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Training Manual
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01.10.1997
Training Manual
Type of machines
ROLL STAND ASR-M ................................................................................................................................... 3
BUTT ROLL COMPUTER ............................................................................................................................. 5
RRR ............................................................................................................................................................... 5
SPLICER ARW-M.......................................................................................................................................... 6
UNDER/ABOVE FLOOR TROLLEY ............................................................................................................. 8
FB/UFB ....................................................................................................................................................... 8
MODUL FACER............................................................................................................................................. 9
MF-BANDLEADER........................................................................................................................................ 9
PREHEATER VZR-M................................................................................................................................... 12
PRECONDITIONER VBR-M........................................................................................................................ 13
BRIDGE B.................................................................................................................................................... 14
BRIDGE LEVEL CONTROL BMR .............................................................................................................. 15
GLUE UNIT LWR-M .................................................................................................................................... 17
DOUBLE FACER DWR ............................................................................................................................... 19
ROTARY SHEAR KQM ............................................................................................................................... 21
SHEAR ORDER CHANGE .......................................................................................................................... 22
KQF.............................................................................................................................................................. 22
SLITTER SCORER SRA-M ......................................................................................................................... 23
DISC CUT .................................................................................................................................................... 26
WEB DIVERTER.......................................................................................................................................... 28
CUTOFF NQM/HQM.................................................................................................................................... 29
STACKER AAR ........................................................................................................................................... 31
CORRUGATOR CONTROL ........................................................................................................................ 33
01.10.1997
chapter 1 page
Training Manual
CENTER FDM/PDM..................................................................................................................................... 33
QUALITY DATA .......................................................................................................................................... 34
MANAGEMENT QDM................................................................................................................................. 34
SPLICE SYNCHRONISATION .................................................................................................................... 35
SYSTEM SSS ........................................................................................................................................... 35
MACHINE CONTROL CENTER.................................................................................................................. 37
MCC ............................................................................................................................................................. 37
01.10.1997
chapter 1 page
Training Manual
Description of Equipment
Type of Machine:
Roll Stand ASR-M
Functional Principle:
01.10.1997
chapter 1 page
Training Manual
01.10.1997
chapter 1 page
Training Manual
Type of Machine:
Butt Roll Computer
RRR
Functional Principle:
01.10.1997
chapter 1 page
Training Manual
Type of Machine:
Splicer ARW-M
Functional Principle:
01.10.1997
when the paper web runs from the left roll stand, it runs
over the left deflection roll (movable)
chapter 1 page
Training Manual
when the paper web runs from the left roll stand, it runs
over the deflection roll (movable)
01.10.1997
chapter 1 page
Training Manual
Type of Machine:
Under/Above Floor Trolley
FB/UFB
Functional Principle:
01.10.1997
chapter 1 page
Training Manual
Type of Machine:
Modul Facer
MF-Bandleader
Functional Principle:
01.10.1997
chapter 1 page
Training Manual
Safety:
01.10.1997
chapter 1 page
10
Training Manual
wear goggles!
01.10.1997
chapter 1 page
11
Training Manual
Type of Machine:
Preheater VZR-M
Functional Principle:
Safety:
01.10.1997
chapter 1 page
12
Training Manual
Type of Machine:
Preconditioner VBR-M
Safety:
01.10.1997
chapter 1 page
13
Training Manual
Type of Machine:
Bridge B
Functional Principle:
Safety:
01.10.1997
chapter 1 page
14
Training Manual
Type of Machine:
Bridge Level Control BMR
Functional Principle:
When the point where the festoon loops are pulled out in a
web reaches measuring wheel 3, the bridge storage is
synchronised. As soon as the paper storage on the bridge
is running out, i.e. the point where the festoon loops are
pulled out in a web arrives at measuring wheel 2, the
double facer speed is lowered below the speed of the single
facer. Thus paper break is avoided. In case a certain
minimum value is fallen below (e.g. in case of single facer
stoppage), the double facer is switched off.
In order to have sufficient storage availabe on the bridge for
splicing, it is possible to switch over to increased demand.
The increased demand is to be preset by key input.
Increased demand:
Normal demand:
01.10.1997
chapter 1 page
15
Training Manual
Speed Memory:
The Speed Memory is a special function of the bridge level
control. In case it becomes necessary to slow down the
double facer due to a lack of paper, the operating mode
Speed Memory is activated automatically:
The single facer controls the double facer; display in menu
field Production: active Modul Facer
After splicing has been completed, the bridge level control
is automatically activated again, and the modul facer/single
facer speed relative to double facer is increased, until
nominal storage has been reached again:
The double facer controls the single facer; display in menu
field Production: active double facer
01.10.1997
chapter 1 page
16
Training Manual
Type of Machine:
Glue Unit LWR-M
1)
Remedy:
Lift glue pan by means of control valve Lift glue pan
2)
01.10.1997
chapter 1 page
17
Training Manual
danger of contusion
Remedy:
Operate key Lift pressure system
3)
Remedy:
Lower glue pan by means of control valve
4)
Remedy:
Change glue gap by means of key glue gap minus or
glue gap plus
5)
Remedy:
Change glue gap by means of key glue gap minus
or glue gap plus
6)
Remedy:
Operate EMERGENCY-STOP button, if necessary
01.10.1997
chapter 1 page
18
Training Manual
Type of Machine:
Double Facer DWR
a heating section
a traction section
Functional Principle:
01.10.1997
chapter 1 page
19
Training Manual
Remedy:
Operate EMERGENCY-STOP button; lift pressure system.
2)
01.10.1997
chapter 1 page
20
Training Manual
Type of Machine:
Rotary Shear KQM
Functional Principle:
Safety:
Knives:
Both upper and lower knife bar are equipped with one knife
each. When carrying out any kind of maintenance work or
when replacing the knives, utmost caution is advised.
1)
danger of cutting
Residual board:
1)
01.10.1997
chapter 1 page
21
Training Manual
Type of Machine:
Shear Order Change
KQF
General Description of Component:
Functional Principle:
Safety:
Knives:
Both upper and lower knife bar are equipped with one knife
each. When carrying out any kind of maintenance work or
when replacing the knives, utmost caution is advised.
1)
Residual board:
1)
01.10.1997
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22
Training Manual
Type of Machine:
Slitter Scorer SRA-M
Functional Principle:
01.10.1997
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23
Training Manual
Safety:
Slitter knives:
In case of maintenance work or when replacing the knives,
utmost caution is advised.Safety gloves, appropriate for this
purpose, have to be worn.
danger of cuts
Drives:
01.10.1997
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24
Training Manual
01.10.1997
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25
Training Manual
Type of Machine:
Disc Cut
Safety:
Slitter knives:
In case of maintenance work or when replacing the knives,
utmost caution is advised. Safety gloves, appropriate for
this purpose, have to be worn.
Only authorised and trained specialists are allowed to carry
out any cleaning work on this machine. All regulations and
prohibitions, as required by law, must be strictly observed to
prevent serious injury to personnel. Prior to any machine
cleaning, make absolutely sure that the master switch is
locked in its OFF-position.
When working on the electric control system, the fuses of
the power circuit have to be removed by an expert.
When removing the fuses, observe the local safety
regulations of the users country!
01.10.1997
chapter 1 page
26
Training Manual
01.10.1997
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27
Training Manual
Type of Machine:
Web Diverter
01.10.1997
chapter 1 page
28
Training Manual
Type of Machine:
Cutoff NQM/HQM
Functional Principle:
01.10.1997
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29
Training Manual
Safety:
Knives:
Upper and lower knife bar are equipped with one knife
each.
When effecting any kind of maintenance work or when replacing the knives, utmost caution is advised.
Safety gloves, appropriate for this purpose, have to be
worn.
--> danger of cutting
Drives:
When entering the safety area of the drive, after having
stopped the machine, the drives are still hot.
--> danger of fire and injury
Residual board:
Residual corrugated board has to be immediately removed
from the hall floor.
--> danger of tripping and falling
01.10.1997
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30
Training Manual
Type of Machine:
Stacker AAR
Functional Principle:
01.10.1997
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31
Training Manual
Due to the varying belt speeds, the space and time gap
necessary for changing stacks is created in the
shingling board web. As soon as this gap is created,
the venetian blind moves back again to its stand-by
position below the conveyor, and the following belt,
being cleared now, is switched back again from
evacuation speed to normal speed.The rolls of the side
transport section, driven by a flat belt, ensure reliable
evacuation of the sheet stacks.
Safety:
01.10.1997
chapter 1 page
32
Training Manual
Type of Machine:
Corrugator Control
Center FDM/PDM
FDM
Input and administration of corrugator
orders
Supply of machines with nominal values
Review of data input for feasibility
Display of errors in clear text
Storage of the last 100 completed
orders
Acceptance of data from a customer
data processing system
PDM
Acceptance of actual values from the
machines
Storage and administration of actual
values
Order protocol
Quality protocol
Shift protocol
Stop code protocol
Transfer of data to the customer data
processing system
01.10.1997
chapter 1 page
33
Training Manual
Type of Machine:
Quality Data
Management QDM
01.10.1997
chapter 1 page
34
Training Manual
Type of Machine:
Splice Synchronisation
System SSS
Synchronisation of Splicers
When a quality change takes place, usually the area
between the 1st and the last splice joint is waste. To
minimise this waste, the splice joints must be located as
closely together as possible. This is done by the splice
synchronisation.
Functional Principle:
Evaluation of Orders
You can see from the order data, on which splicers
the paper changes. These splicers are included in
the synchronisation. On flute change, no
synchronisation is effected.
Active Display
Approx. 984 ft (300 m) before the order ends, the
warning light is activated to signalise that the splice
synchronisation is in operation now.
Increased Demand
If required, the bridge quantity of the relevant single
facers is increased.
Bridge Detection
The exact bridge quantity is detected. For this
purpose, the fluting in the inclined belt conveyor is
marked with a color stain, and this stain is detected
at the bridge end.
01.10.1997
chapter 1 page
35
Training Manual
Attention :
If the quality run is shorter than 990 ft (300 m), it may
be the case that the bridge quantity can no longer be
detected. Nonetheless it is possible to carry through
the synchronisation, but it is highly probable that
accuracy is affected.
01.10.1997
chapter 1 page
36
Training Manual
Type of Machine:
Machine Control Center
MCC
01.10.1997
chapter 1 page
37
Training Manual
Process Knowledge
INTRODUCTION
General purpose
To help corrugator staff and personnel in the preparation and the running of the corrugator.
In using this paper, especially for in-house training programs, it should create a general
agreement as how to use the equipment the best and most efficient way. It is, however, not a
complete machine description as this was not the intention. The machine manuals provided
with the units should take care of that.
01.10.1997
chapter 2
page 1
Training Manual
1.
PAPER
Several types of paper are used in the corrugated board industry. They are divided in 2 different
types called LINER and FLUTING or MEDIUM. Liner paper is mainly used as a "liner", i. O. W,
the outside papers of the corrugated sheet. We use a top-liner on the single-facer and a bottom
liner at the double facer. There is also a middle liner when running double-double, but in some
cases, fluting or medium is also used as middle liner. Liner paper differs from fluting or medium
paper, mainly through the different fibre length, and through the fabrication methods, it is also
mostly more expensive.
Different types of liner are used on the corrugate, such as: KRAFTPAPER , SCHRENZ or
WASTEPAPER, DUPLEX or TEST LINER.
Different types of fluting: SCHRENZ or WASTEPAPER, SEMI-CHEMICAL, a combination of
both, and STRAW or BOGUS PAPER. All of these papers are available in different grades and
qualitys, one more easy to run on the corrugator than others, depending on different factors.
We call this the runnabillity" of the paper. Especially the fluting plays a big part in the running of
the corrugator. We will look further into the different demands which will decide what makes a
certain paper easy to run, and another difficult.
SCHRENZ or WASTEPAPER. Has been widely used in most of the European countrys,
especially in Holland, Germany, Belgium, Austria, France. This mainly due to the fact that these
country's have practically no virgin wood to be used for the paper industry, as Scandinavia has.
It is a porous paper, who takes up liquid easily such as starch, but is rather weak as a paper. Is
therefore mainly used as fluting paper, due to the fact that it can become a rather stiff paper.
Because it is cheap , it is also widely used as an inside liner.
When used as a fluting, remember that schrenz is rather difficult to take-up heat, therefore it is
essential that we heat the paper sufficiently to reach the correct temperature. Use the
preconditioner to achieve this.
SEMI-CHEMICAL. The name semi-chemical is mostly used to indicate cellulose and less for
paper, as it is nearly always used to mix with wastepaper or old paper. This paper has been
developed especially for the corrugated board industry, and has the advantage to create a very
stiff, strong fluting.
Some scandinavian papers have also a small percentage of Kraft fibre mixed in it, what
increases even more the strength of the fluting, but also makes it more difficult to run! The fibres
are very short and hard, are mainly positioned in length direction and causes therefore a rather
difficult fluting to run. It is nearly impossible to run semi chemical without the steam showers and
without conditioning the paper with the preconditioner.
01.10.1997
chapter 2
page 2
Training Manual
1.1
Caliper
Caliper means the thickness of the paper. It is very important that the caliper of the paper is
even over the full width, as it may cause wrinkling, bad gluing, warp and twist on the sheets.
1.2
Humidity
Humidity means the moisture contents of the paper. It is essential that the moisture content is
even, and within a restricted percentage. The moisture content of liners and fluting are different,
usually liners should contain between 6 and 10%, and fluting between 4 and 8% It is however
essential that the papers are in "balance", meaning that when your top-liner has a humidity of
5%, and your bottom-liner 10%, you will have the greatest problems to run flat board. From this
it is obvious that the moisture content of your paper will greatly decide the flatness of your
board.
Important Note: There are many different types of moisture meters, but most of them give a
very inaccurate moisture content of the paper. To check the humidity over the width, these
meters are very useful, but to determine the moisture content, the best way is to use a proper
moisture analyzer, whereby the paper is put on a balance, and by first weighing the paper,
drying the paper out by means of heating, weighing the paper again, the moisture content can
be properly obtained. This method is also useful to check the humidity content of the board.
1.3
Even structure
Even structure, without streaks, caused by the papermachine. When the paper runs into the
machine, it should be straight, evenly tensioned. When not, the streaks will be lower in
temperature, due to bad contact with the preheaters, therefore will cause bad gluing at higher
speeds and cause warp.
1.4
Winding
Winding of the paper is very important too, plus the general condition of the reel. Badly
wounded reels can cause problems at higher speeds, due to the "jumping" of the paper going
into the machine.
Most liners have a smooth and a ruff side, especially the Kraft qualitys This depends on the
calendring of the paper, therefore, most rolls have direction indicators on the sides of the reel. It
is essential to follow these indications, as severe peeling might occur at the finishing machines,
or even at the hotplates if these instructions are not followed.
01.10.1997
chapter 2
page 3
Training Manual
1.5
Weight or Grammage
Weight or grammage. Wrong or uneven weight will cause trouble at a further stage of the
boxmaking, as the demands for strength of your finished box will mainly depend on the
grammage of your paper. Extreme big grammage differences will show up on the board as weak
spots, due to the fact that it is mostly combined with caliper loss. Note: It is an important part of
the foreman job to keep a close check at the paper at all times, and keep a record of all defects
and or abnormalitys which occurs during the production. It is a good habit to do this, even if in
most cases you have to run the bad reel anyway. When it comes to the point where heavy
production losses occurs due to the paper, it is always handy to have these records.
1.6
Schrinkage
Shrinkage of paper is always present, due to the fact that paper is heated when used on the
corrugator. Heating means reducing the moisture content of the paper, and by doing so, the
paper "schrinks", i. O. W. the width of the paper is reduced.
The mis alignment of the fibre in the paper can also cause extreme schrinkage, but this is a very
rare phenomena, as this is usually a serious paper machine fault, therefore mostly cured on the
paper machine after detection!. This fault can also be detected by observing the even structure
of the paper, very large, loose bands over the paper width with no higher moisture content will
indicate this problem.
From the above remark, it is easily deducted , that fluting paper has less schrinkage due to the
fact that the fibre is much shorter, thus less risks of unaligned fibres!.
The amount of schrinkage will depend highly on the moisture content (humidity), the amount of
heating used on the machine, the type of paper used and the speed of the machine. It is
obvious that when running slow, more moisture is removed from the paper, therefore schrinkage
is more important.
