Common Corrugating Problems

23-Mar-20
CAUSES OF COMMON CORRUGATING

PROBLEMS
Presented by
Ram Kumar Sunkara
S S Consultants
Common Problems
• Adhesive Problem
• Corrugating Equipment Problem, and
• Corrugated Board Problems
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23-Mar-20
Adhesive Problems
• Viscosity problems
• Gel Temperature problems
• Adhesive circulation problems.
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Adhesive viscosity
• Adhesive viscosity is a critical parameter for quality corrugated
board.
• It is a relatively easy variable to control when the underlying
cause of a problem is understood.
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23-Mar-20
DIAGNOSING VISCOSITY PROBLEMS

• Low viscosity at the mixer.
• High viscosity at the mixer
• Low viscosity at the storage tanks
• High viscosity at the storage tanks
• Low viscosity at the machine
• High viscosity at machine
• Viscosity decrease after overnight storage
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Low Viscosity at the Mixer

• Not enough starch in the cook portion of the formula
• Too much water in the cook portion of the formula
• Too much water in the secondary addition or secondary
mixer
• Cooked portion too hot (+71⁰ C)
• Finished batch too hot
• Too much shearing of the cooked portion of the adhesive
• Finished batch being mixed too long
• Substituting incorrect borax (5 mol vs. 10 mol)
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23-Mar-20
High Viscosity at the Mixer

• Too much starch in the cook portion of the formula
• Too much starch in the secondary mixer
• Not enough water in the cook portion of the formula
• Cook portion too cold
• Finished batch too cold (optimum temperature 38 to 40 CE)
• Not enough shearing of the cooked portion of the adhesive
• Finished batch not being mixed long enough
• Improper distribution of borax
• Substituted incorrect borax (5 mol vs. 10 mol)
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Low Viscosity at the Storage Tanks

• Temperature of the adhesive set too high
• Storage tank agitators running continuously
• Unwanted water in adhesive
• Over shearing of the adhesive
• Old adhesive (stored too long)
• Adhesive treated with resin (WPA) mixed with domestic
paste
• Low solids adhesive formula
• Microbiological contamination of adhesive
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23-Mar-20
High Viscosity at the Storage Tanks

• High viscosity paste coming from the mixer
• Adhesive viscosity “growing” in storage
• Adhesive cold
• Storage tank agitators not operating properly
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Low Viscosity at the Machine

• Adhesive too hot
• Low viscosity adhesive coming from the storage tanks
• Adhesive being sheared
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23-Mar-20
High Viscosity at Machine

• Paste too cold
• High viscosity paste coming from the storage tanks
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Viscosity Decrease After Overnight or Weekend

Storage
• Cleanup water returned to storage tanks
• Agitators/circulating pumps left running
• Circulation lines full of water
• Neglected extra preservative to compensate for wash up water
or process water
• Bacteria
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23-Mar-20
Adhesives viscosity growing in storage
• Too much caustic in the formula

– Scale not calibrated
– Caustic meter out of calibration
• Not enough borax in the formula
– Scale out of calibration
– Borax timer set improperly
– Wrong type of borax (5 mol vs. 10ml)
13
DIAGNOSING GEL TEMPERATURE PROBLEMS

• Gelatinisation temperature too high
• Gelatinisation temperature too low
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Gelatinization Temperature Too High

• Not enough caustic in the adhesive
– Caustic meter set too low
• Too much borax in the adhesive
– Borax timer not working properly
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• To much starch in the adhesive
• Too much water in the adhesive
– Water meter out of calibration
– Mixer scale out of calibration
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• Substituted incorrect borax in formula (5 mol vs. 10 mol vs.
boric acid)
• Borax too old (dry, becomes more concentrated)
• Caustic soda beads too old
• Liquid caustic too cold
17

• Caustic stratified in storage tank sending low concentrations of
caustic
• Wrong concentrations of caustic
• Adhesive stored too long
• Addition of resin into adhesive
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23-Mar-20
Low Gelatinization Temperature

