Professional Documents
Culture Documents
INTRODUCTION
This manual is intended as a resource on starch, its relationship to, and use in corrugating. It is designed to make it easier to respond quickly and effectively to adhesive and machine problems. The information presented is based upon actual field and laboratory work. It should not be viewed as providing advice or solutions to particular applications, each of which is unique and not susceptible to general advice. We encourage you to call your representative at Corn Products U.S., CASCO, Inc., or CPIngredientes to discuss your specific situation. We will be happy to lend our support.
TABLE OF CONTENTS
Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 The History of Starch . . . . . . . . . . . . . . . . . . . . . . .3 The Corn Wet Milling Process . . . . . . . . . . . . . . . . .4 The Role of Corn . . . . . . . . . . . . . . . . . . . . . . . . . .6 Starch Basics for Corrugated Board . . . . . . . . . . . . .7 Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Low Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 High Viscosity (Thick, Heavy Adhesive) . . . . . . . . . .9 Effects of Shear on Viscosity . . . . . . . . . . . . . . . . . .9 The Temperature Viscosity Control System . . . . . . . .10 Viscosity/Time Relationship . . . . . . . . . . . . . . . . .11 Viscosity/Resin Relationship . . . . . . . . . . . . . . . . .11 Microbiological Degradation . . . . . . . . . . . . . . . . .11 Care with Biocides . . . . . . . . . . . . . . . . . . . . . . . .11 Gelatinization Temperature . . . . . . . . . . . . . . . . . . . .12 Gel Temperature Too High . . . . . . . . . . . . . . . . . . .12 Gel Temperature Too Low . . . . . . . . . . . . . . . . . . .12 Gel Temperature/Time Relationship . . . . . . . . . . . .12 Determination of Caustic Concentration In Liquid Caustic . . . . . . . . . . . . . . . . . . . . . .12 Corrugating Additives . . . . . . . . . . . . . . . . . . . . . . . .13 Penetrating Aids . . . . . . . . . . . . . . . . . . . . . . . . .13 Antifoam Agents . . . . . . . . . . . . . . . . . . . . . . . . .13 Liquid Additives . . . . . . . . . . . . . . . . . . . . . . . . .13 Resins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Corrugating Processes/Systems/Equipment . . . . . . . . . .15 Stein Hall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Jet Cook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 High Shear . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 No-Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Starch Properties and Testing . . . . . . . . . . . . . . . . . .17 Alkali (Caustic) Sensitivity . . . . . . . . . . . . . . . . . .17 Measuring Viscosity of Finished Starch Adhesive . . . . . . . . . . . . . . . . 17 Calibrating the Stein Hall Cup . . . . . . . . . . . . . . . .17 Gelatinization Temperature . . . . . . . . . . . . . . . . . .17 Microbiological Testing . . . . . . . . . . . . . . . . . . . . .17 Starch Solids Concentration . . . . . . . . . . . . . . . . .17 Board Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Quality Monitoring and Control at the Adhesive Station . . . . . . . . . . . . . . . . . . . . . .21 Statistical Process Control . . . . . . . . . . . . . . . . . .21 Troubleshooting Common Corrugating Problems . . . . . . . . . . . . . . . . . . . . . .23 Diagnosing Viscosity Problems . . . . . . . . . . . . . . . .23 Diagnosing Typical Gel Temperature Problems . . . . .26 Diagnosing Corrugating Equipment and Board Quality Problems . . . . . . . . . . . . . . . . . .27 Diagnosing Warp Problems . . . . . . . . . . . . . . . . . .31 Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Corporate Headquarters Corn Products U.S. 5 Westbrook Corporate Center Westchester, IL 60154 United States (800) 443-2746 www.cornproductsus.com
Toronto Casco, Inc. 401 The West Mall, 2nd Floor Etobicoke, Ontario M9C 5P7 Canada (416) 620-2300 (Toronto) (514) 694-4700 (Montreal/Eastern Canada) www.casco.ca
CPIngredientes, S.A. de C.V. Av. Mariano Otero #1249, Floor 9 Torre Atlantico Rinconada del Basque 44530 Guadalajara, Jalisco Mexico (33) 3884-9000 ext. 3520 www.cpimex.com
FARMING
Background
The History of Starch
The first uses of starch stretch back to the ancient Egyptians and Chinese. They were quite adept at using starches, a fact duly recorded in Catos Treatise written in 184 B.C. It was much later in Europe, however, that the industry flourished. The source of grain supply then was wheat and rice. As demand for starch increased, other raw materials, including potatoes, were tried. It was the English who brought the knowledge of producing starch to the New World, where, after the Revolutionary War, numerous small potato and wheat starch plants were operating in the eastern United States. However, the price of wheat and potatoes was rising to the point where profit margins were seriously endangered. The search for substitute raw materials resulted in Americas most abundant crop as the answer, and the first corn starch factory was built in 1844 in Jersey City, New Jersey. From that point on, the industry grew by leaps and bounds. In 1906, New York Glucose and the Glucose Trust merged into Corn Products Refining Company under the management of E.T. Bedford.
