Metal Structured Packing Automatic Production Line

Complete Turnkey System from Coil to Finished Module

Metal Structured Packing welding  machine  | Structured Packing Welding Machine Supplier

🔹 Overview

With over 10 years of R&D and production experience, KABORY is among the few Chinese manufacturers capable of delivering a complete metal structured packing automatic production line 
from Decoiling → High-Speed Punching → Embossing → Corrugation → Cutting → Automatic Welding.

The process includes:
Decoiling → Punching → Embossing → Corrugation → Cutting → MFDC Welding

The entire line operates under servo-synchronized control with automatic start-stop linkage, ensuring precise timing and full automation throughout the process.

Using MFDC (Medium Frequency Direct Current) Resistance Welding, the system achieves one-second welding speed, rivet-free connections, no metal debris, and no corrosion risk.

Compatible with SUS304, 316L, and 2205 stainless steels, this production line is widely applied in petrochemical, distillation, absorption, desulfurization, and decarbonization columns.

⚙️ Process Flow

One Line, One Supplier — From Coil to Finished Module

KABORY’s complete line covers every stage of structured packing production:
Decoiling → Punching → Embossing → Corrugation → Cutting → MFDC Welding.

Each module is designed and built in-house, ensuring perfect mechanical integration and synchronized control across all processes.
Only four operators are required to manage an entire production line — a true benchmark for efficiency and consistency.

“When all machines speak the same language — servo, PLC, and logic — productivity becomes predictable.”

1️⃣ Decoiler & Feeder

Responsible for automatic decoiling, alignment, and constant-tension feeding of stainless-steel coils.
Equipped with servo drive and tension control systems, ensuring stable, centered feeding.
A dual-station design enables coil replacement without stopping production.

Technical Parameters

Item	Specification
Strip Width	125–300 mm
Strip Thickness	0.10–0.30 mm
Max Coil Weight	800–2000 kg
Inner Diameter	508 mm
Outer Diameter	1200 mm
Max Speed	30 m/min
Voltage	AC 380V 50Hz (3-phase)
Expansion Type	Hydraulic
Servo Motor Power	4.4 kW
Decoiler Motor	2.2 kW
Operation	Touch-screen HMI interface

 

2️⃣ High-Speed Punching Press

A 45-ton high-precision press featuring an integrated steel frame for maximum stability and reduced vibration.
Combined with servo feeding and progressive die design, it achieves ±0.02 mm punching accuracy.
Automatic chip removal and cooling systems ensure consistent performance and longer die life.

Technical Parameters

Item	Specification
Nominal Force	45 Tons
Stroke	30 mm
Stroke Rate	100–150 spm
Table Size	750 × 550 mm
Punch Diameter	3–5 mm
Main Motor Power	15 kW
Machine Size	1575 × 950 × 2800 mm

3️⃣ Embossing Machine

Dedicated for creating spiral micro-pattern textures on the metal surface, improving wettability and structural rigidity.
Equipped with frequency converter speed control and auto start-stop logic — starts automatically when the punching press is running.
Embossing depth ranges from 0.05–0.15 mm, optimized for mass transfer performance.

Technical Parameters

Item	Specification
Roller Diameter	150 mm
Roller Length	260 mm
Embossing Depth	0.5–1.5 mm
Tooth Pattern	2.3 × 2.3 mm
Material Thickness	0.1–0.4 mm
Rolling Speed	30 m/min

4️⃣ Corrugation Forming Press 

Forms embossed strips into continuous corrugations.
Corrugation height: 6–12 mm; angles: 30° or 45°.
All dies are vacuum heat-treated for precision and long life.
PLC synchronization maintains forming accuracy and stable speed.

Technical Parameters

Item	Specification
Material Width	50–300 mm
Thickness Range	0.1–0.8 mm
Drawing Speed	0–50 m/min
Corrugation Angle	30° / 45°
Corrugation Model	200(yx)–1000(yx)
Stroke Rate	100–600 spm
Accuracy	±0.05 mm

5️⃣ Structured Packing & Cutting Machine

Performs automatic length cutting according to tower diameter and module height.
Servo-driven with photoelectric detection, cutting tolerance ≤ ±0.5 mm.
Automatically detects corrugation direction for alternating X/Y cutting.
Can be linked directly with the welding unit for fully unmanned production.

