MHI-MS Develops AI-Based Corrugated Board Warp Control System for Global Markets

Mitsubishi Heavy Industries Machinery Systems, Ltd. (MHI-MS), part of the Mitsubishi Heavy Industries (MHI) Group, has developed and commercialized an artificial intelligence-based system designed to control warping in corrugated board during manufacturing. The company plans to launch full-scale sales of the system in Japan and international markets.

The system uses AI predictive models to determine optimal corrugating machine settings for different paper types, addressing warping caused by moisture imbalances between the inner and outer paper liners. It can be integrated into MHI-MS corrugating machines used in corrugated board production.

The control unit consists of sensors that measure board warping, temperature and moisture content, an AI-powered computer and a machine control system. It continuously collects production data for individual paper types and uses AI training to identify appropriate machine settings.

Traditionally, corrugated board production involves bonding three layers: the outer liner, inner liner and corrugated fluting medium. The material is then dried at high temperatures. Since standard machine settings can cause warping with different paper types, experienced operators have typically relied on their knowledge and judgement to adjust production parameters.

However, the retirement of skilled operators and labour shortages have made it increasingly difficult for manufacturers to retain and transfer this expertise.

The need for more adaptable production systems has also grown alongside demand for varied cardboard box formats and small-lot manufacturing in Japan. Conventional warp control systems can struggle to respond quickly to changing production requirements, potentially causing fluctuations in board warping.

Warped corrugated board can jam in box-making machines, affecting product quality and manufacturing productivity.

MHI-MS developed the system by combining its existing corrugated board warp control technology with AI technology from MHI's Research & Innovation Center. According to the company, the system can predict optimal machine settings for each paper type and enable warp-free production from the initial run of each lot.

The technology is intended to support manufacturers producing a wider variety of cardboard boxes and handling smaller production runs while reducing reliance on operators' experience for machine adjustments.