Steeping
Germ
Corn Oil
Steepwater
Germ Meal
Starch Separation
Corn Syrup
Gluten Feed
Starch Slurry
Syrup Refining
Industrial Starches
Starch Drying
Food Starches
Dextrose Family
smaller granules have reduced amounts of amylose, the linear molecule fraction in starch.2 Larger starch granules gelatinize more easily than small particles.3 It also is known that starches with lower gel temperature than entire high quantities of amylose yield much higher gelatinization temperatures than conventional corn starch. (See Figure 2.) When heated in water, native starch granules, regardless of molecular type, hydrate (absorb water), increase in size and thicken to form a viscous liquid, gel or paste. This single property is probably the most important characteristic of the starch and is relied upon to provide thickening. In the corrugating industry, this gelatinizing property of starch is encouraged by the addition of caustic soda and used effectively to suspend or carry pearl starch that has not been gelatinized.
FIGURE 2 Reported Gelatinization Temperatures of Conventional Corn Starch and High Amylose Starches
Identification of Starch Type
(Unmodified)
Conventional Corn
143F 158F 167F [61.7C] [70.0C] [75.0C] 153F 176F (Note) [67.2C] [80.0C]
Location B
147-165F [63.9-73.9C]
Note: Complete gelatinization of high-amylose starch is not affected in boiling water, 212F [100C]. It has been stated that high amylose requires pressure for complete gelatinization.
FIGURE 3
The Corrugating Process S. F. to bridge Open steam shower Greenline steam shower Medium preconditioning roll 250F [121.1C]
Bridge
236-266F [113.3-130.0C]
180-190F [82.2-87.8C]
370F [187.8C] Doctor roll Starch Dance roll Open steam shower
D. F. Line
Roll stan
Footnotes: 1. F.R. Earle, Protein and Oil in Corn: Variation by Crop Years from 1907 to 1972, Cereal Chem., Vol 54(1), pp. 71-79. 2. R.L. Whistler, J.N. BeMiller and E.F. Paschall, Starch: Chemistry and Technology, 2nd Edition, (Academic Press, 1984) Chapter III, pp. 34 & 36, Jack C. Shannon and Douglas L. Garwood, Contributing Authors. 3. R.W. Kerr, Chemistry and Industry of Starch, 2nd Edition, (Academic Press, Inc.,1950) Chapter I, p. 3
The primary value of borax is to buffer the caustic soda present in the formula. It also provides viscosity control and adds tack to the finished adhesive. For equivalent amounts of borax for starch formulations, see Appendix A. Generally, 1520 percent of the starch is fully cooked in part of the water with caustic to provide a carrier for the pearl starch. Starch solids levels usually are 2335 percent to achieve finished adhesive viscosity of 3050 Stein Hall seconds. After the adhesive is applied to the flute tips and heated, the pearl starch gelatinizes in place. When the starch swells and gelatinization begins, a green bond is formed. Nearly all of the corrugated board produced today is bonded with a starch-based adhesive. Since the quality and bonding properties of the starch directly affect final board quality, decisions regarding starch should be made carefully and treated with importance in the process. Pearl starch, or unmodified starch, typically has been the key product used for starch adhesive. However, with the introduction of high performance papers and the increased use of recycled paper, the porosity of the corrugated medium and liners has changed. Therefore, the adhesive must change, too. Modified, or carrier, starches, when used in conjunction with pearl starch, allow an increase in solids for better bonding and the ability to achieve higher machine speeds.
Bridge S. F. liner Adjustable wrap roll Preheater 36" 150-160F [65.6-71.1C] Adjustable wrap roll Preheater 36" Doctor roll Starch Hold down Rider roll roll
itioning F [121.1C]
en am ower
D. F. Liner
Roll stand
7
SHIPPING
Viscosity
In the corrugating industry, the term viscosity is used to describe adhesives flowability. (Tests for measuring viscosity can be found on page 17.)
Low Viscosity
When adhesive paste is too thin, or has low viscosity, the water tends to wick into the medium. This wicking action may remove the needed water from the glue line, which means the pearl starch may not have enough water to gelatinize completely. Many times the board will be dry and brittle coming off the corrugator, or may become brittle as it stack cures. If a pin adhesion test is performed on a sample of this board, low numbers will result. There may be very little fiber pull and the glue line will have an amber appearance. Since the bond is marginal, one solution is to open the glue settings on the machine to deliver more adhesive to the glue line. The downside to applying more adhesive is the potential for warp, washboarding, higher starch consumption and slower machine speeds.
In mixing systems, mixing blades shear the adhesive to a workable viscosity. When an adhesive formula is developed, the mix times are calculated to perform this task correctly. When the mix times are changed, quality of the finished adhesive will vary. The secondary mixer blades must be properly placed and in good repair to prevent areas of over-agitation. Missing or broken blades will add mixing time and may reduce the flexibility of the formula. The storage tanks should have agitators operating on timers. Agitators should be set to mix for five minutes out of every 30 minutes. These agitators also should operate if the Temperature Viscosity Control (TVC) system calls for heat. Temperature is very important when taking a viscosity reading. The viscosity of the adhesive will vary proportionally with the temperature of the adhesive. As the temperature goes up, the viscosity will drop (become thinner). Conversely, as the temperature decreases, the viscosity will increase (become thicker). This inverse relationship of viscosity to temperature is approximately 10 percent for every 2F [1.1C] change. (See Figure 4.) The piping system used in the plant should not have dead ends. Fewer elbows and turns help reduce friction and pressure buildup within the lines. The lines should be pitched to ensure adequate drainage for cleanups. The pumps (often positive displacement pumps) used to transfer adhesive from the mixer to storage tanks and from storage tanks to corrugator can cause unwanted shear. It is important to have the proper size pump operating at the correct rpm. A plants starch supplier should be able to help calculate system needs.
