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Smurfit Kappa Dublin Corrugator Upgrade Project


The Smurfit Kappa Dublin Corrugator Upgrade Project was proposed to address immediate risks concerning electronic obsolescence, on-going process control limitations and also the longer term productivity and reliance of the machine.

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To support the extremely positive and beneficial investments in the Smurfit Kappa Dublin corrugator in recent years (automatic steam system, automatic starch kitchen) there remained a pressing requirement to improve all aspects of process control within the B flute facer.  The previous facer was a 1990 Simon 300 which was unable to maintain consistency in terms of wrap, temperature, glue application and most notably gap control.

Similarly the previous 1973 Langston Double Facer and 1990 Short Press had deteriorated to the extent where a full replacement was required if the benefits of the upgraded starch kitchen and steam management system could be leveraged fully. Both of these investments had been identified by Operational Excellence as priorities and will have a marked impact on the control of heat, glue and pressure within the Smurfit Kappa Dublin corrugator which will in turn improve waste levels.

The current upgrade consists of;

1) New Fosber B/E Cassette Single Facer

2) New Fosber Double Backer

3) BHS wet end spares

4) Marquip DECC replacement

5) Machine aesthetic upgrade.

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In addition the investment in the new facer / double-backer will also facilitate the Smurfit Kappa Ireland development of Performance Packaging through lighter-weight fluting and liners together with the option of S flute technology via the multi-cartridge system being proposed.

Furthermore it will enable the corrugator to run to the full width of the machine (currently restricted to 2450mm) and also standardise to 10mm “shy fluting” (currently restricted to 5mm) thereby optimising the Smurfit Kappa Ireland supply chain from the Smurfit Kappa UK Paper Division.

Smurfit Kappa Dublin Corrugator Upgrade Project