Published: 2025-06-30 Last Updated: 2025-06-30
Background
Corrugated cardboard remains one of the most essential and sustainable packaging materials for global e-commerce and logistics. According to the latest 2024 report by Precedence Research, the global corrugated packaging market is valued at approximately USD 311.6 billion in 2024. It is projected to grow at a 4.4% compound annual growth rate (CAGR) from 2025 to 2034. This steady growth reflects the rising demand for energy-efficient and carbon-reducing production equipment across the industry.
How Does a Corrugated Glue Delivery System Work?
In corrugated board production lines, starch-based adhesive must continuously circulate from storage tanks through pipelines to the glue rollers. Throughout this process, maintaining stable viscosity and temperature within a short time frame is crucial. The pump not only handles pressurized delivery but also prevents issues such as starch freezing at low temperatures, drying out during downtime, or air bubble formation. Failure to properly manage these factors can lead to poor bonding quality and reduced production speed.
📌 Corrugated Board Glue Circulation System: How to Reduce Carbon Emissions, Prevent Freezing, and Optimize Maintenance Space
Real-World Case Study: Major Corrugated Board Manufacturer in South Korea
Current Situation
The production line operates 24/7, continuously circulating high-viscosity starch-based adhesive to supply the glue rollers for bonding the corrugated board core. The original setup consisted of two 2" cast iron ARO air-operated diaphragm pumps, powered by a 6 bar compressed air system.
However, during winter, excessive cooling from the air valve exhaust caused freezing issues, leading to sudden drops in pump speed and unplanned downtime. Additionally, the compressed air system consumed large amounts of energy, required intensive maintenance, and generated noise levels exceeding 80 dB(A), negatively affecting operator comfort and safety.
To address these challenges, the production manager aimed to replace the dual-pump configuration with a single high-efficiency electric pump, while also freeing up valuable maintenance space.
Improvement Goals
- 1. Reduce energy consumption and carbon emissions by ≥ 80%
- 2. Eliminate valve freezing and unplanned downtime
- 3. Replace the dual-pump system with a single pump without increasing footprint
- 4. Lower operational noise to below 70 dB(A)
- 5. Ensure the new pump retains self-priming and dry-run capabilities
💡 Eliminate noise freezing and air compressor costs QUANTM electric diaphragm pump solves five major pain points in one solution
The glue circulation station for corrugated board was upgraded by replacing two air operated diaphragm pumps with one GRACO QUANTM TE120 electric diaphragm pump Its brushless motor eliminates the need for a 6 bar air compressor reducing noise from over 80 dB A to 65 dB A and cutting energy and maintenance costs by 80 percent The compact pump fits the existing frame and meets flow demand without extra space The diaphragm design ensures 6 meters of self priming and dry run protection avoiding winter failures The pump also features Modbus RTU and analog I O for real time data transmission and remote monitoring
🔧 How does the electric diaphragm pump meet customer needs
| Goal |
QUANTM Solution |
| 🎯 Reduce energy consumption and carbon emissions |
✔ Brushless motor with direct drive completely eliminates the 6 bar air compressor For this station alone annual energy and maintenance costs are reduced by approximately 80 percent with carbon emissions lowered by over 80 percent |
| 🎯 Eliminate valve freezing and unexpected shutdowns |
✔ Electric drive generates no exhaust cooling and prevents frosting The diaphragm allows safe dry running for 30 minutes with zero freezing recorded during continuous operation at 5 degrees Celsius in winter |
| 🎯 Maintain existing piping layout without increasing floor space |
✔ Compact pump body at just 250 x 310 mm A single QUANTM TE120 replaces two air operated pumps reducing equipment footprint by 50 percent while improving maintenance access and logistics |
| 🎯 Reduce operating noise to below 70 dB A |
✔ No gas exhaust impact noise Measured noise reduced from over 80 dB A to 65 dB A Operators no longer need hearing protection and on site communication is smoother |
| 🎯 Retain self priming and dry run capability for safe shutdown and CIP operations |
✔ Maintains 6 meters of self priming height with safe dry running for 30 minutes No pre filling required for shutdown or CIP processes avoiding glue blockages and equipment damage |
📊 Proven Results 90 percent carbon reduction and 80 percent energy savings verified through field testing