• Too much caustic in the adhesive
– Caustic meter set too low
• Not enough borax in the adhesive
– Borax timer not working properly
– Borax discharge tube plugged
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Low Gelatinization Temperature

• Not enough starch in the formula
• Problems with caustic soda
– Liquid caustic too cold
– Liquid caustic crystallised in storage tanks, sending high
concentration of caustic
– Using wrong concentration of liquid caustic
• Substituted incorrect borax in the formula (5mol vs. 10 mol vs.
Boric acid)
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23-Mar-20
Adhesive Preparation and

circulation problems
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Adhesive too hot
• Bad flow through the starch pan

• Cooling jacket problem
– Cooling jacket not installed
– Bad or no water flow (plugged)
– Water not cool enough
• Adhesive supply pipes run next to un-insulated steam pipes
• Ambient air temperature too high (seasonal)
• Long adhesive pipe runs along ceiling
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23-Mar-20
Adhesive being sheared

• High rpm supply and return pumps
• Air pumps operating at too high an air pressure
• Too many elbows in the supply and return lines
• Valves in the supply lines partially open
• Adhesive supply lines reduced in size
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Over shearing of the adhesive

• High rpm supply and return pumps
• Too many elbows in the supply and return lines
• Supply and return line pipe diameter too small
• Pipe size reductions in supply and return lines.
• Partially open valves in supply and return lines
• Air pressure too high on air diaphragm pumps
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23-Mar-20
Temperature of the adhesive too high

• Temperature set too high
• Adhesive returning from machine at an elevated temperature
• Finished batch temperature too high
• Bad bearings on the agitator, causing the shaft to overheat
• Bad bearings on the supply/return pump
25
Adhesives viscosity growing in storage

• Too much caustic in the formula
– Scale not calibrated
• Not enough borax in the formula
– Borax timer set improperly
– Wrong type of borax (5 mol vs. 10ml)
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23-Mar-20
Adhesive too hot

• Bad flow through the starch pan
• Cooling jacket problem
– Cooling jacket not installed
– Bad or no water flow (plugged)
– Water not cool enough
• Adhesive supply pipes run next to un-insulated
steam pipes
• Ambient air temperature too high (seasonal)
• Long adhesive pipe runs along ceiling
27
Foaming of Adhesive in Pans

• Poor bonding and high starch consumption
• Air in starch lines
• Leak in pumps
• Wrong wiper blade or dirty wiper blade on metering roll
• Wash waste water used for adhesive make up
• Resin in the adhesive
• Low viscosity adhesive
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23-Mar-20
Adhesive Gels on Fingers

• Impact is -
– High starch consumption,
– Poor bonding,
– Low pin adhesion,
– Poor top to bottom compression,
– Low production speeds.
• Gel temperature of adhesive too low
• Adhesive viscosity too high
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Adhesive Gels on Fingers

• Temperature high in glue pan
• Medium improperly conditioned
• Medium surface temperature too hot
• Paper temperature of medium too high
• Fingers worn
• Cleanout fingers too loose or tight against glue roll
• Taper speed set above 96 percent of paper speed
• Water flow to cooling pan is incorrect
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23-Mar-20
BOARD QUALITY PROBLEMS

• Soft Board
• Washboard
• Dry Board, tipper Board
• Leaning Corrugation
• Slipping Board General
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• Cracker Board
• Light Glue pattern at Double Backer
• Light Glue pattern at Single Facer
• Foaming of adhesive in pans
• Adhesive Between Flutes
• Dry Streak
• White Glue Line
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• Spotty Glue Application - Single Facer
• Adhesive Sets Up on Fingers
• Loose Edge Single Facer Side
• Loose Edge Double Backer Side
• High and Low - Flutes not Glued
• Highs and Lows Corrugation
• Blisters
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• Normal Warp (Side to Side Up)
• Reverse Warp (Down Warp)
• S Warp
• Machine Direction (End to End Warp)
• End to End A Up ≈ Warp
• End to End A Down ≈ Warp
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23-Mar-20

