Metal Structured Packing Production Line

Metal Structured Packing Production Line | Structured Packing Welding Machine Supplier

Introduction

Metal structured packing is a critical mass transfer element in petrochemical, fine chemical, and environmental industries. Its manufacturing process directly determines the efficiency and reliability of industrial columns.
Traditional manual welding, where each sheet is welded individually, not only results in low efficiency but also causes rough surfaces, irregular dimensions, and unstable quality.

We have broken through these limitations. With our advanced automated welding technology and complete production line solution, we achieve a seamless process from raw material to finished product. The entire line requires only 4 operators, completing what once required dozens of workers, truly realizing high efficiency, low labor demand, and consistent batch production.

From Manual to Automated — The Next Generation

For decades, structured packing manufacturing relied heavily on manual welding. This method is inefficient and fails to guarantee consistent quality. With increasing demand for high-performance and large-scale capacity, manual production can no longer meet modern industry requirements.

Our automated welding machines represent a major leap forward — offering higher precision, faster speed, and stable long-term consistency. Looking ahead, the next step is fully automated production. We are also the only global supplier capable of delivering a complete end-to-end structured packing production line.

Advantages of Automated Welding

• Batch Continuous Welding: Multiple sheets welded in one flow, far faster than manual.
• High Consistency: Smooth weld seams, precise alignment, and uniform block dimensions.
• Industrial Capacity: Effective welding size up to 2000 mm (L) × 500 mm (W) × 200 mm (H) for large packing modules.
• Stable Output: Reduced reliance on operator skill, minimizing defects and ensuring batch repeatability.

Next Generation — Fully Automated Production Line

• End-to-End Automation: From coil feeding, corrugation forming, cutting, and alignment to welding, all completed automatically.
• Significant Efficiency Increase: Much higher output than standalone welding machines.
• Scalable & Flexible: Capable of producing different sizes, angles, and specifications.
• Lower Labor, Higher ROI: Reduced manpower requirements while maximizing productivity.

Complete Line Configuration & Labor Advantage

Our structured packing production line consists of:

• Decoiler — automatic coil feeding for continuous operation.
• High-Speed Punching Machine — rapid corrugation forming.
• Embossing Machine — precise pattern embossing for surface quality and consistency.
• Shearing Machine — high-accuracy cutting to exact lengths.
• Dedicated Welding Machine — block welding with smooth surfaces and strong bonding strength.

Only 4 operators are required for the entire line, compared to dozens needed in traditional workshops. This not only reduces labor costs significantly but also ensures higher productivity and stable quality.

Applications

• Petrochemical: Distillation, olefin separation, hydrogenation units; high efficiency under low pressure drop.
• Fine Chemical: High-purity solvent separation and recovery; stable tower efficiency.
• Pharmaceutical & Fragrance: Small liquid loads, high separation efficiency under vacuum conditions.
• Environmental: VOC and solvent recovery, tail-gas absorption/desorption; lower emissions and cost savings.
• Special Separations: Isotope separation (e.g., hydrogen/oxygen isotopes) and R&D-grade processes requiring extreme precision.

Why Choose Us

• Complete Line, One Supplier: Decoiler → Punching → Embossing → Shearing → Welding, fully integrated, only 4 operators.
• Efficiency Beyond Manual: Continuous welding, smooth seams, neat alignment, fewer defects.
• Industrial-Grade Specs: Effective welding size 2000 × 500 × 200 mm, supporting large modules.
• Comprehensive Coverage: Both corrugated plate structured packing (>70% market use) and wire gauze structured packing (high-end applications).
• Consistency & Traceability: Servo-driven systems with process data records ensure compliance and quality audits.
• Global Exclusivity: The only end-to-end structured packing solution provider worldwide.

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.

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