FIGURE 4
60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96
If air pumps are to be used to circulate the adhesive to and from the machine, proper air pressure is essential. Most air pumps operate at 40 to 60 psi, depending upon the distance to pump. Too much air pressure will force the adhesive through the lines and cause shear. Valves in the lines must be inspected regularly. A worn valve may appear open when it is only partially open, causing shear of the adhesive. 10
temperature 10F [5.6C] lower than the lowest gel temperature of the adhesive in storage. When the temperature of the adhesive falls below 100F [37.8C], the TVC system should activate automatically. Probes inside the TVC water tank and storage tanks monitor temperature. If the water temperature becomes too high (higher than the gel temperature of the adhesive), the adhesive will begin to gelatinize on the coils. When this happens, the heat transfer from the water in the coils to the starch is reduced, which increases the agitation time of the adhesive. This can result in low viscosity. The longer it takes for the temperature to rise, the longer the storage tank agitators must run, and the higher the risk of shear. Plants that have complete steam shutdown on weekends rely on electric units to heat TVC water. This is an important consideration in new installations to insure proper adhesive viscosity control.
Some resins will react with borax in the formula causing a change in viscosity. Using the correct amount of resin in the formula is critical. The resin supplier should be contacted for proper addition rates and/or limitations.
Microbiological Degradation
Starch, a carbohydrate, is often considered food for bacteria. It has been found that some bacteria will survive, and may even thrive, in a strong alkaline medium such as starch-based corrugating adhesives. If the bacteria population increases to, or exceeds, 10,000 colony forming units (cfu) per gram, starch adhesive could show viscosity loss. This results from the gelled starch being attacked by bacteria and converted to a soluble carbohydrate, which will lower viscosity. At levels greater than 1,000,000 cfu per gram, an odor may also develop. However, odor alone should not be considered an indicator of microbiological growth. When microbial problems are suspected, microbiological testing can be a valuable tool. Test laboratories generally require an aseptically obtained sample of the corrugating adhesive to achieve meaningful results. Contact your biocide supplier and request a test of the plants adhesive.
Viscosity/Time Relationship
The length of time the adhesive is held in storage can be critical. Over time, the raw portion of the adhesive will begin to separate from the cooked portion. This causes viscosity to drop. Fast turnover of the adhesive is the best solution. Reducing the amount of material for storage during down periods is also wise.
Viscosity/Resin Relationship
To make adhesive water resistant, you must add resin. This creates a chemical reaction when the mixture is heated on the corrugator. The result produces a water-resistant bond. The degree of water resistance is related to the ratio of resin solids to starch. However, it is difficult to generalize about the amount of resin needed because resin solids vary dramatically. Never mix resin-treated adhesive with adhesive in storage. When resin is added to a batch of adhesive, it is advisable to use all of the adhesive as soon as possible. The adhesives resin potency will last approximately eight hours after a batch is made. After that, the resin loses the ability to react with the starch and viscosity breakdown begins, affecting the entire batch. Also, resins have a finite shelf life. Resin should be added slowly to the adhesive, usually during the final mix. Adding the resin too fast can cause viscosity changes. It is not advisable to add resin to the storage tanks because viscosity changes can occur in storage, to the point that the adhesive will be unable to pump. In addition, the storage tank agitators are not designed to blend resin, and permanent damage can occur.
11
Gelatinization
Temperature
Gelatinization temperature, or gel temperature, is the temperature at which the adhesive begins to thicken and develop its bonding properties. Although it is often expressed as a single temperature unit (F or C), in reality it is a temperature range dependent upon the molecular size and composition of the starch. The natural gelatinization temperature of corn starch is generally too high for normal corrugating operation. Running an adhesive with high gel temperature could affect bonding, especially at the double backer. Machine speed could also be affected. Addition of caustic soda suppresses the gelatinization temperature, thus providing corrugators the flexibility to set the gel temperature at a desirable level for the individual machine conditions and paper combinations. Gel temperature is measured by simply heating the adhesive as it is stirred with a glass thermometer. When the paste begins to thicken (gel), the temperature that appears on the thermometer is recorded. (See Appendix C.)
12
Corrugating
Additives
Penetrating Aids
When dense liners and/or mediums are used, penetrating aids may help bonding by reducing the water surface tension, so the adhesive can penetrate the sheet. If a plant suspects that a penetrating aid would be beneficial, the plant should contact the starch supplier for assistance.
Liquid Additives
Liquid additives are often used to enhance the wet tack, or green bond, of starch-based adhesives. Green bond is the measure of an adhesives wet tack and the major factor affecting the potential machine speed of the corrugator. These products can potentially increase corrugator operating speeds. Although suited for any adhesive mixing system, liquid additives are an ideal choice for high shear mixing systems that may be equipped with liquid dosers. For liquid additive options, contact your starch supplier.