• Cross Machine Direction - Side to Side
• Twist Warp
• Post Warp
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Soft Board
• Impact of soft board on performance of the board are:
• Causes poor pin adhesion,
• Low top to bottom compression,
• Poor print quality
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Soft Board
• Excessive adhesive application due to floating bearings,
worn bronze bushings
• Too much steam in the Gaylord Showers
• Wet paper - medium or liners.
• Excessive rider roll pressure at double backer glue machine,
crushing flute tips
• Uneven roller pressure in hot plates or cooling section of
double backer
• Board cut off knife pressure too high
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Washboard Appearance
• Usually occurs once board has cured and causes poor printing
surface,
• Brittle edges during conversion
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23-Mar-20
Washboard Appearance
• Heavy adhesive application at single facer or double backer
• Low solids adhesive
• Wet paper (roll stock stored outside)
• Excessive heat applied to light weight liners
• Glue roll set to wrong paper speed
• Over dried liners
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Dry Board, Zipper Board

• Creates waste,
• Low pin adhesion,
• Poor top to bottom compression
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23-Mar-20
Dry Board, Zipper Board

• Adhesive application at single facer or double backer too light
• Low viscosity adhesive (water penetrates paper too quickly)
• Too much borax in formula
• Glue roll in double backer at wrong speed (paper comes apart
easily in one direction, but has good fibre pull in the other
direction).
• Too much heat application at single facer or double backer
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Leaning Corrugation
• Causes low board calliper,
• Poor pin adhesion,
• Poor top to bottom compression,
• Poor printing surface.
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23-Mar-20
Leaning Corrugation
• Misalignment of corrugator rolls
• Excessive wear on corrugator rolls
• Pressure between corrugator rolls too low
• Excessive rider roll pressure at double backer glue station
• Excessive drag on the single face web at the double facer
• Adhesive application at single facer or double backer
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Slipping Board - General

• Excessive tension on double facer
• Loose or worn belts
• Belt rollers lift
• Top and bottom belts travelling at different speeds
• Treatment or finish of bottom liner causing excessive drag on
the hot plates
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23-Mar-20
Slipping Board – Surface bond only

Delaminates after curing.
• Excessive drag on single face web
• Loose or worn corrugator belts in double facer
• Hot plate rollers are up
• Rollers are up in pulling section of the double facer
• Corrugator belts travelling different speeds
• Coating on bottom liner creating drag
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Cracker Board
• Generates crackling sound when flexed.
• Slippage between single facer web and double backer liner
• Light glue application
• Use of low solids glue
• Excessive unglued or high-low corrugations
• Excessive borax in formula
• Liners too hot
• Medium too dry
• Too much drag on medium
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23-Mar-20
Light Glue Pattern at Double Backer

• Brittle or zipper board appearance
• Low glue roll setting
• High rider set too high
• Glue roll speed too fast
• Smooth glue roll
• Too much drag on single facer web
47
Light Glue Pattern at the Single Facer

• Glue roll too far from corrugating roll
• Glue roll taper speed too slow
• Smooth glue roll - not transferring enough adhesive
• Glue roll settings too low
• Improper pressure roll setting
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23-Mar-20
Adhesive Between Flutes

• Creates warp problems,
• High starch consumption,
• Poor bonding,
• Poor quality.
• Creates warp problems, high starch consumption, poor
bonding, poor quality.
• Starch setting too high on glue roll
49
Adhesive Between Flutes

• Improper adhesive formula
• Rider roll set too low at double backer
• Improper glue roll speed
• Bad wiper blade on metering roll
• Skip clutch not holding glue roll
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23-Mar-20
Dry Streak
• Poor bonding, low top to bottom compression of finished carton.
• Dirty fingers on the single facer
• Worn fingers-flat spot on tip
• Finger running too close to lower roll
• Dirty clean out prongs
• Water jacket malfunctioning
• High adhesive viscosity
• Poor lateral adjustment of corrugating roll
• Tension on medium too high
51
White Glue Line

