A full chamber retrofit on a corrugated flexo folder gluer with zero site visits

Project summary: Full remote retrofit on TCY corrugated flexo folder gluer

A corrugated board producer in the Middle East was running a TCY 6PA-FG flexo folder gluer with three-color inline printing at 2,800 mm print width. The existing chamber systems had failed beyond repair, with chronic sealing problems causing constant ink leakage and excessive manual cleaning effort. Replacing the chambers through the original equipment manufacturer was not a viable path – the investment required simply didn't align with the economics of the existing press.

AkeBoose delivered a full retrofit with the NOVA TK chamber system entirely remote: measurement, engineering, and installation guidance were all handled without a single site visit. After a successful single-unit trial on one print station, the customer converted all three units. The result is a modern, leak-free chamber doctor blade setup at minimal cost and without operational disruption.

Initial Situation / Challenge

A corrugated producer in the Middle East was facing a familiar but pressing problem: their existing chamber doctor blade systems on a TCY 6PA-FG flexo folder gluer had reached the end of their service life. The seals had never performed reliably: chronic leakage meant ink in the press constant manual cleaning, and unplanned downtime. With three-color inline printing across a 2,800 mm print width running on water-based ink, a poorly functioning chamber system was a direct hit to productivity.

Replacing through the original equipment manufacturer was explored and quickly ruled out. OEM parts came at a price that simply didn't justify the investment for aging equipment. The customer needed a better solution – and a more practical path to get there.

Approach & requirements

The process made this project rather unusual: AkeBoose completed the entire retrofit without ever setting foot on-site.

The customer was guided remotely through the exact measurement procedure required to engineer a precise fit for their press. AkeBoose reviewed and verified the measurements, then engineered the NOVA TK chamber systems to spec. When the systems arrived, installation was carried out by the customer's own team and supported step by step through remote instruction from AkeBoose.

To reduce risk and build confidence, the project started with a single-unit trial on one print station. The results spoke clearly. The remaining two print stations were converted shortly after.

The NOVA TK all-in-one chamber was central to making this remote approach work. It's all-in-one design with no moving parts and a reliable end seal setup is built for straightforward installation and daily handling.  A more complex system would have required hands-on support. The NOVA TK didn't.

Outcome

The plant now runs three NOVA TK chamber systems on a press that previously struggled with leakage and high maintenance demands. Ink containment is reliable, cleaning effort has dropped significantly, and the operation has a modern chamber doctor blade setup that will serve them for years – achieved at a fraction of what OEM replacement would have cost.

For AkeBoose, this project proved something important: with the right product design and the right engineering support, a full chamber retrofit can be delivered entirely remotely – without compromise on quality or fit.