Lamination
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The outer cardboard prepared in offset printing is laminated by gluing it to the corrugated layer. Lamination, also known as coating, is skillfully produced in special lamination machines without damaging the cardboard and corrugated layer. The adhesive ratios to be used are very important. In the lamination performance test, the product's complete adhesion, dryness level, adhesion hardness, drying speed, and strength are examined. It is very important that the values are ideal.

ATEŞLER AMBALAJ uses DLG Fully Automatic Coating Machines capable of laminating at dimensions of 110x145 cm and 148x148 cm in its machinery park.

Products that have undergone lamination must be left to rest for one day. Products are left to rest, taking into account the order delivery dates.

Cutting​​​​​​

ATEŞLER AMBALAJ has extensive experience in cardboard packaging manufacturing and is well versed in all quality factors that need to be considered in the cutting department. The cutting department is a critical stage in the manufacturing of boxes. The details that need to be considered here are production details that affect the ease and speed of use of the box by our customers. Our machines undergo precise calibration for each individual design before the box is cut. The blade cut is ensured to be made precisely and accurately at the correct locations, in line with the design on the cardboard from the offset printing process. Punching is the process of creating marks on the folding lines, with the depth adjusted according to the thickness of the cardboard during the cutting process. The crease lines must be applied at the correct depth and precisely at the correct points. Otherwise, issues will arise in the subsequent gluing and folding machines, and even the slightest error could result in the entire production being wasted. Additionally, the processing speeds of customers who manually fold or use automatic packaging box machines will be affected. These errors, which would cause processing speeds to drop by half both within ATEŞLER AMBALAJ and at our customers' facilities, are prevented through careful inspections by our cutting specialists.

Following initial inspections, the cutting of orders is performed in series on our BOBST, BFK, and MIRAE-branded machines, ensuring the proper positioning of the blade plate within the machine and the suitability of the cutting specifications.

Folding and Gluing​​​​​​

ATEŞLER AMBALAJ will subject the boxes to a final process on folding and gluing machines according to the cutting and shape specifications on the box and our customers' usage information. Operations are carried out using Omega 130, Omega 145 4-6 point side and bottom gluing machines, Lamine 2000 double gluing machine, Uğur automatic sewing machine, Uğur manual sewing machine, and acetate window machine.

Different boxes have different gluing and folding properties. Boxes that will not be glued and will be closed manually are designed according to the locking system; the American interlocking locking system is an example. Other boxes with gluing properties are suitable for automatic and fast use and are named as side gluing, side-bottom gluing, four-point gluing, six-point gluing, and stitched boxes.

If there is a cellophane coating, embossing, or acetate window adhesive, the folding properties of the flaps and lids, as well as the surfaces to be adhesive, are considered when preparing the machine. The sample box is examined by folding experts, and the folding sequence on the machine is determined, with the adhesive points adjusted, to prepare the machine operation sequence. It is very important to prevent errors in advance. The process of completing the machine settings by conducting trials at a slow speed is a time-consuming process that can be significant depending on the detailed characteristics of the box. In order to plan the correct timing for all orders to be processed on the machines, it is necessary to take into account these preparation times for each machine.

During the preparation phase, fold locations and foldability, bursting properties, adhesion errors, and collapse errors are checked. Selecting the appropriate adhesive for bonding and side folding processes based on the type of UV varnish, dispersion varnish, or cellophane coating on the box is a critical detail. This ensures flawless adhesion. Continuous quality control at multiple points during production ensures consistent quality throughout the production process, which is then completed.

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Packaging and Shipping
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Products that have undergone folding and gluing processes on the production line undergo final testing before packaging. Products that pass tests in our quality control department based on paper quality, strength, moisture, shape, color, and other characteristics are approved and ready for shipment.

Depending on the customer's usage needs, products are packaged in boxes or grouped in quantities using plastic straps, wrapped in stretch film on pallets, and are ready for shipment. Factors such as space utilization, moisture protection, contamination prevention, use without dispersion, labeling, and the need for corner tape support on pallets have been taken into consideration.

Logistics planning is carried out and shipped, taking into account the shipping date and urgency status approved by the customer in the order.