Antifoam Agents
The use of antifoam agents is common with todays corrugators. As machine speeds increase, foam is often created in the glue pans as starch cascades off the metering roll and wiper blade. If the foaming becomes severe, it can overflow the pan, causing higher than normal starch consumption; or it can transfer from the glue roll to the flute tips, causing poor bonding. Should foaming occur at the double backer, it could overflow onto the paper, resulting in a poor bond on the double facer side. For antifoam options, contact your starch supplier.
Resins
Resins are used in starch adhesive formulations to impart varying degrees of water resistance to corrugated board. The resins react with hydroxyl groups on starch and render the starch insoluble to water. Degrees of water resistance, ranging from moisture resistance to waterproof, depend on the functional use of the container. Various types of water soluble thermosetting resins are available to the corrugating industry. Ketone aldehyde-type resins are particularly well suited for corrugating applications. They require caustic and heat in order to react. For resin options, contact your starch supplier.
13
CONSUMERS
14
Corrugating
Processes/Systems/Equipment
FIGURE 5
Starch plays an important role in the corrugating process, so the integrity of the starch production process is critical. Four processes are common in starch adhesive production: Stein Hall, Jet Cook, High Shear and No-Carrier methods. Basic adhesive preparation consists of a cylindrical primary mixer with a low-speed, high-torque mixer situated above a secondary tank with a high-speed, lower-torque agitator. A drop valve generally controls the flow of adhesive from the primary mixer into the secondary tank. However, No-Carrier adhesives differ significantly in preparation since only one mixer tank is used and no gelatinization of starch occurs.
FIGURE 5
To storage
Pump
Stein Hall
This system uses a two-phase process. The first phase is referred to as the cook phase. Here, starch, water and caustic are combined to create a gelatinized starch adhesive. This product is also referred to as the carrier. The second phase is the blend phase where starch, water and borax are added together and mixed with the cooked portion to form a finished adhesive. (See Figure 5.)
Steps: (1) Water primary and secondary; (2) Starch primary; Pump To storage (3) Add caustic to primary; (4) Cook primary; (5) Add borax to secondary; (6) Add starch to secondary; (7) Add cooling water to primary;Water primary and into secondary; Starch primary; Steps: (1) (8) Drop primary secondary; (2) (9) Final mix; (10) Pump to storage (3) Add caustic to primary; (4) Cook primary; (5) Add borax to secondary; (6) Add starch to secondary; (7) Add cooling water to primary; (8) Drop primary into secondary; (9) Final mix; (10) Pump to storage
FIGURE 6
Starch FIGURE 6 Water 20 Gal. Slurry Starch tank Raw
Water
Chemical tank
Steam
Raw Steam
Cooling column
Slurry tank
Jet Cook
The Jet Cook system is a modification of the Stein Hall process using a single vessel horizontal mixer. With the Jet Cook system, all the water, caustic and borax are mixed together with approximately half of the total starch in a horizontal mixer. The amounts of caustic and borax are determined by the gel temperature that is needed for a given adhesive. This starch/water/chemical slurry is then circulated through pipes and returned to the mixer. Live steam is injected into the pipe, causing the slurry to swell (gelatinize) as it is being pumped back into the mixing tank. Monitored by an automatic viscometer, the process continues until a given viscosity (set point) is reached. Upon reaching its set point, the steam is shut off and the remainder of the pearl starch is added to the adhesive. A timed mix then finishes the process. (See Figure 6.)
Cooling column
Mixer
Scales
Scales
Pump
Carrier Raw Steps: (1) Raw starch water; (2)190F starch; [87.8C] (3) Transfer to mixer; (4) Add chemicals; 150F [65.6C] (5) Add carrier water; (6) Add starch carrier; (7) Jet(1) Raw starch water; (2) Raw starch; cook carrier; (8) Final mix; Steps: (9) Pump toto mixer; (4) Add chemicals; (3) Transfer storage (5) Add carrier water; (6) Add starch carrier; (7) Jet cook carrier; (8) Final mix; (9) Pump to storage
15
High Shear
The High Shear system is an improvement on the conventional Stein Hall process. When trying to achieve a high solids adhesive formula with the conventional Stein Hall system, the limiting factor is that high viscosities develop as the amount of primary starch is increased. One way to overcome the high viscosity is to mechanically shear the cooked portion of the formula. Using a vertical mixing tank with a mixing blade designed to shear the gelled starch, batches with higher solids can be made faster with better results. Different manufacturers use different mixer and blade combinations to achieve the same results. Adhesive is usually made in a single vessel resting on weight sensors. Water is added (by weight) and heated to a set point. Some automatic systems compensate for condensation by adjusting the programmed ingredient weights to meet any changes caused by the added water. Other systems heat the water using a heat exchanger so no condensation is added to the programmed formula. Starch and caustic (usually 50% liquid) are added and mixed under high shear. Borax, secondary water and starch are then added and mixed for a cycle timed anywhere from 12 to 35 minutes. Some systems allow for up to 20 different formulas to be programmed into the system so customized adhesive can be made for different board combinations or special papers. Most automatic systems incorporate level controls in the storage tanks and automatically make a batch when needed. This allows for lower storage volumes, which results in fresher adhesive being used at the corrugator. One major advantage of the new High Shear mixing system is that it dramatically reduces adhesive preparation time, freeing up manpower to be used in other plant operations. Even though some of the systems are fully automatic, they still must be checked daily and put on a preventative maintenance schedule. (See Figure 7.)
