| How Is Corrugated Made? The corrugator produces corrugated sheets for us to convert into Packaging or Point of Purchase Displays. We order sheets the size needed to produce to our customers specifications. The length and width of sheet are determined by the length by width by depth (Length X Width X Depth) and the thickness of corrugation (caliper). The caliper is based on the type of flute required. There are several flute types, the most common are ‘B’ flute (approx. 1/8″ thick), ‘C’ flute (approx. 3/16″ thick), and ‘E’ flute (approx. 1/16″ thick). The reason there are different flutes is due to the stacking strength of wider flutes. The wider the flute, the more paper per inch gives more strength to the wall of the box. Also, liner basis weight can affect the strength of the wall of the box. The higher the basis weight, the thicker the liner is. Basis weight is the weight of the paper per 1000 square feet times the number of liners and mediums. The process of making corrugated sheets begins with large rolls of liner and medium. The fluted medium is glued with starch to the inner and outer liner. The starch is heated at the hot box to facilitate adhesion between the fluted medium and the liners. The board is then trimmed to length and scored if required at the triplex. The board is then trimmed to width with the concentric knife. The board is then stacked into units at the down-stacker and banded for transport to our plant. The diagram below shows basically how the process would look. 
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