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Corrugator Related Machine

Roll Stand

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Splicer

Guiding System

Double Facer

Sheet Presser

Corrugator Conveying Belt

Engery System

Slitter Scorer

Cut Off

Stacker

Process Control System

Printer Slotter Die-cutter

Flexo Folder Gluer

Digital Printer

Flatbed Die-Cutting

Printing Related

Conveyor System

Folder Gluer

Stitching Machine

Strapping Machine

Laminator

Plant Related

Parts

Blades

Printing Comsumable Material

Dasong DS Bridge Web Alignment and Tension Control System

Get better 3/5/7 Layer cardboard alignment automatically

FUMA Steam System With Intelligent Control for Great Savings

Steam System With Intelligent Control for Great Savings

FUMA HIP Series Splicer

High Performance HIP Series Splicer

FULI SFM25N POSITIVE PRESSURE CASSETTE TYPE SINGLE FACER

Specification: 1. Maximum mechanical speed is 250m/min. 2. The diameter of the corrugating rollers is 380 mm. The diameter of the pressure roller is 520 mm. The diameter of the surfaces of glue roller is 302 mm, The diameter of the doctor roller is 170mm.

XIEYANG MSF-28P/32P Multi-Cassette Positive Pressure Single Facer

Corrugating rolls are placed under pressing roll to lower gravity center, in order to reduce noise and vibration during the operation. So that the machine is running more oothly and stably. In addition, cassette changing is safer, faster and easier with lower position.

DGMJ SP-10 servo type high performance machine

As a dual-head automatic paper splicing machine with an orginal control system made in Taiwan,the SP-10 high-performance paper splicing machine has a long life and great flexbility.With a of automatic splicing for incomplete paper and personalized operation design,it applies to the weights of grams(80g/m2 to 400g/m2) of all kinds of base paper in china and foreign countries.

KaDar Whole plant intelligent logistics control system

Whole plant intelligent logistics control system

Dasong DS Liner

Getbetter single board alignment automatically

Fuli 20NA Fixed Type Single Facer Corrugated Machine

20NA/22NA single facer Single facer represents the heart of the entire manufacturing line and a determining factor of final product quality. Our single facer is a product of optimized design integrating years of designing and manufacturing experience and the principle of human first that’s highly dependable and easily operated with the following characteristics:

Analysis on Rotary die-cutter

Analysis on Rotary die-cutter Corrugated carton die cutting are mainly included rotary die cutter and flat die cutter. Printing die cutting inline generally use rotary die cutter. Rotary die cutter mainly has two kinds, steel cutting board wheel and rubber cutting board wheel.1.Features of steel cutting board wheel1).High requirement on cutter die flatness. The die cutting board of the steel cutting board wheel is made of steel rods, the top knife is steel and so is the bottom. It has a very high requirement for the flatness of the knife. If the flatness of the knife is different, when the upper and lower knives collide, the higher one will be damaged and the lower one will not be cut.But steel cutting board wheels also have benefits. If the cutting die is made well, the performance of the steel cutting board wheel is much better than that of the rubber cutting board wheel.2).Bugled line can be suppressedBecause steel is a hard surface, you can suppress the concave and convex line, it can be produced in a complex way like flat die cutter. Although the rubber pad can also stick dark line, the effect is far from good as steel one.3).Uniform force, all speed differenceThe steel cutting board wheel has a high requirement for even strength and will not wear out, so the speed difference is very all.2.Features of rubber cutting board wheel1).The flatness of the knife is low and can be adjusted by pressureThe knife anvil under the rubber cutting board wheel is rubber, which is elastic, so the requirements for the mold are reduced. Even if the knife is not flat, as long as increase the pressure, you can cut into the rubber, the cutting effect can also be achieved. So it requires less flatness of the knife.2).The rubber pad has large loss and speed differenceBecause the anvil is made of rubber, when the knife cutting the knife anvil, rubber easy to wear. The price of the anvil is also higher, like several thousand yuan for one set, so the loss is larger. And once the knife anvil wear, the circumference will become aller, which will produce speed difference, and the speed difference will bring a lot of adverse effects on the die cutting products.Two models of die - cutter 1).Top cutting die, bottom cutting anvil: This model is very suitable for bottom printing press.Advantages:The biggest advantage of the upper die is that the scraps of paper fall on the rubber pad after cleaning, because of the gravity, the scraps of paper is easier to demold, so the upper die is a very good model.Disadvantages: Only applicable to bottom printing press, which the printing surface downward, so you have to turn it upside down to check the die-cutting effect, and the printing face, this is somewhat inconvenient in operation.2).Bottom cutting die,top cutting anvil: This model is very suitable for top printing press.Advantages: The printing face upward, so you can check the the effect directly, and find out if there is anything wrong with the printing at the first sight.Disadvantages: Paper scraps can easily cause indentation and udge. After the scraps of paper spring out, most of them will stick to the rubber pad, and then fall on the printing surface, which will be sandwiched between the die cutting pad and the template, the printing surface will be damaged by friction.After comprehensive comparison, the upper die is definitely better than the lower die, so try to choose the upper die.There are three aspects about starting the machine:1).We need to first turn on the force glue lateral switch in time, so that the force glue will be about 50 cm lateral movement, the die cutting knife will cut in different rubber pad during the process of moving, so that the superior force adhesive and die - cutting knife have a horizontal movement range in the working process, which can improve the service life of superior force adhesive.2).When installing the template, the bolts should be installed from the bottom of the template, and the bolt holes on the template should be installed as far as possible, to ensure the roundness of the template.3).When adjusting the position of the die hole, the template should be separated from superior force adhesive and then adjusted to avoid damage superior force adhesive.4).Quick die change device: The installation template of die cutting unit is divided into two molds: one is mechanical, generally need to use more than 20 bolts for template installation, if no rapid mold change equipment, it is estimated 25 minutes for mold change; It is also expected to take nearly 15 minutes with the rapid mold change equipment. The second is vacuum adsorption type rapid loading mold, because of the use of vacuum adsorption, only need two bolts for mold replacement. It saves a lot of time, only 5 minutes per order. This is a new type of mold change device, if possible, try to use this rapid mold change as far as possible.

Steam System Purchase and Process Technology

 For most cardboard factories today, "steam recovery" has become a popular energy-saving concept.However, many cardboard factories in the purchase of steam system, there will still be a lot of doubts and concerns, and often end up blindly following the trend, but do not consider their actual needs.This not only does not save energy, but also cause greater waste and loss.So, what factors should be considered when choosing a steam system?1.Introduction to Steam System           Steam has the following unique advantages: it can carry high density of energy, so relatively all diameter pipe is needed ;When dry saturated steam is used, heat can be transferred at constant temperature.Steam can transfer heat efficiently;Steam flows as fast as it can to where it is most needed;Steam is environmentally friendly, non-toxic and non-flammable.There is no doubt that steam is the best medium for corrugator heating.Steam Table▲Steam Supply SystemGenerally, steam system includes the following parts: boiler, steam pipeline, heat transfer and heat exchange system, condensate trap and steam recovery system.Boiler the design of the boiler has no impact on the production of corrugated board, as long as the boiler maintain 15 to 16 bar constant pressure.Steam pipe steam is transported from the well sealed pipe to the corrugated line. Starting from the main steam distribution pipe, steam flows along the pipes connecting the wet end of the corrugated line to a single machine, such as the single facer, triple preheater and double facer hot plate.Heat transfer and heat exchange system: the tranission of steam from the fixed steam pipeline to the rotating roller needs to pass through the "steam rotary joint", which is a rotary sealing joint installed on the roller shaft.Inside the roller, steam transfers heat to the wall of the pipe and restores itself to condensed water.Due to a layer of water film formed on the inner wall of the roll and the thicker inner wall of the roll heated by the traditional method, the surface temperature of the roll usually decreases a lot.However, because there is no water film on the inner wall of the annular drilling roll with steam flowing, the temperature on the surface of the roll increases significantly.This is similar to the condition of the hot plate. Hot plate around the bore hole heat application has the following advantages: paper surface temperature rises 15 ℃ or more;Rapid heating and temperature adjustment under different production conditions;The whole working range is temperature balanced.Condensate trapafter heat is transferred to various parts of the machine, steam gradually condenses. In most cases, condensate water flows into the condensate tank.The  of a condenser tank is to drain condensed water and air from the heating unit.Air discharge from corrugated rollers is a particularly important step.When a corrugated roll is heated, steam pushes air in front of it. As air cannot condense, it accumulates in front of the condensing tank.Air conductivity is very poor and having bad insulation effect, so it will lead to the production of temperature imbalance.At present, there are four common types of traps in the market: disc type, inverted bucket type, floating ball type and pinhole type.The al principle of the floating ball trap is as follows: the pressure in the tank is higher than that in the condensing pipe, and the condensing flow into the tank makes the floating ball inside rise.After the valve seat opens, condensed water flows out. When the water level drops, the float ball sinks and closes the valve seat again.If there is air in the condensation tank, the temperature will drop and the exhaust pipe will be opened. ▲Functional Principle of Floating Ball Trap▲Concentrated hydrophobic▲Separate storageSince the pressure required to drain steam is different from that required to drain condensed water into the condensing pipe, if there are several drainage pipes, several heating devices can share a condensing tank.Although it saves money to share a condenser tank with a group of heating units, there is  shortcoming: less condensed water in the unit requires less heat, so the steam will reach to the condenser tank and close it so that other equipment cannot drain.The result: slow heating;Temperature imbalance;Uneven heating;The production speed is slow.So a better solution is to store water separately, which is to have a condenser tank for each device.Steam recovery system: steam recovery system can be divided into open recovery system and closed high-pressure recovery system.In open recycling system, hot condensate water (the temperature as high as 180 ℃ under 10 bar) into the boiler room, and then enter to the tank.At this time to the tank and atmospheric contact, condensed water as fast as steam flow, most of the heat energy emitted into the atmosphere, but the open recovery system has an advantage, because of its low pressure to the tank, so the operation is relatively safe.Different from the open recovery system, in the closed recovery system, the condensed water of high pressure is concentrated in a separate feed tank and directly pumped back into the boiler at a high pressure state.The biggest advantage of such a system is that it basically doesn't waste energy, water or chemicals, but the cost is a little high. ▲Closed recovery systemWe should pay attention to the closed steam recovery system. When condensed water from different processes enters the recovery system, due to different back pressure, If the recovery system is not properly planned, the problem of poor return water of low-pressure condensate will occur.When the air leakage of individual traps is serious, it will cause the back pressure of the whole system to rise, affecting the balance of the system.2 .Heating Equipment on Corrugated Line1) Steam system of single facerIn the steam system of a single facer with corrugated rollers heated by traditional methods, the new steam pipe delivers steam directly to each roll.The condensed water is siphoned out and then drained separately.In the steam system of a single facer with annular drilling corrugated rollers, the corrugated rollers are directly connected to a new controllable steam pipe.Steam first flows to the high corrugated rollers and then cascades to the low corrugated rollers.Before being stored in the condensing tank, the steam flows into a separate tank, and the new steam also heats the other cylinders on the single facer. In order to effectively take the condensate out of the corrugated roll, 2.5 bar to 3 bar pressure is required to ensure that it flows oothly from all these lines.The steam flow in other heating rollers is the same as that in ordinary heating systems, from siphons to condensing tanks to high-pressure condensing water.For other heating rollers, external heating is not necessary, because their accuracy requirements are not as high as corrugated rollers.2). Hot Part of Double FacerCascade systemIn a cascade system, the waste steam generated by the first part of the hot plate is dehydrated, and then the steam flows into the second part.The pressure in the first part is the highest. In order to ensure ooth circulation, the pressure in the second and third parts will be gradually reduced.In order to make better use of energy, waste steam from the condensing tank in the first part is used to heat the second part.Steam is fed through the electric valve M2. The procedure for the second and third part is the same.The condensate system downstream determines the lowest vapor pressure in the third section.Temperature decreases with the direction of paper transfer, which is suitable for most types of cardboard.However, when processing new micro corrugated (F, G, N and O flute) board will appear the following problems:Flute density and less air inside the cardboard makes it difficult to emit steam, resulting in the formation of bubbles;Gelatinization temperature of starch adhesive is too low;In order to make the surface paper and corrugated adhesion intact, it is best to start at a low temperature, and then gradually rise gradually drying board.This requires further development of parallel cascade systems rather than series cascade systems.Parallel cascade systemAll three parts are connected directly to the new steam pipe so that the pressure can be adjusted during production.The use of secondary steam in different parts is the same as in cascade systems.However, more condensation tanks are required and reflux occurs only at the lowest vapor pressure.The condensate system downstream determines the lowest vapor pressure, which can be reset.3.The Role of Steam SystemIn the production of single facer, the energy is distributed as follows: 70% is used to heat the cardboard and its water and evaporate the water;20% for gelatinizing and drying starch;10% is lost in convection and infrared tranission.Therefore, it is necessary to purchase a steam system to solve the problem of heat utilization.Steam system is an important component of corrugated board production line.And corrugated board molding usually adopts saturated steam heating, steam heating system will be saturated steam continuously sent to the preheater, preset, single facer, three layers of preheater, gluing machine, roller inside and bake, hot plate, corrugated base paper and corrugated board through the steam drum and the surface of the hot plate, due to hot plate surface temperature is high and the steam fed into steam drum , the heat exchange with the base paper or cardboard in low temperature, preheat base paper or cardboard, to take away heat on the surface of the roller and the hot plate part of this will leads to the formation of a heater inside the latent heat consumption of steam condensation water, which will be discharged in a timely through the trap system,while constantly replenishing saturated steam.Steam system evaporates the excess water in the base paper, adjust the water in the base paper to make it evenly distributed, especially in the width direction, to ensure that the base paper forming does not bend deformation in the corrugated coating adhesion, provide a certain amount of heat, ensure that the adhesive quickly gelatinization and shaping, at the same time to evaporate the excess water.It is the most important  of steam system to make heat meet the need of corrugated paper forming and paste gelatinization.On the basis of ensuring the quality of corrugated paper production, it is required to provide steam and heat in line with the speed of production, and enables minimum energy consumption, so as to achieve the highest energy efficiency, production costs to the lowest. ▲Poor recycling results in waste of energyThe role of steam system in corrugated board production line can be summarized as follows:1.The heat to meet corrugated paper forming and paste gelatinization.2. Make the heat meet the needs of production speed and quality3. Maintain minimal energy consumptionIt is not enough to maintain the minimum energy consumption after knowing the role of steam system, because the requirements of steam system are different with different speed, different base paper width and different production line configuration.Therefore, in the purchase of steam system must be based on the production requirements and production conditions.When purchasing steam system, the following two aspects need to be considered:Steam recovery machineSteam distribution layout.4.Factors to consider when purchasing steam systemsSteam recovery machine is the core equipment of steam system, which uses waste steam and high temperature condensate water to directly compress into the boiler in the way of soda mixture to form a cycle system of steam production-use-waste steam recovery, so as to maximize the recovery and utilization of steam waste heat and achieve the purpose of energy saving. Therefore, we should firstly pay attention to recovery machine in the purchase of steam system.There used to be a piston type steam recovery machine, but now it has been basically eliminated, because it is not conducive to the production of the required stable temperature.At present, the steam recovery machine on the market is basically a single cylinder of high pressure pump and double cylinder of high pressure pump these two kinds, their main difference is: the single cylinder of high pressure pump in the control of back pressure to stabilize the temperature of the production line, mainly by controlling the pressure difference between the two ends of the trap, to ensure the stable working state of the trap.And double cylinder high pressure pumps have self-suction , but most of them do not have back pressure control , so it is easy to lead to the trap work instability.At present, there are some dual-cylinder high-pressure pumps are also increasing back pressure control.In fact, single cylinder high pressure pump or double cylinder high pressure pump is not the key to the problem, the key is that the trap to have a pressure difference on both ends, so that the trap can work normally and steadily to meet the temperature requirements of the production line stability. Above is a closed loop steam recovery flow chart.Steam goes from the boiler to the production line to the reclaimer, forming a closed loop.In fact, the steam system does not have to be completely closed loop to achieve the purpose of saving, because the first priority of saving is to meet the production, and then consider saving on the basis of meeting the production.Finally, when purchasing steam system, the distribution layout of steam should also be considered. The following factors should be considered when laying out steam distribution pipelines:1) The pipeline shall have enough inclination to facilitate water discharge2) Drainage at the bottom of the pipe (drainage at the low point) and exhaust at the high part3) Oblique pipe insertion4) Avoid condensation water aggregation with reduced inner diameter of concentric pipe5) Steam is introduced at the top of the pipeIt should be emphasized that the preheating cylinder can use steam to do the secondary utilization of steam.The steam used by the single facer, corrugated roller and pressure roller can be collected, separated by water vapor, and reimported to the preheating cylinder for reuse. ▲Schematic diagram of steam pipe for double facer hot plate   ▲Schematic diagram of steam pipe of single facer5.How to use intelligent control to reduce steam consumptionThe teat energy use of China's corrugated board production line, from the 1970's to the 1980's with fire (gas) heating, from the 1990's is the use of steam heating.As for how to control steam heating and how to reduce consumption, we basically start from steam pipe design of equipment and structural design of heating components.1). Traditional methods of reducing steam consumptiona) Boiler continuous water feeding control energy-saving design, through a all number of continuous automatic water feeding, reduce boiler pressure change, improve boiler thermal efficiency, reduce energy consumption, which can save 3-5% of the energy.b) Energy saving design of recycling confidential backwater pipeline: the heat of backwater will not be lost and the pressure will be repeatedly pressed back to the boiler for use, which can save 10%-15% of energy.c). The energy saving design of steam pipeline utilizes the temperature difference between single and double facer and preheating cylinder for secondary steam utilization.That is, the steam used by the single and double facer through the separation of soda water and then to heat the preheating cylinder, make full use of steam heat, reduce steam loss, which can save 2%-3% of the energy.Single facer and double facer after the use of secondary steam return preheating cylinder and triple preheating cylinder reuse, its design principle is shown in the figure. ▲Schematic diagram of steam pipe of triple preheater and single facer   ▲Chart 1:No secondary utilization ▲Chart2:Secondary utilization ▲Chart3:Secondary utilization plus trapd). The energy-saving design of heating components is mainly manifested in reducing the volume of heating vessel, reducing the consumption of steam loss, and improving the speed of temperature change, which can save 2%-3% of energy.①Design Schematic of Heating Around Corrugated Roller                                               ▲Chart 4:Design Schematic of Heating Around Corrugated Roller②Design of thin hot plate                ▲Chart 5:Design Schematic of thin hot plate③Design of Arc Plate ▲Chart 6:Design of Arc PlateThe above is the current status of the industry, here to introduce how to use intelligent control to reduce steam consumption through process design.2).Energy saving design by process temperature controlProcess design: In fact, it is to control of each kind of grams of heavy base paper through intelligent equipment, glue gelatinization temperature and production speed of the corresponding process point control, to achieve the minimum temperature required by the base paper molding and glue gelatinization.At present, the industry is generally divided into two types of equipment, the first is low-speed machine, steam pressure of 6-8kg/cm squared;The second is a high-speed machine with a steam pressure of 9-13 kg/cm squared.Preheating cylinder through the base paper wrapping angle to adjust the preheating temperature, hot plate through temperature control to adjust the temperature of hot plate, single facer is not temperature control, how much pressure steam main pipe provided, then how much temperature used for board production.In this way, our corrugated board production line can not achieve the minimum temperature production for different weight of base paper grams, nor can we effectively control the cardboard quality and steam energy loss.Temperature control system of corrugated paper :a) Detection of single facer: through the detection of single facer, the feeding in  temperature of all kinds of base paper, linerboard, medium (attachment wet end control)  and feeding out temperature of flute paper , and according to the production speed and the corresponding base paper gram parameter, it automatically adjust and control single facer and preheating cylinder with minimum steam temperature and an appropriate angle, the gluing quantity and equipment all kinds of pressure, etc.b)Detection of double facer : by detecting the feeding in temperature of every layers of flutes linerboard(attachment wet end control) of double facer, and the feeding out bottom temperature of cardboard and linerboard temperature of hot plate of double facer, and according to the production speed and the corresponding base paper gram parameter to automatically adjust and control double facer paragraphs hot plate and preheating cylinder with minimum steam temperature and the preheating cylinder angle, and quantity of the paste on the adhesive tape machine paragraphs cotton pressure, etc.c) Through the dry end of warping intelligent control system to measure the flatness of the cardboard of the current order, the system can automatically adjust and control the corresponding process temperature point parameters and quality (warping) parameters of the wet end control (paper temperature control system) equipment in accordance with the preset process parameters.Through intelligent control of the minimum temperature required for the temperature point parameters of each process, combined with the control of pressure parameters, steam energy loss can be effectively controlled at the same time, the production of stable and high-quality cardboard, reduce the labor intensity and skill requirements of workers, ensure the efficiency of production equipment and reduce the loss.3).Principle and application of low temperature and low pressure productiona) the main role of normal temperature in corrugated productionForming: reduce the reaction force of elastic deformation of the base paper (flute) forming and the internal stress on the board after the forming through the action of temperature.Adhesion: through the role of temperature, the role of the adhesive on the base paper quickly gelatinization, in order to achieve reliable adhesion.Preset temperature: pre-heat the base paper before forming and gluing it into cardboard, adjust the humidity of the base paper before entering the hot plate of single facer, etc.From the above points of view, the temperature of the cardboard has a great impact:(1) Single facer corrugated roll between the corrugated forming temperature conduction is relatively easy (relative to the hot plate adhesion), and the pressure roll and corrugated roll inside paper adhesion temperature conduction is also relatively easy (also relative to the hot plate adhesion), as shown in the figure:  Loading Mode P1: Direct TouchTemperature conduction mode C1: direct conduction temperature on both sides(2) Double facer mainly refers to the hot plate gluing, cardboard in the hot plate loading mode and temperature conduction mode are not as good as the structure of single facer, so the double facer hot plate temperature requirements will be higher.As shown in figure: Loading Mode P2: Indirect Touch, and not too much pressure, not to crush the cardboard, P2 < P1Temperature conduction mode C2: direct touch on one side of linerboardSeptum: heat can only be tranitted indirectly by thermal radiationFor high speed machine, high gram cardboard not only on the double facer temperature requirements.In addition, the gelatinization temperature of the glue on the double facer should be adjusted to match the high speed.In general, the steam pressure of the medium-speed machine is 8-9 kg/cm squared, and the steam pressure of the high-speed machine is 11-13 kg/cm squared.b).Influence of temperature on physical properties of base paper and board(1) The influence of temperature on the humidity of base paperThe figure below is the process test diagram of temperature relative response time and humidity change of base paper:  Figure 1:Curve A, curve B represent base paper of different temperature with different time back to the corresponding temperature.Figure 2: curve A and curve B represent the same type base paper with different temperature, after the same time, corresponding to the change of the temperature.Curve B represents base paper with low heating temperature has lower humidity. The curve A indicates that the high temperature of the base paper has higher corresponding humidity change.Humidity first low then high, that the base paper has a stronger water absorption after high temperature, which is the reason why the cardboard to be more flat right after being produced, and become warped after a period of time.(2) Temperature on the physical properties of base paperThe following figure is the process test diagram of temperature on the physical properties of base paper:  The figure shows that the higher the temperature, the greater the fiber damage of the base paper, the aller the rupture strength, ring compression strength, on the contrary, the lower the temperature, the aller the loss of the physical properties of the base paper.c).Implementation of suitable temperature and pressure production(1) From the single facer forming and gluing of the loading mode and temperature conduction mode, corrugated line production does not need a high temperature.Normal high speed single facer, speed is more than 250 m/min is only required to steam pressure 12 + 1 kg/cm squared (steam temperature to 192 ℃ + 4 ℃), why?Reason 1: chromium plated corrugated wheel in high (in order to extend the service life of corrugated wheel), the need for a higher temperature corrugated wheel elastic deformation.Tungsten carbide corrugated wheel wear is very all, do not need to extend the service life and improve the high, do not need a large elastic deformation, temperature is not one of the conditions for the elastic deformation of corrugated wheel.Reason 1: chromium plated corrugated roll in high (in order to extend the service life of corrugated roll), the need for a higher temperature corrugated roll elastic deformation.Tungsten carbide corrugated roll wear is very all, do not need to extend the service life and improve the high, do not need a large elastic deformation, temperature is not one of the conditions for the elastic deformation of corrugated roll.Reason 2: At high speed, the base paper in the corresponding heating roll stay for a short time, increase the temperature is to ensure that the gelatinization and gluing, it also can not increase the temperature, only reduce the gelatinization temperature of glue to match the speed of corrugated machine.Conclusion: single facer, high-speed, > 250 m/min) steam pressure can be controlled completely in 6 kg/cm squared - 7 kg/cm squared, steam temperature of 165 ℃ to 170 ℃.(3) As to the double facer cardboard gluing loading mode and the temperature conduction  is not as good as the single facer, the hot plate temperature is a very important factor to control and ensure the quality of cardboard (including warping, degumming and other physical performance indicators).Generally, at high speed, the steam pressure of several sections of the hot plate decreases by 12kg/cm squared one by one (according to the condition of the cardboard and the gram weight). In fact, we can match the speed of double facer by reducing the gelatinization temperature of glue, so as to reduce the required temperature of the cardboard.There are two states:A .Three layer board with low gram and five layer board due to low gram, base paper heat conduction is strong, at the same time, lower gelatinization temperature (56 ℃ + / - 1 ℃), to avoid glue form ahead of false gluing, it need some hot plate steam pressure from low to high.B. Due to the poor thermal conductivity of the high-gram heavy base paper, the thickness of the glue line is relatively large, the glue is not easy to be glued in advance, and the steam pressure of several sections of the hot plate is from high to low.Actual whole line temperature control visible corrugated line steam pressure distribution table:d).At this stage, the use of less and less weight of base paper has become the development trend of the industry, corrugated board in the production process to the base paper damage is not only temperature, but also the main damage is caused by mechanical extrusion of the base paper, the water in the cardboard will also cause the damage of the base paper, a large part of the water in the cardboard is brought into the cardboard by glue.These three aspects lead to the base paper production process damage as high as 10-15%, 70% of the damage is caused by mechanical extrusion, 20% of the damage is caused by glue, only 10% of the damage is due to temperature problems.As the base paper moisture and temperature are related, the biggest impact on the cardboard moisture is the glue moisture content, only in the cardboard glue moisture content research has a major breakthrough, can reduce the impact of glue on the cardboard moisture.That is to say, the reduction of water content or natural gelatinization at low temperature and room temperature, then the cardboard production may have a major change.Low temperature and low pressure or room temperature production of corrugated board, in order to better protect the original physical properties of paper, improve the quality of corrugated board, low temperature and low pressure production of corrugated board must solve the glue adhesion performance under low temperature and low pressure, corrugated board molding, to ensure high speed production of corrugated board.  --If there is copyright dispute, please contact us to delete.

