Profile of CalBox Group's Corrugators

  • Corrugated Mailing, Folders, Tubes, Storage & Bin Boxes
In 2013, the 98" BHS corrugator was installed in Mesa, AZ,  producing the best quality corrugated sheets and boxes. Proof? We are AIB (FDA) and ISO 9001-2012 Quality Certified. 

Arizona Corrugated Container produces stock and custom corrugated cartons, inserts and master shippers along with custom tooling, printing, die cutting and on time delivery. Besides flexographic (water-based) inks, ACC can supply dazzling litho-laminated boxes and displays.

In Arizona, we operate two facilities, which are only 110 miles apart with state of the art box-making machinery. For example, a $1-million specialty folder gluer allows us to run at high speeds, die cut boxes, trays, auto lock bottom boxes, tubes, and more.

Six die cutters and six printing presses in Arizona allow for fast set-up features, reliable quality control. and on time deliveries.

ACC Corrugator Advantages

  1. The only 100% completely NEW corrugator in Arizona
  2. Built and installed by BHS, Germany, the #1 corrugator in the world.
  3. Latest technology. Totally computerized. Designed to meet U.S. Electrical Codes, etc.
  4. Able to run short & midsize orders as fast and long volume orders by Arizona competitors.
  5. ACC has the largest total corrugator facility for converting corrugated in Arizona. We own, (not lease) 150,000 sq. ft. in Mesa with a total of 300,000 sq. ft. in Arizona.
  6. Our top management team has a combined total of over 100 years experience.
  7. With two (2) state-of-the-art corrugators, ACC is part of five corrugated box & display facilities.
  8. Since 2016, ACC has installed $700,00 computerized conveyor, making a total corrugator investment since 2013 of more than $12 million.
  9. ACC runs light ad heavy grade paper to produce board from 125 test (27 ECT) to 900 test (120 ECT) double wall.
  10. ACC corrugated sheets have perfect flute profiles, resulting in more ECT value stacking strength. (It can be as high as 40%)
  11. ACC carries over $1 million in roll stock inventory with turn over every 4 to 5 weeks.
  12. We do not sell our quality sheets (to make boxes) on the open market.


Our Basic Corrugator Functions

A 400 foot long corrugator consists of a wet and a dry end to combine three rolls (or reels) of paper to corrugated sheets.

The wet end of a modern corrugator starts with roll stands, splicers, preheaters, a bridge, two single facers with flute changes, glue machine and double facer with hot plates, which complete the combining process. Paper changes on the wet end are a moving caliper target. Mill liners and mediums are specific to their own paper machines. So the caliper of box converting machines is going to be different and will always need proper settings.

The dry end function receives, at speeds over 1,000 ft/min., board from the wet end going to a slitter-scorer and cross-cut with a direct-drive knife. Then the sheets are neatly stacked, ready for transfer to converting into corrugated boxes. Its software provides a detailed diagnostic of processes, control the production schedule and status of the roll stock inventory.


Left Column Boxes