However, the more moisture in the paper, the more moisture can be removed, thus causing
more schrinkage. Schrinkage should not exceed 0.3 to 0.5 % of the paperwidth, as more
schrinkage will cause problems maintaining the correct trim at the Slitter Scorer. Schrinkage will
also cause problems on the SF, when running slow. The edges will show streaks, noticeable
because of the width difference between fluting and medium.
01.10.1997
chapter 2
page 4
Training Manual
1.7
Aging of Petra
Paper freshly produced on the paper machine can cause trouble on the corrugator. It is
generally recommended to store paper for approx. 3 weeks before use on the corrugator.
Reason for this, is usually the bad Gurley value on the fluting paper and the change of the
absorption time with the aging.
It is generally accepted that the absorbtivity decreases , thus absorption time increases with
aging. This is caused by oxidation of the paper. Outside layers of a roll increase in absorption
time 25-fold in the initial stage(an increase in penetration time!)while inner layers did not change
in a 10 month period!. Therefore, to compensate for those expected changes, many mills induce
artificial aging Usually some form of elevated temperatures constitutes the artificial aging
process. Ex: One laboratory found that 2-8 Hrs at 221 F (105 C) gave age equivalent of one
month storing under normal conditions.
The Gurley value is important on vacuum machines as it indicates the porosity of the paper.
With too low Gurley values, the fluting tends to fall out of the corrugator rolls.
1.8
Specifications.
Conditions for good quality and high speed. These specifications are recommended by FEFCO
for Liner and Fluting medium.
Paperhumidity:7% in length and cross direction.
Droptest: 20-30 sec for 3% solution.
Runability conditions to ensure good flute formation and acceptable gluing, at the same time
running flat board.
To avoid for smooth production:
"Jumping rolls.
Freshly made rolls, coming straight from papermachine.
(Between 2/3 weeks storage is recommended!).
Extreme cold paper rolls.
Badly winded rolls, irregular winding.
Smooth, stricken paper.
Extremely high concentration of starch.
Excessive schrinkage.
01.10.1997
chapter 2
page 5
Training Manual
Type of
paper
Weigth Caliper in
in #/msf inch (mm)
(g/m)
Wellenstof
22.5
(110)
Testliner
30.7
(150)
Schrenz
33,3
(160)
0.0067
(0.17)
0.01
(0.26)
Gurley
value
Droptest
inch sec
25-30
18-50
40-20
50-100
22<
71
150-200
40-20
20-50
22 <
71
100-200
w. Starch
Semi-Chem
Kraft
Surface Humidity
struct.
inch %
Cobb
value
30-60
23
(112)
0.007
(0.18)
30-15
26
(127)
0.01
(0.25)
20-50
32.7
(160)
0.01
(0.26)
35.8
(175)
30-10
18-50
50
71
22 <
71
20-35
Explanations:
Drop test: Time needed for a drop of water with a 3% NaOH solution to penetrate inch the
paper surface.
Water absorption or Cobb test:
The Cobb test illustrates the ability of the paper to absorb water.
The values that are indicated are the amount of water, absorbed by 10 sgF (1m) of paper inch
a certain time period. The paper is brought inch contact with a water column. By weighing the
paper before and after the test, the Cobb value is fixed.
Humidity test:
Humidity is measured by means of a Doser or equal instrument. However, the most accurate
way of determining the humidity is with a balance. The paper is put on a (electronic)fine
balance. The weight is determined, then the paper is dried-out. The difference inch weight of a
fixed surface 0.01 sgF (10 cm) gives a very accurate humidity content of the paper.
01.10.1997
chapter 2
page 6
Training Manual
1.9
g/m2
200
mm
300
mm
400
mm
500
mm
600
mm
700
mm
800
mm
900
mm
1000
mm
1100
mm
1200
mm
112
190
425
760
1240
1700
2320
3050
3850
4750
5700
6800
120
175
400
710
1100
1600
2150
2850
3600
4350
5350
6400
125
170
380
680
1050
1550
2075
2750
3450
4250
5100
6100
127
165
375
665
1030
1500
2040
2675
3350
4175
5025
6000
130
160
370
650
1010
1460
2000
2620
3310
4100
4950
5900
140
150
335
600
930
1350
1820
2400
3000
3725
4500
5200
150
140
310
530
860
1250
1700
2200
2800
3450
4200
5000
175
120
270
480
750
1075
1475
1900
2450
3000
3620
4350
180
115
260
465
720
1050
1420
1850
2350
2900
3500
4200
200
100
230
410
640
920
1250
1650
2050
2550
3100
3700
225
95
215
385
600
860
1180
1520
1950
2400
2900
3450
250
80
190
330
510
720
1000
1300
1700
2050
2500
3000
300
70
160
280
440
640
860
1120
1420
1750
2320
2520
350
60
140
250
390
530
770
1000
1280
1570
1900
2250
12
inch
16
inch
20
inch
28
inch
32
inch
35
inch
39
inch
43
inch
47
inch
#/msf
8
inch
24
inch
23
623
1394
2493
4067
5576
7610
10004
12628
15580
18696
22304
24.6
574
1312
2329
3608
5248
7052
9348
11808
14268
17548
20992
25.6
558
1246
2230
3444
5084
6806
9020
11316
13940
16728
20008
26
541
1230
2181
3378
4920
6691
8774
10988
13694
16482
19680
26.6
525
1214
2132
3313
4789
6560
8594
10857
13448
16236
19352
28.7
492
1099
1968
3050
4428
5970
7872
9840
12218
14760
17056
30.7
459
1017
1738
2821
4100
5576
7216
9184
11316
13776
16400
35.8
394
886
1902
2460
3526
4838
6232
8036
9840
11874
14268
36.9
377
853
1525
2362
3444
4658
6068
7708
9512
11480
13776
41
328
754
1345
2099
3018
4100
5412
6724
8364
10168
12136
46
312
705
1263
1968
2821
3870
4986
6396
7872
9512
11316
51.2
262
623
1082
1673
2362
3280
4264
5576
6724
8200
9840
61.4
230
525
918
1443
2099
2821
3674
4658
5740
7610
8266
71.7
197
459
820
1279
1738
2526
3280
4198
5150
6232
7380
chapter 2
page 7
These are approximate figures, and are meant to be of help for the operators.
01.10.1997
Training Manual
01.10.1997
chapter 2
page 8
Training Manual
2.
STARCH
2.1
Generalities
In the early stages of the corrugated boxmaking, the first ways of gluing the paper together was
by means of starch paste, quickly followed by Sodium Silicate, the so-called Water-glass starch.
This type of starch however had many disadvantages, such as slow running speed, it also
tended to eat the machine away due to its chemical properties, and above all, it was extremely
difficult to keep the machine in good running condition(extreme long cleaning times). It became
also problematic to recycle the board, as its starch was practically impossible to separate from
the paperpaste, causing the newly made paper to become famous for its corrugator roll wear, as
the silicate starch was a very abrasive material. Starch is used to glue the different layers of
paper to together. The specific demands on starch to be able to run fast, cost efficient and good
quality board at the same time, are Gel temperature and a stable viscosity of a predetermined
value. In the case of BHS fingerless single facer you need a viscosity of approx.50 to 60 Sec.
Stein Hall.(Stein Hall is the name of the inventor of the Stein Hall formula, the recipient used to
measure the viscosity is called the Stein Hall cup). Other types of viscosity cups include Bauer,
ford, zahn, love, Lory, etc... Lists are available to relate the different values to the different types
of viscosity. However, the most commonly known cup is the Stein Hall, and from here on we will
always refer to this type of viscosity.
2.2
Since starch is the main raw material in most adhesive formulations, it is helpful to understand
the basic properties of this material before discussing corrugating adhesives in more details.
Starch can be extracted from a wide variety of plants such as: maize, potato, wheat, sago, rice,
tapioca etc.., but the most suitable and commonly used is maize.
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2.3
2.3.1
Water
The aim is to apply starch on top of the flute tips by means of glue applicators. To do this, one
has to work in the liquid phase. The water is necessary for the swelling of the starch granules
and therefore has to be in sufficient quantity to allow complete swelling. The remaining water will
have to be evaporated to cure the bond.
2.3.2
Starch
The starch referred to in this paper is corn starch, unless otherwise mentioned. Other starches,
heavily influenced by geography, are Wheat, potato, tapioca etc.. It is the basis of the adhesive
2.3.3
% Amylose
Waxy Maize
Tapioca
17
Potato
20
Maize
24
Wheat
25
50
70
70
Waxy maize
60
Tapioca
50
Potato
40
Maize
30
Wheat
H.A.Maize
20
H.A.Maize
10
0
% Amylose
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2.3.4
Caustic Soda
This is used to reduce the gelatinisation temperature of the raw starch so that the bond
formation takes place at a lower temperature on the machine, meaning increased speeds and
energy savings.
Beside producing more stable adhesive, caustic soda also helps penetration of the adhesive into
the paper by its wetting power
2.3.5
Heat is used in conjunction with caustic soda to cook the primary portion of the Steinhall
process or to promote partial swelling of the starch in the no carrier process.
Agitation stabilizes the glue viscosity at the preparation stage to avoid a drop in viscosity when
circulating the glue at the corrugator.
2.3.6
Borax is added to promote rapid swelling of the raw starch on gelatinisation which leads to a
faster adhesion by increasing the viscosity of the glue produced.
Borax reacts with cooked starch and modifies the texture of the glue affecting flow properties,
glue pick-up and glue penetration. Borax is normally used in the Steinhall process.
Boric Acid has the same properties as Borax. Used in the no carrier process, it also stops the
reaction by neutralizing part of the caustic soda when the required viscosity is reached.
2.3.7
Preservatives
As swollen granules are sensitive to bacterial or fungal degradation, one must not forget to add
a small quantity of preservative, to prevent any loss in viscosity. In good conditions of
temperature and medium, one bacteria would lead to a one million bacteria population after 10
hours.(It doubles every 30 min!)
2.3.8
Slurring
A starch slurry can easily be prepared by adding starch to water while stirring continuously. If
not continuously agitated, the starch readily settles out, forming a dense sludge on the bottom of
the mixing vessel, which is difficult to re-slurry.(think of your kitchen, when trying to make sauce
with flower and you forget to stir!) Starch slurries can be prepared with concentrations up to
40%, and have a thin, watery consistency.
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2.3.9
Adhesive nature
A starch slurry has no adhesive properties whatsoever. However, on heating, water migrates
into the granules, causing them to swell, and eventually burst to produce the familiar cooked
starch paste. This starch paste now has a very high viscosity and behaves as an adhesive. The
increase in viscosity is due to the reduction in mobility of the starch as a result of the swelling
action. This cooking process is often referred to as gelatinisation.
2.3.11 Viscosity
If the concentration of the starch is above 7% then the cooked paste is very viscous and is very
difficult to pump through the pipes and trays. Above 15% starch solid contents, the cooked
paste on cooling forms an immobile rubbery mass. If a cooked starch paste is required to give a
low enough viscosity for convenient pumping at a higher solids content than 7%, then it has to
be chemically modified by the starch manufacturer.
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2.3.13 Stability
Starch paste, when mechanically moved(such as stirring or pumping, tend to "shear down" or
looses his viscosity. The degree of viscosity loss will depend upon the rate and duration of
pumping, and the way the starch has been prepared.
2.4
2.4.1
Inventors of the "carrier" system, whereby the starch is made using two mixers, one top and one
bottom mixer. The top mixer is called the carrier or primary mix and the bottom mixer slurry or
secondary mix. We will now study such a formula and discuss the pro and contras of this type
of mix. Note that this is still the most used system in the field.
2.4.2
The basic procedure consist of preparing the cooked (carrier) portion in the top tank(primary
mix, and adding to this the uncooked slurry in a bottom tank. (secondary mixer) A typical
formulation follows. The mixers need to be of good construction and the agitators need to be
powerful for good shearing.
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2.4.3
Heat to
86 F (30 C)
Unmodified starch
Borax
35 lb (16 kg)
Unmodified starch
Heat to
140 F (60 C)
37 lb (17 kg)
149 F (65 C)
Agitate for
15 min.
Drop contents of primary mixer into secondary mixer over a 20 min. period.
Agitate bottom mixer for 30 minutes to STABILIZE the viscosity
2.4.4
Steinhall Cup.(CPC)
Adhesive viscosity can be measured and controlled using different kind of viscometers. For
routine monitoring of the adhesive, the Steinhall Cup is the most widely used. The time, in
seconds, needed for the escaping fluid (100 cc.)to flow from the top wire to the bottom wire is
the stein hall viscosity. The value for clear water is 15 Sec.
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2.4.5
Bauer Cup.(AMYLUM)
The Bauer cup is in measurements, exactly the same as the Steinhall Cup (Bauer was an
employee from Stein Hall!) except for the thickness of the bottom plate of the cup. Although the
orifice diameter is also 0.1 inch (2.65 mm), the thickness of the bottom plate for the Steinhall
Cup is 0.13 inch (3.3 mm) and for the Bauer cup 0.06 inch (1.5 mm)
2.4.6
42 Sec Bauer
46 Sec Bauer
52 Sec Bauer
60 Sec Bauer
2.4.7
Microbial spoilage
Starch solutions can be affected by microbial spoilage, resulting in a drop in viscosity coupled
with an unpleasant odour. To prevent such spoilage, all areas of the plant where starch
adhesives are handled and used should be kept clean. In addition, a small amount of a suitable
preservative should be added to the adhesive, particularly the carrier portion. A carrier starch is
usually only present at about 5 or 6% starch solution and it is very susceptible to attack by
bacteria even at the very high alkalinity which exist in corrugated formulas. Particularly
disconcerting is the fact that these bacteria can attack the carrier starch before causing any
objectionable odor or otherwise making their presence obvious. Formaldehyde or other
equivalent materials, such as sodium pentachlorphenol or sodium orthophenylphenate is
normally added to domestic batches
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2.4.8
No Carrier Starch
This process does away with the carrier portion of the adhesive hence the name "no carrier
adhesive. In the process, a solution of caustic soda is added to a slurry of starch to swell all the
starch granules uniformly until they reach the required adhesive viscosity. An acid(usually alum
solution)is then added to stop this swelling process short of gelatinisation. Finally borax is
added. A recent improvement is the use of boric acid to stop the swelling reaction. In reacting
with the caustic soda, the necessary borax is formed.
Advantages of "no carrier compared to Stein Hall Adhesives.(This is claimed by CPC, the
maker of the system)
It requires less heat for the bond formation as the starch granules are already partially
swollen.
There is less free water. This is because the water in the adhesive is bound up inside the
swollen starch granules. Follows:
Increased machine speed-especially with double wall boards and the heavier single wall
boards.
Reduction in warped board production resulting in considerable savings
Superior storage and shear stability.
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2.4.9
Water
Caustic soda
62 lb (28 Kg)
Temperature
124 F (51 C)
MIXING TANK
Water
Collys TCF
Temperature
97 F (36 C)
100 F (38 C)
Set point
70 %
Reaction time
10-30 min.
Boric Acid
40 lb (18 Kg)
Agitation
15 min.
Dry Solids
22.9 %
Gel point
135-136 F (57-58 C)
35-40 Sec.
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compounds. A moist, warm glue line with sufficient starch application and time in the stack
(usually 12-24 hours)should enhance water resistance.
Colorants
Occasionally it is useful to color the starch to help ensure that the changeover from the domestic
adhesive has been completed at the machine. The addition of a very small amount of pigment
usually suffices.
Wetting agents
Additives are occasionally added to the adhesive with the purpose of increasing the rate of
wettabillity of the liner. Improvement in wettabillity has occasionally been noted by this practice.
However, caution must be exercised, because when the shipment of "hard to wet" paper has
been used, the wetting agent may still be in the adhesive. The next lot of paper may be
relatively easy to wet. This might allow the water in the adhesive to literally rush into the
medium, leaving insufficient water to gelatinize all of the raw starch. This would result in a white
glue line and possibly brittle bonds, loose back, etc.
Urea
Another additive has been noted to improve bonds, particularly at the single facer. The Urea
appears to help hold moisture at the glue line. The amount usually added is about 22-33 lb
(10-15 Kg) per 793 gal (3000 lt) batch.
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2.5
Application of Adhesives
2.5.1
All of us are familiar with the typical starch based corrugating adhesive as it is used in the typical
box plant. Most of us are familiar with it in its final dry form as it bonds the corrugated paper
components. However, few understand the complex sequence of events through which the
corrugating adhesive must pass as it is transformed from the liquid state of its application 4ton
the dry solid state. The process itself consist of the following sequence that most occur in this
order in the presence of adequate heat.