• Delaminates after curing, low pin adhesion, poor top to
bottom compression
• Insufficient Gelatinization
• Gel temperature too high
• Temperature incorrect at pressure roll, corrugator rolls or hot
plates
– Low boiler pressure
• Low viscosity
• Wet paper
– Roll stock stored outside
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23-Mar-20
Spotty Glue Application on the Single Face Side

• Poor bonding,
• Low pin adhesion,
• Low top to bottom compression.
53
Spotty Glue Application on the Single Face Side

• Glue roll motor problem
• Finger setting too low
• Worn finger
• Medium not properly conditioned
• Medium not forming properly
• Medium sticking to corrugator roll
• Dirty corrugator rolls
• Water dripping on medium
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23-Mar-20
Loose Edge Single Face Side

• Impact is -
– Poor quality board,
– High waste,
– Low production speeds.
• Wet paper roll
• Adhesive improperly applied to medium
• Not enough brake on medium
• Fingers improperly adjusted
55
Loose Edge Single Face Side

• Dirty corrugating rolls
• Improperly set slitter knife
• Lack of pressure on roll
• Wet liner edge
• Medium wider than liner
• Roll stand out of parallel
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23-Mar-20
Loose Edge on the Double Backer Side

• Impact is -
– High waste,
– Low production speeds,
– Poor print quality.
• Sheet guide compressing flutes
• Wet streak on liner edge
• Worn corrugator belt
• Worn rollers in hot plates
• Wet paper roll
57
Loose Edge on the Double Backer Side

• Dirty hot plates
• Low adhesives solids
• Too much heat
• Low viscosity
• Bridge guides too tight
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23-Mar-20
Flutes not Glued – Single face / Double back side

• Fingers set too low
• Pressure between corrugating rolls too low
• Dirty rolls
• Corrugating medium too wet
• Glue roll angled improperly
• Too much drag on the single face web at the double back glue line
• Excess drag on medium
• Low calliper medium
• Medium surface temperature too high
59
High and Low Corrugation Flutes

• Impact is -
– Poor top to bottom compression,
– Poor print surface,
– Overall poor quality.
• Fingers improperly adjusted, worn, old, dirty.
• Medium improperly conditioned
– Lack of steam
• Improper pressure on corrugating rolls
– Worn or old rolls
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High and Low Corrugation flutes

• Glue roll out of parallel
• Rider roll out of parallel at double backer glue station
• Improper pressure on rollers in hot plates
• Improper brake on single face web
• Excess drag on medium
• Low calliper medium
• Medium surface temperature too high
61
Blisters
• Impact is -
– Poor quality,
– Poor print surface,
– Poor top to bottom compression.
• Fingers worn, old dirty
• Fingers adjusted improperly
• Incorrect heat in corrugator rolls, pressure rolls, hot plate
section
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Blisters
• Poor quality paper
• Wet paper
• Medium not properly conditioned
• Liner too hot
• Medium too hot
63
Normal Warp (Side-to-Side-Up Warp)

• Caused by moisture in the single facer liner.
• Add more heat (increasing wrap) to the single face web at the
double backer glue machine.
• Reduce heat (decreasing wrap) to the double facer liner at the
double back glue machine.
• Increase single facer liner wrap on the 36 inch preheated at the
single facer
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23-Mar-20

• Increase the wrap on the medium pre-conditioner
• Decrease steam shower into the medium
• Increase the amount of single face web on the bridge
• Increase machine speed
• Reduce the amount of adhesive used at the single facer
• Increase the amount of adhesive used at the double backe
• Lift some ballast rolls in the hot plates
65

