Rivet-Free Metal Structured Packing Production Line

Metal Structured Packing Automatic Production Line

Metallurgical Bonding · MFDC Fusion Welding · Full-Line Automation

🔹 Overview

KABORY provides a complete, fully automated structured packing production line that replaces punching + riveting with MFDC (Medium Frequency Direct Current) fusion welding.
Decoiling → High-Speed Punching → Embossing → Corrugation → Cutting → MFDC Welding.
The entire line runs under one PLC with servo-linked timing, automatic start-stop interlocks, and digital recipes.

Key Advantages  of Metal Structured Packing Welding Machine

• No holes, no rivets → no corrosion initiation, no stress concentration

• MFDC fusion → ≈1 s/weld; uniform metallurgical bonding

• Full-line servo synchronization → predictable, repeatable output

• Only 4 operators for the entire line → >50% labor reduction

• Full weld traceability → current / pressure / time / displacement recorded

🔹 Why Change to Rivet-Free Metal Structured Packing Welding Machine

Riveted modules became the historic standard for their low entry barrier. But riveting is a mechanical fastener, not an integrated structure. It introduces:

• Stress & corrosion origins at rivet holes

• Loosening under vibration/thermal cycling

• Metal debris from punching/riveting

• Operator-dependent accuracy and throughput

As plants pursue longer run cycles, fewer shutdowns, and auditable QA, rivet-based assembly has reached its performance ceiling.

Shift: From mechanical fastening → to metallurgical bonding.

⚙️ 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.”

🔹 System Modules & Technical Parameters

1️⃣ Decoiler & Servo Feeder

Responsible for automatic coil unwinding, alignment, and constant-tension feeding of stainless-steel strip.
Servo closed-loop tension control ensures the strip enters the punching and forming sections centered, stable, and free of vibration or skew.
The dual-station coil setup supports non-stop coil replacement, enabling continuous production for long-run manufacturing.

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

Optional

• Automatic edge guiding system

• Anti-scratch roller treatment (for 316L / polished surfaces)

• Coil loading trolley

2️⃣ High-Speed Punching Press

A 45-ton high-precision punching press used for perforating metal structured packing sheets.
The machine adopts a one-piece steel frame to minimize vibration during high-speed operation, ensuring stable punch accuracy and extended die service life.
Integrated with servo strip feeder and progressive tooling, it achieves ±0.02 mm positioning accuracy for continuous production.
Equipped with an automatic chip removal and cooling system to support long-duration, high-duty operation.

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

Control & Integration

• Linked servo feeding ensures synchronized stroke timing

• Automatic chip removal + coolant circulation for tool life and thermal stability

• Suitable for continuous high-volume perforation processing

3️⃣ Embossing Machine

Used to form the characteristic surface micro-texture on metal structured packing sheets.
The embossing rollers adopt a helical micro-pattern, improving surface wettability, promoting liquid film distribution, and increasing panel rigidity for more stable corrugation forming.
The unit is equipped with frequency converter speed control and automatic start/stop logic, synchronized with the punching press to ensure stable continuous operation.

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

Control & Synchronization

• Automatic start when the punching press is active

• Stops synchronously when upstream operation pauses

• Ensures consistent embossing profile across continuous processing

4️⃣ Corrugation Forming Press 

Used to form the embossed strip into a continuous corrugated profile, which is the core structure of metal structured packing.
Corrugation height ranges 6–12 mm with 30° / 45° corrugation angles.
All forming dies are vacuum heat-treated, ensuring dimensional stability, uniform wave geometry, and long tool life.
The forming press is PLC-synchronized with upstream punching and embossing sections, and supports frequency-controlled speed adjustment for continuous production.

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

Process Characteristics

• Continuous wave geometry ensures flatness and consistency for downstream cutting and welding

• Vacuum heat-treated dies maintain precision during long-duration operation

• Forming parameters are controlled through PLC for repeatability and stable production

5️⃣ Structured Packing Cutting Machine

Used for automatic length cutting of corrugated sheets according to tower diameter and module height.
The unit is servo-driven and equipped with photoelectric detection, ensuring stable and consistent feeding.
The system automatically recognizes corrugation direction and performs X/Y alternating cutting, enabling proper stacking alignment for module assembly.
Can be directly linked with the welding machine to achieve fully unmanned continuous 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

Process Integration

• Linked operation with welding unit for continuous production

• Automatic corrugation orientation detection ensures correct X/Y alternating stacking

• Stable cutting accuracy supports precise assembly and weld alignment

6️⃣ Automatic Structured Packing Welding Machine

Metal Structured Packing Welding Machine (MFDC Resistance Welding)

This unit is the core process module of the production line, designed to replace traditional punching and riveting.
It applies MFDC (Medium Frequency Direct Current) resistance welding, forming a metallurgical fusion bond between adjacent corrugated sheets.

Operators simply stack corrugated sheets in alternating orientation (one up / one down);
the system automatically performs positioning, clamping, and welding, with ≈1 second per weld cycle time.

Since the process requires no holes and no rivets, it eliminates residual stress points, prevents crevice and edge corrosion, and increases joint integrity.
Typical structural strength improvement is approximately 30%, compared with riveted assemblies.

All welding parameters — current, force, and time — are monitored, recorded, and traceable to ensure consistent weld quality across shifts and batches.

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

Process Features

• ✅No punched holes, no rivets, no metal debris

• ✅Smooth weld surface with minimal heat-affected zone

• ✅Metallurgical bonding → improved structural stability

• ✅Welding records stored and traceable for quality auditing

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.