts parameters

“It’s not just about speed anymore,” explained Sarah, our operations manager, after returning from a demonstration at one of the factories where Martins Corrugator Engineering supplied new enhanced equipment into a UK facility. “The precision of the new double facer means we can reliably produce lighter weight board without compromising strength. That translates directly to material cost savings and more sustainable products for our customers.”

Sustainable Packaging Production: No Longer Optional

Sustainability has moved from a marketing advantage to a fundamental business requirement. Major retailers across the UK are now mandating sustainability metrics for their packaging suppliers, including carbon footprint, recycled content percentage, and end-of-life recyclability.

Modern corrugating and laminating equipment address these requirements through:

1. Precise adhesive application systems that minimise chemical usage
2. Optimised heating systems that reduce energy consumption
3. Advanced paper path designs that enable the use of lighter basis weight and recycled papers
4. Intelligent tension control that reduces waste during production
5. Digital workflows that eliminate paper-based production records

One particularly impressive case study comes from a Southeast England packaging producer who specialised in food-grade corrugated packaging. After installing a new corrugating line with advanced moisture control systems, they were able to reduce their carbon footprint by 15% while simultaneously improving board strength by 10%.

The Competitive Edge of Custom Corrugating Solutions

“Off-the-shelf machinery wasn’t going to work for our specific needs,” admitted Robert, an engineering manager I regularly meet in our industry working group. “Our facility height constraints and unique product mix required customisation.”

This is where suppliers like Martins Corrugator Engineering have distinguished themselves as one worth looking at in the UK market place. Rather than simply offering standardised equipment, they’ve developed a consultative approach that begins with understanding the specific production challenges and constraints of each operation.

For Robert’s operation, this meant a custom-designed corrugator line with a unique stacker configuration that accommodated their limited ceiling height while maintaining high-speed operation. The result was a 25% productivity improvement without requiring facility expansion. 
“A note here from Martin low ceilings are still a challenge with some customers, as new premises are so expensive to build. It often becomes a total move or build a new higher roof over the existing building and then remove the old roof piece meal as production continues as much as possible.”

Beyond the Hardware: The Service Factor

Anyone who’s experienced an unplanned corrugator breakdown knows the painful cost of downtime. At current production values, each hour of downtime typically costs UK manufacturers between £1,100-£4,000 in lost production alone, not counting rush shipping costs and potential contractual penalties.

This makes the service and support infrastructure behind the machinery nearly as important as the equipment itself. Questions worth asking potential suppliers include:

• What is your emergency response time for technical issues?
• Do you maintain a UK-based parts inventory for critical components?
• What preventative maintenance programs do you offer?
• Can your systems integrate with our existing production management software?
• What training do you provide for our maintenance and operations teams?

The Financial Case: Numbers That Demand Attention

Let’s talk numbers. Based on some typical operation patterns for a medium-sized UK corrugated packaging producer, the financial impact of upgrading corrugating equipment is compelling:

With modern financing options and the current UK tax advantages for capital equipment investments, many operations are achieving positive cash flow from the very first month after installation.

Taking the Next Step: Evaluation Without Disruption

“My biggest concern was having salespeople disrupting our operation,” admitted David, a production manager I met at last year’s Packaging Innovations exhibition in Birmingham.” But the assessment process was actually valuable in itself. Their engineers identified inefficiencies in our existing setup that we could address immediately, even before considering new equipment.”

One of the top suppliers in this space, will include Martins Corrugator Engineering, they have evaluation methodologies that minimise disruption while providing concrete data on potential improvements. These typically include:

1. Initial production analysis using non-invasive monitoring equipment
2. Benchmarking current performance against industry standards
3. Modelling potential improvements with different equipment configurations
4. Detailed return-on-investment calculations based on actual production data

A Decision Framework for Forward-Thinking Manufacturers

As I consider our own upcoming equipment decisions, I’ve developed a framework that might be helpful for other UK packaging manufacturers:

1. Audit current performance: Establish baseline metrics for speed, quality, energy usage, and material efficiency
2. Identify bottlenecks: Determine which production stages are limiting overall throughput
3. Evaluate technology gaps: Compare current equipment capabilities with state-of-the-art options
4. Calculate comprehensive ROI: Look beyond purchase price to total lifetime value
5. Consider future requirements: Ensure new equipment can adapt to changing market demands
6. Assess supplier partnership potential: Evaluate technical support, parts availability, and upgrade paths

Conclusion: Making the Decision That Shapes Your Competitive Future

The corrugating and laminating machinery you select today will determine your operational capabilities, cost structure, and competitive position for the next decade. As e-commerce continues to drive packaging demand across the UK, the gap between manufacturers with optimised production systems and those struggling with legacy equipment will only widen.

After examining the options available from UK suppliers like Martins Corrugator Engineering (https://www.martinsengineering.com/), I’m convinced that the question isn’t whether to upgrade, but how to sequence the improvements for maximum impact with minimal disruption.

If you’re facing similar decisions about your corrugating equipment, I’d recommend starting with a comprehensive evaluation of your current production efficiency. The insights gained will provide clarity on the potential return from different investment options.

The packaging industry is evolving rapidly, and those of us responsible for production capabilities need to ensure we’re positioned to meet tomorrow’s challenges. With the right corrugating and laminating equipment partners, UK manufacturers can achieve the perfect balance of productivity, quality, and sustainability that today’s market demands.

What steps are you taking to optimise your corrugating operations this year? The team at Martins Corrugator Engineering would be interested to hear about your specific challenges and requirements.