LAMIGATOR: Laminate. Corrugate. Innovate.

The luxury packaging market increasingly requires lighter secondary packaging with the highest graphic quality, capable of protecting and enhancing the products they contain.

In this scenario, the lamination process has proven to be the most effective solution to combine packaging strength with outstanding lithographic quality through the use of pre-printed sheets or paper webs, while maintaining high productivity and process stability.

With the new LAMIGATOR (both laminator and corrugator), Fosber and Quantum introduce a solution that combines two worlds that have traditionally been considered separate into a single production line: corrugated board manufacturing and lamination of printed sheets/liners, with the flexibility to operate using both PVA adhesive and starch.

The result is a compact, high-speed solution designed for maximum production versatility.

The line provides maximum operational flexibility, allowing operation with “mixed gluing” – traditionally used in laminators, with starch-based adhesive applied to the flute and vinyl adhesive used to laminate the pre-printed sheet – as well as starch-only bonding when producing pre-printed or conventional corrugated board from reel. The result is a compact, high-speed solution engineered to deliver maximum production versatility.

Why LAMIGATOR changes the rules of the game

Two functions in a single machine: specialized both in the production of singlewall or doublewall corrugated board with a pre-printed liner and in the production of single or double flute board to be laminated with pre-printed sheets using vinyl adhesive. Switching from one mode to the other is fast, simple, automatic and extremely efficient.

• Dual Glue Support: starch is used for the production of flutes (single or double), both as support for the sheet to be laminated and for board production; vinyl adhesive is used exclusively for bonding the pre-printed sheets.

• More stable finished product: thanks to advanced management of gluing and lamination processes, higher-quality sheets are obtained, with less waste and lower costs, delivering a more environmentally sustainable result.

• Greater sustainability: the ability to run lightweight paper grades with significantly reduced use of vinyl adhesive benefits both the environment and the eco-friendly profile of the final product.

• Compact and innovative layout: no civil works are required and the paper path is substantially simplified. During the production of pre-printed corrugated board, the outer liner never comes into contact with mechanical parts, ensuring protection against rubbing, friction or surface damage.

A new layout: from reel to finished sheet

LAMIGATOR integrates a next-generation wet-end and a special dry-end that combines the functions typical of a corrugator and a laminator. The singleface web (flute), once aligned and trimmed, is handled with maximum precision up to the lamination point, where the offset sheet is bonded.

When producing doublewall board for lamination or pre-printed corrugated board, the hot plate section ensures optimal bonding between substrates, guaranteeing superior flatness and stability of the finished product.

The vinyl adhesive, characterized by an intermediate environmental profile, is used exclusively for bonding the pre-printed sheet, while all other bonding phases — including the production of doublewall board intended for lamination — are carried out using starch-based adhesive, recognized as a 100% environmentally friendly solution.

The result? A technology that combines high performance, reduced waste and lower environmental impact, delivering a finished product that is more sustainable, more stable and aligned with the expectations of the most demanding brands.
 

Applications and materials: full market coverage

• Lamination onto single or double flute of offset pre-printed sheets for very high-quality packaging (displays, premium e-commerce packaging).

• Use of special outer liners: pre-printed papers, colored papers, substrates with PE/PET coating for the production of specialty corrugated sheets.

• Modular configurations: standard, singlewall or doublewall, with significant advantages in doublewall thanks to the presence of the hot plate section.

Performance and automation: productivity in numbers
(depending on configuration)

Intelligent controls

LAMIGATOR is the first sheet lamination line to install an advanced OEM process control system. It is compatible with Fosber process controls (wet-end, dry-end and process controls) and can integrate the full Industry 4.0 software suite:

Pro/Care, Pro/Quality, Target Speed Supervisor, Realtime Production Supervisor and Data Traceability Supervisor.

One line, more products, zero compromise

With LAMIGATOR, manufacturers can competitively address both the demand for traditional corrugated board and the high-value premium packaging segment, reducing footprint, setup times and plant constraints.

LAMIGATOR was therefore conceived from a clear industrial concept: overcoming the traditional separation between corrugator and laminator by integrating two historically distinct processes into a single line.

Thanks to its hybrid architecture, LAMIGATOR allows fast and efficient switching between:

• production of traditional corrugated board with starch-based bonding

• production of laminated corrugated board using PVA adhesive to bond offset sheets or pre-printed liners

All this without complex reconfiguration, without duplication of equipment and while maintaining production continuity.

In this way, the plant is no longer limited to a single product but becomes capable of adapting in real time to market demand: standard volumes, premium jobs, short runs or high value-added production.

LAMIGATOR is a next-generation line designed for those who want to turn flexibility and quality into a commercial advantage — today, and even more tomorrow.