Production Control System and Process Technology

 Like other industrial processes, automation is a key factor in increasing corrugator line output and reducing operating costs.Compared with 20 years ago, the production of corrugated board has changed from a hard and boring process to a simple and computer-controlled process, which is largely monitored by operators.No less than 10 computers are installed on a modern corrugator line, all equipped with a variable range controller system.Its is to monitor the corrugator line, improve its degree of automation, and improve its production efficiency.Corrugated machine production management system is one of the sets of automatic corrugator line management has leapfrog progress of computer equipment.1.Introduction of Production Control SystemCorrugator production control system (hereinafter referred to as PCS) is a kind of computer control system used for auxiliary corrugated machine automatic production, it utilizes accurate sensor and the fast operation of the computer, at the right time to detect and controla series of corrugated machine equipment, simulate artificial operation action, these control including the speed adjustment, clearance adjustment, glue feeding adjustment, base paper materials, etc., aiming to save manpower, increase production, reduce loss, thus achieve the purpose of planned production.It can be simply regarded as a set of computer equipment used in corrugated board production line to assist each operator, improve production efficiency and reduce loss.Due to technology and various of reasons, some s of domestic and foreign production and management systems are not stable at present, which is a very practical problem. We can only make up for it from the aspect of office work.Strictly speaking, the PCS should be in the full automatic stage. However, most of the PCS are still in the monitoring stage and some of them are in the control stage.1).Components of PCS●A vehicle control station (VSC-A)●B vehicle control station (ASC-B)●Control station of D vehicle (laminator) (VSC-D)●Stacker working station●Dry end control station (HOST)●Office monitoring station●Office ERP system●Production control planAmong them, the office monitoring station is responsible for the simultaneous control of the workshop production situation, according to the status, real-time processing, production order scheduling review and improve business mobility. Production control plan is responsible for customer management, order management, production management, report management and file management. 2).Corrugator part to be controlled by PCS●Single facer●Gluer unit●plicer●Double facer 2.The function of PCS1). Standard functions of the PCS●Order management●Data tranission and display●The of order change without stopping at high speed for dry end●Automatic waste cutting●Detection and management of bridge paper stacking volume●Paper preparation calculation●Synchronous speed control●Automatic paper splicing control●Label printing●Report printing●Monitoring●Glue volume automatic control, wrapping angle automatic control, butt monitoring2).The functions of the PCS should meet the following requirements:a). Production factors monitored by the PCS include: tension control, wrap angle and steam control, glue volume control, pressure control, deviation correction control and temperature control.b). Automatic control of operations related to production costs●Automatic paper splicing●Automatically switch the calculation and connection of orders●Interaction with the central control system●The automatic PCS system in accordance with the rules greatly improves the degree of automation of corrugator production, not only reduces labor costs, but more importantly, reduces the loss caused by human factors, making the production more energy saving and more efficient.c). Control and measurement accuracy, error in line with the company's requirements  ▲PCS to monitor the production factorsExpert Tips:The following factors should be taken into consideration when purchasing the PCS:●Meter measuring system (angle wrapping, paper splicer testing)●Speed synchronous paper splicing●Production data analysis (scrap cause analysis)●Integrated tension control, wrap angle and steam control, glue volume control, pressure control, deviation correction control and temperature control system●Automatic order change3.Elements to be Considered in Purchasing PCS1). Meter metering system (including angle measurement and testing of paper splicer) the purchase of PCS should first consider whether its meter metering system can accurately measure the number of meters.In addition, it should be considered whether the PCS can detect wrap angle and automatic paper splicing.2). Speed synchronous paperAs a production system, one of the most important role is automatic replacement, and automatic replacement first to achieve synchronous paper, so when purchasing the production system, we should focus on whether it can be synchronous paper.The PCS must be able to clarify the paper to reach the position, when it judges that the paper is used up, it can cut as well as splice paper at the same time, realizing zero-tail paper, avoiding unnecessary waste in paper splicing. Or when the PCS judges that the paper is broken, it can automatically connect the paper, reduce the downtime and quality problems of corrugated board production line, reduce human intervention, and effectively ensure stable high production speed and high quality of corrugated board.3). Production data analysis (scrap cause analysis)The data analysis of the production management system is mainly completed through the data automatically recorded by the production management system and the generated statements.Data record:●Speed of per region●Amount of glue per machine●Wrap angle position ratio●Temperature at different wrap angles●Steam setting of single facer●Steam setting of double facer●Pressure setting of double facer press plate●Check the volume of base paper according to the orderReport file is one of the essential tools in data analysis. In order to realize the of data analysis, the PCS needs to follow the basic reports:● Daily report: A detailed record of all production conditions and data● Daily efficiency report: Calculate the production performance based on the production data of the day according to the shift, including the number of parking time, average speed, average paper width and various loss analysis● Monthly efficiency report: Print the detailed statistical analysis report based on the production data of the whole month● Detailed report of production paper: According to the paper material and width, make statistics on the usage amount and consumption amount based on its length and area.● Detailed report of base paper consumption: Make statistics on the use weight and consumption amount according to the paper material●Detailed report of monthly paper consumption: According to the date and material, the base paper weight of the month is calculated 4). Integrated tension control, wrapping angle and steam control, glue quantity control, pressure control, deviation correction control and temperature control systemIts automatic control is mainly reflected in the following aspects:●Add/subtract wrapangle control●Tail direction wrap angle control● Newspaper tension control on the bridge● Tension control on the paper splicer● Fully automatic control of dry end and wet end database●Speed control● Curve control●Tension control● Level change control● Glue quantity optimization● Steam optimization● Data collection● Completed orders can be selected and then graphically displayed with production time● Display and print dry/wet end orders● Query data by day and by exact time, or by metrics● Data can be stored in the system for one year. In addition, in the actual production process, the PCS can set or modify pre-set parameters according to the personalized material.Among them, the gluing making process is the biggest fluctuation in the whole corrugated board production process, the most critical process for corrugated board quality.Traditional glue formula is simple, easy to be caused inaccurate feeding due to human factors , resulting in the instability of the adhesive performance, with too much glue caused by the cardboard soft, slow speed, with too little glue will cause the cardboard bubble degumming. The PCS through the detection of paperboard production speed, timely adjusts the gap between gluing rollers and glue distributing roller , accurately control of paperboard glue volume.It can reduce the influence of human factors, make the operation of the production line more stable, completely solve the quality problems of corrugated board foaming, flute showing and softening, and reduce the waste rate.5). Automatic order arrangementIn order to achieve the of automatic order arrangement,the PCS should be able to achieve the following operations:●Real-time monitoring of production status across the line●Daily efficiency data display●Details inquiry of non-produced orders●Material preparation display of each vehicle●Order modification● Order rescheduling● Order exchange●Printing the material preparation sheets●Display the efficiency information of each order●Vehicle speed and paper butt display●Check for non-produced order preparation● Order entry● Order delete● order moving● order printing●Printing the production reportThe PCS should be able to automatically arrange orders according to some priority principles, including:● From large to all arrange the order with same width●Paper with same material go first●Dry end stacking principle (long list first, short list last)●Trimming principle (major trimming first, minor trimming last)● Principle of three and five ply (the same three ply should be placed together as far as possible).--If there is copyright dispute, please contact us to delete.