2.5.2
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e) Carrier loss. The carrier starch is the true adhesive because it is "dissolved" and
capable of forming a continuous film. The carrier starch is analogous to the Portland
Cement that binds the aggregate (the raw starch) in the concrete. To the extend that
carrier is lost in the paper, the proportion of aggregate to cement increases and the
quality of the "concrete"is reduced.
2.5.3
The corrugating bonding process is a highly dynamic one that is occurring on very hot moist
medium that is an ideal absorbent. After adhesive application, wetting, diffusion, and absorption
to the cellulose fibre, raw starch gelatinisation must occur very rapidly or the "Great Race" might
be lost. The competing events of 1) Water loss,2) carrier loss,3) adhesive components
separation discussed before also occur very rapidly. If they have progressed to too large an
extend, the bond at best will be marginal and the glue line will show white, ungelatinised starch.
On the other hand, if gelatinisation of the raw starch takes place to rapidly, insufficient wetting
and adhesive penetration will occur. This ultimately yields a dry crystalline surface bond and the
"popcorn" board with which, unfortunately, we are all familiar.
2.5.4
Multiple sequence
The sequence of application, wetting, diffusion, and absorption actually occurs twice at every
glue line. It first occurs on the flute tips of the medium, as weve discussed before, but it also
occurs again when the adhesive at the flute tip comes in contact with the liner which is to be
bonded. The adhesive has the ability to wet the liner and form an adhesive bond even if the raw
starch portion is completely gelatinized, provided a significant amount of drying of the adhesive
has not occurred.
Very dry corrugated medium can present a significant problem due to premature drying of the
adhesive. Excessive wet components on the other hand, also cause major difficulties by
maintaining a high moisture level in the adhesive and allowing diffusion and penetration of the
adhesive into the components to continue.
There are enormous differences in the time allowed for the bond formation process described
before to take place at the Single Facer and the Double facer.
At the Single Facer, flutes are being formed and bonded at rates approaching 600 flutes per
second with high temperatures and high pressures. At normal operating speeds, as the web
emerges from the Single Facer, at best a tenuous green bond" usually exist so that drying and
final bond formation must be effected on the bridge.
In addition, the adhesive is "killed" at the tip of the flute. That is, little or no adhesive bond exist
at the flute tip because the dwell time of the components in the nip of the pressure and
corrugating rolls is too short to allow the sequence of wetting, diffusion, absorption, and raw
starch gelatinization to occur before drying.
At the Double facer the situation differs entirely. There, the time between the application of the
adhesive to the flute tip and final green bond formulation may be hundreds or times greater than
at the Single Facer. The Double facer conditions demands the ultimate of the adhesive in terms
of water holding ability and wet tack development. This is why specialty starches invariable allow
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higher running speeds than do simple corn starch adhesives. The same properties allow
increased running speeds and improved bond quality at the Single Facer because they can be
run wetter and with less total heat from the machine and the preheaters. In addition, there is
evidence that suggest that less "killing" at the Single Facer flute tips exists with specialties than
with simple corn starch
Ex: Number of flutes per minute and second at 250 m/min.
2.5.5
Flute
Dist. Fl.
Nr Flutes
Fl/min
Fl/sec
11.7
101
21.367
356
8.66
136
28.868
481
7.95
148
31.446
524
6.5
181
38.461
641
3.25
362
76.923
1285
2.4
490
104.166
1736
Wheat Starch
Lately, the use of wheat as a component to make starch in the corrugated industry has
increased dramatically, specially in Europe because of the ready availability of wheat against
corn.
Several advantages are claimed against corn such as:
Energy savings up to 25 %, due to the use of lower steam pressure.
Reduced consumption (approx. 10 %)
More stable viscosity
Retrogradation lesser than for corn, lesser Thixotroop.
Better quality, due to the use of reduced temperatures.
2.5.6
Primary tank
Water
Meriwit AA(Wheat)
Temperature
104 F (40 C)
NaOH
SF 20 lb (9 Kg)
DB 26 lb (12 Kg)
Mixing
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Secondary tank
Water
Meriwit AA
Borax
SF 13 lb (6 Kg)
DB 20 (9 Kg)
2.5.7
Mixing
15 Min.
Viscosity
35" Bauer
Temperature
82-86 F (28-30 C)
Potato Starch.
Potato starch has become rather popular today, because of his low gelpoint possibilities.
Especially when running Triple or Double wall, this starch can give spectacular results!.
It has to be said that very often, the carrier is a mix of potato and maize starch, to increase the
stability and reduce the splashing effect of the potato starch.
Advantages and disadvantages of potato starch:
Advantages
Low gelpoint
Very high tack after gluing
A relative high solid content
A carrier system who has a good water absorption retention
These specifications are the reason for several positive advantages against other starches,
such as
Increased machine speed (increases of up to 50% have been achieved!)
Easier to run flat board(lower temperatures !)
Reduced dry board (lower temperatures !)
Possibility to run pre-printed, or with thermoplastic resins laminated paper, where the
blocking point is approx. 248 F (120C).
Much easier gluing process, less badly glued board.
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Disadvantages:
Not always price friendly
One need two separate lines towards DB
Splashing due to shorter fiber
Some potato starch specifications.:
2. pH value:
ca 12
3. Gelpoint:
203 F (50C)
4. Solid
content:
ca.27% lutro
18.4% 0,5 %
5. Humidity:
2. pH value:
ca 12
3. Gelpoint:
122 F (50C)
4. Solidcontent:
19-28% lutro
5. Humidity:
14-16 %
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2.6
Viscosity
Breakdown or loss of viscosity.
Loss of viscosity of starch can cause serious problems, such as scrap, loss of speed, brittle
bonds, low glue application, bad starch penetration, etc. and can be caused by a number of
problems, such as:
excessive water
Shear
Bacteria
The carrier starch
temperature rise.
2.6.1
Viscosity Breakdown-Water
The addition of extra water is an obvious cause of loss of viscosity. Possible causes:
Wash-up water (Cleaning!)
Water jacket at SF leaking.
Water meter inaccurate, loss of calibration, inaccurate
Excessive condensate in steamlines to heat the batch.
Starch mix equipment, leaks.
Even more important than the loss of viscosity is the loss of total solids for a given volume of
adhesive. The solids of the corrugating adhesive, usually expressed in percent, are very
important to the quality of the finished product. Higher solids may increase the total cost of a
batch of starch, but are often used today in a corrugating plant.
2.6.2
Viscosity Breakdown-Shear
This type of viscosity loss is caused by intense mechanical action and friction. Breakdown by
this cause is lessened the better the adhesive is mixed or pre-sheared while still in the mixing
tank. Specific causes are:
Agitation. The agitators in the storage tanks.
Pump and lines. Supply and return pumps, specially the gear type pumps.
Glue-metering roll gap. The squeeze through the gap.
Friction in the piping, tees, etc. Especially if the storage tanks are located at considerable
distance from the corrugator.
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2.6.3
Viscosity Breakdown-Bacteria.
The cooked starch is attacked by bacteria, which convert in to sugars which dissolve in the
water causing a lowering of viscosity. This can usually be prevented by periodically cleaning the
whole system, with Trisodium Phosphate(TSP) and Chlorine containing compounds like Clorox
or swimming pool chemicals, and adding preservatives to domestic corrugating adhesives.
Weekend storage requires additional preservatives.
Some common sources of bacteria are: dirty storage tanks and mixers, dirty circulating lines,
water, air, sweat, etc.
2.6.4
Viscosity Breakdown-Carrier
The carrier is the cooked portion of the adhesive and is the major contributor in determining the
viscosity. The type of carrier may influence the viscosity stability of the adhesive.
viscosity breakdown or initial low viscosity may be caused by a number of factors. These include
excessive shear and inadequate carrier dry weight. Excessive temperature in the carrier may
also lead to viscosity breakdown.
2.6.5
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TEMPERATURE IN F
90
91
93
95
97
100
102
104
106
108
110
42
38
34
31
28
25
23
21
19
17
15
Sec.
44
40
36
32
29
26
23
21
19
17
15
Sec.
46
41
37
33
30
27
24
22
20
18
16
Sec.
48
43
39
35
32
29
26
23
21
19
17
Sec.
50
45
41
37
33
30
27
24
22
20
18
Sec.
52
47
42
38
34
31
28
25
23
21
19
Sec.
54
49
44
40
36
32
29
26
23
21
19
Sec.
56
50
45
41
37
33
30
27
24
22
20
Sec.
58
52
47
42
38
34
31
28
25
23
21
Sec.
60
54
49
44
40
36
32
29
26
23
21
Sec.
62
56
50
45
41
37
33
30
27
24
22
Sec.
64
58
52
47
42
38
34
31
28
25
23
Sec.
C,
66
60
54
49
44
40
36
32
29
26
23
Sec.
in
68
61
55
50
45
41
37
33
30
27
24
Sec.
Sec.
70
63
57
51
46
41
37
33
30
27
24
Sec.
V isc o s ity b re a kd o wn
60
50
40
30
20
10
0
T e mp e ra ture
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3.
STEAM
3.1
General
Dry saturated steam is used to heat the surfaces of the heater drums, the corrugator rolls , the
pressure roll and the hotplates. It is also used to humidify the paper. Pressure is usually
between 174 and 203 psi (12 and 14 bar) at the machine, which means that the boiler should
run with approx. 232 psi (16 bar). Maximum steam consumption varies but a 5 to 6 ton/hr
capacity is usually recommended, as peak consumption for very heavy quality board can be
rather high.
3.2
System description
The boiler produces saturated steam at 203 psi (14 bar), which is fed direct into the Single
Facers, preheaters, glue unit heater drums and first hotplate section.
The condensate of these units is collected in the pressurized condensate tank Nr 1.
The condensate from hotplate section 2 is collected in the flash tank. The flash steam is used to
feed the 3 th hotplate section, and the condensate is directed to condensate tank 2. The
condensate of the 3 th hotplate section flows through the steam trap in to tank 2.
The individual machines have steam valves in the main and condensate lines, and steam traps
in the condensate lines.
The flash steam in condensate tank 1 and 2 is used for the steam showers. This is done through
a self acting pressure reducer who reduces the pressure to approx. 45 psi (3 bar)
The first section consists of usually between 5 and 8 hotplates.
The first hotplate section is sometimes uncontrolled, and works at line pressure. However, the
possibility to control even the first hotplate section becomes more and more practical. Especially
in case of E and F Flute, it is a must to reduce the first section as well. It is also the case for
special qualitys, such as pvc coated liners, who can only sustain certain temperatures.
The second section consist generally of 5 to 6 hotplates as well as the third section. The
pressure in these plates is regulated by means of a motorized valve, and can generally be
maintained within 1.5-3 psi (0.1 to 0.2 bar) pressure. Most of the machines today have also
temperature indicators. This gives the operators a much more realistic picture of the actual
temperature in the plates.
Far too often it is thought that a pressure difference of 29-44 psi (2 to 3 bar) gives big
temperature differences, but generally speaking, 14.7 psi (1 bar) pressure equals approx. 40 F
(4.5C) temperature. The other advantage is that a problem in the steam system, filling up the
plates with water, will be detected much quicker than with pressure indicators only.
Always regulate the sections downwards, i. O. W start with the highest pressure/temperature in
the first section, and gradually reduce the pressure/temperature in the next sections.
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3.3
Pressure is regulated in the hotplates according the type of board run, the type of starch used, i.
O. W. gel point, and the qualitys.
As a general rule, settings have to be done following two parameters:
1. The heat has to be in descending order, i. O. W. The highest pressure or temperature has to
be in the first section, and
2. The lighter the quality, the lower the pressure.
Some examples:
Type of board
Section 1.
Section 2.
Section 3
Single Wall
E/F Flute
72/102 psi
5/7bar
44/58 psi
3/4 bar
14.7/29 psi
1/2 bar
Light grade
Single wall B/C
87/116 psi
6/8 bar
58/87 psi
4/6 bar
29/58 psi
2/4 bar
Heavy grade
Single Wall B/C
145/174 psi
10/12 bar
131/145 psi
9/10 bar
131/145 psi
9/10 bar
160/174 psi
11/12 bar
160/145 psi
11/10 bar
145/131 psi
10/9 bar
Heavy grade DD
C+B, a+B, triple
203/189 psi
14/13 bar
189/174 psi
13/12 bar
174/160 psi
12/11bar
Relation Pressure/Temperature.
bar
Temp C
bar
Temp C
bar
Temp C
bar
Temp C
bar
Temp C
16
204
10
184
170
152
120
15
201
9.5
182
6.5
168
3.5
148
0.8
117
14
198
180
165
144
0.6
114
13
195
8.5
178
5.5
162
2.5
139
0.4
110
12
192
175
159
134
0.2
105
11
188
7.5
173
4.5
156
1.5
128
0.0
100
psi
Temp F
psi
Temp F
psi
Temp F
psi
Temp F
psi
Temp F
232
400
145
363
102
338
58
306
14.5
248
217
394
138
360
94
334
51
298
11.6
243
203
388
131
356
87
329
44
291
8.7
237
189
383
123
352
80
324
36
282
5.8
230
174
378
116
347
73
318
29
273
2.9
221
160
370
109
343
65
313
22
262
212
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3.4
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As already mentioned in previous chapters, it is essential that the siphon pipes are set very
accurately in the corrugator and pressure rolls.
Consequences of inaccurate setting:
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3.5
As well as siphon pipes, steam traps who are not functioning satisfactory, can cause serious
trouble on the corrugator. It was found on several occasions, that the malfunctioning of a steam
trap caused heavy production losses, due to lack of heat in the vessel.
To check the steam trap, check the temperature just before the trap. A small temperature
difference with the main pressure should be measured, but certainly not more than 50 F
(10 C).
Another way to check the steam traps is with an ultrasonic meter. This instrument indicates the
functioning of the trap by means of a sonar system. There are several types on the market, who
are also useful for other purposes, such as checking the functioning of hydraulic valves, finding
air leaks or water leaks, etc...
It is good practice to check the traps once a month. At the same time, strainers, filters etc..
Should also be checked.
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4.
PERSONNEL
4.1
General
Very often, the question is put forwards who shall we put on the new machine"? The answer is
not always easy ! The modern corrugator has completely different demands from the operators
than 10-15 years ago. In principle everybody who has the interest and the willingness to accept
the fact that a corrugator puts special demands on people. Because of the ever increasing
speed and the use of modern technology such as computers, micro processors, faultfinding
systems etc.. It is absolutely essential that the operator on the corrugator has the condition to
react quick and precise whenever the need for such action is occurring. Although age is an
important factor, it is however not the most important factor. Over the years, it was proven that
although young people tend to learn quicker, in many cases, it turned out that it was worth to
show some patience with the so-called older people, as very often, they turned out to be the
best ones after a somewhat longer learning period. The main problem when a new machine bas
been bought, is usually the fact, that so many things have been said and showed to the
interested people, that they become scared of the machine before it even started! Therefore, it
is very important to create confidence and take away the fear, by explaining to the people that
one advantage working with sophisticated, computerized machines is, that no matter what
mistake they make, the computer will tell them, and at the same time refuse to do whatever it
was told to do, or the wrong command will create such a jam-up, that the person in question will
not likely forget his mistake. In both cases, it would be extremely rare to have a breakdown
caused by wrong operation of the machine.
4.2
4.3
Job Description
Every plant has different working methods, and different machine combinations, therefore, it is
rather difficult to decide who should do what. We will however, summarize certain
responsibilitys which under normal circumstances are done by the respective operators.
Ex:More and more, the foremans job is combined, with the teltrol operators job, as the loading of
orders in the respective units, is done by on-line connections with the planning department. In
many cases however, it remains the key figure at the machine..
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4.3.1
He controls the process of making flat board, all the necessary adjustments to obtain flat
board are in his hands, therefore he must have knowledge of the complete range of
adjustments to obtain flat board.
He is responsible for quality, all defects are reported to him by the stacker operator, and he
regularly checks the quality himself. He corrects the fault himself if he can, but also
communicate the problems to the different operators.
He is responsible for quantity, which means he runs the machine at maximum speed, still
obtaining perfect board.
He keeps all operators continuously informed about possible changes in program, paper,
orders, etc...
He fills in the necessary documents, so that production supervisors are constantly kept
informed about the production data.
He checks the sheets for measurements.
He can operate the complete dry-end units.
He keeps the machine in good condition, i. O. W, he reports possible defects, gets his
operators(stacker) to clean the machine and assist himself on the proper cleaning of the
machine.
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4.3.2
He makes sure he has the right paper in his machine for the right order.