FIGURE 7
Caustic Starch Motor 40 hp Borax Water
FIGURE 8
Bulk starch From liquid caustic storage
130F [54.4F] Caustic tank Caustic supply line Boric acid Boric acid addition system
Steps: (1) Water; (2) Starch; (3) 130F [54.4C]; (4) Mix to X Norcross Units; (5) Add boric acid to terminate; (6) Final mix; (7) To storage
No-Carrier Adhesive System
No-Carrier
This process is very different from the others. No gelatinization of any of the starch takes place. In the No-Carrier process, starch, water, 50% liquid caustic and boric acid are used to swell the starch granule. This is accomplished by monitoring the viscosity of the adhesive. All mixing of ingredients takes place in a lower mixer. (See Figure 8.)
16
Starch
Properties and Testing
Alkali (Caustic) Sensitivity
One critical property of the starch is the ability to perform in alkali (caustic) conditions. During the manufacturing process, starch granules can become damaged. When a sample of starch containing an excessive amount of damaged granules is mixed in a solution of caustic (alkali), the starch swells at too rapid a rate. This results in a viscosity that is higher than normal. There are several methods used to check for the alkali sensitivity of pearl starch. One is the settling test for unmodified starch. (See Appendix E.) This test can be accurate and reproducible with relatively inexpensive testing equipment. Minor deviations from the procedure, or less than ideal conditions, may result in inaccurate results. There is a second, more rapid test for alkali sensitivity that is just as accurate as the settling test. However, this test uses a more costly Brookfield Viscometer. (See Appendix F.) A reading other than 15 seconds may indicate a plugged or enlarged opening, or the pins may have become bent. Carefully clean the orifice and check the volume between the pins. Recheck the flow of water. If it is not correct, replace the disk.
Gelatinization Temperature
Gelatinization (gel) temperature will affect the corrugating operation and is frequently measured. Gel point is the temperature at which liquid adhesive is transformed into a semi-solid mass or gel. (See page 12 and Appendix C for test procedures.)
Microbiological Testing
Bacterial growth in starch adhesives is detrimental because it causes molecular breakdown. If the growth reaches a certain point, viscosity will be drastically reduced, making the adhesive unusable. This growth cannot be measured at the plant site. Typically, adhesive samples are sent to a laboratory capable of measuring bacterial growth. The plants biocide supplier can assist in arranging testing. Laboratory reports speak in terms of colony forming units (cfu) per gram. When the cfu level reaches 10,000 cfu/g, it is advisable to clean the system. (See page 11 and Appendix B.)
17
MANUFACTURING
18
Board
Testing
Traditionally, moisture is determined with a forced air or vacuum oven, but other devices that incorporate infrared or microwave technologies have shown to be just as accurate and are faster. There are many tests for determining the quality of combined board. Below are some of the more frequent tests. Many of these standard tests have achieved a TAPPI designation, which is noted next to the test name. Specific test procedures may be obtained by contacting TAPPI.
19
DISTRIBUTION
20
Quality Monitoring
and Control at the Adhesive Station
The fitness of the adhesive is related directly to the quality of the bond that will be produced at the corrugator. Therefore, it is critical to maintain control of several key characteristics of the adhesive. Adhesive temperature, viscosity and gelatinization temperatures are the critical points to monitor and control in order to maintain consistent adhesive. Many problems can be avoided and eliminated through the regular use of statistical process control (SPC). Development of a data collection program is recommended to achieve meaningful statistical control of the process. The starch supplier can be a valuable resource. Many suppliers offer SPC consultation or even training. Another resource for SPC training is the American Society for Quality Control (ASQC). Generally, the SPC or Quality Control Coordinator in the plant will work closely with the starch supplier to set up control and monitoring systems and determine consistent, meaningful measurement points in the system.