Analysis on Stacker in Multi-order stacking

 Output conveyor belt in terms of cardboard specifications is an important part of the stacker, especially for E flute, aller flute or even B flute.Roller conveyor belt will cause the bottom of the cardboard movement that is called "cardboard move" or "elephant foot" phenomenon, especially when the cardboard warped downward.The wider the roll hole, the more serious the phenomenon.Therefore, conveyors and/or output conveyors usually use plate chain conveyors, plastic link conveyors, or even rollers covered by common conveyors to solve this problem.Vibration or impact board is usually located below the conveyor belt output, impact against the cardboard on the back baffle, so that the cardboard stacked neatly.Some suppliers also offer optional side baffles. When order changing, the rear baffle stacker is the main adjustment components.The position of the rear baffle can be adjusted according to the length of the board, and the rear baffle also defines the back edge of the stack.Since the purpose of stacking is to form a neat stack of cardboard, the design of all components of the stacker, its accessories and optional parts should be able to adjust and control the cardboard delivered from the cross cutter to the stacking place so that it is well aligned, regardless of whether a new stacking has been started or the order has been changed. At present, there is a cardboard stacker differential single device on the market, its characteristics are: the paper conveyor belt is grille shape, adjacent grille between the lower than the paper conveyor belt and the transfer of cardboard under the surface is not in contact with the paper acceleration belt;Paper conveyor belt and paper pushing acceleration belt are mutually spaced in the same direction;The outer side of the paper pushing acceleration belt is connected with the paper pushing convex and fixed, and is controlled by the speed control device of the conveyor belt, or stops moving and is in the state of reset, or accelerates synchronously with the paper feeding conveyor belt.The positive effect of the device is: Once the front cross cutter signals the number of sheets (or pieces) per piece of cardboard, the push feeding belt accelerating, pushing feeding crib bump with a specified points before the end of the last a piece of cardboard, cardboard slip back to prevent stated, and a specify the last piece of cardboard to accelerate before stacking, gap occurs between the falling position of the first piece of cardboard after the stacking to achieve the purpose of accurate stacking count (or sheet).Refer to table 2 for  analysis of stacker in multiple order stacking.Table2: Anaylsis of Stacker in Multiple Order StackingIn addition, folding cardboard for large household appliances (such as refrigerators) and furniture transport can play a certain role in protecting.This folding board is continuously folded into piles, rather than cut into single pieces of cardboard.Carton factories in the industry are more likely to use scoring roll than crossing cutters to process folded cardboard.The scoring roll presses the line horizontally on the board to reach the specified length.The cardboard is delivered to the stacking site and then drops almost vertically into the stacking site.Place the cardboard horizontally and fold left and right alternately until it reaches the specified height or quantity.This operation is much slower and more complex than normal operations.  

Comparative Analysis of Advantages and Disadvantages of Several Stacking Forms

 There are two systems in the stacker - upper stacking and lower stacking.The two systems can be mixed.The upper stacking type is formed by stacking on a fixed conveying device installed on the ground.The output conveyor belt is constantly raised so that the output cardboard is always above the stacked cardboard.When the stacking reaches the specified height, the transfer will be interrupted. The movable base plate conveyor will move the stacking to one side of the machine, and then the stacking transfer outlet position will be lowered to the conveyor belt device and the stacked cardboard will be unloaded. Then, as the cardboard starts to pile up again, the stacking conveyor will gradually increase.The lower stack also sends the cardboard to the top of the stacked cardboard, but the cardboard is output from a fixed conveyor to a raised/lowered conveyor station.When a stack of cardboard stacking is completed, the cardboard transfer will be interrupted, the transfer platform will be lowered to the horizontal position on the ground, the cardboard stack will be removed and the highest position under the transfer outlet will be returned.The conveyor then reloads the cardboard, and the conveyor decreases at an appropriate rate.It is obvious that the replacement cycle of the top stack is much shorter than that of the bottom stack.If the stack of all low-gram cardboard, the time difference is more obvious.In addition, the cardboard must be raised to 2 meters above the ground between the cross cutter and the lower stacking room.Due to the limitation of lifting angle, the lower stacking room must be far away from the cross cutter.The additional conveyor belt required can also provide buffer for cardboard stacking, thus providing sufficient time for the longer stacking replacement cycle at the lower stacking place.Therefore, the reasonable design of the double stacker should be equipped with the lower tool site for the use of the upper stack stacking and the upper tool site for the use of the lower stack stacking, because the conveyor must carry cardboard through the first stack, and the conveyor is longer.This design minimizes production line speed and can be installed on shorter machines.In terms of triple cutter and stacker, down-stack stacking is an ideal choice for the third work station.Continuous all batch orders can be completed by combining one or more additional stacking rooms and delivery units.Once the stacking replacement time exceeds the order running time, the conveyor can quickly move the cardboard from one room to another and back again.The finishing of cardboard stacking can be realized by the appropriate design of stacker or the rear equipment of conveying system.If it is done on a stacker, it is easy tothe connecting cardboard to increase stability.However, keep in mind that connecting cardboard can cause problems at the pre-feeding machine.In view of this, the stacker can be set up a all under heap stacking station, the height of the stack on the roller table is less than 400 mm.It is then transferred to the second roller table in parallel or connected (if the board is short), and then transferred to the descending roller table as a whole. Stacking is formed here.Whatever combination of stacks you use, you should pay attention to the first part of the conveyor belt after the cross cutter after order change. It is necessary to slow down the delivery speed of the cardboard of the new order and/or speed up the cardboard at the end of the last order, but the order should be clearly separated without damaging the cardboard, and the cardboard of the previous order will not be mixed into the new order cardboard.Theoretically, large bundling piles should not be formed.Stacking conveyor belt surface should have a high friction coefficient to prevent the board slip or skew.At the same time, there should be corresponding parts to output to the stacking process of cardboard control, such as the top roller, brush, etc.The output angle of the stacking conveyor belt and the distance between it and the stacking platform should be adjusted according to the length of the cardboard, so as to prevent the gas from entering the lower part of the cardboard due to the large angle (which may cause the cardboard to bounce from the rear baffle or cause deviation), or the damage of the long cardboard due to the steep angle.Such angle adjustment is very important in the upper stacker, otherwise the cardboard contact angle will change with the increase of stacking. Right-angle horizontal stackerIn addition, right-angle horizontal stacking can complete the horizontal discharge of cardboard, its performance is outstanding, economic and practical.But this stacking speed is very slow, and all by manual operation, suitable for low speed corrugated board production line.Please refer to table 1 for the analysis of advantages and disadvantages of down-stack stacker, up-stack stacker and right-angle horizontal digital stacker.                                               Table1:Comparative analysis of advantages and disadvantages of several stacking forms  

Factors to consider when purchasing cut-off

▲Cut-off Cut-off is also known as the final process cutting machine, it is composed of measuring roll, weight block, sun wheel, cutter shaft, the main is to continuously crosscut the slitting cardboard into a certain length of cardboard, and feeding the cardboard to the stacking conveyor belt for neat stacking.                                                                       ▲Operation procedure of cut-offThe working principle of the cut-off: the cardboard after slitting is feeding to the crossing cut process, and the electronic eye of the paper wheel sends out a cardboard detection signal;Under the action of the rotation of the crosscutting knife and the sun wheel, the length of the crosscutting knife is cut according to the size set by the system.Under the pressure of paper shrapnel, the cross-cut finished products are decelerated and arranged on the conveyor belt.Under the rotation of the conveyor belt, the cardboard is output through the paper receiving department and feeding to the stacking process.The accuracy of crosscutting should be at least + / - 1 mm and square at right angles to machine speed changes and order change.The board is sent to the crosscutting knife site by either a traction roller or a clamped feed roller.The design of the traction roller or clamping rod has the self-adjusting , and the operator does not need to adjust the clearance according to the thickness of the board.They usually have a motor driven steel roller, the surface speed of the roller slightly higher than the speed of the cardboard, so as to maintain the tension of the cardboard.The upper roll is usually covered with a thick, soft, elastic covering, such as synthetic rubber, so that the board can be in close contact with the driving roll without collapsing.The main working element of a cut-off is to carry two axes of a tool that are very precisely interlocked with each other.These machines are designed with the operator in mind so that they can easily set up cutters and remove blockages caused by cardboard.The working principle of the cutter here is relatively complex.First, there should be a certain amount of pressure between the cutting knives during crosscutting. One knife should be close to the other to cut, so as to ensure that the crosscutting is clean and the cardboard will not get stuck between the cutting tools and force the blade to separate.The gear is mounted on both ends of the cutter drum in a 1:1 ratio.These gears generate torque between the tool rollers through torque, and this torque forces the two sides of the cutter together, preventing the cutter from separating.The principle is similar to that we use finger strength to operate scissors.Second, the cutter is not installed along the direction of the length of the cutter roller straight, but installed at a certain angle.This is done to prevent large amounts of repetitive vibration loads, noise, and wear, forming a gradual cut along the width - just like with scissors.But the board must be in the transverse accurate, square cutting.Third, the cutter will carry out circular motion, but the cutter and the cardboard cut-in the bite point, must be equal to the speed of the cardboard running along the direction of linear movement.Otherwise, if the cutter moves too fast, the cardboard will not be cut but torn, and when the traction roller will feed the cardboard into the back of the cutting tool running faster than the speed of the cutter tail, the front end of the cardboard will be deformed (bending or "arch" phenomenon).Fourth, in order to meet the requirements of different lengths of cardboard, the cutter must speed up immediately after cutting the short cardboard, or cut the next round of long cardboard after slowing down or even stopping for a period of time.It is most convenient to cut the cardboard which is closest to the circumference of the blade.Obviously, to meet the requirements of the above four points and to meet the expected cardboard length and cutting perpendicularity, good mechanical and electronic control is very necessary. The instructions provided by the supplier will guide the user to set up the gear torque angle and adjust the tool.The setting of the tool depends largely on the installation method of the tool on the tool roller and whether the tool has been adjusted to the cut-in or cutting state.The composition structure of the cut-off includes the main and secondary box body, upper and lower cutter shaft tranission part, paper feeding mechani, paper output mechani, length measuring mechani, lubrication system, pneumatic system, electronic control system, etc.The s of the cut-off need to meet the following requirements:● Crosscutting accuracy (1 mm error control and board squareness control).● Automatic adjustment of the thickness of the traction roller and clamping rod.● The shortest cutting length of the cardboard speed, mainly to investigate the ability to speed up the cut-off.● Match the production speed.● Minimize energy consumption.When purchasing cut-off, the following aspects need to consider:1. Position of Measuring meters wheel;2. Debugging of crosscutting line speed;3. Configuration of double motors;4. Power recovery system;5. Marking and cutting;6. Low inertia cutter (carbon fiber plastic drum);7. Waste discharge ;8. Reverse sharpening ;9. Suction drive length of the paper delivery plate.--If there is copyright dispute, please contact us to delete.

Two models of order change for corrugated line

 The order change of cut-off is divided into cut-off order change and non cut-off order change. At present, when one order is in production, the cutter line of the next order is arranged in knife arrangement on another slitting scorer, and the cut-off cuts waste at the intersection of the two orders through the production control system. This is a kind of non-stop order change of the two slitting scorer, which is also the most popular mode at present.Cut-off Order ChangeAnother one is there is a cutting knife in front, and a cut-off knife on the back, when order changing, cutting knife to cut off the first, the length between the AB/speed is the knife arrangement time of the slitting scorer, in principle, the machine under 1 second, in order to avoid the run-out both front and end,the crosscutting knife cuts off the front-end by 30mm, thus cutting off the 400-500mm scrap.According to the following two order change modes, the loss of cut-off order change is lower, and the waste with non cut-off is generally about 600mm. Non cut-off order change Table4:Comparison of the advantages and disadvantages of changing orders between Non cut-off and cut-off                                                                                 ▲Zero Waste Cutting TechnologyIn the selection of slitter scorer and cut-off, we should pay attention to the application of zero cutting waste technology.Zero waste cutting technology refers to the paperboard after scoring to cross cutting process, in the process of order change, there is no waste paper, or paper control in a certain range.There are two ways to use this technology.One is foreign technology, the investment cost is relatively large; Another is the domestic technology, which is two slitting scorers plus a cut-off, zero waste cutting control is achieved by the data transfer between the slitting scorer and cut-off.If each shift has 250 ~ 300 orders, through the slitting scorer and cut-off system transformation, the use of zero waste cutting technology can reduce the waste paper consumption rate by 2% ~ 3%.  --If there is copyright dispute, please contact us to delete.

How to Make Right Choice of Cut-off Unit for Corrugator

The cut-off has two ways of cutting paper, straight knife crosscutting and spiral knife crosscutting .Straight knife cut-off relies on the depth of the groove, the width of the crosscutting knife to achieve the rotary cutting board, by the groove depth, the width of the crosscutting knife restrictions.The shearing angle of the straight knife cut-off is relatively all, and the strength is not good when shearing, suitable for medium and low speed production line.The cut-off of spiral cutter opens a spiral cutter groove on the cutter shaft, and the cut-off is installed on the cutter shaft to form a spiral cutter with large shear angle, ooth paper cutting and labor-saving. It is suitable for cutting high-strength triple wall corrugated board on the medium-high speed production line.The computer control type straight knife cut-off use and the maintenance cost is low,  the straight knife thickness is big, the service life is long, and the price is lower. Computer controlled spiral cutter cut-off is a relatively new technology at present, its design adopts low moment of inertia cutter shaft, cutter shaft is all, relatively easy to control, less power, can achieve high-speed production requirements.For example, the speed of 300 meters/min of the new all inertia cut-off, each motor power is 22KW, two motors power is 44KW.A speed of 300 meters/min of the traditional cut-off, motor power is 75KW.According to the calculation of the daily operation of the cut-off for 16 hours, it can save :(75-44) KW * 16 hours =496 KWH of electricity, and the annual cost can be saved about $21,000.The comparison of advantages and disadvantages of spiral low-inertia cutter and spiral ordinary cutter are as follows:Table3:The comparison of advantages and disadvantages of spiral low-inertia cutter and spiral ordinary cutter Spiral low inertia cutter--If there is copyright dispute, please contact us to delete.

Analysis on Cut-Off Machine Motor Driver

The cut-off control mainly includes frequency conversion control mode, DC servo control mode and AC servo control mode.The digital AC servo control system composed of AC servo motor, AC servo controller and encoder is an ideal cut-off control method.Through the optimization and matching of the cutter shaft inertia, mechanical speed ratio and servo motor rated power, rated speed and rotary inertia of the cut-off, high-speed, high-precision, high-efficiency, energy-saving, reliable and stable cut-off control can be realized.Single servo motor drive cut-off Double(two-side) servo motors drive cut-offA cut-off with only one motor is cheaper. However, when encountering short cardboard, due to the rotation speed is too fast, brake current is too large, resulting in the speed cannot exceed 300 meters/min.While the cut-off equipped with double motors can provide strong enough instantaneous current and power for short board production, so that the production can be carried out quickly, the speed can reach more than 300 meters/min.However, the disadvantages of the double motor cut-off are large power consumption, motor start instantaneous current impact is strong, need to be equipped with capacitance recovery device, so the price is more expensive than the single motor cut-off.Comparison of advantages and disadvantages of single motor cut-off and double motor cut-off, please refer to table 2                        Table 2: Comparison of advantages and disadvantages of single motor cut-off and double motor cut-off--If there is copyright dispute, please contact us to delete.