Technical Parameters

Item	Specification
Cutting Size	1200 × 200 × 50 mm
Cutting Accuracy	±1 mm
Max Length	2300 mm
Capacity	10–20 pcs/min
Air Pressure	0.3–0.6 MPa
Voltage	AC 380V 3-phase
Customization	Available on request

6️⃣ Automatic Structured Packing Welding Machine

The heart of the line — powered by MFDC Resistance Welding technology,
designed specifically to replace traditional riveting.
Operators simply stack corrugated sheets “one up, one down,” and the system automatically locates and welds each joint in just 1 second.

No holes. No rivets. No residue.
Each weld is smooth, strong, and corrosion-free — improving structural integrity by approximately 30%.
All welding data (current, pressure, time) are automatically recorded and traceable.

Technical Parameters

✅ No holes, no rivets, no residue.
✅ 30% higher structural strength.
✅ No corrosion at the weld zone.

Specification	Value
Effective Welding Size	2000 mm (L) × 500 mm (W) × 200 mm (H)
Welding Method	MFDC (Medium Frequency Direct Current) Resistance Welding
Cycle Time per Weld	≈ 1 second
Positioning Accuracy	± 0.5 mm
Operation Mode	Servo-controlled, automatic alignment
Material Compatibility	SUS304 / 316L / 2205 stainless steel
Control System	PLC with full data logging & traceability
Cooling System	Water-cooled tungsten-copper electrodes

Welding parameters (current, pressure, time) are digitally recorded for full traceability and quality control.

Learn more about our MFDC Welding System →

From Riveting to Rivet-Free Welding

The biggest transformation lies in the welding process.
Traditional riveting leaves holes, debris, and weak joints prone to corrosion and deformation.
KABORY’s MFDC (Medium Frequency Direct Current) Resistance Welding system eliminates these issues completely.

With one-second welding speed and 30% higher joint strength, every corrugated sheet is fused into a monolithic structure —
no rivets, no rework, no waste.

Result:
MFDC welding provides a cleaner, stronger, and faster connection, dramatically improving production efficiency and long-term reliability.

⚡ Key Advantages

• ⚙️ One-second MFDC welding — fast, clean, reliable

• 🔩 Rivet-free design — no holes, no corrosion risk

• 🤖 Automatic control system — synchronized operation with 1–2 operators

• 🧱 Stronger joints — 30% higher structural strength

• 🔧 Durable structure — minimal maintenance over 5+ years

• 🧰 Modular design — adaptable for various tower diameters

Applications

• Distillation and absorption columns

• Refining and petrochemical towers

• Desulfurization and decarbonization systems

• Fine chemical process equipment

• High-efficiency gas-liquid mass transfer systems

Why Choose KABORY

Complete Line, One Supplier
From Decoiling → Punching → Embossing → Corrugation → Cutting → Welding, every section of the structured packing production line is designed, built, and integrated by KABORY.
The entire system requires only four operators, with seamless connectivity and zero compatibility issues.

Efficiency Beyond Manual Operation
Compared with traditional manual assembly or riveting, our automatic line achieves continuous welding, perfect seam alignment, and minimal defects, ensuring both high efficiency and precision quality.

Industrial-Grade Specifications
The system supports welding sizes up to 2000 × 500 × 200 mm, meeting the requirements for large structured packing modules in industrial-scale distillation and absorption processes.

Comprehensive Coverage
Supports both corrugated plate structured packing (used in over 70% of global installations) and wire gauze structured packing for high-performance and laboratory-grade towers.

Consistency and Traceability
All servo-driven units operate under unified PLC control with complete data logging.
Every weld, feed cycle, and forming step is digitally recorded and traceable, ensuring compliance with international quality and audit standards.

Global Exclusivity
KABORY is currently the only manufacturer worldwide offering a complete end-to-end structured packing production line — covering raw material supply, forming, and automatic MFDC welding in one integrated system.