• Operating Footnote :
• If the moisture content of the single facer liner roll is greater
than 2 percent over that of the double backer liner roll then
the roll should be changed.
• Pre-heaters on the machine can only remove 1 to 2 percent
moisture from roll stock.
• Should the moisture imbalance be greater than 2 percent,
warp will occur.
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Reverse Warp (Down Warp)

• Caused by moisture in the double facer liner.
• Increase heat to the double facer liner (increase wrap on the
36-inch preheater)
• Decrease the heat in the single facer web at the double backer
glue machine (decrease the wrap on the 36-inch preheater).
• Increase the steam shower on the medium
• Lower all rollers in the hot plate section
67
Reverse Warp (Down Warp)

• Check steam pressure in the hot plates and increase if
possible
• Reduce the amount of single face web on the bridge
• Reduce the speed of the machine
• Reduce the amount of adhesive at the glue machine.
• Increase the amount of adhesive at the single facer
• Add small amount of moisture to the top corrugator belt
(use steam spray across the entire belt).
• Use water spray on single face web.
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S Warp (Combination of Normal and Reverse

Warp)
• Caused by Variations in moisture (wet streaks) across the web
in a roll of liner or medium, or by machine conditions which
apply variable amounts of heat or paste across the web.
• Wet streak in roll of liner or medium
• Thin streak or edge in roll of liner will warp in opposite
direction to wet streak
• Loose edge in roll of liner does not hug pre-heater
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S Warp
(Combination of Normal and Reverse Warp)
• Wet edge in liner due to outside storage

• Out of level or out of square machine condition preventing
liner form contacting pre-heater firmly across the web.
• Single face glue roll or Doctor roll (glue roll and transfer roll)
out of parallel
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S Warp
• Improper crown between single face glue roll and Doctor roll
(glue roll and transfer roll)
• Scraper blade on single face or double back Doctor roll loose,
worn or dirty in some areas.
• Single face glue or Doctor roll (glue roll and transfer roll) galled
in some areas or pitted on ends.
• Double backer rider roll out of parallel
71
S Warp
• Double back glue roll and Doctor roll out of parallel
• Applicator roll out of parallel to the corrugating roll
• Hydraulic lift of the flue mechanism not functioning correctly
at the single facer; partially blocked steam shower
• Distorted steam chests causing uneven board temperatures
across the machine
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23-Mar-20
S Warp
• Operating Footnote :
• If the machine is equipped with a water spray, this is usually
the best way of controlling the S warp.
• The water spray should be used on the single face side of the
web only.
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End-to-End “Up” Warp
• Tension greater on the single facer liner than on the double

backer
• Single face liner is pulling back on the sheet
• Drag on the top liner, usually from a drag belt on the bridge
• Pre-heater locked down and not turning, adding tension to
the single face web going into the double backer
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23-Mar-20
End-to-End “Up” Warp
• Running with too much brake on the single face liner at the
single facer
• Running with too much paper on the bridge
• Running with too much brake on the medium, pulling back
on the single face web
75
End- to-End “Down” Warp

• Tension greater on the double back liner than on the single
face liner
• Drag on the bottom liner, usually caused by a bad break on the
roll stand
• Pre-heater locked down and not turning, adding tension to the
bottom liner
• Dirty hot plates adding drag
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End-End “Down” Warp

• Operating Footnote:
• The corrugator crew may find the only way to control this type
of warp will be with machine speed.
• The higher the speed, the less drag they see, because at higher
speeds they can operate with less brake.
77
Cross Machine Direction (CD) Warp

Side to Side
• This is a warp that usually is found within a few hours after
the board is run.
• The problem is moisture and tension along with the
temperature in the working area.
• Wrap arm or roller is out of parallel giving uneven pressure on
the double facer
• Out of round glue roll at the single facer, applying adhesive
light and heavy
• Machine speed will from time to time cause the adhesive to
be applied heavy and light
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23-Mar-20
Cross Machine Direction (CD) Warp