Checks his planning and makes sure he has the correct order of run.
Checks if his machine is operational, and ready to run.
Lines-up his paper correctly, regarding width.
starts the machine, and assist on readying the complete wet-end.
Knows the complete operation of the units (Modulfacer or Single Facer, bridge, glue Unit,
double facer.
Corrects settings which are in his reach only
(glue roll/corr. Roll gap, pressure roll gap).
Adjust paper tension, checks that the web is perfect.
Zeros his meter counter on bridge control and switches in AUTO.
Reports any anomalys to the foreman or the machine leader.
Inspects visually the good function of the machine on regular intervals.
Keeps his machine in good condition, and cleans thoroughly.
4.3.3
This job consists of controlling the bridge, bridge guides, bridge brakes, preheaters, glue unit,
hotplates.
Although it looks a complicated job, it is probably the easiest part of the machine to control,
because of the highly automated remote controls available on the modern machines.
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5.
General
CHECKLIST FOR CORRUGATORS
5.1
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5.1.1
Humidity(generally 8 %)
Loose edges, bad winding
Absorption
Starch penetration.(drop test!)
Caliber
Calandering, smooth surface
5.1.2
Viscosity
Gelpoint
Solid contents and consequences
Starch temperature and consequences
Bacteriological problems
Waterproof starch
Adhesion (pin adhesion test)
Starch film:
- too much
- not enough
Splashing
- glue line too wide, too small)examples
Starch penetration (absorption) Borax, caustic soda
5.1.3
Steamfaults
Check:
Pressure regulating for different quality
Single Flute
Double-Double
Triple
Pressure setting on different hotplate sections
(see list in Trainings program)
Condensate return
Syphon pipes and how to check if correct
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5.1.4
Wrong operation
Operator recognizes fault: correcting the fault
Operator denies fault: investigating fault by checking cause
- machine or operation
Fault is not recognized or is not repeated: search for cause from start, and if too late, wait for
repetition
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5.2
Checklists
5.2.1
Modulfacer group
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5.2.2
5.2.3
Splicers
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5.2.4
Bridge
5.2.5
Glue Unit LW
5.2.6
Double facer
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5.2.7
5.2.8
5.2.9
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5.3
5.3.1
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5.3.2
1. Check if all systems are switched on: Oilpump, vacuum pump, auxiliary glue roll drive
2. Put pressure on corrugator rolls
3. Open pressure roll
4. Put glue unit in auto-position, clamps in vertical position.
5. Make sure starch level is correct
6. Set glue-dams at approx. Correct width, and switch to auto when machine is running with
paper.
7. Set glue-film at correct gap
8. Thread paper into machine
9. Note: there are 2 different ways of threading the S. F:
10. Check if all systems are sw
5.3.3
Paper is threaded through splicer, preconditioner and into the S. F. The paper is run through the
machine, until the complete corrugator roll is covered with paper, the machine is then stopped,
the pressure roll closed, the glue unit is closed, the machine restarted, and the paper fed into
the take-up conveyors. This way of threading in the paper is particularly interesting for fingerless
single facers running with vacuum systems, as it prevents glue being picked up by the suction
system if glue unit is switched in to quickly. This way of threading up does not apply for
pressurized Single Facers.
5.3.4
Liner first
This is the most common way, and was always used on normal single facers. Open pressure
roll, put pressure on the corrugator roll Start the machine, thread paper through machine, pull
the paper straight, and feed the liner into the take-up conveyors. Stop the machine, close
pressure roll, insert the fluting, start the machine. When the corrugator roll is fully covered with
paper, switch the glue roll "in"and guide the paper through the take-up conveyors.
Cut a point diagonally across the machine, to prepare the web for threading through the double
facer. Switch the bridge control into automatic. Switch the paperbreak system "on", and check
your board.
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5.3.5
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5.3.6
Checks to be made before production start, make sure everything is in correct position:
1. Rotary shear if ready for cutting
2. Slitter scorer is ready: are the doors closed, no red indicators on the unit such as
emergency stops, air pressure should be minimum 87 psi (6 bar).
3. Paddles are set correctly if in manual mode.
Note: paddle setting causes more stoptimes than anything, mainly due to the fact, that very
often, one or two paddles are in the "up" position, whereas they should have been "down". Make
sure that there are always enough paddles "down".
4. Check trim suction for correct setting, if 2 units are being used (sra-t), check if change over
valve is at the right position.
5. Check if cut-off is ready.
6. Check if automatic take-off is ready: backstop setting, brushes, belt speed program is
correct .
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6.
6.1
Types of warp
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6.2
Warp is caused by imbalanced forces, either created by the machine, operator, or paper faults.
We will look into these possible causes, and discuss what we can do to improve the board
flatness and where the limits are before we have to accept that we can under certain
circumstances, no longer guarantee flat board.
6.3
This is mainly due to imbalanced forces in the machine direction. There is some dimensional
change(shrinkage) due to moisture effects which will be explained later, but generally speaking,
this type of warp is mainly due to uneven tension in the liners, after leaving the double facer.
Therefore, the solution is usually easy. Too much tension on the SF Liner can also cause length
warp.
Down warp:
Too much brake at the bottom liner, not enough at the web.
Action:
- Release the brake at the roll stand
- Increase the bridge brake
- Decrease the liner brake
- Decrease the tension on the SF Liner
A good functioning bridge brake is the best tool to prevent this type of warp.
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Up warp:
- Too much brake at the bridge brake, not enough at the liner
- Too much pressure between rider roll and glue roll
Note: Because the glue roll is running slower than the board, in many cases this excessive
pressure between rider roll and glue roll is the sole reason for upwarp. This can also cause twist
warp if the rider roll is not perfectly parallel with the glue roll!.
Action:
- Release the bridge brake
- Increase the liner brake
- Adjust the rider roll on the glue unit
Note: Preheaters can cause a lot of brake in the paper, due to friction. Many machines, if not
most have their preheaters blocked either because of technical problems, such as bearing
broken or blocked, or oil or grease systems out of order due to the use of wrong oil or grease.
Remember to use high temperature oil or grease, as this is the main reason for faulty bearings.
Once a preheater has been blocked for an extended period, it will be very difficult to make the
preheater to turn again. For light qualitys, this can have disastrous consequences regarding
length warp. Blocking a preheater is in most cases absolutely not necessary, and can only
cause trouble. It has to be remembered that the preheaters have mainly a braking system, not a
blocking system. Only when running very heavy liners 61.5-82 #/msf (300-400 gr/m2) can a
brake help to increase the temperature or even out the paper
6.4
The main reason that up or down warp occurs is shrinkage. This is due to a property of paper
called "hygroexpansivity". Which means that when moisture is put in the paper through starch or
other means, the paper will expand, but when this moisture is driven out, it will contract to a
smaller size than it was originally. In other words, the result is shrinkage. The effect is more
noticeable if the bond is formed whilst a liner is in the WETTED stage, when sufficient moisture
has been driven off. In this and similar cases, the warp may not become apparent immediately
after the board leaves the machine, but only after the board has been aged in storage. By
contrast to length warp, since there is little if any web tension across the machine, warpage
more frequently occurs in this direction. It can be said that cross machine direction warp (up or
down warp) is mainly due to moisture differences between the liners, particularly at the point of
firm double facer bonding.
It is probable that the single face liner will be wetter than the double facer liner, due to the
amount of moisture that has been added to it before it reaches this point. The moisture is added
by the water in the single facer adhesive which has not been driven off; by steam absorbed into
the S. F web during its time spent on the bridge, absorbing in addition that moisture driven off
from the double face glue line whilst in the double facer. Also whilst losing moisture from its glue
line, the double facer liner between the flute tips is being dried out considerably within the
double facer. On leaving the double facer the two liners will undergo moisture equalization with
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the surrounding atmosphere. This will involve the S. F liner in losing moisture and shrinking, and
the D. F liner in gaining moisture and expanding, therefore causing normal warp.
Note: Since the introduction of heavy concentrated starch, the above effect has become less
apparent, mainly because of the reduced amount of water in the starch. Also since the
introduction of the fingerless single facer, glue films can be set much more accurately. At the
same time, we have to conclude that the paper humidity content becomes much more of a
problem. On several occasions, tests where carried out on high speed machines 820 ft/min
(250 m/min and more) by using scanners across the machine, it was found that the warp
diagrams obtained from moisture readings, coincided completely with the warp profile at the end
of the corrugator, hence the need for extremely accurately balanced liners in cross machine
direction.
6.5
Within the corrugator there are several units and parts of units which can influence the moisture
content or the tension of the paper passing through them. Some, such as preheaters or showers
or water sprays can be used directly as control elements, and the careful monitoring of others
such as glue gap and paper temperature can lead to the reduction eventually the disappearance
of warp all together. Modern, high speed machines have much more possibilities and are much
easier to handle. It depends very often mainly from a very attentive and quality conscience
operator how good the quality of the board will be that is produced. When we talk about quality,
warp is a major factor in it. The following sections will discuss what variables in the corrugator
can be used to limit the warp to an acceptable degree, if there is such thing as an acceptable
degree" of warp
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6.6
1. DOWN WARP.
2. UP WARP.
3. S or TWIST WARP
SINGLE FACER
Check and adjust (-) Glue gap at Check and adjust (-) glue gap at Check for glue roll/
SF if possible
corrugator roll parallelism at
DB if possible.
SF
Reduce wrap at SF Preheater.
DOUBLE FACER
Reduce wrap at DB web
preheater
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1. DOWN WARP
2. UP WARP
6.7
6.7.1
Preheater
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Another consequence from not using the preheater can be very badly twisted board. It is
therefore essential to check the paper going into the different machines for temperature, as this
might help you by detecting faults on the machine.
Wrapping the paper
Incorrect wrapping
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There are two ways to thread the liner into the preheater. We can thread the paper over or
under, thus heating the inside or outside of the liner. There have always been numerous
discussions why we should use one way or the other. Lets look at the reasons why we thread
differently towards different conditions.
As a general rule, we always heat the opposite side of the glue line, i. O. W. we heat against the
side where the glue is applied. This makes the moisture to be forced through the paper, thus
wetting the side where the glue is applied. This means that the S. F paper is threaded under,
and the D. B is threaded over. This way of threading assures us the best starch penetration into
the paper.
However, in reality we should really test the paper for its glueability. With a good absorbent
paper, it could be more efficient if we heat the bonding side or the side who comes in contact
with the glue.
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We also have to look at the closeness of the paper. A closed paper which is difficult to humidify
by the glue, should not be heated to much, because this will accelerate the gelatinisation of the
glueline and disadvantage the humidification.
Heavy liners 61.5 #/msf (300 g/m2 and above)are usually run better when heating the bonding
side. However, most of the modern Single Facers have the possibility to heat both sides, as the
small liner pre- heater directly at the front of the Single Facer is used, or the machine is
equipped with a double Preheater. It is certainly worth to consider the introduction of a second
preheater when running a lot of heavy board.
Again as a general rule, we should be very careful to heat the bonding side, as this might cause
very brittle gluelines, and will show very bad pin adhesion test figures, especially when running
very light qualitys, such as white 25.6 #/msf (125 g/m2) Kraft as a liner
Another point of discussion is the fact that some people run with stopped preheaters against
running preheaters. The main disadvantage of stopped preheaters is the fact that the reason
they are usually stopped, is waterlagging, i. O. W. The siphon pipes in the preheaters are not
correctly fitted, or broken, and when the preheater is used, the bottom half is sometimes filled
with water, reducing the effectiveness of the preheater to a bare minimum. Especially when
starting on a Monday, this could have very serious consequences for the production. The only
time that stopped preheaters can give you good results, is when you need extra tension on the
paper, for ex. when there is space over the paperwidth, causing blisters, or when the roll stand
brakes are too weak to apply sufficient brake on the paper, or when the bridge brake is not
functioning properly.
Also when running very heavy liners a stopped preheater can improve the quality, again due to
the ironing effect of the preheater. In any case, a preheater should be running as much as
possible, because if stopped for longer periods the drum might not rotate at all any more,
causing most of the time too much brake on the liners.
6.7.2
Preconditioner
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6.8
It is well known that paper should have an open surface in order to allow formation of strong
glue bonds during production of corrugated board.
ECP laboratories have developed a procedure to evaluate the surface porosity of paper. It is
based on the determination of the glue uptake on a laboratory size press.
The procedures are as follows:
1. Preparation of the adhesive.
0.66 lb (300 g) one bag mix product (c. B.) are added to 0.24 gal (900 ml) water while
agitating with a propeller stirrer at 750 rpm. Subsequently agitation proceeds for another two
hours at 1450 rpm. The end viscosity should be approx. 50 SH seconds.
2. Preparation of the paper.
A plastic layer is glued on one side of the paper, the side not under investigation. The
sample is cut, 4 inch (10 cm) wide and 5.5 inch (14 cm) long. The weight is determined.
3. Determination of the glue uptake
The adhesive is added to the laboratory size press (see fig.)and the paper sample is allowed
to run between the rolls, with the side under investigation directed to the rubber roll(plastic
side to the ceramic roll)
The pressure between the rolls should be kept constant and the running speed low. The
paper samples are immediately weighted again. The difference in weight before and after
the experiment indicates the glue uptake
4. Conclusions.
Experiments with hundreds of paper samples show the following:
2
*The minimum and the maximum value obtained is 0.8 #/msf (4 g/m ) and 6.1 #/msf
2
(30 g/m ), respectively.
2
*Papers with a value above 3.1 #/msf (15 g/m ) have an open surface, allowing strong
bonding.
2
*The surface of the paper with a value at or below 2.3 #/msf (11 g/m ) is difficult to penetrate
from the adhesive, strong bonding is not self-evident. Contrary to traditional methods, such
as Cobb-test and Bendtsen porosity measurements, the so called glue pick-up test allows
evaluation of one of the paper properties of major importance. The method is quick, allows
easy handling and can be used on a frequent basis as quality control procedure.
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6.9
6.9.1
Performance liners should be wrapped with the smooth felt side against the preheaters. This
drives the moisture toward the wire side that will be bonded, thus improving the pin adhesion.
Exceptions: certain duplex papers (testliners can be very difficult to heat, thus demanding the
reverse.)
6.9.2
Paper tensioning
All medium and web liners should have equal tension across their entire widths as they wrap
around a preheater or any other heated roll. Uneven tension will result in the formation of heat,
moisture streaks, as well as uneven stretch streaks in the liners or medium. Therefore, it should
be checked if every roll, preheater or preconditioner is well aligned in the machine and easily
adjustable web idler rolls should be installed before preheaters and preconditioners, and these
should be continuously used to keep the web tensions as balanced as possible.
Whenever installing these rolls, make sure the central or parallel position of these rolls are well
marked!
6.9.3
Because performance liners heat faster, great care should be taken to use as little wrap as possible
at the preheaters. Ideally, an optical infra red Pyrometer should be used to measure and control the
temperatures of the Single Face liner and the medium before it reaches the corrugating rolls,
insuring that both papers have reached the necessary temperature for bonding, and have not
seriously exceeded it.
The temperature will vary slightly depending on the adhesive and other variables, but usually will be
around 194-230 F (90-110 C) for the liner, and about 176 F (80 C) for the medium. Across-theweb temperature measurements are also an excellent method for ensuring that the entire web is
uniform and constant. Continuously monitoring with infra red sensors across the web and reacting
accordingly is the ideal way of ensuring top quality board.
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6.9.4
A good performance medium in order to flute properly without damage, needs to be temporarily
softened by both heat and moisture. Depending on the condition of the paper, the amount of
wrap is decided towards the temperature of the outgoing paper and the humidity contained in
the paper before reaching the preheater, i. O. W. It is absolutely nonsense to put excessive
amount of shower steam in the paper without heating the surface, hence bringing the moisture
at the outside of the paper. The correct amount of wrap will result in a perfect bonding and an
ideal flute formation, preventing fluff-out after being glued. Bad preconditioning will result in
reduced flat crush, e. C. T and pin adhesion strength.
Correct tensioning of the paper will ensure a good heat transfer and even temperature over full
width
6.9.5
The width of the glue line is very important to obtain good bonding. The Single Facer glue line
should have a width of approx. 0.1-0.11 inch (2.5-2.8 mm). If the glue line is substantially below
this value, reduced (insufficient) pin adhesion strength will result. If much wider lines are
observed, wash boarding will result. This width should be checked over the machine width, to
ensure even glue lines at different speeds.
6.9.6
Parallelism of rolls.