Analysis of Meter Wheel

The meter wheel (a sensor that measures length, also known as a measuring wheel) collects information about the length of the board and the speed of the production line and tranits it to the cut-off. The cut-off itself cannot be more accurate than the information it obtains.The precise measurement of the cardboard movement into the cut-off is tranitted to the cutter, which determines the length of the cross-cutting board.The meter wheel equipped with a pulse generator is anchored in front of the crosscut cutter above the board, which is usually supported by a steel plate to prevent wear and tear.The surface of the meter wheel must be kept clean to ensure the accuracy of the cutter signal. During the clearance order change, the signal will be automatically transferred from the meter wheel to the encoder of the feed roller of the cut-off, so that the signal accuracy will be slightly reduced.   ▲Single Measuring Meters Wheels ▲Double Measuring Meters Wheels Traditional single meter measuring wheel is generally installed about 30cm in front of the cut-off, that is, meter measuring wheel B is located in the front section of the cut-off and the back section of the slitter score.Its disadvantage is due to vibration, the cutting length error in 5mm, more than 10mm.(the error mainly depends on whether high-end servo motors and brakes are used.)Double meter wheel is to add another meter wheel at the position of meter wheel A.Because, we usually use measuring meters wheel A, this position has virtually no vibration, and at the time of order change, the cardboard is cut off, the meter wheel leaves the cardboard, knife shaft will not rotate, then need to start the measurement meters wheel B to measure the position, so to use two meters measuring wheels for length measurement, this will be very accurate.It has the advantage of mutual error correction mechani, which makes the equipment debugging and management more convenient, and eliminates vibration. The cutting length error can be controlled within plus or minus 1mm. Table 1 for comparison of advantages and disadvantages of single meter wheel and double meter wheel.   Table1:Comparison of advantages and disadvantages of single meter wheel and double meter wheel.--If there is copyright dispute, please contact us to delete.

Elements to Consider when Purchasing Double Facer

Double facer (hot plate) is the gluing of single face corrugated board and linerboard, heating curing, drying and cold shaping into three wall, five wall or triple wall of corrugated board, and then the corrugated board after the formation of transport to the longitudinal scoring machine and other equipment for cutting and processing cardboard.The double facer is the last part of the wet part of the corrugated line. Its is to complete the final adhesion of the cardboard and the production of flat cardboard. Cardboard out from the double facer whether in the longitudinal or horizontal are stiff and flat, this cardboard is the raw material for the manufacture of cartons. The double facer consists of hot and cold sections.The heating section is composed of several groups of heat oven with ooth surface. Corrugated board is directly attached to it. On the upper plane of corrugated board, there are special canvas belts, pressure rollers or pressure plates with good air permeability, certain tension and gravity, so that corrugated board is heated and dried under certain pressure.Heating section is divided into high temperature zone and low temperature zone, high temperature zone makes the adhesive gelatinization, drying, enhance adhesion.Low temperature area makes corrugated board dry and tend to be stable.The of the cooling section is to dissipate excess heat, evenly distribute water, avoid warping, so that corrugated board into the next process after leveling and shaping.To sum up, the functions of the double facer need to meet the following requirements:1.The paper between the appropriate temperature gelatinization bonding;2.Flute as far as possible to maintain no loss;3. Most economical energy consumption;4. Easy to clean.When paper packaging manufactures purchase double facer, they need to consider the following aspects:1.The choice of pressure plate: pressure plate has three forms: pressure roller, contact pressure plate, air bag pressure plate.2.Heat transfer, mainly consider: (1) steam control system layout;(2) conveyor belt selection.3. Correction mode.4. Install quality and prevent deformation of hot plate.5. Mirror treatment of hot plate when necessary.--If there is copyright dispute, please contact us to delete.

Parameter configuration and process selection of glue making

 Glue is called blood of corrugated board line , the quality of glue, the appropriate proportion will have an important impact on the quality of cardboard.This article mainly introduces the parameter configuration of the glue making process, the selection of the glue making method and the control of the glue amount, etc., hoping that everyone has a clearer and more comprehensive understanding of the glue making process.1.Parameter configuration of glue making(1) Solid content solid content = starch/(water + starch) x 100%    (2) Gelatinization TemperatureWinter: 56-58 ℃Summer: 60-62 ℃(3) Viscosity Single facer: 20-25 secondsGluer: 25-30 seconds 2. The process of glue making(1) One-step method (no shrinkage) and two-step method (traditional) :the traditional two-step method has simple operation technology and high viscosity of glue;The one-step method has the advantages of low viscosity, easy gluing and low cost.(2) Selection of tapioca and corn starch     (4) How to accurately determine the amount of glueA. Moisture content of normal paper and boardThe current moisture content of cardboard and corrugated paper is (8 + 2) %;Corrugated board national standard (14 + 2) %Note: the excess (6 + 2) % is basically from glue - more glue is more water.B. Relation between the amount of glue and cardboard moistureGenerally, the glue is 1:4 (1 part starch,4 parts water), and the analysis of three current domestic starch consumption:* less than 10g/m2, watering 10 * 4=40g/m2;* less than 14g/m2, watering 14 * 4=56g/m2;* under 18g/m2, the water supply is 18 * 4=72g/m2·Starch consumption increased by 4g, cardboard water increased by 16g/m2;·Starch consumption increased 8g, cardboard water increased 32g/m2Based on the paper formula 120g-95g-100g-95g120g, the basic quantity is 610g/m210 g/m2 production board theory of moisture content :(610 x 40 +)/(610 + 10 + 40) = 13.4% < 14% (National Standard)14 g/m2 production board theory of moisture content (610 * 8%+56)/(610+14+56)=15.4%18 g/m2 production board theory of moisture content (610 * 8%+72)/(610+18+72)=17.1%3.On the premise of good adhesion, the less glue is applied , the betterThe damage of large amount of glue:A. The quality of cardboard is decliningB. Cardboard strength is not up to standardC. The board thickness is not up to standardD. The surface quality of the linerboard is not good and flute exposureE. Corrugated edges wrinkledF. cardboard warpingG. The speed decreases and the production capacity decreasesH. Large glue consumption and economic lossIn a single consumption of 12 g/m2 rose to 14 g/m2, the monthly output in 4 million ㎡Starch loss about $37,000 /year* (14-12 g/m2) x 4 million ㎡ * $400 /ton*12months=$37,000/ year --If there is copyright dispute, please contact us to delete.

How to use Intelligent Control to Reduce Glue Consumption

1. Disadvantages of Large amount of Glue ApplicationIn general, operators are willing to increase the gap of glue when controlling the amount of glue in the normal production process, so as to avoid degumming. However, it does great harm:A. The cardboard is soft, easy to be compressed, and the thickness decreases, resulting in a decline in the paperboard's flat press strength, edge press strength and rupture resistance.B. Poor surface quality of cardboard, linerboard flute exposure, corrugated edges wrinkles, inner linerboard blistered etc.C. Cardboard is prone to warping.D. Increase the temperature of baking and reduce the speed.E. High glue consumption and increased cost.Cost variance calculation: in terms of the average monthly output of 5 million square meters, if starch consumption rise 2 g / ㎡, then more starch consumption in one year : 2 g / ㎡ x 5 million ㎡ * 12 months = 2800 yuan/ton, 336000 yuan.Calculate the starch consumption area as standard square:Area of three layers x 0.6+ area of five layers x 1+ area of seven layers x 1.5Industry usually starch consumption: 11-13 g / ㎡Starch consumption is mainly determined by the following four aspects:1) the width of glue thread accounts for 50%;2) 30% of the glue is thrown by the gumming wheel;3) 10% glue agglomeration;4) solid content accounts for 10%. 2.Gluing Gap ControlUnder the condition of different materials and different speeds, the gap between gluing wheel and cutting pasting can be automatically adjusted through the process control to reach the minimum gluging thickness under the corresponding material.120 g / ㎡ below the base paper gram corresponding glue gap 0.8 1 mm;120 g / ㎡ - 170 - g / ㎡ base paper gram corresponding glue gap 1-1.2 mm;More than 170 g / ㎡ base paper gram corresponding glue gap 1.2 1.5 mm.  ▲Glue Gap Control Diagram Key points for implementation:1. Whether the actual clearance between gluing wheel and cutting pasting wheel is consistent with the display clearance of equipment.2. Whether it is feasible to set parameters of glue gap thickness for different materials and corresponding materials.3. Whether it is feasible to set parameters for the relationship between the gap between gluing wheel and cutting pasting wheel and the thickness of glue under different speeds and the same glue viscosity of the debugging equipment.                                                                     ▲Double facer - the amount of glue in the middle layerMainly for the quality of cardboard, the aller the thickness, the less damage to the quality of cardboard;Secondly, for the consumption of glue, the thinner the thickness, the aller the consumption of glue.So on the premise of ensuring effective adhesion, the less glue, the better. Glue Line Width Test  The structure difference of gluing wheel running glue: 3. Automatic control of glue baffleGluing wheel baffle (single facer, gluer) automatically adjusts the position of glugin wheel baffle according to the single process control of wet part, so as to reduce the influence of glue overflow on production quality.Key points of implementation: real-time control of the single facer, gluing wheel baffle tracking linerboard. The automatic control of the gluing wheel baffle of the gluer can increase the air permeability and service life of large cotton belt by 20%, at the same time to reduce the cotton belt of the rubber block on the quality of cardboard, cardboard can produce corrugated paper larger than the linerboard.Through automatic control of gluing baffle, the quality of cardboard can be improved while the cost and labor intensity can be reduced.Calculation of benefit of baffle plate:1. Reduce the shoveling time by twice a day, 10 minutes each time, increase the production capacity by 20 minutes * 150 meters/minute =3000 meters, increase the production capacity by 3% per shift.2. The life of cotton belt, with a cotton belt calculation of 100,000 yuan, a year for a change, the minimum savings of 20,000 yuan.

Glue unit, How to Improve the Quality of Cardboard by Intelligent Control

1.Flute compressed after glue application is the most common problem of a gluer.When the pitting board passes between the rubber roller and the riding wheel of the gluer, the riding wheel flattens the gummed pitting board, which means that the operator fails to adjust the gap between the rubber roller and the riding wheel in time.Due to the structure of the order, in the production of cardboard base paper basis weight (g) is different, the thickness of the paper is also different, so is the thickness of pitting board. Timely and accurately adjust the clearance between the riding wheel and rubber roller, can have certain difficulty for operators, at the same time, the operator worries about cardboard degumming more than that of cardboard squished, so it will lead to the cardboard quality defects.In practice, the gap between the rubber roller and the riding wheel will be less than the thickness of the board, the cardboard will have a certain degree of load deformation damage, resulting in cardboard edge pressure and physical properties of the decline.      ▲Glue unit The most important core of gluer is the configuration of gluing structure.Gluer is also called glue-application machine, the most important core is the configuration of gluing structure.The gluing structure is divided into: 1. Riding wheel structure There are three forms of wheel structure: manual adjustment, automatic adjustment and follow-up adjustment.(1) Manual adjustment: manually adjust the gap between the rubber roller and the riding wheel.Advantages: load and glue is steady, not easy to degumming. Disadvantages: the clearance is not easy to adjust accurately, easy to crush the cardboard.(2) Automatic adjustment: automatically adjust the gap between the rubber roller and the riding wheel.【Detecting pitting cardboard type】 through detecting pitting cardboard sensor, the clearance control is automatically adjusted.The disadvantage is that it needs to check whether the clearance position is accurate;Intelligent detection point/line;When the pit roller is worn, the error is large;The control is complicated and the cost is high.【Testing the loading type of the upper cots】Automatically adjust the control of the gap between the upper cots by testing the loading of the upper cots.The advantage is that the paperboard load is steady, will not crush the paperboard.The disadvantage is the high cost.(3) Follow-up adjustment: automatically adjust the gap between the rubber roller and the riding wheel according to the change of the weight of the cardboard.Its structure is: riding wheel is mobile, different grams of paper through the base, the same pressure on the riding wheel, achieving riding wheel glue optimization.The advantage is the paperboard load steady, will not crush the paperboard;Simple structure and low cost. 1. Platen Structure This structure is the use of spring automatic adjustment, pressure can be automatically adjust if paper and flute shape changed, so as to avoid flattening cardboard.Advantages and disadvantages of platen structure: Advantages: simple structure, low cost.Disadvantages: high requirements for installation, unstable load and gluing, easy wear of the pressure plate.The automatic matching speed  of the gluer can improve the quality of the board.If the same cot on the gluer needs to apply glue for corrugated cardboard with different flute shape, you need this .Because of the different flute height, linear speed is different, the speed of the cots is different, and the speed of the flute tip should be equal to the linear speed of the cots.At present, most gluers in China do not have this . Gluer equipped with slurry board is also conducive to improving the quality of cardboardAnother concern in configuring the gluer is the slurry plate baffle, also known as the slurry baffle.Have slurry board, when the paper web of corrugated paper is larger than the linerboard, the glue of flute tips on both sides of the corrugated board will contact the surface of the hot plate, accumulated hard block, wear and tear large belt and stick to the big belt extrusion board and produce indentation affect the quality of cardboard printing.At the same time, because the upper cots are half immersed in the plastic plate, both ends of the upper rolls are easy to throwing the glue, resulting in waste, and the slurry baffle plate structure is simple, low input can solve the above two problems.2.Automatic gluing control system to improve the quality of cardboardIn the production process of corrugated board, in the premise of ensuring the cardboard adhesion, the less glue the better.If the amount of glue is large, it is easy to cause:· cardboard quality decreases;· cardboard strength is not up to standard;· board thickness is not up to standard;· the surface quality of the linerboard is not good, and the surface is exposed;· corrugated edge wrinkled;· cardboard warping;· decreased speed and production capacity;· large glue consumption and economic loss.Traditional electrically controlled glue control requires manual control of the gap between the scraping wheel and the upper rubber wheel, so as to control the thickness of glue.Generally need operators according to paper and corrugator speed manual adjustment, the disadvantages are frequent and not easy to adjust quickly.The use of automatic glue control system is to achieve in different speed, different paper, corrugator production system can automatically adjust the amount of glue.The automatic glue control system is helpful to reduce the amount and consumption of glue. It can also reduce  scrap cardboard caused by human error, reduce the original paper waste caused by broken glue. Automatic glue control system setting parameters are in PLC, according to the speed and glue formula, according to the set thickness of glue coating automatically adjusted.The disadvantage of automatic glue control system is that although it greatly reduces the workload of manual operation, packaging enterprises should set parameters according to the actual production needs.The central automatic control mode of the glue control system, its PLC can automatically calculate the thickness of paper based on the paper and speed in the production control system, while automatically adjusting the paste cutting clearance, and the riding wheel clearance. It can also automatically fine-tuning the amount of glue based on the other parameters (such as temperature) on the corrugated line. At present, the technical strength of the equipment suppliers, its corrugated line equipment configuration of the central automatic control mode glue control system, not only can achieve the single facer glue usage control, and each corrugated type is equipped with a set amount of glue curve, and according to the different base paper material with glue offset set .In addition, it can also automatically match the speed of the rollers according to the corrugated type, so as to obtain the best gluing effect. Comparison of advantages and disadvantages of several gluing control systems  --If there is any Copyright Dispute, please Contact us to Delete.

The Damage of Improper Control of Gluing Volume

  In corrugated board production, the most important link is gluing.Glue is just as important as human blood. Once the glue is abnormal, the quality and production efficiency of the whole board will be affected. Even if you make a very good glue, you should see whether the amount of glue is appropriate.In general, once the amount of glue on the wrong control, it will affect the following: 1.Poor adhesion of cardboard   If the amount of glue is too all, it will lead to degumming, paper of high material or applying too much is particularly obvious, resulting in poor paper adhesion.However, when the amount of glue on the cardboard is too much, the board will become soft, in other words gluing is like watering, when the amount of glue on the paper water is large, the water is large once the high speed of production, resulting in poor adhesion.This is because the water is large, the paper by the heat is low, the glue can not reach the appropriate temperature for gelatinization, resulting in poor adhesion.So many factories corrugated line once the speed is fast, the adhesion is bad, and this has something to do with the amount of glue applied.Experience: the amount of the gluing and the size of the paper has a relationship, generally high material paper has a large volume of gluing, other paper on the amount of glue to be aller. 2.Physical index reduction There are two biggest factors in gluing process that affects the physical cardboard : one is the volume of the gluing amount, the other is the gap between the rolls and pressure rollers.Many operators are worriedthat cardboard degumming will reduce the gap between the pressure roller and the rolls, that is to say, the corrugated height is 2 mm, adjust the gap of only 1.7 mm, then corrugated in the gluing time will directly destroy the flute, so that the edge pressure of the cardboard will undoubtedly become lower.So on the gap between the physical destruction of cardboard is much higher than on the amount of glue. 3.Starch content increased When the amount of glue is high, the use of starch will increase, which will directly lead to the increase of production costs, so the carton factory must control the amount of glue of the line width.  Gluing LineSo, how to determine whether the glue is too much?You can make a good judgment by the following figure. You can see the two fingers on the figure. When the fingers are pressed on the (roll) and there are two grooves, the occurrence of this situation indicates that the amount of gluing is too large.Conclusion: gluing seems to be a very simple thing, but in the actual production operation affects the quality of cardboard far more than the above, gluing a large amount not only affects the production cost and production efficiency, but also damage the physical properties of cardboard.  --If there is any Copyright Dispute, please Contact us to Delete.