Side to Side
• Roll stock with wet streaks or moisture content higher than
normal
– The corrugator crews should have a good understanding of the
adhesive system within their machine and also understand the
use of water sprays.
– Using the adhesive and water sprays properly is the best way to
control this type of warp.
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Twist Warp (Combination of End-to-

End and Side-to-Side Warp)
• Twist warp is cause by uneven tension or stress across the web
of any or all the components during the combining process.
• Roll stand out of level
• Pre-heater out of level
• Splice Roll out of level
• Roll stand, pre-heater out of square to the machine
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23-Mar-20
Twist Warp (Combination of End-to-

End and Side-to-Side Warp)
• Dirt on wrap roller or pre-heater
• Bridge web guide out of level, out of square or off centre
• Crown breaker roll in double back glue machine out of level
• Double back glue machine rider out of level
• Top double back belt pulls unevenly across web
• Loose or tight edge in roll of liner
• Uneven or diagonal stress in roll liner
81
Twist Warp (Combination of End-to-End and Side-

to-Side Warp)
• Twist warp is seen more often on machines that run a two
piece top corrugator belt.
• One belt will be running faster than the other adding stress to
the web.
• If the twist warp occurs off the machine, a wet streak will be
noticed in one of the liners.
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Post Warp (Warp Observed Several

Hours or Days Later)
• The degree of this type of warp will depend greatly on the
way the sheets were stacked and the location of the stack.
• About the surest way to minimise in-storage warping has
proved to be producing as dry as possible a board on the
corrugator, using as little adhesive as possible, and using pre-
heaters to their fullest capacity.
83

• Check liners for wet streaks
• Reduce web tension on the single face side
• Reduce brake drag on all roll stands
• Pre-heaters should be free turning
• Hot plate section should be clean and free of dirt build up
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• Adhesive formula should have the proper solids for the mix
within the plant
• If the machine uses a two piece belt, check the speeds of the
belts
• Sheets must be stacked properly
• Board coming off the machine should be dry and firm
• Should have proper storage area for the finished sheets
85

• When sheets warp after they leave the corrugator, moisture
is most likely the problem.
• The sheets coming off the machine will be wet or damp to
the touch.
• Storing finished sheets near open doors or windows, or
loading the sheets into a cold truck before they have
properly cured, will cause warp.
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23-Mar-20
Thank you – have a nice day

e-mail:
ramkumarsunkara@hotmail.com
Mobile: +91 98200 86841
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Common Corrugating Problems

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23-Mar-20

CAUSES OF COMMON CORRUGATING

Ram Kumar Sunkara 2

Ram Kumar Sunkara 3

Ram Kumar Sunkara 4

DIAGNOSING VISCOSITY PROBLEMS

Ram Kumar Sunkara 5

Low Viscosity at the Mixer

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High Viscosity at the Mixer

Low Viscosity at the Storage Tanks

High Viscosity at the Storage Tanks

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Low Viscosity at the Machine

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High Viscosity at Machine

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Viscosity Decrease After Overnight or Weekend

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Adhesives viscosity growing in storage

• Too much caustic in the formula

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DIAGNOSING GEL TEMPERATURE PROBLEMS

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Gelatinization Temperature Too High

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Gelatinization Temperature Too High

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Gelatinization Temperature Too High

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Gelatinization Temperature Too High

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Low Gelatinization Temperature

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Low Gelatinization Temperature

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Adhesive Preparation and

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Adhesive too hot

• Bad flow through the starch pan

Adhesive being sheared

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Over shearing of the adhesive

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Temperature of the adhesive too high

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Adhesives viscosity growing in storage

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Adhesive too hot

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Foaming of Adhesive in Pans

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Adhesive Gels on Fingers

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Adhesive Gels on Fingers

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BOARD QUALITY PROBLEMS

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BOARD QUALITY PROBLEMS

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BOARD QUALITY PROBLEMS

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BOARD QUALITY PROBLEMS

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