Tri-Wall, a world-leading supplier of high-performance corrugated packaging solutions, has consistently set industry benchmarks with its innovative approach to heavy-duty packaging. With a global manufacturing footprint spanning Asia, Europe, and North America, Tri-Wall serves diverse industries, including automotive, electronics, and machinery, where precision and durability are paramount.
To address the challenges of producing small-batch, multi-size heavy-duty corrugated boxes, Tri-Wall has adopted Aopack BM3000-HD Heavy-Duty Box Making Machine across its operations in China, Europe, and the Middle East. This strategic investment has transformed the company’s production efficiency, accuracy, and cost-effectiveness for low-to-medium volume orders.
The Challenge: Inefficient Production of Small-Batch Heavy-Duty Boxes
Heavy-duty corrugated boxes are typically produced in small quantities with various sizes. Traditional box factories typically require a complex, multi-step production process to manufacture heavy-duty corrugated boxes.
1. Cutting to Height (Vertical Saw)
- The corrugated board is first cut to the required box height using a vertical panel saw.
2. Slitting to Width & Longitudinal Creasing (Slitter-Scorer)
- The board is then fed into a slitter-scorer (or slitter-scoring machine) to trim it to the correct width and apply vertical creases (for folding along the grain of the corrugation).
3. Scoring & Slotting (Slotter-Scorer)
- Next, the cardboard moves to a slotter-scorer for Horizontal creasing (for folding across the corrugation). and Slotting (if needed, to create flaps or interlocking edges).
4. Glue Flap Crushing (Compression Machine)
- Before assembly, one side of the box (where stitching/nailing will occur) is passed through a glue flap crushing machine.
- This reduces the thickness by ~4.5mm to prevent paper bursting during stitching.
5. Vertical Stitching (Vertical Stitcher)
- The box is assembled using a vertical stitching machine (for standard sizes).
- Heavy-duty boxes (e.g., AAA or AA flute, which replace wooden crates) typically use metal stitches instead of glue for superior load-bearing strength.
6. Horizontal Stitching (Horizontal Stitcher For Extra-Tall Boxes)
- If the box is exceptionally tall, a horizontal stitching machine is used instead, as it supports unlimited-length panels.
This fragmented workflow posed several challenges:
1. Low Efficiency–Each machine required individual setup and calibration for every order, leading to significant downtime.
2. High Labor Costs–Manual handling between machines increased labor dependency and error risks.
3. Inconsistent Precision–Multiple machine transfers introduced dimensional inaccuracies, affecting product quality.
Today, Tri-Wall operates a global manufacturing network with 6 corrugated sheet plants and over 100 box production facilities across Asia, as well as 2 corrugated sheet plants and more than 30 box manufacturing sites in Europe and North America. Each of Tri-Wall's box plants may utilizes various types and brands of box-making equipment. Optimizing their heavy-duty packaging box production process is crucial for Tri-Wall to maintain competitiveness in industries where packaging strength and precision cannot be compromised.
The Solution: Aopack BM3000-HD – A Game-Changing Innovation
The Aopack BM3000-HD is a fully integrated heavy-duty box making machine designed to replace the traditional multi-machine approach. Its advanced engineering consolidates all production stages into a single, automated workflow, delivering unmatched efficiency and precision for heavy-duty corrugated packaging.
Key Features & Benefits
1. Multi-Function Integration
- Combines board feeding, slotting, scoring, creasing, slitting, trimming, gluing, printing, vibrating knife cutting, all in one compact box making machine.
- Eliminates material handling between machines, reducing production time by up to 70%.
2. Superior Heavy-Duty Performance
- Processes E-flute to AAA-flute corrugated boards, from 3-ply to 7-ply constructions. Corrugated cardboard from 2mm to 16mm, up to 2400g/sqm
- 7-21mm adjustable slotting width for diverse box designs.
- Handles cardboard widths up to 3000mm with unlimited length flexibility.
3. Rapid Order Changeover
- All tools are driven by separate motors, with 1-6 seconds quick-switch technology between jobs, ideal for small-batch production.
4. 150+ Box Style Pre-programmed
- Covering the majority of commonly required box styles.
- With Free Style software, free creation available, with unlimited box styles.
5. Highlight Functions
- Double-sided creasing and inconsistent creasing capabilities for complex structural requirements.
- Vibrating knife cutting round holes, rectangles, slashes, curves, and other irregular shapes. No mould needed.
- Auto knife sharpener ensures consistent cutting quality.
Tri-Wall’s Global Deployment & Results
Since 2024, Tri-Wall has installed four BM3000-HD box making machines across its global facilities, including:
- China (2 units – 2024 & 2025)
- Europe (1 unit – 2024)
- Middle East (1 unit – 2024)
The decision to repurchase additional machines underscores Tri-Wall’s confidence in Aopack technology.
Tangible Improvements
80% Reduction in Setup Time – No more individual machine adjustments.
50% Labor Cost Savings – Reduced manual handling and operator dependency.
30% Increase in Production Speed – Faster turnaround for urgent orders.
Higher Precision & Fewer Defects – Improved customer satisfaction.
Why Aopack? A Trusted Global Partner
Aopack reputation as a leading corrugated box machinery manufacturer is backed by:
800+ Machines Installed Worldwide – Serving clients in 80+ countries, including the USA, UK, Germany, Japan, and Australia.
Industry-Leading Support – Comprehensive training, maintenance, and spare parts services.
Continuous Innovation – Machines designed for evolving packaging demands.
Conclusion: A Strategic Leap Forward
For Tri-Wall, the Aopack BM3000-HD has redefined heavy-duty corrugated box manufacturing. By consolidating multiple production stages into a single, high-speed machine, Tri-Wall now delivers:
Faster order fulfilment for small-batch clients.
Lower operational costs with reduced labor and waste.
Superior box quality with unmatched precision.
As Tri-Wall continues to expand its global presence, Aopack remains a trusted partner in driving efficiency, innovation, and sustainability in corrugated packaging.