How to Purchase a Satisfactory Glue unit

1. Factors to consider when purchase a glue unitOne of the advantages of the glue unit over the single facer is that there is no need to preheating rollers around the paper during the gluing process.Before the gluing process starts, make sure that the single-sided board should be as ooth as possible when entering the gluing roller clamp.The board can be in contact with the gluing roller through "contact rubber roller" or "contact rod".Contact bars are relatively inexpensive and do not require a lot of effort to maintain, and are perfectly suited to most gluing processes.But if some special cardboard, such as micro corrugated board, then the contact with rubber roller is an advantage, because it is more linear pressure, but also can reduce the flute tip and gluing roller contact arc (compared with the contact bar).The surface of the gluing roller is sandblasted or sculpted, usually with a chrome coating or stainless steel as the raw material. The purpose is still to evenly apply the starch adhesive film to the flute tip.Because the distance to the adhesive is relatively long, so the staying time of starch adhesive on the edge of the flute longer than the single facer on the gluing roller.Some corrugated lines have two sets of starch adhesive circulation system, so on the adhesive machine can choose a higher solid content of adhesive.The speed of the gluing roll of the glue unit is still lower than the paper transfer speed of about 3%, which is conducive to continuous transfer of starch adhesive to the flute point. Wiper roller surface for the flat chromium coating layer or ceramic coating.Starch adhesive tray system is widely used in the glue unit, because of its simple operation, and low temperature environment (relative to the single facer) that means there will be few problems in the tray adhesive gelatinization.Automatic adjustable gluing tray on the glue unit or single facer is equally important, its position should be adjusted to the lower layer of paper edge to 3 mm ~ 4 mm, so as to avoid starch adhesive overflow to the double facer on the hot plate.Without the use of adhesive pallet system, the upper layer will soon harden, and then form a cut edge, the cut edge will damage the subsequent processing of the larger width of the cardboard, if the subsequent processing of the cardboard width is aller will damage the expensive conveyor belt.The lack of this kind of glue tray will make the operation of multiple conveyor belt frequently appear problems. Before the glue unit runs, it is necessary to put an appropriate amount of corn starch adhesive into the upper and lower gluing boxes, and drop the pressure roller. The gap between the pressure roller and the gluing roller should be slightly less than the thickness of the single-sided corrugated board coated, and the size of both ends should be the same.After starting up, adjust the hand wheel to make the gap between the cots and the uniform cots suitable, and observe whether the amount of glue on the cots is appropriate.When single-side corrugated board and surface paper from the multiple preheater transport, with manual guide to the cardboard and linerboard into the preheating roller and cots, and then feeding two layers of single-side corrugated board and one layer of linerboard into the adhesive dryer. Observe whether the pressure roll rotation or collapse, if the pressure roll did not rotate the cardboard but with flute collapse,it is caused by the single facer.If the cardboard with collapsed flute after the glue applying, it is because the gap between the cots and pressure roller is too all, bolt should be pulled up, increase the gap between the pressure roller and the cots.The s of the glue unit shall meet the following requirements:1. Glue the board with the minimum amount of glue;2, Maintain a stable speed while not deguming;3. Maintain the stability of glue quality;4. Easy to clean When purchasing gluing machines, the following six aspects should be considered:1, Gluing quantity adjust type:2. Automatic glue quantity control system;3. Glue temperature control system;4. Glue plate;5. Glue run-out control;6. Slurry board control system. 2.Comparison and analysis of glue roller and press plate The composition structure of the glue unit is mainly composed of upper gluing mechani, lower gluing mechani, linerboard preheating mechani, operating side protective cabinet, power side protective cabinet, power and tranission system, electronic control system, pneumatic system, etc.glue unit is an essential and important equipment in corrugated board production line. Its  is to gluing corrugated paper before it enters double facer forming. The quality of corrugated board products will be directly affected by its performance.Paperboard flatness is not good, paperboard foaming, paperboard fit is not good, bending deformation, paperboard is compressed, paperboard having too much glue, low compressive strength and other problems, are more or less related to the Gluing quantity adjust typeThe traditional way of gluing is accomplished by pressing corrugated pit paper on the pasting wheel through a pressing wheel. Its disadvantages are as follows: first, it is difficult to adjust the gap between the pasting wheel and the pasting wheel (for example, pit B, the wheel height must be lowered to 2.5mm to gluing evenly), and it is easy to crush the flute of corrugated pit paper. The crushed corrugated board is easily to gluing too much, that the compressive strength or hardness are both poor, both a waste of glue \ and pressure of thin cardboard, cardboard is also easy to bend deformation moisture return soft.Second, because of the wear and tear for a long time, the middle part of the glue roll and pressure roll all will be worn down.When processing the board with a wide web, the corrugated cardboard at both ends of the board is easy to be compressed, and the middle position of the gluing is not uniform or even not gluing.The cardboard made in this way is easy to poor gluing, bending deformation is very serious, resulting in a large number of waste. If replace the pressure wheel with the touch-bar, the above cardboard quality problems can be solved.Because the contact bar it is a piece of stainless steel plate and stainless steel spring coated with a special wear-resisting layer and connected together, the spring and wear-resisting pressure plate of the elastic balance of the joint action of corrugated board has always been uniformly pressed on the pasting wheel (regardless of whether the pasting wheel wear), so that the board gluing uniform and not be compressed corrugated.Less gluing and uniform, making flute deformation, such a cardboard compression strength is good, will not bend deformation.  There are suppliers with rich experience, can achieve uninterrupted testing torque in order to timely adjust the pressure roller pressure, according to the calculation of torque to control the gap between the applicator roller and gumming roller, applying the glueon the accurate position of flute peak, there will be no collapse of the cardboard phenomenon.Several common load applying glue methods of glue unit, a comparison between advantages and disadvantages (Table 1)                                              Table1:Comparative analysis of three kinds of load gluing methodsTypeAdvantages VS DisadvantagesGlue the pressure roller (riding wheel) 1.line pressure contact, pressure uniformity, easy to crush cardboard.2. cardboard due to paper changes, thickness changes, flute height, if the riding wheel is not adjusted in time, it will be greatly compressed corrugated.Clamping Gluing1.Use of spring automatic adjustment, when paper and flute shape changed, it can automatically adjust the pressure, so as to avoid flattening cardboard.2.greatly reduce the operator's difficulty in operation, improve efficiency and reduce loss.Improved riding wheel1. Pneumatic pressure control.2. Detect paper thickness and automatically control pressure. 3 .Automatic glue application control systemIn the production process of corrugated board, in the premise of ensuring the cardboard adhesion, the less glue the better.If the amount of glue too much, easy to cause cardboard quality decline;Cardboard strength is not up to standard;Cardboard thickness is not up to standard; Linerboard surface quality is not good, flute exposure; edge of cardboard wrinkled;Cardboard warping;Speed down, capacity down;Large glue consumption, economic losses.Traditional mechanical glue control requires manual control of the gap between the scraping wheel and the upper rubber wheel, so as to control the thickness of glue.Generally need operators according to paper and corrugator speed manual adjustment, the disadvantages are frequent and not easy to adjust quickly.The use of automatic glue control system is to achieve in different speed, different paper, tile production system can automatically adjust the amount of glue.The automatic glue control system is helpful to reduce the amount and consumption of glue.Can also reduce scrap cardboard due to human error ;Reduce the original paper waste caused by shortage of glue. Automatic glue control system setting parameters are in PLC, according to the speed and glue formula, according to the set thickness of glue coating automatically adjusted.The disadvantage of automatic glue control system is that although it greatly reduces the workload of manual operation, packaging enterprises should set parameters according to the actual production needs. The central automatic control mode of the glue control system, its PLC can automatically use the paper ,speed in the PCS, automatic calculation of the thickness of the paper, while automatically adjusting the paste cutting clearance, and adjust the riding wheel clearance.Can also use other parameters (such as temperature) of corrugated line , automatically fine-tuning the amount of glue.At present, the technical strength of the equipment suppliers, its corrugated line equipment configuration of the central automatic control mode glue control system, not only can achieve the single facer glue usage control, and each corrugated type is equipped with a set amount of glue curve, and according to the different base paper material with glue offset set .In addition, it can also automatically match the speed of the cots according to the corrugated type, so as to obtain the best gluing effect.The advantages and disadvantages of traditional mechanical glue control system, automatic glue control system and central automatic glue control system are compared as shown in table 2.                                              Table2:The advantages and disadvantages of gluing control systemTypeAdvantages VS DisadvantagesConventional mechanical typeManual control is adopted to move the gap between the wiper wheel and the upper rubber wheel, so as to control the thickness of glue.Generally need operators according to paper and tile speed manual adjustment, the disadvantages are frequent and not easy to adjust quickly.Automatic glue control systemSet parameters in PLC, according to the speed and glue formula changes, automatically according to the set thickness of automatic adjustment.The disadvantage is that although the manual operation workload is greatly reduced, packaging enterprises should set parameters according to needs. Central automatic control mode  PLC can automatically calculate the thickness of the paper according to paper and speed in the production control system at the same time automatically adjust the paste cutting clearance, and at the same time adjust the riding wheel clearance. It can also use corrugated line other parameters (such as temperature), automatically fine-tuning the amount of glue. 4. Optimization of glue trayGlue application plate of glue unit is generally made of plastic material.The glue tray is provided with a glue liquid inlet at the middle position, a glue liquid groove is provided between the circumference of the glue tray and the glue liquid inlet, and a glue concave is provided at the corresponding glue liquid groove on both sides of the glue tray.The glue tray is also provided with a glue liquid guide outlet, and the glue liquid guide outlet is provided with a glue liquid outlet channel .So, the glue unit not only can oothly feeding starch, when the plastic plate is dirty or stuck with foreign matters also can facilitate optional to this glue dish undertakes changing, avoid the inconvenience that cleans up.The gluing plate generally has the characteristics of high temperature resistance, low temperature resistance, corrosion resistance, non-adhesion and so on.When the glue unit is configured with gluing plate, the gluing plate,glue tray temperature and the starch run-out should be considered.The glue baffle plate is a wedge shaped baffle inserted between two rollers of the glure and in close contact with the two rollers.When working, the rubber baffle plate keeps the rubber material within the width range of the required roll surface to prevent the accumulation of rubber from running out of the roll surface.If the plastic plate has automatic thermostatic , it can prevent the temperature too low to lead to glue freezing.The reason why the glue is running, one may be the glue viscosity is too big, the other may be the number of anilox roller anilox line is too low.In the actual production process, to control the viscosity of glue, at the same time to use the glue baffle plate, but also pay attention to the configuration of a high number of lines of the anilox roller, the paper on the rubber anilox roller is generally controlled in line 38. Table 3:Several functions of the glue trayTypeAdvantages VS DisadvantagesGlue baffle plateIt is used for blocking glue and preventing glue overflow. Adjust the door width.Glue tray thermostatWith automatic thermostatic , it can prevent glue from freezing under low temperatureMeasures to prevent glue running1.Glue viscosity too large is easy to running the glue, the use of baffle plate can be effectively controlled.2, the number of anilox linear of anilox roller is too low, resulting in the glue running, need a slightly higher number of anilox linear.  --If there is any Copyright Dispute, please Contact us to Delete.

Comparative Analysis of preheater wrap Control System

 A corrugator line should be equipped with multiple preheaters, both single cylinder preheater and multiple preheater. Among them:Medium quality control cylinder -- Before the paper feeding into the single facer, plus steam spraying equipment;Linerboard preheater -- To adjust the angle-wrap of paper web before the paper enters the  single facer;Multiple preheater -- To heat single corrugator and linerboard before the paper web is fed into the double-sided machine. In the production process of three-layer and five-layer corrugated board, if there is a problem of applying glue, the solution is: through the other direction into the preheater for reverse preheating, that is, to heat the other side of the paper and reverse removal of paper moisture.Usually, a three-layer cardboard production line (one set of single facer) should be equipped with two preheater groups, and a five-layer cardboard production line (two sets of single facer) should be equipped with three preheater groups.If a single facer needs to run a large amount of heavy kraft paper at high speed (more than 350 grams/square meters), equipped with three preheater groups will also play a good role.Seven-layer board production line, heavy duty corrugated board production line can have up to five preheater groups, so that the angle-wrap is more diversified. ▲Seven-layer board production line, heavy duty corrugated board production line can have up to five preheater groups, so that the angle-wrap is more diversified. On the preheater, the aller the angle between the angle-wrap adjusting roll and the paper guide roll, the aller the contact area between the paper width and the drum dryer;The larger the angle between the angle-wrap regulating roll and the paper guide roll, the larger the contact area between the paper width and the drum dryer.Because the preheater to balance the humidity and moisture content of the base paper, to ensure the ooth production of cardboard, so the preheater has to maximize the angle-wrap adjustment, in order to timely change the  heating area of paper web on the drum dryer.  ▲Comparison diagram of wrap control system If the preheater has an encoder interface connected to the production pipe, it can automatically control the angle-wrap -- the angle-wrap can be automatically adjusted according to the speed and paper quality, and the length of angle wrap can be calculated automatically.If the preheater does not have an encoder interface to the pipe, the operator manually adjust the angle-wrap.Depending on the operator's personal experience to adjust the size of the angle-wrap is very easy to cause the paper web too wet or too dry, resulting in the production quality of the subsequent process. Table 1:Comparative analysis of advantages and disadvantages of angle-wrap control system?                   In addition, the current drum dryer of preheated in the market is generally fixed.But equipment suppliers have also developed more advanced configurations that allow the durm dryer to rotate.If the preheater drum dryer can rotate, the surface area of the drum dryer in contact with the paper will no longer be fixed, which is conducive to the uniform use of steam in the drum dryer, on the other hand, it can be more energy saving. -- If there is any Copyright Dispute, please Contact us to Delete.

Elements to Consider when Purchasing Preheaters

  When in the production of corrugated board, first of all, place the base paper in the size of cylinder on the non-shaft frame, and gradually unrolled under the tension control , the paper web goes into the corrugated machine through preheater, and produce flute to glue with inner linerboard, forming a single-side corrugated board;Secondly, the single-sided cardboard is transported to the gluing machine for applying, and gluing with linerboard, and then sent to the dryer;Finally, cardboard of various of specifications according to the requirements of scoring, longitudinal cutting, crosscut are exported through stacking output and corrugated board production completed. The preheater is mainly composed of drying cylinder, paper guide roller, angle adjustment roller and steam system (rotary joint, siphon, etc.), electrical control system.In the production process of corrugated board, the role of preheater is to provide heat to the paper web, through preheating paper web, so that the water content of the paper to meet the corresponding requirements, to facilitate corrugated forming,and energy saving.A preheater is usually heated by saturated steam.The surface temperature of the dryer is generally about 160 degrees (if it is high-speed tile line, the surface temperature of the dryer to achieve 180 degrees), the preheater work mainly by adjusting the paper web on the dryer package angle, in order to change the contact area, to adjust the water content and temperature of the paper. If the paper web is not preheated, the following problems may occur:1. Paper web is too wet.Water will affect the paper fiber absorption adhesive, resulting in the process of paperboard degumming cracking.2. The paper is too dry.Paper fiber will absorb a lot of water adhesive, adhesive can not be very good penetration and stay in the paper surface, adhesive part is all and shallow, easy to cause poor adhesion.3. Uneven water content of paper.One layer of paper moisture is high, while another layer of paper moisture is low, resulting in corrugated board warping.When purchasing equipment, the following five aspects should be considered for preheater:1). Angle range (200-270 degrees), the preheater should be able to adjust the maximum angle;2).What kind of angle control system being used to effectively control paper temperature;3). What kind of steam control system is adopted to save energy;4). Whether it is able to control tension;5). Whether it has the humidification capacity of the preprocessor.   --If there is any Copyright Dispute, please Contact us to Delete.

