Interview with Mr. Sam Mani, Director, Karunya Machinery
A leading Manufacturer of Oblique paper corrugation machine, Corrugated Paper Board Making Plant, Fingerless Paper Corrugation Machine, Fingerless High Speed Single Facer Corrugation Machine and High Speed Single Facer Corrugation Machine from Chennai, India.
Corrugman : Could we know more about Karunya Machinery?
Sam Mani : Our Parent Company Divine Grace Print Pack Association, incepted in 2016, are well-known manufacturers, wholesaler, retailer, importer and exporter of Gluer Machine, Slotter Machine, Reel And Roll Stand, etc. We have positioned ourselves well in this competitive market by providing high quality products to our customers.
To bring out the best quality products, we use cutting-edge technology in the manufacture of these products at our well-equipped infrastructural plant. In addition, we have a highly qualified and trained group of experienced professionals, who continuously put in efforts for developing innovative products and features to meet the requirements of the end users.
CM: What are all the products manufactured by Karunya Machinery?
SM : Karunya Machinery primarily manufactures equipment for the corrugated box and paper converting industry. Our product range includes various machines for corrugation, printing, die-cutting, and box production. We offer a variety of machines such as corrugation machines (including fingerless and oblique types), printer slotters, die-cutting machines, folder gluers, and box stitching machines.
We have been able to set new benchmarks for the competitors and Adhering to ethical business policies coupled with integrity, we have established a reputed name as a leading brand offering numerous products.
CM : How does KARUNYA improve efficiency when loading and feeding raw paper rolls?
SM : KARUNYA employs advanced shaftless reel stands that allow rolls to be loaded without the need for inserting shafts, significantly reducing setup time. These reel stands use hydraulic or pneumatic clamping mechanisms to securely hold the rolls, ensuring smooth unwinding without slippage. The system also allows quick changeover between rolls, minimizing production downtime. Proper tension control is maintained to avoid paper breaks or jams. This setup leads to improved feed consistency, which is critical for downstream processes like corrugation and printing.
CM : What key parameters must KARUNYA control while forming a corrugated board?
SM : During corrugation, KARUNYA must carefully control several parameters such as the temperature of the heating elements, pressure between the corrugating rollers, and the speed of paper feeding. Correct heat levels ensure proper softening of the adhesive and paper to form well-defined flutes, while precise pressure guarantees strong bonding between the liner and medium papers. The speed must be synchronized to avoid flute deformation or tearing. Additionally, adhesive viscosity and application rate are monitored to maintain bonding quality. Any deviation in these factors can affect board strength and durability.
CM : How does KARUNYA ensure accuracy when cutting sheets to size?
SM : KARUNYA uses automated sheet cutting machines equipped with servo motors or mechanical drives that provide precise control over cutting length and speed. Operators input desired dimensions through control panels, and sensors verify sheet position for consistent cuts. The blades are regularly maintained and adjusted to prevent misalignment or dullness, which could cause uneven edges or material waste. The cutting system can adjust dynamically to different board thicknesses and flute sizes, ensuring high accuracy. This automation reduces manual errors and increases throughput in sheet preparation.
CM : How should KARUNYA respond to issues with wave patterns in board production?
SM : Wave patterns or irregular flutes during board production usually indicate problems with the corrugation process. KARUNYA technicians first inspect the flute rollers for wear or damage that could distort the paper medium. Next, they check the temperature uniformity across heating elements to ensure even softening of paper. Adhesive application is also examined, as uneven glue spread can cause flute collapse or weak bonding. Adjustments to roller pressure and feed speed may be necessary to restore flute regularity. Timely troubleshooting helps maintain board quality and reduces scrap rates.
CM : How does KARUNYA maintain precision while creating fold lines on packaging sheets?
SM : KARUNYA uses scoring machines equipped with thin, sharp blades to create fold lines that enable easy and precise folding of packaging sheets. The scoring blades are regularly checked and replaced when worn to prevent cracking or tearing of the board. Pneumatic systems allow precise adjustment of blade pressure and depth according to board thickness and flute profile. Proper scoring ensures that folding lines are clean, which is essential for producing boxes with sharp, professional edges. Consistent scoring reduces defects and improves assembly efficiency.
CM : What issues can arise at KARUNYA during the bonding and pressing of multilayer boards?
SM : During bonding and pressing, KARUNYA may face issues like uneven pressure application or insufficient adhesive curing, leading to delamination or air pockets within the board layers. Improper pressure settings can cause warping or inconsistent thickness, affecting box strength. KARUNYA addresses this by using hydraulic presses with adjustable force control to ensure uniform pressure distribution. Temperature control within the press is also critical to properly cure the adhesive. Regular monitoring and calibration of these parameters guarantee strong, flat, and defect-free boards.
CM : How does KARUNYA adjust cutting tools for clean slotting across various board types?
SM : To achieve clean slots in different board types, KARUNYA adjusts die clearance—the gap between the cutting blades and the die—to match board thickness and flute profiles. Correct die clearance prevents tearing or crushing of the board edges during slotting, ensuring smooth fold lines. The blades are sharpened regularly, and their position can be fine-tuned pneumatically or mechanically. These adjustments maintain consistent slot quality and reduce rework or waste. Operators monitor slot quality closely, especially when switching between single-wall and double-wall boards.
CM : How does KARUNYA ensure consistent glue application at maximum production speed?
SM : KARUNYA employs automated gluing systems that precisely control adhesive flow rate and pressure using sensors and pumps. The glue viscosity is maintained within optimal ranges by temperature control to prevent clogging or dripping. Hot-melt or cold glue types are selected based on box material and speed requirements. Nozzles are regularly cleaned and aligned for even coverage on flaps. This system ensures that despite high line speeds, glue application remains uniform, avoiding weak joints or glue overflow.
CM : What adjustments are needed at KARUNYA when producing packaging dividers in varying sizes?
SM : When switching between different divider sizes, KARUNYA adjusts blade positions and slotting depths on partition slotter machines. Feed rates and blade pressures are calibrated to ensure clean cuts without crushing the board. Operators also verify that the dimensions match customer specifications and that the slots allow for easy assembly inside boxes. Regular blade maintenance ensures sharpness, and pneumatic systems help maintain consistent pressure across varying material thicknesses. These adjustments maintain production flexibility without sacrificing quality.
