Robatech redesigns PerfectFold to attack fishtailing and folding variation in corrugated boxes

The last millimeter matters

In the corrugated industry, a bitter truth haunts every box plant: a carton can be perfectly printed, flawlessly die-cut, and still end up in the reject pile if the final fold fails. Gap-width deviation and fishtailing during automatic folding remain persistent headaches, especially as automated erecting lines demand tighter tolerances. To address this critical bottleneck, Swiss manufacturer Robatech has rolled out the second generation of its PerfectFold liquid creasing system.

Originally introduced to the market in 2023, the technology relies on applying a specialized fluid to the fold lines, temporarily reducing the board's stiffness and neutralizing the restoring forces that cause fold breakage and misalignment. Now, in late 2026, Robatech has overhauled the system's architecture to meet the rigorous demands of modern converting lines.

Upgraded architecture and Sirius integration

The most significant upgrade in this second iteration is the integration of the new Sirius control system, which Robatech introduced earlier this year. This addition provides converters with enhanced connectivity and more precise pattern control at high production speeds. Beyond the software and control layer, the physical hardware has been completely redesigned. The new housing offers superior protection for internal components against the abrasive dust typical of corrugated environments, while simultaneously simplifying maintenance access for operators.

By attacking the physical resistance of the corrugated board right before the folding section, the system allows folder-gluers and inliners to run at higher speeds without sacrificing the internal dimensions of the box. This is particularly crucial for double-wall board and complex packaging designs where inserts must fit with zero margin for error.

The evolution of PerfectFold demonstrates that the converting sector is finally treating the folding process with the same technological rigor as printing or die-cutting, moving away from brute mechanical force toward smart material conditioning. Will liquid creasing eventually become a standard requirement for all high-speed folder-gluers handling heavy-duty corrugated board? Follow The Paper for daily news, market signals and key updates from the global paper, corrugated and packaging industry. — Sigue toda la actualidad del sector en www.thepaper.ai