At least once each month, non carbon required (N. C. R.) impression patterns should be made
of the corrugating rolls, checking for uniform loading pressures and crown, as well as the
parallelism of the corrugating rolls. N. C. R. Patterns should also be taken between bottom
corrugating roll and pressure roll. This can be done with a running SF across the full width of the
machine.
Equally important is the parallelism between applicator roll/doctor roll and corrugator
roll/applicator roll. These checks will assure that corrugator rolls are parallel, and that applicator
roll/doctor roll and corrugator roll/applicator roll settings are correct.
6.9.7
The DB liner should also be run with the felt side against the preheater (heating against the
glue-side)to drive the moisture toward the side to be glued, and with as little wrap as practical.
Again an Optical Infrared Pyrometer can be used to adjust the wrap to a target temperature of
approx. 176-194 F (80-90 C)on the side of the paper to be glued as it begins to enter the hot
plates. Web alignment and even web temperature are equally important as on the SF liner.
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6.9.8
The width of the DB glue line should be approx.0.08 inch (2mm). If this width is exceeded,
unnecessary wash boarding will result, and if this width is too small, reduced pin adhesion
strength will occur. Here again, checks across the machine width should be made to ensure
parallelism of applicator roll/doctor roll and applicator roll/pressure roll. Check that caliper is set
correctly!.
6.9.9
By monitoring the combined board temperature with an Optical Infrared Pyrometer leaving the
Double facer, you should be able to ensure that enough heat is present to obtain good bonding,
without overdrying the board. This temperature is usually between 176-194 F (80-90 C) at the
SF side and between 194-230 F (90-100 C) at the DB side. Keeping control of the temperature
at all times, will prevent potential problems with your board quality.
All these figures are guides, small variations can occur depending on the quality and the weight
of the papers, but these figures can help you in resolving quality problems.
6.9.11 Steam
Good functioning of the steam system is of utmost importance for your speed and quality of the
board.
Check at least once a month for :
Proper functioning of steam traps
Correct positioning of the siphon pipes. This can easily be done by checking the roll or drum
surfaces at the top and compare with the bottom. Temperature differences should be
minimal, if not, water lagging will occur in the drums or/and rolls.
Clean filters. Particularly with new installations, it can take up to one year to get rid of all the
dirt in the pipes, rolls caused by welding, cutting etc...
Check regulating valves for good functioning. Especially with machines running a big variety
in quality's (ex: from E-Flute up to heavy grade Double Wall).Good regulation of heat in your
machine will prevent warp and waste.
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7.
7.1
7.1.1
Production
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7.1.2
1. Switch off bridge control, paper break, and glue dam automatic
2. Slow down machine to idling speed and cut the paper, making sure the glue roll is away
from the corrugator rolls before the fluting is out of the rolls!
3. Shut off pressures, corrugator rolls and pressure roll
4. Shut off starch lines, empty glue tray
5. Bring glue trolley out of machine
6. Switch on automatic cleaning of the suction nozzles
7. Stop vacuum pump, close cooling water system
8. Clean the glue roll and glue tray with water and stop the idling roll. (Once a week, take out
the glue dams and clean completely)
9. Clean the complete machine with steam jet
10. Clean surroundings and outside of the machine, take special care for the glue dam guides
11. Clean filters(motors, panel etc.)
12. Close steam lines and stop machine
13. Switch off main panel
7.1.3
Production
During every long stop time.:
- Retract glue trolley to avoid starch heating and gelling
- Clean the suction nozzles in "auto, always make sure the glue trolle
is out of the machine.
Caution: Before starting the cleaning sequence, make sure nobody is in the machine!
- Switch off all hydraulic pressures
- Stop the vacuum pump
- Run the machine at idling speed
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Maintenance
During every long stop time.:
Oiling the glue tray rails (a few drops of oil will do)
Grease the Glue Dam guides
Make sure the limit switches are clean and work properly
7.1.4
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7.2
7.2.1
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7.2.2
To start machine
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7.2.3
7.2.4
When not in use, close steam valves and stop rolls. Clean rolls with steam jet delivered with the
machine. If necessary remove all residues from rolls. Make sure no foreign material or dents or
other damages are present. If so, report to maintenance personnel immediately.
Do not spray cold water onto heated corrugator rolls! This might result in cracks or
distortion of the rolls!
Do not use cleaning agents which contain abrasive material! Seriously reduced roll
lifetime will result.
When it is necessary to use, start rolls ONE HOUR PRIOR TO OPERATION, and open steam
valve slowly.
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7.2.5
7.2.6
Changing Modules
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7.2.7
In order to maintain continuous operation of the Modul Facer, it is essential that the machine is
kept clean. The following instructions have to be followed when cleaning the MF.
Before starting the cleaning, make sure all safety precautions have been taken!
Safety provisions for cleaning.
Prior to any work carried out on the MF, machine and blower must be switched OFF. Make sure
all movements have ceased.
If, for any reason, work has to be carried out on a running machine, the utmost care has
to be taken, such as:
Wear no loose or suspending clothing
Long hair has to be covered!
Suspending jewelry, rings as well as other personal items, which might be entangled by the
machine have to be removed!
No work may be performed in the immediate vicinity of roll intake, swivel range or moving
mechanisms with machine running
It has to be ascertained that machine is running at bottom speed, and that a qualified person
is positioned at the EMERGENCY STOP switch
Be careful when working at heated machine, wear protective clothing and/or close off steam
valves
For machine protection!
Make sure:
- the glue-unit is fully retracted
- that the pressure roll does not touch the top corrugator roll
- the pressure on all rolls is zero ("0")
- not to spray water onto the corrugator rolls or other heated parts
Caution: Heat shock might result in cracks or distortion of heated parts!
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7.2.8
Do not spray cold water onto heated corrugator rolls! This might result in cracks or distortion of
the rolls!
Do not use cleaning agents which contain abrasive material! Seriously reduced roll lifetime will
result.
7.2.9
7.2.10 General
Clean the machine surroundings completely and remove all paper rests, gelled starch and
other foreign materials
Clean gangway, steps and floor. Remove any oil or other liquids from operational and
maintenance range to avoid accidents caused by slippery surfaces!
Look after your and others safety at all times!
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7.3
Splicer ARW-N
7.3.1
Production
Splicer Start up
Always check first that the unit is free and nobody is in the machine.
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7.4
Always check that the roll stand has clearly defined markings of the paper widths. Markings
should be on the floor, so that no matter what the positions of the reel stand arms are, the
paper reel should always be in the correct position. Make sure the hydraulics are not leaking,
the paper reel should not drop!.
7.5
7.5.1
Operation.
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7.5.2
Cleaning instructions
1. Bring Tensioning roll in bottom position, by reducing the pressure at the tension gauge
Below 29 psi (2 bar), the roll will start to descend
2. Put accumulator in threading position (forward)
3. Take paper out of the roll stands
4. Switch off power at the main panels
5. Close air valve at the splicer
6. Clean the machines completely with air or steam jet
7. Clean all filters
7.5.3
7.5.4
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7.6
7.6.1
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7.6.2
Splice Preparation
1. Cut point on paper and feed between rolls and splicer carriage
2. Apply brake on paper reel
3. Pull paper straight, fold paper over cutting edge, and push the magnets onto splicer
carriage. These magnets are simplifying the cutting of the paper
4. Clamp the paper by pushing the "Clamping bar"->||<- push-button
5. Apply tape to paper. Making sure the tape is even with the cutting edge of the paper. By
doing so, the "Zero Tail" is obtained
6. Cut edges at 113 F (45 C) and cut paper over the full width
7. Remove tape cover and turn rubber roll back until pointer(visible in mirror!)is at front of the
tape
8. Reduce brake and bring prepared unit into splicing position by pushing "Forward" button
9. Tighten paper and push "Brake ON" button (approx. 14.7 psi (1 bar) brake power.)
10. Check if "Splice Start" button is illuminated
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Release button.
Push button.
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7.7
7.7.1
Production.
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7.7.2
Cleaning instructions
7.7.3
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7.7.4
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7.8
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8.
Influence on Production
General
Why should Maintenance people understand so much about production?.
While the first can not be split from the latter
In every corrugated board plant, what counts is the quality and quantity of produced board. To
reach this goal, with a minimum amount of waste, the maintenance and production personnel
must work as a team!
Lets run through the main parts of the machine, which can cause breakdowns, at the same time
causing stop times for the production. It is, however, not possible to mention all reasons for stop
times. We hope that this is a guide to help find the faults in your units, no matter what make of
machine you have.
8.1
Roll stand
Machine problems
Production Influence
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8.2
Production Influence.
Fail splices.
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8.3
Production Influence.
Preheater is stopped.
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8.4
Production Influence.
Inadequate vacuum.
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8.5
The Preconditioner
Machine problems
Production Influence.
Paper breaks.
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8.6
Overhead Bridge
Machine problems
Production Influence.
8.7
Machine problems
Preheater is stopped.
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8.8
Production Influence
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8.9
Production Influence
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Machine problems
Machine problems
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Machine problems
Bad cutting.
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Production Influence.
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Troubleshooting
1.
1.1
Correct type and color of paper (Kraft, testliner, white Kraft etc..)
Correct winding. Ex: Running Kraft paper the wrong way can cause peeling on hotplates and
Printer Slotter pull-rolls!
Correct weight, check against specifications!
Correct flute(A, b, c, AB, AC etc..)
Smooth, flat surface, none or minimal wash boarding
Pressure lines at SF are minimal, no splitting can be done
DB side, check for dirt marks in length directions(dirty hotplates!)
Check for glue patches on SF side, belts are clean!
Edges are cleanly cut, no ragged edges
1.2
Measurements checks
Check:
Width
Length
Score distance
Score depth
Correct score alignment(top and bottom)
Caliper
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1.3
Gluing checks
1.4
General
1.5
Some of these tests are more important than others. We will look at these important tests and
see what can cause loss of test values on the corrugator.
1.5.1
This test is of high importance for the final strength of your box, and can be seriously influenced
by the corrugator.
Corrugator rolls out of parallel
Over tensioning on the fluting
Rider roll on Glue Unit too low!
Too much starch on glue unit
Rolls in DB out of parallel
Too much weight at D. B. On low grade board (too many rolls or too much pressure!)
Gap infeed rolls on cut-off knife too small
Gap outfeed rolls on cut-off knife too small
These faults can be detected through the FCT Test, but only when done after the corrugator
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Fig 1
1.5.2
The edge crush test will in most cases be reduced by damaged fluting in length direction.
Badly adjusted fingers or suction nozzles. (Touching the paper!)
Too much suction or too much pressure in pressure chamber
Worn corrugator rolls
Uneven glue lines in length direction
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1.5.3
Poor bonding, bad glue lines and all the same reasons as for the edge and flat crush test will
diminish the values of the Compression test.
1.5.4
BT or Burst Test
1.5.5
Mullen Test
These tests determine the strength of the paper or board for bursting strength. Can be highly
influenced by :
Pressure lines on board, due to pressure lines on SF. Cause: too much pressure on pressure
roll.
Too humid board, caused by wet paper or too heavy glue lines.
1.5.6
Tests the bonding of the board. Pulling the paper apart will show fibre tearing. When starch
penetration is good, it should be impossible to tear paper off without fibre sticking on to the flute
tips.
1.5.7
T or Thickness test
Thickness of the board should be measured with a thickness gauge. A list with theoretical
caliper of the different board grades should be available at all times in the appropriate place
(most of the time, at central control desk).
This list should contain the theoretical caliper with the allowed tolerances. Very often, caliper
gets ruined because of the badly adjusted rider roll at the glue unit.
1.5.8
Drop Test
Measuring at which speed the water is absorbed into the paper. A drop of water is put onto the
paper and the time of absorption is checked.
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1.5.9
Cobb Test
Measures the volume of water absorbed into the paper. This test is important for the gluing of
the board, and for deep freeze product, where the de-congelation causes condense water,
which will be taken-up by the paper.
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2.
Different factors which can cause waste on the corrugator are in order of appearance on the
machine:
2.1
Paper
2.2
Machine
2.2.1
Single Facer
Double Backer
Proper use of the bridge(do not overfill!)
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2.2.3
Rotary shear
2.2.4
Slitter Scorer
2.2.5
Cut-off knife
Pull rolls are down and set to board caliper (board thickness 0.004 in/0.1mm) .
Correct length setting
The orders are going to the correct knifes
Unit cuts correctly (no ragged cutting)
Accuracy is within limits
Board is going into unit without "jumping", board line is steady
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2.2.6
Stackers
2.2.7
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3.
3.1
Paper reels
Modern high speed machines, equipped with fingerless Single Facers have the reputation of
running extremely good quality board with poor quality paper. Although this is through in many
ways, we have to consider a few important facts.
The higher the speed, the more accurate the winding has to be, because of the influence of
jumping" at the SF. So the reels have to be perfectly "round", if not, immediate speed
reductions are the consequence, if not waste!
The cores have to be of good quality, and well positioned in the reels. Due to the fact that
very heavy reels (up to 3 tons and more!) are today being run at extremely high speeds, the
forces put onto the cores by the brakes are much higher than before. The cores have to be
of a fixed diameter, preferably a solid strong quality, so as to be able to run reels until the
last meters!.
Bad or extreme thick splices in the paper cause long stoptimes and waste. The splices
should be well marked, so that the operator can react towards these bad splices.
Paper stored outside always causes more trouble than paper stored inside, again, this
shows up much more with high speed machines and this practice should be abandoned.
Transport from the store to the machine is in many occasions, very damaging. It should be
remembered that due to the higher amount of rolls in the machine, it is practically impossible
to run badly damaged paper reels through the splicers.
Handling of the paper on the machine should be carried out with the necessary caution, to
avoid missed splices or even blocked suction nozzles due to big cuts in the paper.
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3.2
Machine
3.2.1
Single Facer
The heat transfer is a major factor in the whole machine, therefore, regular checks of the
steam condensate system will help considerably. Bad condensate return or badly positioned
siphon pipes will cause serious trouble, not only speed wise but also regarding warp.
Considering that 14.7 psi (1 bar) of steam represents aprox. 39 F (4 C), it is sometimes
surprising to find preheaters with temperatures at the bottom part of 149-158 F (65-70 C)! This
means that the siphon pipes are not there anymore or badly positioned.
Lining up of the paper is essential for good running with a Fingerless S. F. More than a
conventional Single Facer, if the paper is not lined up properly, and glue does get into the
corrugator rolls, inevitably the flute formation will be poor, and the paper will prematurely leave
the corrugator rolls, because the vacuum will not be strong enough to hold the flutes in the
corrugator rolls.
Glue roll-Corrugator roll setting is also vital. Due to the fact that the suction does not allow for
any fluff-out, the distance between the corrugator roll and the glue roll has to be extremely
accurate. The simple fact that the side frames of the SF take aprox.3 to 4 hours to heat up,
means that during this time, regular checking has to be done, to make sure the distance is still
OK. When changing from light to heavy fluting, the same adjustment should be done, to allow
for the paper thickness.
Pressure roll setting is equally important. In this case, too much pressure will cause badly cut
liner, not enough pressure will give unglued board. It has to be remembered that although we
talk about pressure, we really mean distance. The hydraulic pressure on the Single Facer
Pressure roll should remain fixed, and the gap correction is done by adjusting the gap by means
of two independent electric motors with electronic digital indicators.
Glue Dams can cause a lot of waste if not in the correct position. Although usually equipped
with automatic positioning system with photo cells, it is always possible that the system is not
functioning properly, or the glue tray is packed with gelled starch, or the glue dams are
extremely dirty. It is good practice to check on regular intervals if the dams are still in the right
position, because if not, the machine will run waste very quickly. As soon as some glue is
running in the corrugator rolls, the nip pressure will be insufficient to form proper flutes, and the
fluting will fall out of the corrugater rolls. When running full reels, it is recommendable to switch
the automatic to manual, so that the dam can not move during the time the reel is running.
Glue gap setting has to be optimal, i. O. W. The minimum glue should be applied. Too much
glue causes up warp, not enough glue causes bad gluing and dry sheets. The surface of the
board should be unmarked by the suction nozzles, on condition that the glue roll -corrugator roll
setting is correct, and the glue gap is set correctly.
Note: Check the Glue roll surface on regular intervals for cleanliness. Check also for chalk
deposits on the surface, due to excessive presence of chalk in the water used for starch making.
This can cause serious glue film problems. If necessary, clean with a solvent (ex: ARDROX
1050). Attention: This product should only be used in pure form (not mixed with water), if not,
serious damage on the chrome surface might occur!.