21
FIGURE 9
CHARACTERISTICS
UNIT OF MEASURE
Starch Kitchen
DATE TIME OPER. INITIALS MEASUREMENT PREVIOUS MOVING RANGE
Adhesive Viscosity
2-2 2-3 2-3 2-4 2-4 2-5 2-5 2-5 2-6 2-6 2-6 2-6 2-10 2-10 2-10 2-11 2-11 2-12 2-12 2-12 2-13 2-13 2-13 2-17 2-17 2:15 8:00 12:30 9:00 12:00 9:00 12:00 2:30 7:12 10:30 1:00 2:45 7:45 9:00 11:30 8:30 10:15 6:30 10:30 1:30 8:30 11:30 1:45 7:00 9:25
JS
41 42 41 1
1 2
42 42 0
3
47 42 5
4
45 47 -2
5
39 45 -6
6
34 39 -5
7
43 34 9
8
35 43 -8
9
41 35 6
10
44 41 3
11
31 44 -13
12
42 31 11
13
43 42 1
14
32 43 -11
15
37 32 5
16
41 37 4
17
37 41 -4
18
41 37 4
19
43 41 2
20
44 43 1
21
35 44 -9
22
36 35 1
23
32 36 -4
24
42 32 10
25
50
INDIVIDUAL MEASUREMENTS
45 40
X
35 30 25
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
15 10
MOVING RANGES
5
MR
0 -5 -10 -15
NOTES:
22
Troubleshooting
Common Corrugating Problems
DIAGNOSING VISCOSITY PROBLEMS - System: Primary/Secondary Mixing Systems, Single Tank Mixing Systems, High Shear Mixing Systems
Adhesive viscosity is a critical parameter for quality corrugated board. It is a relatively easy variable to control when the underlying cause of a problem is understood. Problem: Low viscosity at the mixer Common Causes: Not enough starch in the cooked portion of the formula Scale out of calibration Too much water in the cooked portion of the formula Water leak Water meter out of calibration Improper measuring device Condensate from steam lines Condensate from steam leak Unwanted wash water going into the mixer Too much water in the secondary addition or secondary mixer Water leak Water meter not calibrated Improper measuring device Condensate from steam lines Condensate from steam leak Cooked portion too hot (+160F [71.1C]) Steam leak Temperature controller out of calibration Temperature gauge out of calibration (reading too low) Finished batch too hot Cooked portion too hot Temperature controller out of calibration Cooling water too warm (seasonal) Mixer shaft overheating due to bad bearings Improper balance between the cooked portion and cooling water Too much shearing of the cooked portion of the adhesive Cooked portion mixed too long Drop time too slow or slow pump over time Too long a time on high shear Finished batch being mixed too long Substituting incorrect borax (5 mol vs. 10 mol vs. boric acid)
Too much starch in the cooked portion of the formula Scale out of calibration Too much starch in the secondary mixer Scale out of calibration Not enough water in the cooked portion of the formula Water meter out of calibration Improper measuring device Not enough water in the secondary addition or secondary mixer Water meter out of calibration Improper measuring device Cooked portion too cold Temperature controller out of calibration Temperature gauge out of calibration Cooling water too cold (seasonal) Finished batch too cold (optimum temperature 100 to 102F [37.8 to 38.9C]) Cooked portion too cold Temperature controller out of calibration Temperature gauge out of calibration Cooling water too cold (seasonal) Bulk starch too cold (seasonal) Improper balance between the cooked portion and cooling water Not enough shearing of the cooked portion of the adhesive Cooked portion not mixed long enough Too fast a drop or fast pump over time System not left on high shear long enough Finished batch not being mixed long enough Incorrect amount of borax Substituting incorrect borax (5 mol vs. 10 mol vs. boric acid)
23
24
25
26
Washboard Appearance: This problem usually occurs once the board has cured and causes a poor printing surface and brittle edges during conversion
Dry Board, Zipper Board: Creates waste, low pin adhesion and poor top-to-bottom compression
Leaning Corrugation: This causes low board caliper, poor pin adhesion, poor topto-bottom compression, poor printing surface
Slipping Board: This problem is produced by a surface bond only and delaminates after curing
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Adhesive Between Flutes: This problem creates warp problems, high starch consumption, poor bonding and overall poor quality
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Spotty Glue Application on the Single Face Side: Poor bonding, low pin adhesion, low top-to-bottom compression
Adhesive Sets Up on Fingers: High starch consumption, poor bonding, low pin adhesion, poor top-to-bottom compression, low production speeds
Loose Edge on the Single Face Side: Poor quality board, high waste, low production speeds
Loose Edge on the Double Back Side: High waste, low production speeds, poor print quality
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Problem: High and Low Corrugation: Low pin adhesion, poor topto-bottom compression, poor print surface, overall poor quality
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Operating Footnote: If the moisture content of the single facer liner roll is greater than 2 percent over that of the double backer liner roll, then the roll should be changed. Preheaters on the machine can only remove 1 to 2 percent moisture from roll stock. Should the moisture imbalance be greater than 2 percent, warp will occur.
Operating Footnote: If th e moisture content of the double back roll is greater that 2 percen t over the single face liner roll, then the r oll should be changed. A difference of 2 per cent or more in moisture between the single face liner and the double back liner will create warp.
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Operating Footnote: If the machine is equipped with a water spray, this is usually the best way of controlling the S warp. The water spray should be used on the single face side of the web only.
Machine Direction Warp (End-To-End Warp): The end-to-end warp can be either up or down, but is always in the machine direction End-To-End Warp
Tension greater on the single face liner than on the double back liner Single face liner is pulling back on the sheet "Drag" on the top liner, usually from a drag belt on the bridge Preheater locked down not turning, adding tension to the single face web going into the double facer Running with too much brake on the single face liner at the single facer Running with too much paper on the bridge Running with too much brake on the medium pulling back on the single face web Incorrect tension on web; increase tension Tension greater on the double back liner than on the single face liner "Drag" on the bottom liner usually caused by a bad break on the roll stand; preheater locked down not turning, adding tension to the bottom liner Dirty hot plates adding drag Need to lubricate double face liner, especially when running coated liners
Cross Machine Direction (CD) Side-To-Side Warp: This is a warp that usually is found within a few hours after the board is run. The problem is moisture and tension along with the temperature in the working area
Wrap arm or roller out of parallel giving uneven contact pressure in the double facer Out of round glue roll at the single facer, applying adhesive light and heavy Machine speed from time to time will cause the adhesive to be applied heavy and light Rollstock with wet streaks or moisture content higher than normal
Operating Footnote: The corrugator crews should have a good understanding of the adhesive system within their machine and also understand the proper use of water sprays. Using the adhesive and water sprays properly is the best way to control this type of warp.