Technology on Bridge Stacking Paper Volume Control

The  function of the bridge is mainly to transport the two layers of cardboard produced by the single facer, which will be coated with glue after gradually cooling.Therefore, semi-finished products on the bridge should not be piled up too much, to avoid flute unable to timely heat dissipation by extrusion due to a large number of stacking , resulting in cardboard deformation.In order to avoid this problem,the following measures should be taken in actual production:1. Single facer should keep pace with the speed of double-side locomotive ;2. Add double oblique roll device, so that the two layers of cardboard keep in the middle of the position, affected by bridge suction, quickly aligned on both sides;3. To install ceiling fan or strong exhaust fan in the corresponding place, speeding up corrugated heat dissipation;4. The amount of bridge air suction should be adjusted based on the size of the door, material hard brittle, to avoid breaking or dislocation due to the large or all tension. The speed control of bridge not only avoids the problem of paper tearing, but also affects the accuracy of paper changing in the whole wet part and the automatic compensation of manual paper tearing.The reason is very simple, in the entire corrugated board production line, in addition to the wavy bridge product paper not easy to predict, from the original paper frame to climbing belt, and from the bridge guide to the crosscutting machine distance, is almost constant. It is in fact to calculate the actual amount of stacking paper on bridge, and how to automatically compensate for the amount of bad paper manually torn off on the bridge.At present, there are basically the following calculation methods in the market:Using ink-jet technology, high accuracy: the principle of this way is to install ink-jet machine on corrugated medium, and then in the vicinity of the bridge paper guide induction ink machine, from ink-jet to detection of ink all completed by the computer automatically tracking calculation, so the accuracy can be controlled within 1 meter.Ink-jet device used for measuring the length of stacking paper on bridge of corrugated board production line, including installed on the top of the corrugated tape nozzle body, the nozzle body has the upper end for the ink pipeline to connect the mixing chamber, the lower end of the nozzle body is connected with a liquid cap with an ink hole;There is an empty cavity between the nozzle body and the liquid cap.The lower end of the nozzle body is also provided with a number of crushing holes in the form of through-hole.The mixing cavity and atomizing cavity are connected by a number of crushing holes.Through the ink-jet device,the volume of stacking paper on the bridge can be accurately calculated , so as to effectively reduce the original paper consumption rate.Electric eye detection: the method is to install two reflective infrared detectors on the bridge and calculate the bridge retention by using the relationship between the speed and the speed ratio of the bridge belt.For example, if the distance between two electric eyes is 3 meters, and the speed ratio between the speed of the car and the speed of the bridge belt is assumed to be 6:1, the inferred result is that the distance between the two electric eyes is only 18 meters.This works for users who don't change much with paper;However, for users who use high and low materials with great changes, they may feel confused. Why is it that some materials are accurate in calculation and some errors are as high as 20-30 meters?In fact, the reason is very simple, paper material and thickness are different, so wave size is different in height, so the error value will be high.There are infrared eyes and ink-jet dual identification system, dual control identification rate is high, but also can avoid the lack of ink or water shortage caused by the fault, but the disadvantages of the system installation cost is high, expensive. Comparison of advantages and disadvantages of three common speed control systems on bridge(Table 1)TypeAdvantages VS Disadvantages Suction + baffle  Old models of equipment are in this form.Its disadvantage is that the suction is relatively all, easy to produce flute exposure;Suction control is not quantified;Manual control baffle reaction is slow, high loss, baffle easy to break the edge of the paper, paper is easy to break Brake + servo motorAdvantages: through the servo motor to achieve rapid deviation correction, automatic control can be achieved, and the cardboard alignment is fast;Through brake tension adjustment, digital control can be achieved, while reducing paper break. Bridge paper volume appropriate at 70~100m , too much will cause the bending problem of cardboard. We should also notice that the cardboard produced by single facer on the bridge should not be stacked too much, to avoid the double-sided locomotive speed too fast or broken, the machine should always observe the amount of stacking on bridge, keeping the space with the double-sided machine production speed. --If there is any Copyright Dispute, please Contact us to Delete.

Analysis on Key points of Bridge Purchase

1.Elements on bridge Purchase After the single-sided board leaves the single facer, it is transported to the overhead bridge via the inclined conveyor belt (the speed is slightly higher than the running speed of the board). The conveyor belt gently clamps the board to avoid the corrugated deformation after the initial bonding.The bridge is composed of paper device, conveyor device, cardboard alignment device, tension adjustment device and walkway on the bridge frame. Single pit board exported from single facer enters the subsequent processing after the paper feeding device, conveying device, aligning board device, tension adjusting device on the bridge conveying frame. The  of the bridge is the single-side corrugated board produced by layered wave stacking single facer enables single facer has different speed difference buffer, so that the later stage of the process can not interrupt production.  ▲The slanting conveyor belt carries the single-sided cardboard onto the overpass Single-sided board in the longitudinal elastic, and in the transverse is not easy to bend.Single-sided board from the inclined conveyor belt down, need to rhythmically guide down to the horizontal bridge conveyor belt, so that the board can be stacked evenly flat on the horizontal conveyor.The running speed of the horizontal conveyor belt is relatively slow, generally 1/10 ~ 1/7 of the speed of the production line.The  of the bridge is to provide buffer stock for the single-sided board, so as to meet the needs of the occasional speed switch between single-sided and double-sided machines.The ideal amount of paper on the bridge should be kept stable and reduced as far as possible, because the atmosphere around the bridge is often warm and wet, if the machine is against the wall, the natural air circulation around the wall will make the machine drive side humidity becomes higher due to less.Just processed cardboard to this moisture absorption capacity, so in that state, the less time the cardboard stay, the more stable the cardboard quality.Most machines have electronic control of the "bridge level control" system, such as paper before the single facer slowed down, the bridge can also quickly adjust the amount of temporary paper.But generally speaking, the bridge can balance the speed of single facer, double facer, so that the bridge product paper keeps in the upper and lower limit.Before the board enters the preheater and gluing machine from the bridge, the board is unfolded and tranitted through the machine to a place several millimeters away from the lower layer of paper.This process requires the use of paper guide, the earliest type of "half-moon" steel guidance paper, but it will damage the edge of the paper, can not achieve the ideal paper guide precision, but also will produce a lot of noise.Most modern machines have one or more soft guide rollers with high surface friction coefficient, which can move on the surface paper and can be replaced at any angle in the desired direction without touching or damaging the edge of the board.  ▲A bridge guide pushes the single facer board to the center line or edge One side of the cardboard after the arrangement of another friction surface, that is, through a brake roller, the roller will eventually eliminate the paperboard stacked in the uneven phenomenon and give the paper tension, so that the paperboard then oothly into the preheating machine and gluing machine.If the tension between the single-sided cardboard and the lower layer of paper is very uneven, the cardboard will produce upward warping (often referred to as cardboard "longitudinal warping").Therefore, the brake drum and surface paper brake are effective adjustment equipment, can control the cardboard "longitudinal warping" probaaCorrugated board production line, the s of the bridge to meet the following elements:1. Single-side corrugated paper storage to synchronize gluing machine and single facer.2. Adjust the tension to keep the cardboard flat.3. Adjust the width of single corrugated and surface paper, keep the same width, to reduce trimming and waste.When purchasing bridge, we mainly consider its operation stability, friction coefficient of friction surface, deviation correction ability etc., To sum up, the elements in the procurement of bridge are: 1).The form of bridge deviation correction.2). Tension control form.3).Stacking paper length calculation and control.The following content will make a detailed analysis in the procurement of bridge.  2. Paper guide and tension controlCorrugated board production line tension control and automatic deviation correction has long been an important problem of corrugated board carton enterprises. In the traditional corrugated board production line, the tension and deviation correction of three-layer, five-layer and seven-layer corrugated board is basically completed by vacuum adsorption and electric regulation.Due to the use of mechanical baffle deviation correction, material rupture and paper break occur frequently, resulting in the loss of materials.More importantly, in continuous production, when the size of the base paper changes, the base paper fit dislocation will lead to the double facer on the hot plate has been dry pulp line residue;This will cause the interruption of production, until the operator will clean up the residual paste before continuous production, and ultimately reduce the efficiency of corrugated board production line.The tension of the base paper can be controlled directly or indirectly.Direct control is the actual paper tension value measured by the tension sensor, and then control the speed of bridge drive;Indirect control is to determine the motor speed so as to calculate the tension value of the base paper, and then control the motor speed according to the size of the difference.For the control of the tension of the base paper, the general situation is the combination of indirect control and direct control.Multi-point air bag brake is installed on both sides of the tension system of bridge to make the tension of paper more even and the anti-slip adhesive more durable.Compared with the traditional fan tension system, it is more cost-effective and environmentally friendly.Regarding the deviation correction control and tension control of bridge paper guide, the following two common forms are listed: first, the form of "vacuum suction air + baffle".Old models of equipment are in this form.Its disadvantage is that the suction is relatively all, easy to produce such phenomena as flute exposure;Suction control is not quantified;Manual control baffle reaction is slow, high loss, baffle easy to break the edge of the paper, paper is easy to break.Second, the "brake + servo motor" form.The advantages of this form are: through the servo motor to achieve rapid deviation correction, automatic control can be achieved, and the cardboard alignment is fast;Through brake tension adjustment, digital control can be achieved, while reducing paper break.A comparison of the advantages and disadvantages of the above two forms are as follows:     Table1: The advantages and disadvantages of the two tension and deviation correction control systems are comparedTypeAdvantages VS Disadvantages Suction + baffle  Old models of equipment are in this form.Its disadvantage is that the suction is relatively all, easy to produce flute exposure;Suction control is not quantified;Manual control baffle reaction is slow, high loss, baffle easy to break the edge of the paper, paper is easy to break Brake + servo motorAdvantages: through the servo motor to achieve rapid deviation correction, automatic control can be achieved, and the cardboard alignment is fast;Through brake tension adjustment, digital control can be achieved, while reducing paper break.  ▲Through the suction device and baffle to maintain a certain tension and deviation correction    ▲Through servo motor and brake for deviation correction and tension control 3. Speed control systemThe  of the bridge is mainly to transport the two layers of cardboard produced by the single facer, which will be coated with glue after gradually cooling.Therefore, semi-finished products on the bridge should not be piled up too much, to avoid a large number of piled corrugated by extrusion and unable to timely heat dissipation, resulting in cardboard deformation.In actual production, we should:1). Single facer shall try to keep pace with the speed of double-side locomotive;2). Install double inclined roll device to keep the two layers of cardboard in the center position, and quickly align the two sides under the suction of bridge;3). In the corresponding place to install ceiling fan or strong exhaust fan, speed up corrugated heat dissipation;4). The air intake of the bridge should be adjusted based on the size of the door, the material is hard and brittle , to avoid too much or too little tension caused by breaking or moving. The speed control of bridge not only avoids the problem of paper tearing, but also affects the accuracy of paper changing in the whole wet part and the automatic compensation of manual paper tearing.The reason is very simple, in the entire corrugated board production line, in addition to the wave bridge product paper not easy to predict, from the original paper frame to climbing belt, and from the bridge guide to the crosscutting machine distance, is almost constant.To really calculate, to put it bluntly is how to calculate the actual amount of paper bridge, and how to automatically compensate for the amount of bad paper manually torn off the bridge.At present, there are basically the following calculation methods in the market:Using ink-jet technology, high accuracy: the principle of this way is to install ink-jet machine on the medium, and then in the vicinity of the bridge paper guide induction ink machine, from ink-jet to detection of ink all completed by the computer automatically tracking calculation, so the accuracy can be controlled within 1 meter.Used for corrugated board production line bridge length of paper meter ink-jet device, including installed on the top of the corrugated tape nozzle body, the nozzle body has the upper end for the ink pipeline to connect the mixing chamber, the lower end of the nozzle body is connected with a liquid cap with an ink hole;There is an empty cavity between the nozzle body and the liquid cap.The lower end of the nozzle body is also provided with a number of crushing holes in the form of through-hole.The mixing cavity and atomizing cavity are connected by a number of crushing holes.Through the ink-jet device can be achieved on the corrugated board production line bridge paper volume of accurate calculation, so as to effectively reduce the original paper consumption rate.Electric eye detection: the method is to install two reflective infrared detectors on the bridge and calculate thebridge retention by using the relationship between the speed and the speed ratio of thebridge belt.For example, if the distance between two electric eyes is 3 meters, and the speed ratio between the speed of the car and the speed of thebridge belt is assumed to be 6:1, the inferred result is that the distance between the two electric eyes is only 18 meters.This works for users who don't change much with paper;However, for users who use high and low materials with great changes, they may feel very strange. Why is it that some materials are accurate in calculation and some errors are as high as 20-30 meters?In fact, the reason is very simple, paper material, thickness are different, of course, the bridge shape of the wave is different in size and height, so the error value will be a lot worse.There are infrared eyes and ink-jet dual identification system, dual control identification rate is high, but also can avoid the lack of ink or water shortage caused by the fault, but the disadvantages of the system installation cost is high and expensive.The comparison of advantages and disadvantages of the three common speed control systems on bridge are as follows:                                                   Table 2: The advantages and disadvantages of the three speed control systems are comparedTypeAdvantages VS DisadvantagesInk-jet/Water-jet RecognitionInk jet is easy to identify, high recognition rate, but easy to run out of ink or block the nozzle does not work;Spraying water is environmentally friendly, but the recognition rate is slightly lower than inkjet.Infrared Electric Eye RecognitionNo need to use water or ink to identify the length of paper; But the error is high. Infrared and inkjet dual system Dual control, slightly higher cost, but high recognition rate;Can avoid the failure caused by lack of ink or water. Bridge paper volume of 70~100m is appropriate, too much will cause the bending problem of cardboard.In the production should also pay attention to the single facer produced cardboard on the bridge should not be too much accumulation, to avoid the double-sided locomotive speed too fast or broken, the machine should always observe the amount of bridge accumulation, with the double facer production speed.  --If there is any Copyright Dispute, please Contact us to Delete

Do you know, What’s is the W flute ?

Although there are several flute profiles in the industry that are offered as alternatives to B flute. Dasong(RMM) claims to be the only company that can offer W flute, which has a flute height of 2.2mm. The company says its new flute profile provides better test results by 10 per cent for ECT and 30 per cent for FCT. “We have found that the other common B flute alternatives usually have a flute height of 1.7mm and they are more similar to E flute than B flute,” states llker Arguc, Sales Director, EMEA Region.     He continues, “China has in operation every type of corrugator in terms of width, speed, performance and product quality. China is also still using the widest range of corrugated papers of different qualities and gram mages . Manufacturing 3,000 sets of rolls in 2014, Dasong is determined to have a product range covering the requirements of the entire Chinese market.”  Mr.Arguc explains, “With the free of charge, tailor-made flute profile design service(TFP), every customer is given the opportunity to evaluate alternative flute profiles by making direct comparison with their current flute profiles . This comparison is made possible thanks to our advanced know-now and our ability to simulate the results of ECT, BCT, FCT and take-up values for tailor-made flute profiles. Customers can make a risk free decision to choose the profiles that best suit their expectations and needs. The main benefits of the TFP service , as confirmed by customers, are that it helps reducing vibration on single facers, especially for lightweight papers. Another benefit is the increase in board strength and control of paper consumption for the targeted board quality.”New W FluteComparison Between W & B FluteUp to 6% TUR Reduction9% Improvement in ECT30% Improvement in FCTLower Logistics Costs Less Vibration “corrugating rolls are among the most risky consumables for corrugators,” comments Peter Ma, Global Sales Director .” Replacing rolls requires an element of time and has high ongoing costs for materials such as bearings and grease . If there are quality issues on the corrugating rolls, it would result in serious product quality issues and an instant increase of waste. Therefore, our Quality Control Department is well organised and inspects every single roll throughly at all stages of the production process. Our inspection results are presented in reports with all the details for the rolls, including reground rolls that might have originated from another manufacturer.”All rolls originally manufactured by Dasong can be reground two times, with guaranteed results. “While some manufacturers have been using softer base materials with 55 HRC hardness to reduce manufacturing costs, Dasong always uses base materials with at least 60-65 HRC hardness before” coating, depending on the brand and type of single facers in order to obtain the best production quality and lifetime,” confirms Mr Ma.” After coating, the hardness of our corrugating rolls reaches 1200HV with tungsten coating and 1000HV with CT coating . There have been many Dasong customers that have reached a lifetime of more than 100 million meters comfortably with tungsten coated rolls .”Another innovative and environmently-friendly decision from Dasong is to replace the traditional chrome coating with a special coating named CT coating , that has been developed and offerred exclusively by Dasong as a lower priced alternative to tungsten coating .” Chrome coating was very popular before the industry had seen the benefits of tungsten coating .” states MrArguc. “With the latest manufacturing technologies , tungsten coating can be precisely applied for all flutes including E and F flutes, but now we can confidently offer CT coating that is proven to have many of the benefits of tungsten coating, including longer lifetime in comparison with the traditional chrome coating. With that said , ninety-per cent of the rolls manufactured by Dasong are still tungsten coated, using the top quality tungsten powders imported both from Europe and the USA.” --If there is any Copyright Dispute, please Contact us to Delete