One-Stop Turnkey Solution

KABORY provides a complete one-stop manufacturing solution, not just standalone equipment.
We integrate every stage of structured packing production — from raw material supply to automated production and finished modules.

Our capabilities include:

• Supply of stainless-steel raw materials (SUS304 / 316L / 2205)

• Complete line equipment: punching, embossing, corrugation, cutting, welding

• Process parameter development and die design

• Final assembly, inspection, and technical support

All systems share unified PLC control and standardized process data, ensuring compatibility, easy maintenance, and fast commissioning.
KABORY delivers a true automatic turnkey intelligent production line, ready for immediate deployment.

Main Types of Structured Packing

Metal Corrugated Plate Structured Packing

• Market Share: The most widely used type, over 70% of global applications.
• Representative Models: Sulzer Mellapak, Koch Intalox Structured Packing (ISP).
• Features: High mass transfer efficiency, low pressure drop, cost-effective, materials include SS304, SS316L, and alloys.
• Applications: Petrochemical distillation, energy-saving retrofit columns, absorption/desorption towers, large-scale solvent recovery.

Wire Gauze Structured Packing

• Market Position: High-end use; indispensable where ultra-high separation efficiency is required.
• Market Share: Around 10–15%, but with much higher added value.
• Features: Large surface area, excellent efficiency, ideal for low liquid loads and vacuum operation.
• Applications: High-purity solvent separation, pharmaceutical & fragrance production, isotope separation.

Specifications (Structured Packing Models)

We supply a complete range of models from 125 to 700, covering different specific surface areas, corrugation heights, and angles to meet diverse tower design requirements.

Model	Surface Area (m²/m³)	Corrugation Height (mm)	Corrugation Pitch (mm)	Corrugation Angle
125Y	125	24.5 ± 1.2	42 ± 3.2	45° ± 2°
125X	125	24.5 ± 1.2	42 ± 3.2	30° ± 2°
150Y	150	20 ± 1	35.5 ± 2.5	45° ± 2°
150X	150	20 ± 1	35.5 ± 2.5	30° ± 2°
175Y	175	16.8 ± 0.8	30 ± 2.1	45° ± 2°
175X	175	16.8 ± 0.8	30 ± 2.1	30° ± 2°
200Y	200	14.5 ± 0.7	27 ± 2	45° ± 2°
200X	200	14.5 ± 0.7	27 ± 2	30° ± 2°
220Y	220	13 ± 0.6	24 ± 1.5	45° ± 2°
220X	220	13 ± 0.6	24 ± 1.5	30° ± 2°
250Y	250	11.5 ± 0.6	21.5 ± 1.5	45° ± 2°
250X	250	11.5 ± 0.6	21.5 ± 1.5	30° ± 2°
300Y	300	10 ± 0.5	18 ± 1.2	45° ± 2°
300X	300	10 ± 0.5	18 ± 1.2	30° ± 2°
350Y	350	8.2 ± 0.4	16 ± 1	45° ± 2°
350X	350	8.2 ± 0.4	16 ± 1	30° ± 2°
400Y	400	7.6 ± 0.4	12.4 ± 1	45° ± 2°
400X	400	7.6 ± 0.4	12.4 ± 1	30° ± 2°
450Y	450	6.8 ± 0.3	11.2 ± 0.8	45° ± 2°
450X	450	6.8 ± 0.3	11.2 ± 0.8	30° ± 2°
500Y	500	6.5 ± 0.3	10.2 ± 0.8	45° ± 2°
500X	500	6.5 ± 0.3	10.2 ± 0.8	30° ± 2°
700Y	700	4.3 ± 0.2	7.5 ± 0.6	45° ± 2°

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Call to Action

Looking for process design support or column retrofit solutions? Contact us today for sample matching, process evaluation, and ROI/energy consumption analysis.

Conclusion

With our world-leading structured packing production line, you gain not only high efficiency and reliable output, but also a decisive edge in global market competition. Whether in petrochemical, fine chemical, pharmaceutical, or environmental industries, we deliver tailored solutions to meet your needs.
Choosing us means choosing higher capacity, lower cost, and a more sustainable future.