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3.2.2
Double Backer
Proper use of the bridge. A bridge can cause waste in the sense that when misused, warp
can be created when overfilled. Also badly compressed web will cause marked sheets, thus
waste. It is important to regulate the bridge content such that a reasonable amount of web
should be stored. This is done automatically when an automatic bridge control is available,
but even so, when the D. B is stopped, it depends on the common sense of the operator not
to continue running with the SF at bottom speed until the bridge is overfilled so much that in
many instances, it is only detected when the bridge belts slip over the pulleys due to the
excessive weight loaded onto the bridge. At the same time, board which has been run at
bottom speed at the Single Facer, is too dry and therefore nearly always badly warped.
Do not try to run bad web (badly glued at SF, broken flutes, etc.) through the machine. In
most instances, again the common sense of the operator at the D. B will avoid long
stoptimes if he takes the right decision. By trying to run the bad web through the D. B it
happens very often that extreme long stoptimes are caused at the rotary shear due to
blockages, or at the next units due to jam-ups.
Set bridge guides at correct position. This unit, although very simple, causes more waste
than anything else at the D. B. When the web and the bottom liner are not lined up properly,
usually a lot of waste is the result at the Slitter Scorer. In the best case, only one side of the
board is wasted, but in many cases both sides (drive and operator sides) have to be wasted.
It is therefore very important that the D. B operator keeps a close watch at the position of the
web guides. In many instances, the best solution is to go on the bridge and check visually if
the guides are in the proper position. Web can be much smaller as required, due to
shrinkage, paper can be smaller than indicated on the reel etc.
Use correct amount of brake on the web brake unit. Running flat board in length direction
will depend mainly from proper balance between top and bottom brake units, one applied
onto the bottom liner, the other applied onto the web. A good operator will very quickly
remember the different settings of the brake values.
Correct use of the preheaters. As already described in previous chapters, the correct use
is vital for the board quality. Wrong use of the pre-heater will inevitably cause waste either
by causing bad bonding(cold) or by causing badly warped board.
Glue unit Major causes for waste are inaccurate caliper settings, causing crushed flutes and
bad length warp caused by the speed difference of the glue rolls. Wrong glue application
due to badly adjusted glue film. Too much glue causing warp, not enough causing bad
bonding. Badly adjusted glue dams, causing unglued edges.
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4.
GENERAL
One of the most difficult jobs on the corrugator is the detection of faults, to determine where it is
originated from, and to take the correct action to solve the problem. The difference between a
good running corrugator with high production figures and low waste, lies usually in the presence
of a exceptionally good foreman, crew member or operator. With the modern high speed
machines, the rapid detection of a board fault can make a huge difference in the waste figures.
It is therefore essential to organize the corrugator crew such a way, that over the full length of
the machine, every operator takes care of the quality, and report the defect to the right man. It
will then depend highly on the skill of the man, how quick and how accurate the fault will be
remedied.
In the pages, we will try to summarize the most common faults which occur at the board and
their relation towards the machine.
In the first column, we will describe the fault, the second we will try to give the reasons for the
fault, and in the third column, we will summarize the possible solutions to cure the fault.
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4.1
No.
Fault
Cause
Remedy
1.
2.
3.
4.
5.
6.
Insufficient vacuum
Blocked suction tubes
Too low pressure on corrugator
rolls.
Glue in corrugator rolls, causing
bad flute formation.
Badly lined fluting, too close to
slots.
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7.
8.
Broken Flutes.
Damaged flutes
9.
10.
11.
Run faster.
Reduce steam pressure.
(Between 147 & 189 psi / 10 & 13
bar.)
Apply steam with shower.
Reduce pre-heater wrap.
Reduce wrap at liner preheater(small pre-heater before
pressure roll.)
Check water absorption of
papers.
Check and improve starch if
necessary(Borax!)
12.
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13.
4.2
Modulfacer (Pressurized)
No.
Fault
Cause
Remedy
1.
2.
Excessive glue
Pressure corrugator rolls too low
Starch in corrugator rolls, due to
badly adjusted dams
3.
Insufficient heat.
Starch gel point too high.
Starch viscosity too low.
4.
Flutes disturbed
(falling out of corrugator
rolls)at high speeds.
5.
6.
7.
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8.
4.3
Increase pressure
Check and replace seals
Check and replace damaged
clean-out fingers
No.
Fault
Cause
Remedy
1.
Remedy:
Adjust bridge brake
Adjust pressure at PR roll SF.
Check condensate return system
Adjust hotplates.
2.
Check temperature.
Check condensate return system
Adjust weight rollers.
3.
Clean hotplates.
Change belt.
Clean rollers
Adjust rollers.
4.
5.
Leaning flutes.
Adjust gap.
Reduce weight rollers
6.
Length warp.
(Upwards).
7.
Twist warp.
S-Warp.
8.
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Badly adjusted weight rollers.
Worn hotplates.
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9.
10.
11.
Clean hotplates.
Remove paper
4.4
Slitter Scorer
No.
Fault
Cause
Remedy
1.
2.
3.
Correct 0-point
4.
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4.5
Cut-Off
No.
Fault
Cause
Remedy
1.
2.
Adjust backlash.
3.
Adjust speed.
Adjust gap.
Replace pull roll.
4.
5.
4.6
Stacker
No.
Fault
Cause
Remedy
1.
Creases in board at
stacker.
2.
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Knowlegde Review
Introduction
This questionnaire is to help you to test your understanding of the function, control and
operation of the various BHS Corrugated machines, which make up a complete corrugator. Also
topics such as starch, paper, steam and maintenance will be addressed.
OBJECTIVE
After completing this questionnaire, participants should have:
1. A general understanding of the function, control and operation of the various machines in a
complete corrugator both in the wet-end as in the dry end.
2. A general understanding of the bonding process, which is used to make corrugated board.
Also problems with bonding will be discussed.
3. A general understanding of the various paper types, which are used in the corrugator and
the problems that can occur in this area.
4. A general understanding of the steam system used on the corrugator.
5. Some basic information about the routine maintenance on the various machines.
PREREQUISITES
The participants should have a basic understanding of running a corrugator. This can be from
experience or from pre-training.
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QUESTIONNAIRE LAYOUT
The theoretical part is made out of following chapters:
Machines in the Wet-end
Machines in the Dry-end
Starch
Paper
Steam
The practical part is made out of following chapters:
Machines in the Wet-end
Machines in the Dry-end
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Theoretical Part
1.
1.1
1.
A.
B.
To splice the paper running from a roll stand and coming to an end, to the new prepared roll.
C.
2.
What is the function of the brake-units attached to the roll pick-up arms?
A.
They enable tensioning of the paper web between the roll stand and the succeeding machine
(splicer).
B.
C.
3.
What is the min. roll diameter on your roll stand? (25,4 mm. = 1 inch)
A.
B.
C.
4.
A.
B.
C.
5.
On a 110 inch (2800 mm) width machine what is the max. allowed roll weight? (1 Kg. =
2,2 lb.)
A.
B.
C.
6.
On a 110 inch (2800 mm) width machine what is the min. working width of a roll?
A.
B.
C.
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7.
On a 110 inch (2800 mm) width machine what is the max. working width of a roll?
A.
B.
C.
8.
A.
B.
C.
9.
A.
Pneumatically.
B.
Electrically.
C.
10.
When you try to lift a roll which exceeds the max. allowable weight, what happens?
A.
B.
C.
A pressure control valve at the drive side limits the max. hydraulic pressure, when this pressure
is exceeded lifting is not possible.
11.
A.
The process of unwinding is effected by the pull of the paper web of the succeeding machine
(single facer or double facer), with the possibility of continuously adjusting the web-tension via
controllable, pneumatic brakes in the tensioning arms.
B.
C.
12.
A.
To detach a roll is not possible, when the load exceeds 396 lb (180 kg)
B.
Always.
C.
13.
A.
B.
When the new roll has the same width, you can line it up flush and laterally with the already
running roll. In case different width you can refer to marking plate on the floor.
C.
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14.
A.
B.
C.
1.2
Splicer ARW-M
1.
A.
The function of the splicer type ARW-M is to splice the paper running from a roll stand and
coming to a end, to a new prepared roll.
B.
C.
2.
A.
The splice must be firm and reliable (high degree of splice reliability), corrugator speed does
not have to be reduced during splicing process, web tension hardly changes during splicing, all
paper qualities in common practice can be used and splicing is done fully automatic.
B.
All off the above, but splice reliability is the least important.
C.
It is important that at low splice speeds the splice is firm. We accept that this goes done, when
the speed goes up.
3.
A.
B.
C.
Automatically, when the weight of the roll comes below a predetermined level.
4.
A.
Web brakes, clamping bar, storage carriage with storage rolls, pressure rolls, splicing
carriages, toothed knife bars.
B.
C.
5.
A.
Report to maintenance.
B.
C.
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6.
The green Splice Start luminous key does not light, what does this mean?
A.
B.
C.
7.
The red luminous key for collective fault is flashing, what could this mean?
(1 bar = 14.7 psi.)
A.
B.
C.
Air pressure has fallen below 73.5 psi (5 bar) or the knives are not in the top position.
8.
What is the function of the marking lever above the splicing roll?
A.
To line up the beginning of the adhesive tape with the end of the marking lever brings the
paper end with tape in the correct position for splicing.
B.
C.
9.
What happens when the protective covering band is not removed from the double-sided
tape and you perform a splice?
A.
B.
C.
10.
Name some reasons that the splicer is not ready for splicing?
A.
B.
C.
Storage is empty and second splicing carriage (which is not needed) is not in its outer position
(pull towards you).
11.
Explain how the splice operation works, when you have splice release at min. diameter
selected?
A.
Rotary switch selected to release on diameter. On reaching first min. diameter (approx. 7.9
inch [200 mm]) of the old paper roll orange luminous key flashes, when the second min.
diameter is reached (approx. 5.5 inch [140 mm]), automatic splice is released.
B.
C.
This function can only operate if there is an optional Rest Roll Computer installed.
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12.
A.
When you interrupt the automatic release on min. diameter by pressing the flashing orange
luminous key (light off) the operator is in manual control and must therefor release the splice by
pressing the green Splice Start luminous key.
B.
C.
13.
A.
B.
C.
Operate the Basic position on (Home position) key on the operating box, this moves both
splicing carriages to their outer position and the clamping bar to the opposite side.
14.
A.
B.
C.
Only electrically.
1.3
1.
Why can the flute change on the BHS Modul Facer (MF2) be carried out so quickly?
A.
B.
C.
Due to the two pivoting corrugating roll modules, whereby one is in the working position and
the other is in the parking position. For easy cleaning and access also both corrugating roll
modules can be parked in the parking position.
2.
What is the max. production speed of the machine? (1 m/min = approx. 3.3 ft/min)
A.
Depends on the flute which is chosen, paper quality, glue type and properties, etc.
B.
C.
3.
A.
One of the three cylinders of the bandleader, upper and lower corrugating roll, the second
corrugating roll module, preheater and preconditioner.
B.
Only the two corrugating rolls which are in the working position in order to save on energy.
C.
The three cylinders of the bandleader, upper and lower corrugating roll, the second corrugating
roll module, preheater and preconditioner.
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4.
A.
It does not really matter, any pressure between 29.4 and 117.6 psi (2 and 8 bar) will do.
B.
BHS recommends between 176.4 and 205.8 psi (12 and 14 bar).
C.
5.
A.
B.
C.
6.
A.
An hydraulic motor.
B.
C.
7.
The second corrugating roll module which is not in use can also be driven, how?
A.
Electrically
B.
C.
8.
A.
For lubrication.
B.
To prevent local spots which have a lower temperature as the rest. When this corrugating roll
module is required for production the rolls are heated equally.
C.
9.
A.
B.
C.
The rolls inside the glue unit and the two corrugating rolls.
10.
A.
B.
By an air compressor.
C.
By a fan.
11.
What is the normal working pressure in the glue unit? (1 bar = 1000 mbar)
A.
B.
C.
Atmospheric pressure.
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12.
On the Modul Facer with Bandleader how is the glue unit sealed, when it is loaded?
A.
It is not sealed.
B.
C.
A springloaded Teflon sealing bar seals at the bottom against the lower corrugating roll, two
rubber seals one on each side of the glue unit seal against the frame of the corrugating roll
module and a felt sealing strip on top of the glue unit seals against the belt of the Bandleader.
13.
A.
B.
In order to keep the formed fluting medium in contact with the upper corrugating roll module.
C.
To make sure that there is positive contact between liner and medium.
14.
A.
To create a differential pressure between the pressure inside the glue unit and the ambient
pressure; this keeps the fluting medium firmly in the flute profile of the upper corrugating roll.
B.
C.
This allows the fluting medium to come out of the profile of the corrugating rolls in order to pickup glue from the glue-application roll.
15.
A.
B.
C.
16.
A.
To prevent contamination with starch on the corrugating rolls outside the width of the fluting
medium.
B.
They make sure that the glue level outside the dams stays always high in order to lubricate the
scrapper blade of the doctor roll.
C.
To control the glue film, which is applied onto the flute tips.
17.
A.
A fibre optic system at the fluting infeed before the preconditioner detects the width of the
fluting medium by detecting both paper edges.
B.
C.
18.
Where is the control system, which sets the glue dams automatically; selected?
A.
B.
C.
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19.
Can you also set the glue dams manually and why is this function required?
A.
B.
Yes, if we want some more glue on the paper edges, we can move the glue dams a little more
outward.
C.
Yes, to give an offset i.e. when the width of the liner is smaller then the fluting medium the glue
dams can be moved more inward to prevent that we get starch on the corrugating rolls.
20.
Describe the manual operation of the glue dam positioning, when the glue dam
automatic is on?
A.
A total of four rotary switches allow manual adjustment of the glue dams. Two are located at
the operator side and two at the drive side. One selection moves the applicable glue dam
approx. 0.4 inch (10 mm) in one or the other direction.
B.
Same as above, but the adjustment (offset) is only approx. 0.08 inch (2 mm)
C.
As long as you select and hold one of the four switches the applicable glue dam moves.
21.
A.
The doctor roll applies the glue onto the flute tips.
B.
The applicator roll applies starch to the flute tips according to the gap adjusted between the
applicator roll and the upper corrugating roll.
C.
22.
A.
B.
C.
To heat the single faced web, to achieve better bonding with the bottom liner.
23.
A.
It is used for moistening the fluting medium and thus improving the formation of the fluting. The
use of the steam shower is used when heavy grammage fluting medium, with a too low
moisture contents used or i.e. Semi-Chemical paper.
B.
To increase the moisture of the fluting medium, when its own moisture content is already very
high.
C.
24.
What is the function of the wrap roll on the preconditioner and preheater?
A.
B.
C.
To control the wrap around the heated drum. These adjustable guide rolls can decrease or
increase the wrap and thereby control resp. the temperature of the fluting medium and the
liner. The wrap arms move automatically in relation to corrugator speed.
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25.
A.
B.
When the main switch on the switch cabinet is in the on (1) position
C.
26.
When you start the Modul Facer, what do you thread up first the liner or the fluting
medium?
A.
The liner.
B.
C.
Both together.
27.
When you thread up the fluting medium, what must you do with the lower corrugating
roll?
A.
B.
C.
28.
Why is it better to heat up the machine for some time before you start production?
A.
B.
C.
29.
A.
By making sure that during production the glue return pump is not running.
B.
C.
30.
Why is it so important that the glue dams are in the correct position?
A.
B.
Otherwise starch can contaminate the corrugating rolls, resulting into bad fluting formation.
C.
If they are not in the correct position, too much glue is applied onto the flute tips.
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31.
A.
B.
Machine runs at base speed, briefly start the air pressure system and inclined conveyor. You
increase the automatic web tension on the liner roll, cut the paper to a point on the operator
side, feed the liner through the external preheater, insert the liner via the integrated preheater
into the Modul Facer, between the upper corrugating roll and the Bandleader. Pull liner though
and feed into inclined conveyor. Decrease the web tension on liner. Now stop the machine.
C.
Machine runs at base speed, briefly start the air pressure system and inclined conveyor. You
reduce the automatic web tension on the liner roll to 0 psi (0 bar), cut the paper to a point on
the operator side, feed the liner through the external preheater, insert the liner via the
integrated preheater into the Modul Facer, between the upper corrugating roll and the
Bandleader. Pull liner though and feed into inclined conveyor. Increase web tension on liner.
Now stop the machine.
32.
Why is the web tension of the liner roll removed prior to feeding in the web?
A.
