<\/span><\/h3>\nPP corrugated sheets are manufactured using 100% virgin PP resin, recycled PP resin, or a combination of both depending on the desired quality and performance requirements.<\/p>\n
High quality PP corrugated sheets are manufactured using mainly virgin\u00a0PP resins. Even though it is possible to use recycled material in certain applications, food-grade and export products require more pure PP. In case you require strong and clean material,\u00a0you can\u00a0use the sheets that contain more pure PP.<\/p>\nPP corrugated sheet material<\/figcaption><\/figure>\n<\/span>Step 2:<\/b><\/strong>\u00a0<\/b><\/strong>Mixing Raw Material and Additives<\/b><\/strong><\/span><\/h3>\nEven before the first sheet comes off the production line, PP pellets are mixed with several additives that improve durability, safety, aesthetics, and functionality.<\/p>\n
Additives used are:<\/b><\/strong><\/p>\n\n<\/b>UV protectors:<\/b><\/strong>Protect the sheets from exposure to sunlight, keeping them from fading, cracking, and deteriorating when used outdoors.<\/li>\nAnti-static additives:<\/b><\/strong>\u00a0Minimize the presence of static electricity, vital for electrical equipment and fragile items.<\/li>\nFlame retardant additives:<\/b><\/strong>\u00a0Increase fire resistance, particularly important in industries and construction.<\/li>\nColor master-batch:<\/b><\/strong>\u00a0Ensure consistency in color and appearance.<\/li>\nAnti-ageing additives:<\/b><\/strong>\u00a0Extend product lifespan by protecting against heat and external damage.<\/li>\n<\/b>Conductive additives:<\/b><\/strong>Handle static electricity in packaging electronics and semiconductors.<\/li>\nFood grade additives:<\/b><\/strong>\u00a0Make the material safe for food packaging and beverages.<\/li>\n<\/ul>\n Today, most manufacturers have dosing machines that automatically mix these additives, ensuring consistency in quality and performance in all products.<\/p>\nPP corrugated sheet Melting and Extrusion<\/figcaption><\/figure>\n<\/span>Step 3: Melting and Extrusion<\/b><\/strong><\/span><\/h3>\nThis step lies at the very core of the entire manufacturing process. The polypropylene pellets enter the extruder and become melted into a smooth and liquid substance.<\/p>\n
The extruder uses the screw system that melts, mixes, and pushes the material forward at constant pressure.<\/p>\n
Temperature and pressure control is important in order not to affect the quality of the sheet produced.<\/p>\n
The process depends heavily on:<\/b><\/strong><\/p>\n\nTemperature: 180-230\u00b0C (barrel & die temperature)<\/li>\n Pressure: 80-200 bar (8-20 MPa) when extruding<\/li>\n Screw speed: 20-80 rpm depending on sheet thickness and output<\/li>\n Flow of material: 100-600 kg\/hour depending on capacity of extruder line<\/li>\n<\/ul>\n<\/span>Step 4: Creating the Hollow Structure<\/b><\/strong><\/span><\/h3>\nAfter exiting the extruder, the melted plastic falls into a specially designed die.<\/p>\n
The die forms the unique double wall structure that makes PP corrugated sheeting such an exceptional combination of strength and weightlessness.<\/p>\n
In liquid form, the ribs serve as silent protectors against compression while reducing material usage and providing the durability you need for your PP corrugated sheet applications.<\/p>\n
<\/span>Step 5: Cooling and Calibration<\/b><\/strong><\/span><\/h3>\nAfter the sheet has been formed, it undergoes vacuum calibration and cooling process. The temperature of the cooling water should be maintained at a range of 15-25\u00b0C. The vacuum pressure needs to be adjusted at a point between 0.02-0.08 MPa while the production speed should be controlled at around 3-15 m\/min.<\/p>\n
At this point, the manufacturer adjusts the following factors concerning the sheet:<\/b><\/strong><\/p>\n\nThickness of the sheet,<\/li>\n Width of the sheet,<\/li>\n Flatness of the sheet,<\/li>\n Smoothness of the sheet,<\/li>\n alignment of the ribs within the sheet.<\/li>\n<\/ul>\nPP corrugated sheet Corona Treatment<\/figcaption><\/figure>\n<\/span>Step 6: Corona Treatment (Optional)<\/b><\/strong><\/span><\/h3>\nIf the sheets are to be printed, then they are subjected to corona treatment.<\/p>\n
Since polypropylene has a very low surface energy level, the ink and glue do not stick properly to it.<\/p>\n
With corona treatment, the surface energy becomes temporarily higher to allow:<\/b><\/strong><\/p>\n\n<\/b>UV printing<\/b><\/strong>: This technology involves using ultraviolet light to instantly harden the ink on the surface of the sheet, providing you with vivid colors, sharp imaging and long-lasting graphics for your applications.<\/li>\n<\/b>Screen printing:<\/b><\/strong>Used to print ink on the sheet using a mesh screen. Screen printing is best suited for your logos, simple design, and for areas needing solid ink coverage.<\/li>\n<\/b>Digital printing:<\/b><\/strong>Print on your PP corrugated sheets through digital means, allowing you to produce images and designs that can be customized to fit your personal or professional needs.<\/li>\n<\/b>Lamination:<\/b><\/strong>It involves putting a protective layer on your sheets, improving your looks, durability, water-resistant properties, and scratch-resistant properties among other advantages depending on your needs.<\/li>\n<\/b>Gluing<\/b><\/strong>: is a method of binding together pp corrugated sheets with other components using adhesive properties. This helps you develop your own packaging design, assemble products, and meet your special requirements.<\/li>\n<\/ul>\n Otherwise, the print may peel off or fade early on.<\/p>\ncorrugated plastic cutting<\/figcaption><\/figure>\n<\/span>Step 7: Cutting to Size<\/b><\/strong><\/span><\/h3>\nThe sheet, when cooled, is fed into the automatic cutter.<\/p>\n
The dimensions can be tailored to suit any specification by manufacturers.<\/p>\n
Some common thicknesses include:<\/b><\/strong><\/p>\n