January 22, 2026
Valmet IQ solves an eternal corrugator warping issue
“By automatically controlling IQ Moisturizer and preheater wrap arms, the system ensures sheet flatness 24/7, with Valmet’s IQ Moisturizer system, we now have full potential to fight against the warp challenges we experienced in the past but could not control, such as S-warp and edge warp. Compared with other solutions on the market, Valmet’s system has huge advantages that are beneficial for our quality,” says Ivo Basmadzhiev, Quality Specialist at Dunapack Rodina.Warp challenges caused too much waste
The target was to eliminate the existing challenges with warping, improve quality, decrease waste and increase the productivity of both internal customers within our company and external customers. “A reference visit and Valmet’s system development fully convinced us of the functionality of the IQ Quality Control System for corrugators,” Basmadzhiev recalls. Valmet supplied a Valmet IQ Warp control system for a corrugator to Dunapack Rodina. The delivery included a Valmet IQ Moisturizer, and an intelligent Valmet IQ Warp Control, which automatically controls the moisturizer and preheater wrap arms to ensure sheet flatness, even on the edges. Boxes are now being made of lighter-weight board, production speeds are increasing, and production batches are smaller, resulting in more grade changes for a corrugator. The Valmet IQ Quality Control System now complements the existing temperature-based process control system. It eliminates the warp issues caused by moisture imbalances and CD profile challenges that have been impossible to correct without it.
Better quality, less waste, higher sustainability
“We were like partners, not like a customer and a supplier. This actually made the project successful for better quality, less waste and higher productivity for internal and external customers,” according to Basmadzhiev. Thanks to better moisture control and sheet quality, there has been a clear drop in waste. Basmadzhiev adds, “Waste is something that we always want to decrease. At the same time, increasing the performance of the converting machines is also very important.” He goes on to mention more benefits: “Now, sustainable production and raw material savings are more important than ever. Traceability is increasing in importance as well. With the IQ system, we can easily track the production performance of different board grades and even predict the behavior of papers involved in the combinations. This actually gives us a chance to optimize our portfolio.”
