MANUFACTURINGDEFECTSIN

CORRUGATED BOARD/ BOXES,

THEIRCAUSESANDREMEDIES
BY
DEEPAKKILLAWALA

PRESENTEDAT
32ndCERTIFICATECOURSEINCORRUGATED
PACKAGING
WICMAAUDITORIUM,
237,MITTALINDL.ESTATENO.3,
M.V.ROAD, ANDHERI (E),
MUMBAI-400 059

AUGUST01.2012
MANUFACTURINGDEFECTS
IN CORRUGATED BOARD/
BOXES, THEIR CAUSES AND
REMEDIES
1. INTRODUCTION

2. CORRUGATORDEFECTS

3. CORRUGATORROLLDEFECTS

4. PASTINGOPERATIONDEFECTS

5. CREASING &CUTTING AND SLOTTING

OPERATION RELATED PROBLEMS

6. DIECUTTINGPROBLEMS

7. STITCHINGRELATEDPROBLEMS

8. PRINTINGDEFECTS

9. CONCLUSIONANDREFERENCES
 BLISTERS
VARIOUS SHAPED LOOSE, UNBONDED AREAS IN EITHER LINER.
LINERSAPPEARTOBULGEIRREGULARLYAWAYFROMFLUTES.

CAUSES REMEDIES

1. THINSTREAK INLINER 1. CHANGELINER

2. SPOTTYGLUEAPPLICATIONAT 2. ADJUSTFINGERS
FINGERS
3. LOOSECORRUGATION 3. CHECKMEDIUMMOISTURE

4. WETSTREAKINLINERORMEDIUM 4. CHANGEROLLIFCANNOT
BALANCEMOISTURE
 COCKLES
APPEARASWRINKLESINTHELINERBETWEENTHEFLUTETIPS

CAUSES REMEDIES

1. ADHESIVEAPPLICATIONTOOHEAVY 1.REDUCEADHESIVE

2. TOO MUCH HEAT 2.RUN AT FASTER SPEEDS OR

BYPASS PRE-HEATERS WITH
MINIMUMPOSSIBLEGLUELINE
 CORRUGATIONS– CUTATFINGERS

PERFORATIONSINTHEMEDIUMATTHETIPSOFTHEFLUTESINLINEWITHTHE FINGERS.

CAUSES REMEDDIES
1. DIRTYFINGERS 1.CLEANFINGERS
2. FINGERSTOOTIGHT 2.RELIEVE FINGERS
3. BURRONFINGERS 3.FILEORCHANGE FINGERS
4. DIRTYCORRUGATINGROLLS(SILLICATE) 4.CLEANROLLS
5. WET CORRUGATING MEDIUM 5.INCREASE WRAP ON
PRECONDITIONERORADJUST
FINGERS FOR TYPE OF
MEDIUM
 CORRUGATIONS–CUTORFRACTURED

CORRUGATINGMEDIUMWHICHHASBEENCUTORFRACTUREDALONGSIDESOR TIPS
OF FLUTES.

CAUSES
1. HIGHTENSIONONMEDIUM
2. MEDIUMTOOWETORDRY
3. CORRUGATINGROLLSTOOTIGHT
4. DIRTYORWORNCORRU. ROLLS
5. ROLLMEDIUM OUTOFROUNDNESS
6. CORRU.ROLLSNOTPARALLEL
REMEDIES
1.ADJUSTBRAKEPRESSURE
2.INCREASEWRAPONPRECONDIONER
ORADJUSTSHOWERS
3.REDUCE PRESSUREBETWEENROLLS
4.CHECK,CLEAN, REGRINDORREPLACE
5.SLOWCORRUGATOR,CHANGEROLL
6.ALLIGNCORRUGATINGROLLS
 CORRUGATIONS– LEANING

CORRUGATIONSARELEANINGORTILTEDTOONESIDE,BUTOTHERWISEWELL
FORMED.

CAUSES REMEDIES
1. CORRUGATINGROLLSNOTPARALLEL 1.ADJUSTALIGNMENTOF
CORRUGATINGROLLS

2. WET MEDIUM 2.INCREASEWRAPOFMEDIUM

ON PRE-CONDITIONER

3. UNEVENPRESSURE ON CORRUGATING 3.EQUALISEPRESSURE

ROLLS
 WARPEDBOARD
BOARDDOESNOTLIEFLATONTHELEVELSURFACE.

