A method and system for automatically changing the flute size in a corrugation process without stopping or slowing the overall corrugation process utilizing a first single-faced web having a first flute size and a second single-faced web having a second flute size. The first single-faced web is conveyed along a track into a double backer forming a first corrugated material. When a flute change sequence is initiated, the single-faced web is cut using a pressurized stream of water such that the single-faced web disengages with the double backer. Generally simultaneously, the second single-faced web is introduced into the double backer using an air jet, wherein a second corrugated material is formed.