TIP 0304-66

ISSUED – 1996
REVISED – 2002
2002 TAPPI

The information and data contained in this document were prepared

by a technical committee of the Association. The committee and the
Association assume no liability or responsibility in connection with
the use of such information or data, including but not limited to any
liability under patent, copyright, or trade secret laws. The user is
responsible for determining that this document is the most recent
edition published.

The impact of doublebacker hot plate level on board

quality and how to measure it

Scope

Hot plates in the doublebacker (DB) section must be maintained so that the leading edge of any plate is level with
or slightly lower than the trailing edge of the preceding plate. The consequences of a leading edge plate that is higher
than the previous plate’s trailing edge can be:

• Flutes crushed as the hot board “runs into” and rides over a high lead edge. This can negatively affect caliper and
box compression.
• Disturbance of the DB glue line can occur, especially if the high leading edge is early in the hot plate section
when the glue line is still in the early stages of bonding. This can cause weakened bond and delamination.

A low lead edge is one that is 0.010 in. (0.025 cm) or greater lower than the preceding plate’s trailing edge. In
most hot plate sections, it is desirable that the lead edge drop no more than 0.010 in. (0.025 cm). If a ballast roll is
located where the plates meet, it is critical that the drop not exceed this amount. Consequences of a low leading edge can
be:

• Board creasing caused by the abrupt drop of green, wet board from one plate to the next;
• Board bending caused by ballast rolls at the junction of two such plates, and possible caliper loss;
• Disturbance of the DB glue line, especially if the low leading edge is early in the hot plate section when the glue line
is still in the early stages of bonding.
• Skewed hot plates is a situation in which the lead edge is high on one side and low on the other.
• This can lead to all of the above problems.
• It can lead to twist warp because of uneven tension placed on the wet board, if enough of the hot plates are skewed
as described.
• Can cause liner scuffing, peeling, and possibly smearing of preprinted liner.
• High amounts of drag can cause excessive drive motor amperage, and reduced production speeds.

It is easy to see that maintaining hot plate level is important to the quality of corrugated board. A simple method
to determine hot plate levelness will be described.

Safety precautions

Safety precautions should be utilized when measuring the hot plates on the edges while hot (operator/drive sides)
and masking the required adjustments to plates while hot. Use long sleeve shirts and heavy gloves. Insure that the double
backer is “Locked Out” and “Tagged Out” plus in a “Zero Energy State.”

TIP Category Automatically Periodically Reviewed (Five-year review)

TAPPI
TIP 0304-66 The impact of doublebacker hot plate level / 2
on board quality and how to measure it

Content

Equipment

• A straight edged bar, preferably steel, approximately 1 in. × 1 in. × 12 in. (2.54 cm × 2.54 cm × 30 cm).
• This straight edge should have a nut welded to the center of the 12 in. (30.48 cm) axis. A threaded rod that is at
least 4 ft. (120 cm) long should be screwed into the straight edge to serve as a handle.
• A set of feeler gauges, 0.003 - 0.025 in. (0.008 - 0.064 cm).

Procedure

It is necessary to measure the double backer's plate when they are hot because this is the run condition. Heat
causes the plates to expand and possibly distort.

Follow these steps to determine if high leading edges and/or high trailing edges exist in the hot plate section:

1. Place the straight edge flat on the first hot plate in the DB section, approximately 6 - 12 in. (15 - 30 cm) from the
operator edge.
2. Slowly drag the straight edge toward the second (leading) hot plate, letting the straight edge pass completely over
the junction between the plates.
3. Slowly bring the straight edge back over the plate junction, back onto the first (trailing) hot plate.
4. If the straight edge passes from the first to the second hot plate with the feeling of resistance (i.e. the feeling that
the straight edge is bumping into the leading edge of the second plate), then the second plate has a high leading
edge at that position.

NOTE 1: If the straight edge passes over the junction of the first plate to the second plate with no resistance, the leading edge is level to, or
lower than, the trailing edge of the first plate.

5. If on the return pass of the straight edge from second to first plate, there is resistance (the straight edge bumps into
the trailing edge of the first plate), then the first plate may have a trailing edge that is too high at that position
across the corrugator (remember that the drop from first to second plate is recommended at no more that 0.010 in.
or 0.025 cm).
6. Move the straight edge in to approximately the operator - center position across the corrugator and repeat Steps 2 -
4. Then move in to approximately center position and repeat Steps 2 - 4.
7. Repeat Steps 2 - 5 for the junctions between Plates 2 and 3; Plates 3 and 4, etc. until the entire operator side of the
DB has been checked.
8. Move to the drive side of the DB and repeat Steps 2 - 6.
9. If any of the junctions indicate high leading edges at any point across the corrugator, those plates with the high
leading edges should be leveled during the next corrugator shutdown.

If any of the junctions indicate high trailing (low leading) edges at any point across the corrugator, it is a good idea
to level those plates as well if the difference is greater than 0.010 in. (0.025 cm). An excessively low leading edge can
result in reduced heat transfer, poor bond, and production speeds. By using feeler gauges, the drop may be measurable,
and a judgement on the need to level these plates can be made.

Conclusion

By following the above procedures in a timely manner, the DB hot plates may be maintained as level as possible,
thus reducing the potential of board quality defects that out of level plates can cause. It is a relatively simple and quick
check that anyone can do.

Keywords

Corrugating machines, Doublefacers, Plates

3 / The impact of doublebacker hot plate level on TIP 0304-66
board quality and how to measure it

Additional information

Effective date of issue: June 26, 2002

Working Group Members:

Richard Croker - Chairman, Georgia Pacific Corp.

John Troyke, Georgia Pacific
Robb Tripsmith, Retired
Carlos Jurado, Cartorama
Ron Jacobs, CORR – TEK
Guy Asher, International Paper