With the establishment of its facility in Goch, Germany, TRICOR Packaging & Logistics AG has invested in one of the most advanced corrugators in Europe. The result is a production line that combines high speeds, stable processes, and exceptional flexibility – designed for the production of singlewall, doublewall, and triplewall corrugated board, while also being prepared for future requirements such as digital-print-driven packaging solutions.
The Challenge
With several locations across Germany, Tricor is one of the established players in the corrugated industry. For its Goch project, the company chose a true greenfield approach, building the facility entirely from the ground up.
This provided the opportunity to develop corrugated board production from the outset around the requirements of modern markets. The objective was to create a fully integrated manufacturing operation designed not only to meet current performance and quality standards but also to accommodate future developments, such as customised packaging enabled by digital printing.
“Our investment in Goch is a clear step forward. We are creating a production site that combines maximum performance with the flexibility we need, while providing long-term strategic security,” says Philipp Kosloh, Chairman of the Board, Tricor Packaging & Logistics AG
Against a backdrop of growing demands for productivity, flexibility, and sustainability, two priorities were at the forefront: the reliable production of demanding double-wall and triple-wall board grades, and the flexible processing of a wide range of paper qualities.
The objective was clearly defined: a corrugator designed without compromise for maximum performance, stable processes, and long-term future viability – while offering the flexibility to integrate future technological developments.
The Solution
Together with BHS Corrugated, a future-oriented corrugator was implemented at the Goch facility, consistently engineered for performance, flexibility, and long-term expandability.
At the heart of the installation is a high-performance corrugator featuring a 2.8m working width and a design speed of 450 m/min. It delivers consistently high production output while maintaining stable operation even under demanding production conditions.
A key focus was the reliable production of doublewall and triplewall corrugated board. For this reason, both the wet-end and the dry-end were designed in a triplex configuration. Equipped with three Single Facers and three stacking chambers the corrugator achieves maximum process versatility while maintaining exceptional process stability – a critical factor in ensuring consistent board quality across all grades and formats.
The three installed Modul Facer® MF-A with belt technology provide the flexibility required for daily operations. They enable the processing of a broad range of paper grades – from lightweight papers to heavyweight liners – while maintaining highly stable production conditions.
The corrugator concept is further enhanced by a Double Dual Boost System, which delivers significant advantages at high production speeds, particularly when manufacturing complex double-wall and triple-wall board combinations. This ensures reliable operation even at maximum production rates.
“Goch demonstrates what is possible when corrugator design, automation, and operating concepts are aligned from the outset: a production system that not only achieves the required output but consistently maintains it over the long term,” adds Lars Engel, Managing Director, BHS Corrugated.
The corrugator was designed from the beginning to accommodate future expansions, particularly in the area of digital printing. As a result, the Goch facility was conceived as more than a traditional corrugated board plant and already reflects the growing importance of customized packaging solutions.
Digitalization and Future Readiness
In addition to its technical performance capabilities, the corrugator was designed for the comprehensive integration of digital systems. At the center of this approach is the interaction of various higher-level systems that support and continuously optimize production processes in real time.
One key element is the BHS Corrugated AutoPilot. Process parameters are continuously monitored and automatically adjusted to maintain production at optimal levels. This enables highly reproducible, fully automated production, reduces manual intervention, and ensures consistently high corrugated board quality.
The plant also utilises BHS Resource Monitoring, providing transparency regarding key utility consumption figures. Steam, compressed air, and electricity usage are recorded, centrally visualised, and systematically analysed, forming the basis for efficiency improvements and structured energy management.
At the same time, the corrugator has already been prepared for the future integration of the BHS Jetliner Monochrome (MCP) digital printing solution. This allows Tricor to proactively address trends such as customised packaging, shorter product lifecycles, and smaller production runs.
The Operating Concept
Another key contributor to the success of the project is the operating concept implemented at the Goch site. Here, Tricor relies on a close partnership with BHS Corrugated through the M2P® – From Maintenance to Productivity program.
The concept is based on an expanded understanding of maintenance. The goal is not only to ensure high machine availability but also to continuously increase the productivity of the entire corrugator.
The underlying full-service maintenance model combines traditional service activities with data-driven analysis and a clear focus on sustainable operational performance. Key elements include:
- Comprehensive full-service maintenance with clearly defined performance targets;
- Continuous analysis of operating and process data;
- Close integration of service, production, and technological expertise.
This approach is implemented through the permanent on-site presence of qualified specialists who are actively integrated into operations and able to implement improvements immediately. As a result, the corrugator is not merely operated – it is systematically developed toward maximum productivity.
The Results
With the successful completion of the greenfield project, Tricor has established a manufacturing operation in Goch that is fully aligned with the requirements of modern markets.
The success story of Tricor Goch demonstrates how a consistently executed greenfield strategy, combined with the targeted integration of technology, digitalization, and an innovative operating concept, can create sustainable competitive advantages.
Together with BHS Corrugated, Tricor has established a corrugated board production facility that not only meets today’s requirements but is also prepared to actively support future developments. By combining maximum production performance with long-term strategic readiness, the Goch facility is ideally positioned to maintain a leading role in modern corrugated board manufacturing for years to come.
