Method and system for producing corrugated material

A method for producing corrugated material comprising the steps of:

• forming a first single-faced web of corrugated material having a first edge and a spaced apart second edge;
• conveying the first single-faced web along a first track and through a clamp;
• providing a first air stream to convey a portion of the first single-faced web off the first track and towards a double backer;
• engaging the portion with the double backer, whereby the double backer pulls the first single-faced web therein and begins producing a first corrugated material therewith;
• applying a cut through the first edge of the single-faced web to form a cut portion of the first single-faced web;
• moving the clamp from an open position to a closed position to prevent the first single-faced web from passing therethrough;
• pulling the generally immobile first single-faced web into the double backer whereby the first single-faced web separates completely from the first edge to the second edge and generally proximate the cut portion;
• forming a second single-faced web of corrugated material having first edge and a spaced apart second edge;
• conveying the second single-faced web along a second track;
• providing a second air stream to convey a portion of the second single-faced web off the second track and towards the double backer;
• and
• engaging the portion with the double backer, whereby the double backer pulls the second single-faced web therein and begins producing a second corrugated material therewith.

A method of changing flute sizes in a corrugation process comprising the steps of:

• forming a first single-faced web of corrugated material having a first flute size;
• conveying the first single-faced web along a first track and into a double backer to form a first corrugated material having the first flute size;
• applying a cut to the first single-faced web to form a cut portion of the first single-faced web;
• stopping conveying the first single-faced web along the first track;
• increasing tension on the first single-faced web, whereby the first single-faced web separates into a first portion and a second portion, and generally proximate the cut portion;
• passing the second portion through the double backer;
• maintaining the first portion on the first track;
• forming a second single-faced web of corrugated material having a second flute size, whereby the second flute size is different from the first flute size;
• conveying the second single-faced web along a second track;
• providing an air stream to convey the second single-faced web off the second track and towards the double backer;
• and
• engaging the second single-faced web with the double backer, whereby the double backer pulls the second single-faced web therein and begins producing a second corrugated material having the second flute size.