CAUSES REMEDIES
1. WETLINER 1.INCREASEWRAPON
PRE-HEATERORREDUCE
SPEED

2. EXCESS MOISTURE ON SINGLE 2.a) INCREASELINERPRE-

FACE SIDE HEATER WRAP
b) INCREASEOPERATING
SPEED IF PRACTICAL
c) USEMIN.ADHESIVEIN
SINGLE FACER
 WASHBOARDING
REFERS TO APPEARANCE OF SINGLE FACE OR DOUBLE FACE LINER WHICH
STANDSTOFOLLOWFLUTEFORMATION(MOSTPREVALENTINLIGHTWEIGHT
LINERS.

CAUSES
1. EXCESSIVEADHESIVEAPPLICATION
2. IMPROPERVISCOSITY
3. GLUEROLLSPEEDNOTMATCHING
PAPERWEBSPEED
4. EXCESSIVEMOISTUREINTHELINERN
REMEDIES
1. ADJUSTDOCTORINGROLL
2. ADJUSTVISCOSITY
3. ADJUSTGLUEROLLSPEED
4. INCREASEWRAPOFLINER
ONPRE-HEATER
WASHBOARDINGISCAUSEDBYEXCESSADHESIVE
 ROLL IN PROPERADJUSTMENT
FLUTEPATTERNGIVENSHOWSROLLINCORRECTALIGNMENTANDUNDER
UNIFORMPRESSURE.

OPERATORSIDE CENTER DRIVESIDE

 IMPORTANCEOFTEETHPROFILE

GEARTEETHINCONTACT GEARTEETHPROFILE
 PASTINGOPERATIONRELATEDPROBLEMS
PASTINGOPERATIONISCARRIEDOUTTOJOINCORRUGATETOPAPERTO PRODUCE 3-
PLY, 5-PLY, 7-PLY SHEET.

CAUSES
1. CRUSHINGOFFLUTES
2. EXCESSIVEADHESIVEAPPLICATION
3. LESSAPPLICATIONOFADHESIVE
4. UNEVENADHESIVEAPPLICATION
5. SHEETNOTMOVINGSTRAIGHT
6. CORRODED, WORN OUT AND
PITTED ROLLERS
REMEDIES
1.INCREASEGAPBETWEENROLLERS
2.a)ADJUSTDOCTORINGROLL
b)REDUCEADHESIVEVISCOSITY
3.INCREASEVISCOSITY
4.CHECKSURFACEOFAPPLICATOR
ROLL
5.EQUALISEPRESSUREATBOTHENDS
6.MACHINE,GRINDANDELECTRO-
PLATEROLLERS OR REPLACE
 ROTARYCREASERRELATEDPROBLEMS
CAUSES
1. SHEETCRACKING DUETODRYBOARD
2. SHEET CRACKING DUE TO NOT USING
CORRECT CREASING HEAD
3. ROUGHCUTTING
4. MACHINEVIBRATIONS
REMEDIES
1.MAINTAINMOISTUREINTHE
SHEETS
2.USERIGHTCREASINGHEAD
3.a)SETGAPBETWEEN CUTTERS
b)GRINDORCHANGECUTTERS
4.a)CUTTERSJAMMED
b)DAMAGEDBEARINGSORGEARS
 ECCENTRICSLOTTINGMACHINERELATEDPROBLEMS

CAUSES REMEDIES
1. RAGGEDSLOTSORROUGHCUTTING 1.IMPROPERLAMINATIONORWORNOUT
SLOTTINGKNIFEANDSIDECUTTERS, ADJUST
CUTTER SCREWS
 PUNCHINGOR DIECUTTINGRELATEDPROBLEMS

CAUSES REMEDIES

1. POORPRINTPUNCHREGISTRATION 1. CORRECTPRINTINGAND
PASTINGREGISTRATION

2. TRIMNOTSTRIPPINGPROPERLY 2. PROVIDEPROPERNICKDEPTH
AND GAP, DAMAGED CUTTING
RULE OR IMPROPER CORKING

3. PAPERCREASEFRACTURES
3. PROVIDECREASINGRULEOF
CORRECT THICKNESS,
REDUCEPRESSURE,IFEXCESS
DRY SHEET CAN ALSO CAUSE
FRACTURES

