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Exilva WarpWarrior
Improve board flatness, reduce downtime and support efficient converting operations with Exilva® cellulose fibrils.
Exilva® WarpWarrior improves warp control
Warp is a critical factor in corrugated board performance, directly impacting converting efficiency, throughput, and final box quality. Downwarp, upwarp, or S-warp can lead to machine stoppages, reduced conversion speeds, increased waste, and customer complaints.
Exilva® WarpWarrior is an innovative, bio-based cellulose fibril technology that enables precise balancing of glue application and energy input. By controlling the moisture introduced through the adhesive, it makes it possible to actively manage warp formation.
The result is consistently flatter board, improved runnability, and more efficient downstream operations
Bio-based and eco-friendly
100% bio-based and biodegradable. Derived from natural cellulose, Exilva® supports more sustainable corrugating while improving board stability and converting performance.
Documented performance
Controls warp formation, improves board flatness, reduces converting stops, and supports more stable, high‑efficiency production.
Compliance
Meets key regulatory requirements, including food contact approvals, and is free from VOCs and hazardous substances.
Technical highlights
- Application: Drop-in, compatible with all starches and corrugating processes – with no CAPEX required and minimal disruption to operations.
- Appearance: White paste
- Mechanism: Exilva® forms a fibrillar network that stabilizes adhesive behavior and controls water distribution and penetration. This improves moisture balance across the board, reducing warp formation and enabling flatter, more dimensionally stable sheets throughout the process.
- How it works: It regulates adhesive penetration into the fluting and liner, materials that often vary in porosity, enabling improved moisture control in the outer liners.
Performance snapshot
| Parameter | With Exilva |
| Downtime | Up to 40% less downtime linked to board instability |
| Throughput in converting | Up to 20% higher converting speed on heavy grades |
| Board flatness | Flatter sheets with significantly reduced post-warp |
Commercial benefits supported by trials
REDUCED DOWNTIME AND STOPS
REDUCED DOWNTIME AND STOPS
Up to 40% reduction in downtime linked to warp and board instability in industrial trials.
HIGHER THROUGHPUT IN CONVERTING
Less warp-related instability keeps converting lines running and reduces costly interruptions.
LOWER WASTE AND FEWER CONVERTING DEFECTS
Reduced post-warp and improved board geometry help minimize rejects and rework.
MORE STABLE PRODUCTION ACROSS CONDITIONS
Consistent board flatness reduces operator intervention and supports predictable output.
These improvements translate directly into measurable value: lower material loss and reduced production costs, fewer converting disruptions and quality issues, higher yield, and improved operational efficiency.
Ultimately, better warp control enables corrugators to run more smoothly through both the corrugator and converting stages—reducing hidden costs while improving productivity, reliability, and overall plant performance.