Inline flexo printing for corrugated PP Sheets (Twinwall Polypropylene)

The large-format printing system engineered to mark rigid and corrugated sheets directly on the extrusion line.

Modular™ 935 by Giugni® is a flexographic printing unit engineered to address one of the most critical challenges in plastic extrusion: direct printing on corrugated Polypropylene (PP) sheets (also known as Hollow Profile Sheet or Correx).

Unlike flexible films, twinwall sheets feature an internal rib structure that results in an uneven surface and makes the material sensitive to crushing. Modular™ 935 employs a calibrated pressure technology (“kiss impression”) that allows the printing plate to gently conform to the sheet’s “valleys” and “peaks,” ensuring uniform ink transfer without compromising the rigid structure of the substrate.

With an outstanding print width of up to 2500 mm, this 2-color machine is installed directly on the extrusion line, upstream of the cutting unit. It is the ideal solution for applying large-format logos, brand markings, recycling instructions, and coding on panels intended for reusable packaging, construction, and signage, using environmentally friendly and safe water-based inks.

Key advantages for corrugated PP extrusion

• Wide web capability: Covers the full width of the extruded sheet (up to 2500 mm), enabling printing on complete panels.
• Structural integrity preservation: The controlled impression system prevents crushing of the internal chambers (cells) of the panel.
• Inline integration: Designed to operate at typical thick-sheet extrusion speeds (approx. 10 m/min), automating the decoration process.
• Inking system: Utilizes rubber-covered rollers for reliable and straightforward ink laydown, ideal for solid areas and sharp logos.
• Sustainability: Optimized for water-based flexographic inks (Flexo H₂O), reducing the environmental impact of the finished product.

Key applications

• Reusable packaging: Printing on layer pads and boxes made of twinwall polypropylene.
• Construction: Marking of protective and insulating panels.
• Visual communication: Base printing on sheets for signage applications.

“The term Twinwall Polypropylene is used on this website as a common name to indicate Corrugated polypropylene sheet.”