The Correct Method of Single facer Machine Maintenance

Matters on Single Facer  Daily Maintenance  The degree of maintenance of paperboard production equipment affects the level of equipment downtime.The reason is simple: the more downtime, the longer the downtime, and the lower the productivity. Many enterprises can stop the cardboard line for about 1 hour a day, if the work is 10 hours, then only 9 hours in production, equivalent to the effective production time of only 90%.Good enterprises can achieve 98% effective time, the number of downtime is only 1-2, downtime is also a single digit.Single machine is the key single machine of the entire corrugated board production line, its maintenance other than the impact of production efficiency, also directly affect the quality of corrugated board produced. Now let’s focus on daily maintenance of the single side machine. 1. Before the formal every day production, it should be refueling first, especially corrugated roller and pressure roller supporting shaft. Check if any foreign matters on the corrugated roller if any, clean up in time.2. Steam in, open the bypass valve, release condensed water, close the bypass valve after 1-2 minutes. If the bypass valve has been opened the day before, close the bypass valve before venting.3. The machine began to preheat, corrugated roll fueling with N32 oil, start the air compressor, pressure 0.2mpa or so mechanical start empty operation.Note that pressure roller is not allowed to pressurize. When the temperature reaches a certain requirement, feeding glue, open the suction motor, start to feeding paper.4. After the two sides of the paper feeded, sent them to the glue plate, making it with glue, press on the roller pressure, began to work normally. In normal operation, if the downtime is long, the glue plate exits the machine, the upper cots run empty, the downtime of corrugated rollers is long, due to heating, will produce bending deformation.5. After work, start cleaning the machine. No. N32 machine oil on corrugated roll is running empty, the adsorption fan is stopped, the rubber plate, applying roll, rubber roller must be cleaned, pay attention to the cold water must not be sprayed on the corrugated roll, prevent the corrugated roll deformation 6. The suction hood shall be cleaned once every half a month, the upper cover of the suction hood shall be opened, and all foreign matters shall be cleaned.Pay attention to observe the air compressor water should be released in time.7. The air compressor needs to be observed every day to see if there is oil, if not, to timely refueling, regular replacement of oil.8. Corrugated roll after a period of time will be wore, especially when often using narrow width paper, the middle wear is more severe, and then use wide width paper, the middle foaming, at this point with grinding sand on both ends of the mill. If seriously wore, height does not meet the requirements, it is necessary to re-repair the corrugated roller, or replace a new corrugated roller.9. Frequently check the top of folder gluer that if the bolts on the conveyor frame are loose, do not fall on the corrugated roller, in order to avoid crushing corrugated.10. The applying roller should be often checked whether with glue, if with glue, then need to adjust the applying board.11. Often observe whether the cylinder movement is flexible, reliable, if it can ensure the pressure, or to carry out maintenance.12. The use of narrow paper, glue baffle plate to move to the middle, and the width of the paper, and observe whether there is glue on the pressure roller, there must be timely clearance. Machine should be stopped no matter any part being adjusted, to prevent accidents of people or equipment.13. The main corrugated roller suction groove should be cleaned up every quarter, preventing foreign matters from affecting the adsorption effect. Machine should be stopped when cleaning up,to prevent any accident.14. The lubricating oil in the gearbox should be filtered once a year and supplemented to reach the middle of the oil standard.15. Low main corrugated roller, pressure roller, spinning and preheat roll adopts high temperature (above 200 ℃) grease lubrication, check with oil once a week.16. check the paralleli of main and deputy corrugated roll, pressure roll, cots, squeegee roller once a week, using "carbon paper method" and "lead wire method".Paralleli is generally 0.03 mm, if not parallel to adjust in time.17. The main and deputy corrugated roll, pressure roll, preheating roll temperature is normal once a week, if the temperature difference is large between the upper and lower, the siphon may be damaged, should be replaced in time.

Basic operation of Single Facer machine

 The inspection and operation of the single facer is divided into the two different post responsibilities including captain and the deputy , the captain mainlythe boot, check the operators, machine, ring, and then the test run; The deputy is mainly to prepare materials, understand orders, check paper and glue; Finally loading paper, threading paper, and start cardboard production process.1. Responsibilities of the Captain1.) Starting upStarting up includes: turn on the power supply and glue pump, let the glue into the single facer; Open vacuum pressure, whether positive or negative pressure, corrugated paper should be adsorbed on the corrugated roller;Turn on steam pressure to allow steam to pass through and warm up.2).Check up OperatorsThe captain first needs to check whether the personnel's dress is in line with the company's requirements, whether to wear a work uniform, whether to wear a helmet, women having long hair should be tied, not to wear skirts, high heels, etc.; Secondly is to should check the mental state of personnel, cannot fatigue works; Thirdly is to check the knowledge and skills, whether the new staff training on the post, do not understand the safe operation.3). Equipment Appearance InspectionCheck the fastening degree of each fastener of the equipment.How's the cleaning going?In particular, is there any dirt on the roller? Are there any foreign matters?4). Equipment Pressure InspectionThe most important thing to check the equipment is to see if the pressure meets the production requirements.For example, vacuum pressure is generally 6-9kg/cm2, steam pressure is generally 8kg/cm2, oil pressure is generally 40-60kg, and suction pressure is generally 500-1000m3/h.  5).Equipment Temperature Inspection Equipment temperature inspection includes preheating cylinder, corrugated roller, pressure roller temperature inspection.These places are all steam, need to check the temperature whether in place.There are two ways to detect temperature, including infrared thermometer and contact thermometer, which is more accurate relatively.What temperature is required? Mainly on two parameters.First, the comparison of steam pressure with temperature.This comparison can be seen if any mal inside of corrugated roll , steam pressure is generally 0.5MPa, MPa divided by 9.8 is the number of kilograms.About 5 kg of steam temperature is about 158 ℃, 13 kg of steam temperature is about 190 ℃ or so, the two are compared.That is to say, at what vapor pressure, what temperature should be reached, and if not, there is water in the roll, or there is something wrong with the piping system.Comparison table of steam pressure:   Second, as a single-sided machine, it needs temperature in order to make the paper to reach the appropriate temperature.So, the temperature check is more important to measure the temperature of the paper, even if the corrugated roller temperature can not be reached, as long as the speed of the slow down, the temperature of the paper can meet the requirements.Recommended temperature of the bottom paper is 85-95 ℃, the temperature of the corrugated paper in is 70-80 ℃, the temperature of a piece of paper produced on corrugated line is 90-100 ℃.This is a reference temperature obtained by experts after many tests. We need to  know that all the temperature control is to control the temperature of the paper.  6).single facer Clearance Adjustment"Single-side clearance adjustment" will be introduced in the fourth section of this chapter, which will not be described here.7). Environmental InspectionThe captain also checks the leaking of the equipment;Whether the indicator light is normal; or if any abnormal sound etc.8). Machine Test RunThe captain must well inspect before starting up, forming good habits, and then start the machine test run.Take general traditional equipment as an example, when starting up, the main motor press the "enter" light and then press the "start" button, and then press the "speed up" button to preheat the machine at a constant speed, the speed is controlled at 10-20m/min for test run. 2. Responsibilities of the Deputy1).Prepared MaterialsFirst of all, we need to prepare tape, including high temperature double-sided tape, cow leather tape, double-sided tape.For example, high temperature double-sided adhesive is used to connect paper, because this adhesive will enter the high temperature corrugated machine inside, if not high temperature double-sided adhesive, the paper will be broken.Secondly, whether the paper cutter is well prepared, the paper cutter should be used when cutting paper, and the place where the paper is broken should be cut off.Thirdly, you should measure the width of the door when you are in production.Fourth, we need to mark after the paper is removed, so a marker pen is needed.   2). To Understand the OrderTo understand what is the next order according to the PCS, scheduling the orders to determine which one goes first, what kind of paper is needed, instruct the forklift operator to cross the paper first, and prepare the paper for the next order.All this coordinated work to be done by deputies.  3). Check the Base PaperFirst of all, check whether the original paper material is correct, whether the paper web and direction is correct, whether the original paper is stained.Secondly, to check the tightness of the base paper, the moisture content measurement under normal circumstances, in the paper "loose" in the area of the moisture removal is lower than in the "tight" area, the tightness of the base paper is not the same as the best not to use, if you must use, it is necessary to make appropriate adjustments in the preheating cylinder base paper tension position.4).Check the GlueGlue inspection is mainly to check the gelatinization temperature, glue viscosity, glue color.After the glue on the machine, need to observe the glue on the machine operation, check glue width, glue thickness, glue quantity is uniform. 3. Starting Production Process1). Matters while in the Process of Paper Loading:a . We should pay attention when operating the rocker arm of the base paper frame, the base paper chuck must be aligned with the base paper core, or the end of the original paper will be damaged, and difficult to feeding paper next time .   b .We should pay attention in using automatic splicer, when we begin to threading paper, after paper pulled to the roller, to press out a straight line with the hand, so that the paper is easier to tear, press the line, affixed double-sided adhesive tape, the role of double-sided adhesive tape is to connect to another piece of paper while paper splicing.The two ends of the double-sided adhesive shall be torn into a 45-degree bevel angle, which is for the convenience of paper connection, so as not to stick the double-sided adhesive to the roller. c . After tear the double-sided adhesive, usea mirror to observe whether the paper is aligned, if not aligned with the paper,it will be connected to the dislocation. 2). Matters while in the Process of Paper Threading:  The steps of paper threading: The Clamped base paper→Board Receiving wheel→rubber wheel→free wheel→ fixed guide wheel→free guide wheel→ regulating wheel. We should pay attention of the direction of paper threading, if installed wrong way, the free wheel will not move.Tear the end of the paper into a bevel angle before putting it through the paper, so that the back part of the paper can be put through. After the paper threading, having the inner linerboard or medium crossing the preheater, and then having corrugated paper crossing the preheater roller of a single corrugated machine, from the pressure roller and the lower corrugated roll out.After the paper on the bridge crossing the triple preheating cylinder, going into the laminating machine.  3). Paperboard ProductionPaper finally formed a piece of cardboard after through the double-sided machine, hot plate, and then through the longitudinal cutting machine and crosscutting machine, Above is the operation and inspection of the whole single facer, and finally summarize the matters to pay attention to: (1) Cleaning, inspection before the boot of the equipment;(2) carefully check the processing of products and processes, raw materials and quality requirements;(3) the captain needs to start the motor running at low speed, to confirm whether there are abnormal phenomena;(4) execute the next action after each operation completed . 

Factors to consider when purchasing a splicer

If the paper splicing is not successful or the speed of paper splicing is not fast enough, it means break paper, and that leads to downtime, finally caused cost loss. Therefore, the following aspects should be considered when purchasing splicer:1. Splicer configuration and its speed (mainly considering the speed of paper splicing)2. Tension control (mainly to know tension range and control methods )3. Understand the control mode of PCS4. Calculation of storage length of free roller5. Success rate of paper splicingNow to specifically introduce the factors to purchase splicer from these five aspects :1. To Consider Splicer Speed. The speed of paper splicing is divided into two types: 250m/min above and 200m/min below. The paper splicing speed above 250m/min is much shorter, this kind of splicer requires: 1). to have a longer distance to adjust the free roll storage paper;2). Faster servo motor speed;3). to have a higher precision of tension adjustment to prevent paper break;4). Generally, the speed ratio between linerboard and medium should be 1:1.5, because the speed of medium should be a little faster. While servo motors are not required for splicer with speeds below 200m/min.In addition,there is a reminder: the higher the speed of the splicer, the better, only the speed of the splicer is up, the whole speed will not be affected by paper splicing.2.To understand the Paper Tension Range and Tension Control Methods. In the production process, in order to ensure the quality of corrugated board, the base paper output tension of splicer should be kept as constant as possible during the operation of the splicer. The modern splicer has the of tension induction and control, which can automatically detect and timely control of the original paper tension in corrugator production, so as to eliminate the corrugated board production process due to the change of the original paper tension caused by the paper break, greatly improve the production efficiency and the utilization rate of raw materials.As we all know, the relationship between tension and torque M=F * R: F -- tension, unit is N (Newton) R -- base paper roll radius, unit is M (meters) M -- torque N·M (newtons · meters) to keep the base paper tension constant, the base paper roll radius is decreasing, so the demand for torque is also decreasing.Tension control of the basic working principle is: according to the paper material, paper tension requirement when machine is running , set the desired tension values on the tension controller, sensors will detect the tension value of base paper and feedback to the tension controller, which to calculate the output of the corresponding values for converter, it then outputs the corresponding size of the pressure to the pneumatic brake, by the pneumatic brake to perform constant tension control action.Now, the suspension buffer is no longer controlled by spring or pneumatic pressure, but by torque control motor or similar equipment to control its tension, so as to avoid the paper web tension fluctuation after paper splicing. In order to connect paper oothly between two rolls, the splicer should be equipped with double brake tension control system. In addition, if the brake system on the original paper frame needs to change the air pressure, tension measurement equipment will usually send a signal, tension control equipment on the splicer can control its brake torque.3.We need to know how to control the PCS(Production Control system). The production control system is responsible for customer management, order management, production management, statement management and file management, etc., and it can control the single-side machine, double-side machine, gluing machine and splicer on the corrugator line.The operator can manually or through the PCS through the central control on the corrugator line to set the order parameters.The factors that affect the setting of the splicer include: paper grade, width and production line speed.After understanding these conditions, you can do paper control system programming, setting the brake of the base paper frame, and constantly adjust the brake setting to match the diameter of the changing base paper reel.In this way, during the processing of each order, the base paper rack can maintain appropriate tension control.In addition, through the application of PLC and computer control on the splicer, directly set the rest of the paper reel, in the whole process of paper splicing, the paper tension can be maintained at a constant level.Thus, when the speed of the single-sided machine reaches 500 meters per minute, the paper damage caused by the paper and cardboard adhesion problems can be avoided.In addition, the PCS by setting a certain parameter value, can ensure paper to reach the position. According to the paper material ,width, statistics of its length and area, when the paper is used up, the PCS can cut paper as well as achieving paper splicing, therefore zero-end paper can be achieved, avoiding unnecessary waste.4.We should pay attention to the calculation of the length of storage paper. The paper storage of the free roller is to ensure the uninterrupted paper splicing .When the paper on one end of the base paper shelf is running out or needs to be cut off and the paper on the other end of the base paper shelf, in order to slow down the paper tension and avoid  paper break, it is necessary to store paper in advance in the roller, and quickly run to the other end of the paper at the moment of paper breaking.The length of the paper and the speed of the roller are all set and controlled by the PCS.Because of the paper storage of the free roller, the splicer can truly achieve automatic paper splicing, so that the splicer does not need to stop when changing paper and order, and the high-speed operation of the production line can be guaranteed on the premise of continuous paper.5.To consider the success rate of paper. The success rate of splicer directly affects the production efficiency of corrugator line.So what are the factors that affect the success of paper receiving machine?The factors influencing the success rate of paper splicing mainly include the following two points:1). Parameter setting, such as the parameter matching between the free wheel and the tension wheel, the time of the cutting tool and the clamping plate, etc.2). control the tension of the system program parameters, which directly affects the tension of the base paper.In view of the above two points, suppliers are generally required to have strong electronic control programming and design capabilities.    

The Basic Principles of Splicer

 In corrugated packaging industry, splicer is used to connect old and new paper rolls in corrugated board production process, so as to realize continuous production without a downtime. A splicer generally composed of the following basic components: frame, free roller, fixed roller, splicer frame, pressure roller, cutter unit and clamping rod, etc. Now let me introduce several components:Frame: all components are installed or suspended on the frame. Because it is suspended on the bridge support, the frame does not equipped with self-frame.Free Roll: Before the paper web leaves splicer, it is running back and forth between the immovable guide roller and guide roller of the storage frame on the side of the paper outlet of the machine. In this way in the storage rack to form a paper storage. In the process of paper splicing, the free roller moves towards the paper outlet side of the machine so as to release the paper web stored therein for continuous production. After that, the storage rack is moved back to the other end of the machine and the paper webare restocked.Splicer Frame: there is a paper frame at each end of the splicer. The paper frame is composed of an adhesive roller and a guard plate. In the paper frame, the new paper web is first cut in the protective plate, then the paper tape is pasted, and finally the new paper web and the original paper web are pasted through the adhesive roller.Pressure roller: in the process of paper splicing, the pressure roller is pressed to the adhesive roller, so as to press the adhesive points of two paper web.Cutter unit: the cutter unit is composed of a knife holder and a blade. The cutter unit cuts off the original paper web. During cutting, the cutter is inserted into a groove on the clip rod.     The following are a typical set of paper splicing process diagramSee the next page) : 1 represents the original paper web, 2 represents the new paper web, 3 refers to the paper frame, 4 refers to the adhesive roller, 5 refers to the clamping rod, 6 refers to the pressure roller, 7 refers to the cutter, 8 refers to the brake rod, 10 refers to the zero-tail join.The whole process of paper splicing can be simply summed up as: The old paper roll stops running, the brake bar is pressed down, the pressure roll is down, and the cutter cuts off the old paper. The old paper break joint is connected with the new paper with double-sided adhesive under the pressure of the brake roll. At the same time, the paper storage trolley provides the base paper to the corrugated line. After the paper splicing, the new paper roll began to rotate, and the paper cart gradually returns to the position of the maximum splicer. This kind of splicer called “Flying Splicer”. Operators at the time thought that their manual paper splicing technology was higher than the rapid paper splicing. But as far as performance is concerned, the rapid paper splicing is quite reliable. Modern paper splicer have an electronic tension control system that responds instantly. This means that it has two brake systems, one for rolls in process and one for new rolls. And paper tension control system, brake pad, knife, cutting pad, roller balance structure, chain and bearing lubrication degree have played very critical role to the operation of the equipment.Another characteristic of the modern splicer is that the whole process of paper splicing takes less time.Automatic splicer adopts artificial intelligence design, equipped with digital tension control system and computer terminal, so the paper splicing is quite efficient, reliable and fast.Although the procurement input cost is large, the automatic splicer can achieve zero-tail join, avoid unnecessary waste when paper splicing, reduce the downtime and quality problems of corrugated board production line, finally to effectively ensure stable high production speed and high quality of corrugated board.Now the modern splicer are equipped with the following three s:1. Achieve 100% successful paper splicing according to the required speed2. Automatically conduct paper splicing according to PMS3. Enable a stable paper tensionIn addition, it is necessary to know the following additional s of splicer, such as 1). zero tail, that is, no tail when paper splicing, and the paper roll can be basically used up until the light roller. 2). Reducing the loss3).Zero paper splicing and break paper, that is, when the base paper used to roll or use to the end of the damaged, the splicer can automatically conduct paper splicing by determine the tension and electrical eye, to reduce the number of break paper. 