In order that the roll is not braked and the paper can be pulled more easily into the Modul
Facer.
B.
C.
To increase tension in the liner, which improves the threading up of the paper.
33.
In what position is the preheater wrap arm, when you insert the liner?
A.
B.
C.
34.
A.
B.
First the liner is in. Compressed air fan off and inclined conveyor switched on. Reduce web
tension on the fluting roll to 0 psi (0 bar). Guide the fluting medium over the guide rolls into the
preconditioner and over the steam shower to just in front of the corrugating rolls. Start machine
and insert fluting medium in between corrugating rolls. Guide the fluting medium together with
the liner into the inclined conveyor. Increase web tension on fluting. Check pressure lines and
the bonding of the single faced web and make adjustments if necessary. When satisfactory cut
the web diagonally across the width below the inclined conveyor. Remove the waste from the
bridge. Now you can load the bridge.
C.
First the liner is in. Compressed air fan on, inclined conveyor on and drive glue unit on. Reduce
web tension on the fluting roll to 0 psi (0 bar). Guide the fluting medium over the guide rolls into
the preconditioner and over the steam shower to just in front of the corrugating rolls. Cut the
fluting medium to a round point in the middle and apply some adhesive double-sided tape
(remove backing tape). Start machine and insert fluting medium in between corrugating rolls.
When the upper corrugating roll is completely wrapped with the fluting medium load the glue
unit. Guide the fluting medium together with the liner into the inclined conveyor. Increase web
tension on fluting. Check the pressure lines and the bonding of the single faced web and make
adjustments if necessary. When satisfactory cut the web diagonally across the width below the
inclined conveyor. Remove the waste from the bridge. Now you can load the bridge.
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35.
At which stage do you load the glue unit, when you feed in the fluting medium?
A.
When the upper corrugating roll is completely wrapped with the fluting medium.
B.
After you have loaded about 33 ft (10 meters) onto the bridge.
C.
Before you insert the fluting medium in between the two corrugating rolls.
36.
When do you cut the single faced web and remove the bad formed single faced web
from the bridge?
A.
When the pressure lines and the bonding of the single-faced web are satisfactory.
B.
After you have produced at least 330 ft (100 meters) of single faced board.
C.
You dont have to do this, you can collect the bad formed board at the stacker.
37.
A.
Cut the web diagonally across the width below the inclined conveyor.
B.
Cut the web straight across the width below the inclined conveyor.
C.
Cut the web with a point in the middle below the inclined conveyor.
38.
What determines the web tension on the fluting medium and the liner?
A.
B.
C.
39.
Where do you control the alignment of the fluting medium and liner?
A.
B.
At the Splicers
C.
40.
Before filling up the bridge, which other control function must you switch on at the
Touchscreen control?
A.
B.
C.
41.
What must you check when filling up the bridge and once again when reaching
production speed?
A.
The bonding.
B.
C.
Good alignment of liner and fluting medium, bonding and pressure lines.
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42.
After the bridge is loaded and you have started the double facer, which switch must you
operate on the control desk of the Modul Facer?
A.
B.
C.
43.
A.
B.
C.
At the Touchscreen.
44.
Which of the two paper webs do you cut before the flute change?
A.
The fluting medium, because it runs between the two corrugating rolls.
B.
C.
45.
If you want to operate the flute change sequence, in what position must the glue unit be
in?
A.
B.
C.
The position of the glue unit is not important during the flute change sequence.
46.
A.
B.
C.
47.
How do you know which key to press in order to carry out the flute change correctly?
A.
B.
C.
The luminous key switches at the machine switch cabinet flash one by one, to indicate the
correct sequence and guide you through the flute change menu.
48.
A.
No
B.
On the Touchscreen you can select Modul change menu, which allows you to monitor the
flute change on the screen.
C.
Only by observing.
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49.
What is the function of the lamp test key switch, when you perform a flute module
change?
A.
This lamp test key switch checks all lights in the other luminous key switches, which are
required to guide you through the flute change menu.
B.
To test if the light inside the lamp test key switch is OK.
C.
This switch informs you if you can perform a flute module change.
50.
What are the advantages of the Quality menu option which is available at the
Touchscreen?
A.
B.
It tells you the recommended splice speed in relation to the Quality which is running.
C.
Production experience can be saved such as, qualities, wraps, steam shower, glue gap, glue
applicator gaps and can be recalled, if required and send to the machine.
51.
A.
B.
It shows the presence of failures, messages and maintenance items due. It has the build-in
possibility to show (photo images) these items and offer remedies.
C.
All messages, failures and maintenance items are stored in the memory.
52.
A.
Daily.
B.
Monthly.
C.
Every hour.
53.
A.
B.
Water.
C.
Steam pressure.
54.
A.
B.
The glue applicator roll, doctor roll scraper blade and the glue dams.
C.
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1.4
Preheater VZR-M
1.
What is the function of the syphon pipe inside the heated drum?
A.
The syphon pipe removes condensate from the top of the drum.
B.
The syphon pipe removes condensate from the bottom of the drum.
C.
The syphon pipe makes sure that the condensate remains inside the drum.
2.
A.
B.
C.
3.
Besides heating the paper, for what other purpose do we make use of the preheater?
A.
We can control the moisture and in this way we have the possibility to control warp.
B.
C.
4.
A.
B.
C.
The required heat transfer to the paper web is achieved by increasing or decreasing paper
wraps of the heated drum.
5.
A.
Electrically
B.
C.
6.
A.
B.
C.
7.
A.
B.
Through changing the speed of the preheater drum in relation to paper speed.
C.
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8.
A.
B.
C.
9.
When the speed changes of the succeeding machine, what occurs to the wrap?
A.
When the speed changes also the wrap changes; wrap is speed dependent, when the control
is set to manual.
B.
When the speed changes also the wrap changes; wrap is speed dependent, when the control
is set to automatic.
C.
When the speed changes the wrap does not changes; wrap is not speed dependent.
10.
What production problem could occur, when the wrap arm and heated drum are not
parallel?
A.
Warp (End-to-End warp)problems; there is no even contact between the paper web and the
heated drum across the full width, resulting into uneven heat transfer.
B.
Warp (down-warp)problems; there is no even contact between the paper web and the heated
drum across the full width, resulting into uneven heat transfer.
C.
Warp (S warp)problems; there is no even contact between the paper web and the heated
drum across the full width, resulting into uneven heat transfer.
11.
When you switch on the Modul Facer or Double Facer the preheater(s) switches on
how?
A.
B.
C.
12.
What is the recommended BHS procedure to switch on the steam supply to the
preheater(s)?
A.
Heat up the preheater approx. one hour before production start up, open steam valves slowly,
check for steam leaks and run machine at base speed.
B.
C.
Open the steam supply fully and leave the condensate return valve closed till you are ready for
production.
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1.5
Preconditioner VBR-N
1.
A.
B.
C.
To heat the fluting medium and to prepare it for flute formation between the corrugating rolls.
2.
A.
Between the paper outfeed of the single facer and the inclined conveyor
B.
It is directly positioned at the fluting medium paper infeed of the single facer and comes just
before the steam shower.
C.
3.
A.
B.
Hydraulically.
C.
4.
A.
B.
C.
Both.
1.6
Bridge B
1.
A.
B.
C.
Infeed, guiding (Corraligner), tightening (bridge brake) and storage of single faced corrugated
board web(s).
2.
A.
The belt station runs at the same speed as the speed of the corrugator.
B.
The belt station runs slower at a fixed ratio to the speed of the corrugator.
C.
The belt station runs faster at a fixed ratio to the speed of the corrugator.
3.
A.
B.
C.
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4.
A.
To align the middle of the single faced corrugated board web to the middle of the corrugator.
B.
C.
5.
A.
B.
C.
A roll with a rubber surface is driven through a regulated servo drive. By adjusting the speed of
this roll at a lower speed as the corrugator gives the required brake effect and thereby
tensioning the web.
6.
A.
Infrared edge sensors detect the edges of the paper web and detect any width change and
movement away from the corrugator center-line.
B.
C.
7.
A.
B.
C.
8.
What production problem can occur, when the bridge brake is not adjusted properly?
A.
B.
C.
9.
A.
B.
C.
10.
When the corrugator is stopped and we want to thread-up the paper web, what can we
do?
A.
Switch on the bridge brake, which will function as a thread-up help (switch to manual).
B.
C.
Switch off the bridge brake, which will function as a thread-up help (switch to automatic).
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1.7
1.
A.
Detection of the quantity (storage) of single faced corrugated board on the bridge only.
B.
It mainly serves the following three purposes; detection of the quantity (storage) of single faced
corrugated board on the bridge, prevents paper tear when bridge quantity is too low and
synchronizes machine speeds (single facer(s) and double facer).
C.
Prevents paper tear when bridge quantity is too high and synchronizes machine speeds.
2.
A.
B.
C.
Both bridge level control systems are on when you produce single wall.
3.
When producing single faced corrugated board on a duplex machine, what must be the
condition of the second bridge level control of the single facer which is not in use, on or
off?
A.
B.
C.
4.
A.
Through the markings, which are sprayed onto the top liner.
B.
Through calculation using the difference in the liner speed and the fluting medium speed as
parameters.
C.
By calculating how much paper is conveyed onto the bridge and removed from the bridge, the
system can calculate the bridge storage (quantity)
5.
A.
It measures the speed of the single facer, from which the paper quantity conveyed onto the
bridge is calculated.
B.
C.
6.
What is the function of the absolute encoder on the double facer liner infeed into the
lower preheater?
A.
B.
C.
It measures the speed of the double facer liner, from which the paper quantity removed from
the bridge is calculated.
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7.
A.
When you operate this function the speed of the double facer increases.
B.
In order to have sufficient storage available on the bridge for splicing, it is possible to switch
over to Increased Demand. When the increased demand key on the panel is operated the
nominal bridge quantity is increased by a preselected percentage. Example; nominal bridge
quantity of 99 ft (30 m), increased demand 100 %. When we now select the increased demand
key the single facer speeds up to 198 ft (60 m) is on the bridge. After the splice is carried out
the system switches back to normal demand (99ft / 30 m).
C.
8.
A.
When it is necessary to slow down the double facer due to low paper quantity, the operating
mode Speed Memory is activated automatically. Now the single facer controls the corrugator
speed. On start of splice release (lower single facer speed). the bridge level control is blocked
and when splicing has completed switches on automatically again. Single facer speed in
respect to double facer is increased, until the nominal bridge quantity is reached.
B.
C.
9.
A.
As soon as the paper storage on the bridge is running out, i.e. the point where the festoons pull
out into a web arrives at the first measuring point on the bridge, the speed of the double facer
is increased above the speed of the single facer.
B.
As soon as the paper storage on the bridge is running out, i.e. the point where the festoons pull
out into a web arrives at the first measuring point on the bridge, the speed of the double facer
is decreased below the speed of the single facer.
C.
By informing the operator with a horn, so that he can slow down the corrugator.
10.
Where are the two initiators from the bridge level control located?
A.
B.
One on the single facer and the other on the double facer.
C.
11.
What happens, when the paper storage on the bridge runs too low?
A.
The double facer slows down. In case the bridge quantity drops below a certain minimum value
the double facer is switched off.
B.
The bridge level control speeds up the double facer before the paper runs out.
C.
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12.
A.
From the main menu by selecting F5 you get the menu graph Set Speed Double Facer. The
cursor is at the position actual value. You can only decrease this value and by selecting F1 the
new actual value is transmitted to the double facer control. nominal value follows indicating that
the double facer is speeding down.
B.
C.
From the main menu by selecting F5 you get the menu graph Set Speed Double Facer. The
cursor is at the position nominal value. You can increase or decrease this value and by
selecting F1 the new nominal value is transmitted to the double facer control. Actual value
follows indicating that the double facer is speeding up or down.
13.
In the menu graph Production, when you see active: double facer displayed, what
does this indicate?
A.
B.
C.
14.
A.
B.
C.
15.
A.
B.
Resets the quality linear meters to zero (used when quality change).
C.
16.
A.
B.
Resets the quality linear meters to zero (used when quality change).
C.
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1.8
1.
A.
B.
It serves the purpose to apply even glue application to the flute tips of the single faced
corrugated web over the complete width.
C.
2.
A.
The applicator roll runs a preselected percentage faster as the machine speed, this improves
glue application.
B.
The applicator roll runs a preselected percentage slower as the machine speed, this improves
glue application.
C.
The applicator roll runs at the same speed as the machine speed, this improves glue
application.
3.
Explain the difference between the applicator roll and the doctor roll?
A.
The applicator roll has a chromium-plated engraved surface and the doctor roll has a smooth
surface.
B.
The applicator roll has a smooth surface and the doctor roll has a chromium-plated engraved
surface.
C.
4.
A.
B.
C.
5.
A.
Light scanners scan the edges of the bottom liner and control the position of the glue dams.
B.
C.
Light scanners scan the edges of the top liner and control the position of the glue dams.
7.
A.
B.
C.
The paper itself drives the rolls inside the glue unit.
8.
A.
B.
The glue unit runs 20 seconds at 165 ft/min (50 m/min) and then stops.
C.
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9.
A.
Two light scanners positioned in the middle of the working area control the automatic glue level
control. One checks glue level too low (min.) and the other checks glue level too high (max.). In
case the glue level is at the max. level the supply is closed off, if consequently the glue level
drops and reaches the min. level the supply is opened again.
B.
C.
The glue level control operates on the principle that the flow in is less then the flow out, in this
case the glue unit can never overflow.
10.
What is the function of the automatic glue gap stages, which can be set on the
Touchscreen in the Parameter menu?
A.
When the speed of the corrugator is reduced below certain preselected speed levels
automatically a preselected additional glue gap is added to the nominal setting. This glue gap
increase in relation to speed can be set in stages. This function is only active in manual.
B.
When the speed of the corrugator is reduced below certain preselected speed levels
automatically a preselected additional glue gap is added to the nominal setting. This glue gap
increase in relation to speed can be set in stages. This function is only active in automatic.
C.
Answer A. and B. are both correct; it does not matter if we are in manual or automatic for the
glue gap adjustment.
1.9
1.
A.
B.
The double facer is used for bonding the incoming single-faced corrugated web(s) with the
bottom liner.
C.
2.
Can you name a few systems which can be used inside the double facer, that apply the
necessary pressure to achieve correct bonding of the paper webs?
A.
BHS machines are always equipped with a chaintrol, this is the best system especially for light
quality board.
B.
The bartrol system using weightrolls, the chaintrol system using shoes.
C.
3.
A.
With oil.
B.
Electrically.
C.
By steam.
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4.
A double facer with 18 hot plates consists out of how many heating sections?
A.
B.
C.
5.
A.
B.
C.
6.
A.
Glue unit, main drive, heating section, traction section, belt and a bar-, chain- or airtrol system.
B.
Main drive, heating section, traction section, belt and a bar-, chain- or airtrol system.
C.
7.
When the corrugator is stopped, what happens to the belt in the area of the heating
section?
A.
B.
C.
8.
A.
B.
C.
It loads the upper belt and thereby carefully transporting the board between upper and lower
belt.
9.
A.
We dont, always the maximum steam pressure is available on the steam sections.
B.
C.
10.
Can you describe the procedure of switching the double facer on?
A.
When you operate key switch double facer on you first get an audible pre start-up warning,
after approx. 3 seconds the white luminous key switch starts flashing, then you push again and
the key switch lights.
B.
When you operate key switch double facer on the key switch lights and the double facer runs.
C.
When you start the single facer the double facer starts up automatically.
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2.
2.1
1.
A.
Cut out waste and create an open space in the paper so we can make an order-change.
B.
C.
2.
What is the function of the orange indication light on top of the machine?
A.
When it is blinking this means , that there is something wrong with the electronic system of the
machine.
B.
C.
When it is blinking this means , that the machine started cutting or is going to start cutting.
3.
What happens when we open the first security-door on the KQM , when the Corrugator
is not running?
A.
A warning light comes on , and when we start the Corrugator it will go out.
B.
The Corrugator will make an emergency stop and it is not possible to start the Corrugator up
again without closing the door first , together with this a warning light will is on.
C.
We are able to start the Corrugator , but it is not possible to start cutting.
4.
What happens when we open the first security-door on the KQM when the Corrugator is
running?
A.
The Corrugator will continue to run but , it is not possible to start cutting.
B.
C.
5.
What happens when we open the first security-door on the KQM , when the knife is
cutting and the Corrugator is running?
A.
The Corrugator continuous running and the knife stops cutting automatically.
B.
C.
