Corrugated packaging has become one of the most important forces in today’s global packaging industry. Once a simple solution for transport protection, it’s now a high-performance, brand-carrying, eco-conscious product in its own right. As demand for sustainable materials and automated production continues to grow, manufacturers are rethinking how packaging is produced—and the tools they use to do it.
The market for corrugated packaging, valued at $170 billion in 2020, is expected to reach more than $400 billion by 2027. This growth is being fuelled by the expansion of e-commerce, rising environmental standards, and ongoing shifts toward automation and factory efficiency. Corrugated boxes now account for almost 80% of e-commerce shipments, and the demand for stronger, faster, and smarter packaging machines has never been higher.
To meet these challenges, DGM developed the MegaFold Folder Gluer—a high-performance machine built to handle everything from lightweight carton board to heavy, multi-wall corrugated packaging. With speeds reaching up to 300 meters per minute and the flexibility to process a wide variety of box styles, MegaFold was designed not only to perform under pressure, but to evolve with the industry.
Its ability to form and glue thick, rigid corrugated structures is the result of deep R&D efforts. One of the main engineering challenges was achieving stable forming of heavy board at high speed without compromising squareness, folding accuracy, or glue performance. This led to major innovations in the feeder, register, folding, and press sections, as well as improved servo-motor controls that ensure smooth operation under load
MegaFold Folder Gluer is already being used in a variety of packaging segments, including:
• Milk cartons and food packaging
• Appliance and electronics boxes
• Fruit and produce trays
• E-commerce-ready shipping boxes
In real-world use, MegaFold has proven especially effective in full-line automation. For example, when combined with DGM’s Handle Applicator and Colt Bundling Machine, MegaFold becomes the heart of a complete packaging solution. This setup allows high-volume producers—such as dairy or beverage companies—to fold, glue, apply handles, and strap bundles without stopping the line or increasing labour. The result is a faster, cleaner, and more sustainable production flow.
The MegaFold Folder Gluer platform is also modular, offering a wide range of configurations and upgrade options:
• Plasma treatment systems for coated or laminated surfaces
• Grinding modules with dust extractors for UV or film-laminated board
• Scrolling sections for deeper scores on corrugated blanks
• Tape applicators for tear strips or double-sided tape
• Defective box ejectors, pneumatic folding units, and crushing rollers for added precision and versatility
For operations with high job repeatability, MegaFold is also available in a motorized version with memory functions, allowing operators to recall previous setups with a single touch. Combined with a user-friendly interface and remote diagnostics, this makes day-to-day operation both efficient and intuitive.
Since its market debut a decade ago, MegaFold has seen rapid adoption. Annual sales have increased by over 100–150%, as manufacturers around the world recognize the value of a system that combines speed, precision, and adaptability. It has become a go-to solution in industries looking to reduce waste, increase throughput, and shift toward automation—all while meeting the demands of heavier and more complex corrugated designs.
Customer feedback consistently highlights MegaFold’s stability, speed, and ease of integration into existing or new production lines. The machine’s reliability under pressure and ability to handle diverse formats makes it especially attractive for converters serving multiple sectors or adjusting to rapidly changing client demands.
In our latest video, we take you behind the scenes with the engineers who brought MegaFold to life. You’ll hear how they overcame the challenges of forming heavy corrugated structures, and you’ll see the machine in action—integrated into a fully automated milk carton production line. This is more than a demonstration. It’s a real look at the future of packaging production.
MegaFold Folder Gluer by DGM is where engineering, sustainability, and automation meet. It’s not just a solution for today—it’s a platform for what’s next in corrugated packaging.
Post time: Apr-02-2025