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Operating Footnote: Twist warp is seen more often on machines that run a two piece top corrugator belt. One belt will be running faster than the other adding stress to the web. If the twist warp occurs off the machine, a wet streak will be noticed in one of the liners.
Post Warp (warp observed several hours or days later): The degree of this type of warp will depend greatly on the way the sheets were stacked and the location of the stack. About the surest way to minimize in-storage warping has proved to be producing as dry as possible board on the corrugator, using as little adhesive as possible, and using preheaters to their fullest capacity
Check liners for wet streaks Reduce web tension on the single face side Reduce break drag on all roll stands Preheaters should be free turning Hot plate section should be clean and free of dirt build up Adhesive formula should have the proper solids for the mix within the plant If the machine uses a two piece belt, check the speed of the belts Sheets must be stacked properly Board coming off the machine should be dry and firm Should have proper storage area for the finished sheets
Operating Footnote: When sheets warp after they leave the corrugator, moisture is most likely the problem. The sheets coming off the machine will be wet or damp to the touch. Storing finished sheets near open doors and windows, or loading the sheets into a cold truck before they have properly cured, will cause warp.
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Appendix A
English Units, lb
10 Mol (decahydrate) 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 5 Mol (pentahydrate) 15.50 16.00 16.75 17.50 18.25 19.00 19.75 20.50 21.25 22.00 23.00 23.75 24.50 25.25 26.00 26.75 Boric Acid 12.33 13.00 13.50 14.25 14.75 15.50 16.00 16.67 17.25 18.00 18.50 19.00 19.75 20.25 21.00 21.50 10 Mol (decahydrate) 9.0 9.5 10.0 10.5 11.0 11.5 12.0 . 12.5 13.0 13.5 14.0 14.5 15.0 15.5 16.0 16.5
Metric Units, kg
5 Mol (pentahydrate) 7.0 7.2 7.6 8.0 8.4 8.8 9.2 9.6 9.9 10.3 10.7 11.1 11.5 11.8 12.2 12.6 Boric Acid 5.5 5.9 6.2 6.5 6.8 7.1 7.4 7.7 8.0 8.3 8.6 8.9 9.2 9.6 9.9 10.2
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Appendix B
Note for all systems: Growth can occur in an empty section of pipe or on the underside of tank covers. Using proper discretion, the solutions can also be used to clean the starch pans at the machine.
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Appendix C
Procedure
1. Fill a container (beaker) with water to within 1/2 inch of the top, place on a hot plate and heat to between 170F and 180F [76.7C and 82.2C]. (DO NOT BOIL THE WATER.) 2. While the water is heating, pour the starch adhesive to be tested into the test tube (fitted with a test tube holder or clamp) to a level of 1 to 2 inches, or approximately 1/3 of the tube volume. Insert the thermometer as shown to the left. 3. When the water has reached temperature, turn the hot plate OFF and place the tube in the hot water (as shown). Immediately begin stirring the adhesive with the thermometer, being careful to wipe the side of the tube to prevent localized heating and gelling. 4. As the temperature rises, the adhesive will begin to thicken as the gel point is approached (usually between 139F and 152F [59.4C and 66.7C]). The temperature rise will pause (level off) for a few seconds at the actual gel value, then continue upward. RECORD the temperature in degrees, where the leveling occurred. (NOTE: If the water is too hot, the temperature pause will be shorter and often more difficult to detect.) 5. The test requires some skill; it is suggested that the test be repeated and an average value reported.
Equipment
a b c
d e f g
Recommendations
1. Periodically, check the accuracy of the thermometer by placing it in boiling water. It should read exactly 212F [100C]. 2. Glass thermometers are recommended over metal dial-type thermometers.
a. Glass thermometer calibrated in degrees Fahrenheit (F) (See Recommendations 1 & 2 on thermometers) b. Heat stable glass test tube c. Test tube holder or suitable clamp d. Heat stable glass beaker or other suitable container e. Starch adhesive to be tested f. Hot water at proper temperature (see Procedure) g. UL approved hot plate, bottle warmer, etc.
