For more than 240 years, Brohl Wellpappe has been manufacturing packaging from corrugated and solid board. Despite this long tradition, the family-run business remains firmly committed to innovation. One example of this is the use of the Easyfold water-scoring system from Baumer hhs. This involves the targeted application of a folding fluid to the score lines. The result: cleaner and more stable folds, less waste and greater process reliability.
Production manager Lopez and project manager Heintz share their practical experiences with the system, its applications and limitations, as well as the prospects for waterscoring technology.
Tradition meets innovation
Brohl Wellpappe is now run by the eighth generation of the family and offers comprehensive packaging solutions from a single source, from development through to printing and co-packing. Alongside flexo and offset printing, digital printing is also becoming increasingly important.
High quality standards are a hallmark of the entire product portfolio. Customers expect not only a crisp print finish, but also packaging that can be processed reliably and adheres precisely to the specified dimensions.
To meet these requirements, all inliner machines at Brohl Wellpappe are now equipped with the Easyfold waterscoring system. The system applies fine lines or dots of a folding fluid directly to the crease. This makes the material more pliable along the fold line, allowing it to be folded with greater control. Fishtailing and dimensional deviations are significantly reduced.
The road to a decision
Brohl Wellpappe was originally made aware of the waterscoring process by a machine manufacturer. The background to this is that market demands are constantly rising, whilst at the same time the permissible tolerances are becoming ever tighter.
A solution was therefore needed to stabilize the folding processes and make them more reproducible. Waterscoring proved to be an effective tool in this regard.
Effectiveness and limitations
“The effect is particularly evident with FEFCO 201 boxes. Fishtailing and dimensional deviations have practically disappeared here. Even custom designs with interlocking closures or break-away flaps benefit noticeably from the targeted application of the folding liquid,” reports Production Manager Lopez.
Waterscoring is most effective on E-flute and B-flute, particularly in the direction of the fluting. Gap deviations during standard operation are therefore a thing of the past.
With thick, multi-layer corrugated board or very large formats, waterscoring naturally reaches its limits. Material stiffness and structure limit the extent of the effect. Nevertheless, a significant improvement can usually be achieved even with these applications.
Flexible use in day-to-day production
At Brohl Wellpappe, waterscoring is used specifically where the process offers a tangible benefit. The decision to use it is made by the machine operators directly during the production process. If the use of the folding agent can stabilize the folding or increase the production speed, the system is activated.
This means that waterscoring is not an additional process step, but rather a flexible tool that can be utilized within the existing production workflow.
Application from above or below
Depending on the machine, the material is folded upwards or downwards. The folding liquid can therefore be applied with equal flexibility: from above or from below.
The direction of application does not play a decisive role in the result. The liquid is absorbed immediately into the material and does not drip. What is far more important is that the application takes place precisely on the crease line.
Thanks to its fixed mounting on the crossbar, the waterscoring valve automatically aligns itself with the respective crease line. The compact SW-600 waterscoring valves also allow for installation in tight machine spaces and positioning close to the product. Integrated cable and hose guides protect the supply lines from damage during automatic traverse movements.
Less crease breakage, better appearance
Another advantage is immediately apparent at the crease line. Thanks to waterscoring, the flaps are less likely to split when folded, as the material remains more elastic in the critical area.
This effect is becoming increasingly important, particularly against the backdrop of falling paper grammages. If thinner materials can be processed without them tearing at the fold, this not only improves the visual quality of the packaging. At the same time, it creates potential for savings in material usage without compromising on packaging quality.
Quality control right in the production process
Experienced machine operators can tell from the finished pallet whether waterscoring has achieved the desired effect. If the gaps between the flaps are uniform, the format is correct.
This quick visual check is particularly valuable in day-to-day production. Machine operators can see at a glance whether the folding is correctly adjusted. In many cases, no additional measuring tools are required. This saves time whilst also increasing process reliability.
In addition, the application of the folding liquid is checked on a random basis. To do this, a damp cloth is wiped across the crease line. This makes the application of the folding liquid – which is normally difficult to see – visible and allows it to be checked quickly.
No negative impact on BCT and ECT
One obvious question concerns the effect of the additional moisture on the strength of the corrugated board. However, fears that waterscoring might have a negative impact on BCT or ECT values have not been confirmed at Brohl Wellpappe.
The company’s in-house quality assurance department checks these values regularly. The results are within the specified range, and no negative effects on the stability of the packaging have been observed.
High acceptance within the team
The results in day-to-day production have proved convincing. Brohl Wellpappe has now retrofitted all its in-line machines with Waterscoring to ensure a consistently high standard of quality for its customers.
The systems operate reliably and help machine operators to maintain stable control over the folding process. Waterscoring therefore not only contributes to product quality but also makes day-to-day work on the production line easier.
A look ahead
Experience to date suggests that waterscoring will continue to grow in importance within the corrugated board industry in the coming years. The number of systems sold and installed supports this assessment. Numerous systems have already been installed internationally, and in some cases entire production sites are being retrofitted accordingly.
This development is not limited to Europe. Waterscoring systems are also increasingly being used in other markets. In Egypt, for example, the first systems have already been installed, and further projects are under discussion.
The outlook is therefore clear for project manager Heinz: “Waterscoring has the potential to establish itself as a standard technology in corrugated board processing in the long term. A comparatively small tool with a big impact.”
Conclusion
Ultimately, what counts is the result the customer sees: clean creases, precise dimensions and reliably folded packaging.
At Brohl Wellpappe, the Easyfold waterscoring system plays a key role in ensuring this quality is consistently achieved in day-to-day production. Less fishtailing, smaller dimensional deviations and fewer fold breaks ensure more stable processes whilst reducing the risk of scrap and customer complaints.
Brohl Wellpappe thus demonstrates how targeted process innovation can bring about a noticeable improvement even in a production process that has been established for decades.