4. SHEETNOTEJECTINGFROMDIE 4. PROVIDECORKOFRIGHT
QUALITYANDINQUANTITY
5. TRIMSEPARATESINMACHINE 5. INCREASENICKING

6. INACCURATE CREASING AND 6. PROVIDERULEOFCORRECT

CUTTING (DEFLECTION OF RULE) THICKNESS AND HEIGHT

7. NON-UNIFORM CUTTING AND 7. DAMAGEDCUTTINGPLATE

CREASING NEEDS CHANGE
 CAUSES REMEDIES

8. EXCESSIVEMACHINEDEFLECTION 8. HIGHLOADDUETOMORE
CUTTINGANDCREASINGLENGTH OR
BLUNT CUTTING RULES. CHANGE
DIE OR CUTTING RULES

9. BLANK CONSISTENTLY UNCUT IN 9.

LESSMACREADYORLOWRULEONE AREA HEIGHT

10. SLOTISSTRIPPINGDUETO 10. PROVIDETAPPERSLOTS

IMPROPERSHAPE

WARNING: SAFETYGUARDSSHOULDNOTBEBY-

PASSEDASITCANLEADTOSERIOUS ACCIDENT OF OPERATOR’S

HAND.
 STITCHINGRELATEDPROBLEMS

CAUSES REMEDIES

1. CORROSIONOFSTITCHINGWIRE 1. PROVIDECORRECTELECTRO
PLATINGONWIRE

2. BREAKINGOFSTITCHINGWIRE 2. PROVIDESOFTWIRE

3. STITCHING WIRE LEGS BUCKLED 3. WIRESIZEBEINGUSED

OR DULL WIRE CUTTER

4. IMPROPERSTITCHSPACING 4. TRAINOPERATOR

5. WRONG PLACEMENT OF 5. MAINTAINCORRECTGAPFROM

END STITCH THE FLAP SCORE LINE
 PRINTINGDEFECTS
CAUSES REMEDIES

1. INCORRECTINKFORMATION 1.CHECKEACH BATCHOFINKWITH

STANDARDCOLOURSWATCH

2. INK VISIBLE ON THE OTHER SIDE, 2.REDUCEINKAPPLICATION

EXCESSIVE INK APPLICATION

3. POORPRINTINGDEFINITION 3.REPLACEDEFECTIVEPRINTINGPLATES

4. IMPROPERPRINTREGISTRATION 4.COLOURS BEINGOUTOFREGISTER,

ADJUSTONECOLOURATATIME

5. INKOUTOFBOUNDARY (SMEAR) 5. EXCESSIVEINKAPPLICATIONOR

DIRTY PRINTING PLATES. REDUCE
INKORCHANGEPRINTINGPLATES

6. DIRTY PRINTING 6. DRYANDDUSTYBOARD.GETBOARD

WITHBETTER SURFACE FINISH

7. DISTORTED IMAGE DUE TO 7. REDUCETHEPRESSURE

HIGH PRINTING PRESSURE

8. IMAGEDISTORTION 8.DUETODAMAGEDPRINTINGPLATES,
REPLACE PLATES
THANKSARE DUETO

• WICMA&FCBM
• Mr.PankajD.Shah
• Mr.BaldevMehta
• Mr.Y.M.Rao
• AlltheParticipants
 LISTOFREFERENCES

1. CORRUGATEDBOXMANUFACTURERSHANDBOOKBYS&SCORRUGATEDPAPER
MACHINER CO. INC.
2. PAPERANDBOARD,ITSMANUFACTURINGTECHNOLOGY,CONVERSIONAND
USAGEBYROBERTR.A.HIGHAM(VOL.1&2).
3. STARCHPRODUCTIONTECHNOLOGYBYJ.A.RADLEY.
4. CORRUGATEDSHIPPINGCONTAINERS,ANENGINEERINGAPPROACHBYGEORGE
G.MALTENFORT.
5. ROLLAPPLICATIONOFADHESIVESBYRAYMONDR.MYRES.
6. PROBLEMSENCOUNTEREDDURINGPRODUCTIONANDON-THE-SPOT
SOLUTIONS BY SURINDER SINGH BHURJEE.
7. CORRUGATINGDEFECTSTERMINOLOGYBYTAPPIPRESS.