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Appendix D
Specific Gravities and Concentrations of Caustic Soda Solutions Based on International Critical Tables Lbs. of Lbs. NaOH Solution Per Gal. Per Gal. @ 60F [15.6C] @ 60F [15.6C] .17 .35 .53 .73 .93 1.13 1.35 1.57 1.80 2.04 2.28 2.53 2.79 3.06 3.33 3.61 3.89 4.19 4.48 4.78 5.09 5.40 5.72 6.05 6.38 6.72 8.53 8.71 8.90 9.08 9.27 9.45 9.64 9.82 10.01 10.20 10.38 10.56 10.75 10.92 11.11 11.28 11.46 11.62 11.80 11.96 12.12 12.28 12.44 12.60 12.76 12.91
%NaOH
%Na2O
Sp. Gr. @ 60/60F [15.6C] 1.023 1.045 1.067 1.089 1.112 1.134 1.156 1.178 1.201 1.223 1.245 1.267 1.289 1.310 1.332 1.353 1.374 1.394 1.415 1.435 1.454 1.473 1.492 1.511 1.530 1.549
Deg. Baum @ 60/60F [15.6C] 3.3 6.2 9.1 11.9 14.6 17.1 19.6 21.9 24.3 26.4 28.5 30.6 32.5 34.3 36.1 37.8 39.5 41.0 42.5 44.0 45.3 46.6 47.8 49.0 50.2 51.4
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52
1.55 3.10 4.65 6.20 7.75 9.30 10.85 12.40 13.95 15.50 17.05 18.60 20.15 21.70 23.25 24.80 26.35 27.90 29.45 31.00 32.55 34.10 35.65 37.20 38.75 40.30
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Appendix E
Test Procedure
1. Weigh 145 g of test solution into one 250 ml bottle. 2. Weigh 50 g starch into another 250 ml bottle. If starch is being added to a marked bottle, it should be tamped to get proper amount. 3. Quickly pour starch into bottle with test solution. 4. Quickly cap the bottle and shake for 3 to 5 minutes. It is important that steps 3 and 4 be done quickly. 5. Pour the starch slurry without delay into the graduated cylinder up to the 100 ml mark and put a piece of aluminum foil over the top as a cap. 6. Let the graduated cylinder stand for 24 hours.
Equipment
250 ml bottles with caps 100 ml graduated cylinders
Test Solution
From dry caustic: 13.3 g caustic 8.1 g 10 mol borax 1434.0 g distilled water
Observation
Read the bottom of the clear water layer. The reading should be less than 70 ml if the starch is not alkali (caustic) sensitive.
From 50 percent caustic: 26.6 g 50 percent caustic 8.1 g 10 mol borax 1421.0 g distilled water
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Appendix F
Notes
1. Variation in the normality of the sodium hydroxide solution and the moisture content of the sample can have a significant effect depending on the alkali sensitivity. As the alkali sensitivity increases, the effects of these variables increase. Decreasing the sodium hydroxide normality from 0.25 to 0.24 decreases the measured alkali sensitivity by about 1.7 cps at 14 cps and about 0.1 cps at 5 cps. Reducing the sample moisture content from 11.0 to 10.0 percent increases the measured value by 0.6 cps at 14 cps and 0.2 cps at 5 cps. 2. The addition is generally done in 5 to 10 seconds to avoid gelatinization of the intact granules. 3. As an alternative procedure, 200 ml of 0.1875 N NaOH can be used in place of the combination of 50 ml water and 150 ml 0.250 N NaOH. However, this change will eliminate the ability to adjust the formulation for variations in sample moisture content. The 0.1875 N NaOH can be obtained commercially as a special order. 4. The equipment, reagents and method are all available from: Shape Products 1127 57th Avenue Oakland, CA 94621 (800) 444-0015 www.shapeproductsonline.com
Scope
This procedure was developed specifically for unmodified corn starch and may not be used with modified starches without further study.
Equipment
Beaker: Griffen low form, 400 ml capacity Brookfield Viscometer: Model LV equipped with a laboratory stand and UL Adapter with spindle SPOO. Stirrer: Stainless steel 3-blade propeller, 5 cm diameter, on a 0.8 x 31.0 cm shaft Stopwatch Weighing Paper
Reagents
1 percent (w/v) aqueous sodium hydroxide (NaOH)
Procedure
The test is run at room temperature (about 77F [25.0C]). Transfer 150 ml of 1 percent NaOH and 50 ml of distilled water to the 400 ml beaker. Position the stirrer in the beaker and mix the solution at 600 rpm. Weigh 100 g (see note 1) of starch on the weighing paper. Add the starch to the agitated alkaline solution as quickly as possible but avoid lumping (see note 2) and start timer. Transfer 16.0 ml of slurry to the UL Adapter and measure viscosity at 30 rpm.
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Glossary
Recycle
Pearl Shear
Unmodified starch
Carrier Starch Primary portion of adhesive Caustic Soda Alkaline substance that causes starch granules to swell; also called sodium hydroxide Feed Gluten
Co-product of processed corn
Single Facer First glue station of corrugating machine; medium is fluted and bonded to liner Starch Complex carbohydrate from corn, potato, rice
or tapioca processing
Steepwater
Water in which corn has been soaked or steeped during the initial stages of the corn wet milling refining process
Waxy Maize
Glue Roll Component of corrugating machine; transfers starch to flutes at double backer or single facer High Ring Crush High performance paper having a ring crush value of 2 pounds for every pound of basis weight Liners The flat paperboard portion applied to the fluted medium by applying adhesive to each flute tip Medium Fluted portion between the liners, which when combined with the liners, makes corrugated board Modified Starch
or mechanically A starch modified chemically
Wick
Penetrate
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Corporate Headquarters Corn Products U.S. 5 Westbrook Corporate Center Westchester, IL 60154 United States (800) 443-2746 www.cornproductsus.com
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Corn Products U.S. is a business unit of Corn Products International, Inc. Casco Inc. and CPIngredientes are affiliates of Corn Products International, Inc.
021-CM-99 Printed in the USA June, 2006 Quantity: 2,500 2006, Corn Products International, Inc.