6.
What happens when we open the second security-door on the KQM when the
Corrugator is not running?
A.
Nothing happens.
B.
C.
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7.
What happens when we open the second security-door on the KQM when the
Corrugator is running?
A.
Nothing happens.
B.
C.
A red warning-lamp comes on and the Corrugator will keeps running , but we can not start the
knife.
8.
What happens when we open the second security-door on the KQM , when the knife is
cutting and the Corrugator is running?
A.
Nothing happens.
B.
C.
The KQM automatically stops cutting and the Corrugator keeps on running.
9.
A.
With this button we can make one cut across the paper-width.
B.
C.
With this button we can cut the paper and do an order-change at the same time.
10.
A.
B.
C.
11.
What is the maximum speed to make one single cut ? (1m/min = 3.3 ft/min)
A.
B.
C.
12.
A.
With this button we can cut the paper across the width during an order-change.
B.
C.
13.
A.
B.
C.
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14.
A.
B.
C.
15.
A.
B.
With this button we can do an order-change on the whole Dry-End , when the AFW (Automatic
Order Change) is standing in Manual-mode.
C.
With this button we can do an order-change on the whole Dry-End , when the AFW (Automatic
Order Change) is standing in Automatic-mode.
2.2
1.
A.
Cut the board on the desired width and put scores on the board..
B.
C.
2.
Why do we need to make a reference travel on the SRA , in the morning before we start
producing?
A.
B.
C.
3.
A.
B.
We can grind the knives on the machines , when the Corrugator is stopped.
C.
4.
A.
Every hour.
B.
C.
5.
A.
B.
C.
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6.
A.
B.
C.
Normally the knives are grinded automatically , but we can also grind them manually.
7.
A.
B.
C.
8.
A.
B.
C.
This depends on the length of cutted board and the board thickness.
9.
A.
B.
C.
10.
A.
B.
C.
11.
A.
B.
C.
12.
What is swing-change?
A.
A shearless order-change: This means order-change without creating a open space in the
board.
B.
This is an easy to change system for the disc-cut-knives (Less than 5 minutes).
C.
This system allows fast positioning , from all the disc-cut-knives , in the board during
production.
13.
A.
The system makes sure that is impossible to have a Board-jam on the SRA.
B.
C.
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14.
Why do we need the paddle unit after the SRA and KQF?
A.
B.
C.
15.
A.
This one controls the width of the side-trim and also adjusts it when necessary.
B.
We need this one to follow the board in order to control the production.
C.
2.3
1.
A.
B.
The KQF cuts out the waste that we forgot to cut out on the KQM.
C.
2.
What is the function of the orange indication light on top of the machine?
A.
When it is blinking this means , that there is something wrong with the electronic system of the
machine.
B.
C.
When it is blinking this means , that the machine started cutting or is going to start cutting.
3.
What happens when we open the first security-door on the KQF , when the Corrugator
is not running?
A.
A warning light comes on , and when we start the Corrugator it will go out.
B.
The Corrugator will make an emergency stop and it is not possible to start the Corrugator up
again without closing the door first , together with this a warning light will is on.
C.
We are able to start the Corrugator , but it is not possible to start cutting.
4.
What happens when we open the first security-door on the KQF when the Corrugator is
running?
A.
The Corrugator will continue to run but , it is not possible to start cutting.
B.
C.
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5.
What happens when we open the first security-door on the KQF , when the knife is
cutting and the Corrugator is running?
A.
The Corrugator continuous running and the knife stops cutting automatically.
B.
C.
6.
What happens when we open the second security-door on the KQF when the
Corrugator is not running?
A.
Nothing happens.
B.
C.
7.
What happens when we open the second security-door on the KQF when the
Corrugator is running?
A.
Nothing happens.
B.
C.
A red warning-lamp comes on and the Corrugator will keeps running , but we can not start the
knife.
8.
What happens when we open the second security-door on the KQF , when the knife is
cutting and the Corrugator is running?
A.
Nothing happens.
B.
C.
The KQF automatically stops cutting and the Corrugator keeps on running.
9.
A.
With this button we can make one cut across the paper-width.
B.
C.
With this button we can cut the paper and do an order-change at the same time.
10.
A.
B.
C.
11.
What is the maximum speed to make one single cut ? (1m/min = 3.3 ft/min)
A.
B.
C.
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12.
A.
With this button we can cut the paper across the width during an order-change.
B.
C.
13.
A.
B.
C.
14.
A.
B.
C.
15.
What is the difference in use between the KQM and the KQF?
A.
The KQF is being used for shearless order-change and the KQM is used to cut out waste.
B.
The KQM is being used for shearless order-change and the KQF is used to cut out waste.
2.4
1.
A.
B.
C.
2.
A.
B.
C.
3.
A.
B.
C.
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4.
A.
The knife is cutting so fast that the electronic control cant follow.
B.
The knife is cutting on a higher speed than his maximum speed which creates an overheating
in the electronic system.
C.
The paper-speed is higher than the maximum speed of the knife , so that we are cutting the
paper under a wrong angle.
5.
A.
B.
C.
6.
A.
Steel-balk knives.
B.
C.
Carbon-Fibre-balk knives.
7.
A.
B.
That we have to slow down the Corrugator because the knife is overheating.
C.
8.
Which formats can we run the fastest on the Corrugator : Very short-formats or normalformats?
A.
Very short-formats.
B.
C.
9.
A.
B.
C.
10.
What happens when we open one of the security-doors situated around the NQM?
A.
B.
C.
An acoustic signal will warn you that one of the doors is open.
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11.
How can we see if the NQM is cutting the board on the right length?
A.
B.
We can see the nominal- and the actual-value on a display on the machine.
C.
12.
A.
B.
C.
13.
A.
B.
C.
2.5
Stacker AAR
1.
The function of the AAR is , transporting the board to the end of the Corrugator.
B.
C.
2.
A.
B.
C.
3.
A.
B.
C.
4.
A.
B.
C.
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5.
A.
B.
C.
6.
Why do we need the vacuum system on the AAR right after the NQM?
A.
B.
C.
7.
A.
B.
C.
8.
A.
Yes.
B.
No.
C.
9.
A.
B.
C.
10.
What happens when a stack can not be transported out of the AAR?
A.
B.
C.
11.
A.
B.
C.
Yes , we can change this value on the computer-screen and on the switch-cabinet on the AAR.
12.
A.
B.
Yes we can do this , but only when the new value is smaller than the old one.
C.
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13.
A.
We can see this on the computer-screen and on the switch-cabinet on the stacker.
B.
C.
14.
What is the function of the green light on the up- and down-stacker?
A.
B.
C.
15.
What is the function of the red light on the up- and down-stacker?
A.
B.
C.
16.
A.
B.
C.
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2.6
1.
2.
3.
Yes , always.
4.
Because an order-change can also be an quality-change , and then we have to cut out the old
quality until the new quality is arrived , after this we can the order-change from the cut-off-knife.
5.
01.10.1997
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Training Manual
3.
Starch
3.1
General
1.
A.
B.
C.
2.
Starch can be extracted from a wide variety of plants. Can you name some?
A.
B.
C.
3.
A.
Maize.
B.
Wheat.
C.
Tapioca.
4.
A.
B.
This is the temperature at which the starch looses its bonding characteristics.
C.
The gelatinisation temperature is the level at which the starch granules swell rapidly as they
absorb water and eventually burst to produce the familiar starch paste with its adhesive
characteristics. This process is referred to as gelatinisation.
01.10.1997
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Training Manual
5.
A.
Caustic soda.
B.
Water.
C.
Starch.
6.
A.
Starch
B.
Water.
C.
Borax.
7.
A.
B.
C.
8.
Name a few formulation processes which have been developed to prepare a corrugating
adhesive?
A.
B.
C.
The minocar system, which is a steinhall process is used to prepare a corrugating adhesive.
3.2
Bonding Process
1.
A.
B.
C.
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Training Manual
2.
A.
B.
C.
3.
Besides these four stages, which other two elements are needed in the bonding
process?
A.
Only heat.
B.
Only pressure.
C.
4.
A.
B.
C.
5.
A.
B.
C.
6.
When corrugator running speeds go up, what adjustment is required on the gel.
temperature?
A.
B.
C.
3.3
Application Process
1.
A.
The glue gap is the gap between the doctor roll and the glue roll.
B.
The glue gap is the gap between the doctor roll and the rider roll.
C.
The glue gap is the gap between glue roll and the rider roll.
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2.
A.
B.
C.
The glue gap controls the thickness of the glue coating to be applied onto the flute tips.
3.
Is all the glue controlled by the glue gap applied to the flute tips?
A.
Yes.
B.
No, a percentage remains on the glue roll and a percentage remains on the doctor roll. Only
that part which stays on the glue roll can be applied to the flute tips.
4.
What happens, when the glue application roll gap is controlled too large; do we get too
much or too little starch on the flute tips?
A.
If the glue application roll gap is too large, the glue roll moves closer to the flute tips and
therefor it is possible that too much glue is applied at all onto the flute tips.
If the glue application roll gap is too large, the glue roll moves further away from the flute tips
and therefor it is possible that no glue is applied at all onto the flute tips.
5.
A.
The glue application roll gap controls the gap between the glue application roll and the
corrugating roll.
B.
The glue application roll gap controls the gap between the doctor roll and the glue application
roll.
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6.
Why is it necessary that the glue application roll gap is made adjustable?
A.
Various paper qualities have different thickness. In order to achieve the correct glue application
onto the flute tips, this gap is adjustable.
B.
C.
7.
A.
This results in a better glue application. Due to the engraving more glue remains onto the glue
application roll as onto the doctor roll.
B.
C.
3.4
1.
What are some of the more common problems with the adhesive application systems
that can cause bond problems?
A.
Glue application roll/corrugating roll not parallel, Glue application roll/doctor roll not parallel.
B.
Out of round rolls, Rolls with non-uniform diameters, Engraving on glue application roll locally
worn, Mechanical damage, Worn bearings.
C.
Glue application roll/corrugating roll not parallel, Glue application roll/doctor roll not parallel,
Out of round rolls, Rolls with non-uniform diameters, Engraving on glue application roll locally
worn, Mechanical damage, Worn bearings etc.
2.
The doctor roll and glue application roll are not parallel. What is the effect on glue
application?
A.
B.
C.
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3.
What happens with the glue application if in a particular area on the glue application roll
the engraving wears down?
A.
B.
4.
What do we mean with the term Zip bonding and how does this occur?
A.
B.
It is caused by insufficient glue penetration, the adhesive has not remained fluid long enough to
properly penetrate the paper and so final bond has not tied itself into the fibbers of the paper
and consequently the board will pull apart with little or no sign of paper tear. This can be
caused by: Overheating of the papers, especially on lightweight board, slippage between
double facer liner and single faced web, hi-lo flutes, incorrect formulation of the adhesive or
insufficient glue penetration.
3.5
Tests
1.
A.
Heating the adhesive and check when it thickens, the time this takes tells us something about
the viscosity.
B.
The viscosity is checked with an instrument known as the Stein Hall Cup.
2.
Which test do you know that can show the glue lines and therefor give you an
indication of the glue application?
A.
B.
C.
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Training Manual
4.
Paper
4.1
General
1.
A.
B.
2.
A.
When the runnability of the paper is good, this means that this paper is easy to run in the
corrugator.
B.
With the runnability we mean the maximum speed at which the corrugator can run with a
certain paper.
3.
A.
B.
4.2
Paper Properties
1.
A.
B.
2.
A.
B.
As low as possible.
3.
A.
B.
C.
4.
What do we mean if we say that liner and fluting medium are balanced?
A.
B.
The moisture content of the two papers is even and within a certain percentage of eachother
C.
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Training Manual
4.3
1.
What can happen when the paper has no even structure and shows streaks caused by
the paper machine?
A.
B.
The streaks will be higher in temperature, due to excessive contact with the preheater(s)
C.
The streaks will be lower in temperature, due to bad contact with the preheater(s).
2.
A.
B.
C.
Use steam shower and preconditioner to prepare paper for correct flute formation.
4.4
Warp Problems
1.
A.
B.
C.
2.
What can you do on the corrugator to correct for up warp (bonding is good) running
single wall?
A.
B.
Increase the wrap on the preheater for the single faced web, decrease the wrap on the
preheater for the bottom liner.
C.
Decrease the wrap on the preheater for the single faced web, increase the wrap on the
preheater for the bottom liner.
3.
A.
B.
Tension in the single faced web higher then in the bottom liner.
C.
01.10.1997
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Training Manual
5.
Steam
1.
2.
3.
Because water is colder than steam , it cools down the (for example) corrugating-rolls.
Because the water adds weight in to the drums , so the electro-motors can go in over-current.
4.
Why do we need a pressure-difference from minimum 29.4 psi (2 bar) on the hot-plates?
Because of the differences in temperature needed to produce good quality-board and the
condense-system.
5.
We have to shoot the temperature with a temperature gun , to check if we have the right
temperatures on the hot plates.
6.
We can see this on the computer-screens , this means that we will have a actual temperature
on the hot plates that is not corresponding with the actual pressure in the hot-plates.
We will see this on glue-problems that are going to occur during production.
We will see the water flowing out of the bottom side of the hot-plates.
7.
We have to put the full steam-pressure on the hot plates so that the water is being pushed out.
01.10.1997
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Training Manual
8.
We can see this on the computer-screens , this means that we will have a actual temperature
in the corrugating-rolls that is not corresponding with the actual pressure in the hot-plates.
We will see this on glue-problems that are going to occur during production and this over the
whole width.
9.
We can see the water flowing out of the bottom side of the hot-plates.
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Practical Part
Customer: _____________________________________________________________
Instructor: _____________________________________________________________
Student:
_____________________________________________________________
6.
6.1
Initial:
01.10.1997
Date:
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Training Manual
6.2
Initial:
01.10.1997
Date:
chapter 4
page 49
Training Manual
6.3
Initial:
01.10.1997
Date:
chapter 4
page 50
Training Manual
6.4
Initial:
01.10.1997
Date:
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page 51
Training Manual
6.5
What is the function of the glue unit (glue rolls and glue dams) + details
What is the function of the Bandleader system + details
What is the function of the over-pressure system in the glue unit + slots + slot-cleaners
What is the function of the preheaters and preconditioner
How to operate the touchscreens
How to start the machine and thread up the paper
Explain the functions of the controls and pressure gauges of the machine
What to do if the bonding between fluting and liner is not good
How to put the correct settings on the machine (glue dams, glue film glue, application gap
web-tension)
Checking the paper-quality on glue films with Iodine in order to detect glue problems
What is the function of the Quality Change menu
How do we have to clean the machine properly
How can we make a flute change (Modul change)
Initial:
01.10.1997
Date:
chapter 4
page 52
Training Manual
6.6
Preheater VZR-M
Initial:
01.10.1997
Date:
chapter 4
page 53
Training Manual
6.7
Bridge B
Initial:
01.10.1997
Date:
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page 54
Training Manual
6.8
Initial:
01.10.1997
Date:
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page 55
Training Manual
6.9
Initial:
01.10.1997
Date:
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page 56
Training Manual
DWR-Airtrol
Initial:
6.10.2
Date:
DWR-Chaintrol
01.10.1997
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page 57
Training Manual
How does the speed effect the wrap of the preheaters and Chaintrol
How can we avoid having problems with static electricity on the DWR
Initial:
6.10.3
Date:
DWR-Airtrol-Chaintrol
Initial:
6.10.4
Date:
DWR-Bartrol
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Initial:
01.10.1997
Date:
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Training Manual
Initial:
01.10.1997
Date:
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Initial:
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Date:
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Training Manual
Initial:
01.10.1997
Date:
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Training Manual
Initial:
01.10.1997
Date:
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Training Manual
Initial:
01.10.1997
Date:
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Training Manual
On the computer
Permanently
Temporarily
On the stacker
Initial:
01.10.1997
Date:
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Training Manual
Initial:
01.10.1997
Date:
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Training Manual
Initial:
Date:
written by Sylveer Landuyt / Mark van Bosbeke / Jos Giesbers BHS Trainers
layouted by Sichelstiel Peter / Kaschel Wolfgang BHS Documentation
01.10.1997
chapter 4
page 67
Certificate
0U
ERUQ[[[[[
HPSOR\HGE\;;;
was successfully trained by our
staff during the period from
xx.xx.-xx.xx.199x
to operate a
corrugator line
We certify that Mr. .......................
able to operate the above
mentioned machines by himself.
:HLKHUKDPPHU[[[[[
0U
0U