Answers to several common questions for carton factory When configuring the splicer machine

1.Is it Necessary for Small and Medium-sized Carton Factories to Invest a Splicer   If a factory has nearly 60 orders each day, with the total length of paper about 60,000 square meters (all converted into 5 floors).The factory owner hesitated whether it was worth investing a splicer.I believe this is a question many all and micro factories have faced: "generally, it is large and medium-sized enterprises to configure automatic splicer, with such little orders, is it worth the cost?In fact, this is a misunderstanding.A corrugated line with good operators, if there is no operational error, then the most important loss is the loss of order change, and the most core role of production control system(PCS) and splicer is to reduce the loss of order change.So is this factory worth investing in splicer?If do not use automatic splicer, especially the linerboard part, then you must stop to change the order.60,000 square meters per day is calculated according to the base weight of 600 grams/square meters, 36 tons of paper is consumed every day, and 36 times of paper needs to be change.Remove the first 5 times, stop 31 times, each downtime to cause hot plate degumming about 20 meters, discount about 14$ (about 40 square meters,0.35$per square), the conclusion is loss about 442$ a day, equivalent to a year about 140,000$. While configuration of a splicer only about 20,000$, it produces economic benefits far higher than the purchase price, the investment is very cost-effective. The comparison is astonishing. Therefore it is necessary to purchase at least one splicer. 2.Why Paper Splicing Failure Happened?  Now most enterprises are using the splicer, however it is inevitably encounter the problem of paper splicing failure which affects both production loss and production efficiency.The purpose of using automatic splicer is to reduce production loss and improve production efficiency.So why the success rate is difficult to achieve in using automatic splicer? The reasons can be roughly divided into the following situations:Reasons:1. Fail to remove the damaged base paper of outer edge;2. Fail not deal with paper with too tight edges;3. Loose paper on the new paper roll;4. Paper splicing error;5. The clamping roller is not parallel, not glue the whole paper;6. Not run through the entire paper when crosscutting knife is cutting ;7. Slow movement of floating roll and splicer;8. The speed of paper splicing is too fast;9. The new paper roll is not lifted off the ground;10. The operation order of the machine is disordered11. There is damage to the middle or edge of the paper sheet on the paper roll, which is hung on the splicer. It happens to corrugated medium due toits fragile. According to above situation, the improvement measures include:Solutions:1. Cut off any damaged outer paper or notch with a moon shaped knife;2. Cut off loose paper edges, adjust paper edges to align paper web with paper roll, hold paper web tightly, press the paper clip button, then paper web can be accurately positioned, and the whole paper web is in the correct position;3. Check the degree of loose paper web on the new paper roll before starting a splicer. Too loose or too tight will affect the successful running of the splicer;4. If the brake is not properly set in the paper web preparation process, the splicer shall be in the preparation state as required;5. Adjust the clamping roller to make it parallel;6. Adjust the spacing between the cutter and the anvil pad, check the condition of the cutting edge, the anvil pad and the mechanical device, and ensure sufficient air pressure on the clamping rod and the knife;7. Check whether there is debris accumulation on the floating roller or the gear and rack of the splicer;8. Check the gear, whether the gear tooth excessive wear, each paper machine has its own best running speed due to the differences in design, model, paper material, base paper frame and paper machine preparation.It is recommended that both single-sided and double-sided machines be equipped with easy-to-see speed displays so that operators can control all the splicers running at the correct speed;9. Lift the paper off the ground in the order recommended by the supplier before the splicer starting to run ;10. Removing the edge damaged paper, finding and eliminating the cause of paper damage;11. Because the stripping of the paper web costs seriously waste, it is not recommended to peel the damaged scrap.3 . What kind of Splicer is the "First Choice" of Carton Factory?For many carton factories, there is misunderstanding, that is corrugated line production equipment is best equipped, but no paying attention on splicer, for it’s only used for paper splicing. Is this really the case?At present, the price of base paper fluctuates frequently. It is just like having a "virtuous housewife" to provide a piece of equipment that can effectively "save paper" for the carton factory. When facing the situations like lacking paper and high paper price, we have more confidence to break through the siege."Reduce loss" is the most important reference standard for customers in the purchase of splicer.Paper splicing of base paper suited for different paper gram weightIn the actual production process of carton factory, the situation is much more complicated than expected. Especially in our country, in the context of fierce price competition, many cardboard manufacturers have greatly reduced the paper standard, and the quality of the base paper varies: 1. The paper joint is not strong enough after being produced in the factory, or even the paper joint is not glued at all.2. In some paper rolls, there are more than one paper joint, the joint position of the paper roll is not marked, or other problems such as the two sides of the paper roll have different tightness, the water distribution of the paper roll is not uniform, dampness etc. These are seemingly trivial problems, but they are slowly wasting investors' hard-earned money. As is known to all,  because of quality control, the same paper roll with different tightness on its both left and right, or due to improper storage of paper (usually at the bottom of paper roll, paper roll diameter of one end that usually contacted with the ground enlarged due to damp, besides two paper rolls heavy burdened on the surface. We call this phenomenon "the elephant leg").Such paper rolls in the drying cylinder surface because the left and right tension is not uniform, the heat of the paper web in unit time is not the same, the temperature of the paper web between left and right  is not the same, resulting in poor gluing or cardboard warp.Break Papers equivalent to a flat tire. Avoiding break paper in the process of high speed paper splicing.In the normal production process, the break paper often occurs due to many reasons.For high speed corrugated line, break paper is fatal, just like the flat tire while driving on the highway. The waste of high-speed paper is huge, not only the paper, but also labor costs. Some industry experts have calculated that a comprehensive cost of break paper reaches 100-150$. It is easy to count the number of break paper every year, so as to know the annual loss of paper breaking. 

WOW! 36,000 $ year cost save by “Zero-Tail join” Splicer !

 As is known to all, a all butt roll will be more or less formed after the base paper being used. The all roll formed by the base paper is generally placed on the edge of the cardboard line for the convenience use of operators. However, the use of all paper rolls will increase the amount of labor of the on-site operators, resulting in the loss of the use process and the chaos of the base paper warehouse management, paper management chaos etc., so as to increase the production cost. Why do carton factories pay more and more attention to the of zero-tail  splicing?Throughout the current market of splicers, whether the zero-tail paper can be achieved becomes a reference standard equipment for the carton factory to purchase. Now, we will analyze why the carton factory attaches great importance to zero-tail paper. zero-tail paper is mainly to detect the tension of the paper through the pressure sensor on the guide roller , paper breaking tension is zero. As we all know, in order to ensure that the paper joint has enough fastness to resist the paper tension, the way in achieving paper splicing of the corrugated line is overlapped, that is, two pieces of paper overlap up and down, the middle is double-sided adhesive. However, this paper connection also brings about negative effects. In actual production, the width of the joint, in addition to the overlapping part of the tape, also has a all tail left when cutting. The actual overlap part is much larger than the width of the tape. Paper web converted into flute through the corrugated roll extrusion molding, paper web crossed from the two corrugated roll, and the corrugated roll mesh is very precise, any change will cause the corrugated roll vibrated, especially at high speed, this vibration will be magnified countless times. e can imagine, paper joint of the paper web suddenly feeded into the corrugated roller mesh at high-speed production, the gap between the two corrugated roller suddenly increased by one time, the corrugated roller vibration will be huge, resulting in poor gluing. The wider the joint, the longer the vibrating time, the more poorly glued cardboard. Therefore, it is very important to achieve zero end paper (i.e., the joint overlaps the tape width and does not have a all tail).The significance of zero end paper is not only greatly reduce the corrugated roller vibration caused by the waste paper board, meanwhile the joint of the cardboard can also be used as a qualified product due to there is no paper tail. The HV350 high-speed automatic splicer, produced by Fuma Machinery. the joint is on the flute or in the middle, most cases can be used! Saving more than 70%  loss caused by splicer, in particular reducing he cardboard loss produced by the long tail of paper in the corrugated machine that can not be glued to the inside .   A paperboard production line can save up to 36,000$  a year by using the "zero-tail join" splicerLet’s set a situation: when “zero-tail paper” achieved in the second ,third, fourth layer of the board in corrugated board production line. It can be calculated that: (3 sets of splicer, 0.5$ for a piece of cardboard, 40 ~ 80 times for each splicer every day, 300 working days a year) 40 times a day: 3 splicers *0.5$ *40 times *300 days =18,000 $80 times a day: 3 splicers *0.5 $ *80 times *300 days = 36,000 $In fact, the significance of ‘zero-end’ is not only to solve the problem of direct loss for everyone, but also to help the carton factory solve the indirect loss (including labor, water and electricity, coal).    

How Much Money Can be Saved by Using Splicer?

For many carton factories there is such a mistake, corrugated production equipment equipped with the best, but the splicer is not important just with simple paper , there is no need to buy the best.Is this really the case?Especially at present, the original paper price fluctuations frequently, matching your carton factory with a device that can effectively "save paper" is like having a good housekeeper at home. So you can have more confidence and strength to break out of the predicament in the face of a lack of paper, paper prices rise in the general situation.Therefore, "reduce loss" is actually the most important reference standard for customers to purchase equipment.  Small problems erode "hard-earned money" of carton factoryIn the actual production process of the carton factory, the situation is much more complex than expected, especially in our domestic market, in the brutal price competition, many cardboard manufacturers have greatly reduced the paper standard, the quality of the original paper varies:1. There are some paper rolls in the factory when the joint is not strong, or even the paper roll joint is not glued at all.2. In some paper rolls, there are more than one joint, the joint position of the paper roll is not marked, or the two sides of the paper roll have different tightness, the water distribution of the paper roll is not uniform, dampness and a series of problems.These are seemingly trivial problems, but they are slowly eating into investors' hard-earned money.As is known to all, some paper roll after being produced, because of quality control, the same paper roll has a different tightness on both left and right, or due to improper storage of paper (usually at the bottom of paper roll, one end of the contact with the ground because of be affected with damp ,and two paper roll on the surface stress, the paper roll at one end of the ground becomes larger in diameter and is often referred to as the "elephant leg.").Such paper rolls in the drying cylinder surface due to the left and right tension is not uniform, the heat of the paper in unit time is not the same, the temperature of the paper is not the same, resulting in the result is bound to be bad fitting or cardboard warped.Paper Fracture during the production costs 100-120$/ timeFor a variety of reasons in the normal production process, paper fracture often occurs For high speed corrugated board line, paper fracture is very fatal, just like the suddenly burst tire in highway driving .The waste of high-speed paper is huge, not only paper waste, but also labor costs. Industry experts have calculated that a paper fracture accident its comprehensive cost of 100-120$. Each production plant is easy to count the number of times a year paper fracture, so as to know the annual loss in paper fracture accidents.Butt roll management and controlIn addition to the problem of paper breakage, the Butt roll management and control has become one of the important factors that the carton factory considers when purchasing the paper splicer.As is known to all, the base paper after use will more or less form a all Butt roll.The all roll formed by the base paper after the site use is generally placed on the edge of the cardboard line, which is convenient for site operators to use. However, the use of all paper rolls will increase the amount of labor of the field operators, resulting in the loss of the use process and the management of the base paper warehouse chaos, increase the frequency of paper in the field, paper management chaos and other phenomena, so as to increase the production cost. The adoption of excellent splicer, can achieve 'Splicer paper core', greatly improve the use of base paper, reduce the cost Why do carton factories pay more and more attention to the  of “Zero-tail” ?Throughout the current market of splicer equipment, whether the zero-tail paper  can be achieved becomes a reference standard equipment for the carton factory to purchase.Here we will give you an analysis of why the carton factory attaches great importance to zero-tail splicer. ‘zero-tail’ is mainly through the pressure sensor on the guide roller to detect the tension of the paper, paper breaking tension is zero.As we all know, in order to ensure that the paper joint has enough fastness to resist the paper tension, tile line of the paper is overlapped, that is, two pieces of paper overlap up and down, the middle is double-sided adhesive.However, this paper connection also brings about negative effects. In actual production, the width of the joint, in addition to the overlapping part of the tape, also has a all tail left when cutting. The actual overlap part is much larger than the width of the tape. Through the corrugated roll extrusion molding into corrugated paper, paper from the two corrugated roll through, and the corrugated roll mesh is very precise, any change will cause the corrugated roll jump, especially at high speed, this jump will be magnified countless times.We can imagine, corrugated roller in high-speed production suddenly into the paper joint corrugated roller mesh, the gap between the two corrugated roller suddenly increased by one time, the corrugated roller jump can be imagined, resulting in the direct result is bad cardboard fit.The wider the joint, the longer the beating time, the more poorly fitted cardboard.Therefore, it is very important to achieve zero paper tail (i.e., the joint overlaps the tape width and does not have a all tail).The significance of zero paper tail is not only greatly reduce the corrugated roller vibration caused by the waste paper board, but also because there is no paper tail, the joint of the cardboard can also be used as a qualified product. When the joint is on the top of corrugated or in the middle, most cases can be used!Save more than 70% loss caused by the splicer, In particular, reduce the cardboard loss of long tail of paper in the corrugated machine that can not be glued.A paperboard production line can save up to 37,058 $ a year by using the "zero end" of splicer.If the board that corrugated board production line in the second, third, fourth layer of paper reflects the "zero paper tail."Therefore, it can be calculated as follows :(3  splicers, 0.5$ for each piece of cardboard, 40 to 80 times for each splicers every day, working 300 days a year) 40 times a day: 3 splicers *0.5$ *40 times *300 days =18,000 $80 times a day: 3 splicers *0.5 $ *80 times *300 days = 36,000 $In fact, the significance of ‘zero-end’ is not only to solve the problem of direct loss for everyone, but also to help the carton factory solve the indirect loss (including labor, water and electricity, coal).-- If there is Copyright Dispute, please Contact us to Delete.

Inspection of base paper and corrugated board and its influencing factors on quality

Moisture Content of Base Paper and Board and its Influencing Factors Moisture content refers to the moisture content in the base paper or cardboard, expressed as a percentage. The quality standard of water content of carton base paper varies due to different paper grades, of which the water content standard of corrugating medium is: Top grade and first grade are 8.0% plus or minus 2.0% : 80% + 30% of qualified products. The standard of moisture content of carton board is: top grade 8.0% plus or minus 2.0% : first grade, qualified product is 9.0% plus or minus 2.0% : corrugated board delivery moisture content standard: not more than 14%. The moisture content of base paper and corrugated board has a great impact on the strength of the carton body, therefore, this is the main reason why moisture content has become one of the three export carton heavy defect inspection items. Because corrugated has a certain pressure resistance, tensile resistance, puncture resistance and folding strength, if its moisture content is too high, the paper will appear soft, poor stiffness, and the flute and gluing quality will also be badly affected . If the moisture content is significantly lower than the lower limit of the standard value, the paper will be too brittle, flute will be prone to fracture, and the folding tolerance is poor. If the online production of corrugated paper and cardboard moisture content gap is too large, corrugated board produced by single-sided machine , not only flute shape and hardness is not good, and corrugated board is also easy to crimping deformation, when laminating, it is easy to appear foaming and degumming, so that the strength of the carton decreased significantly. To calculate the moisture content of the base paper or corrugated board, the more accurate detection method is to use the drying method, that is, samples a number of from different parts of , with a balance weighing about 50 grams of sample, and tear it into pieces and put it into the oven, drying to constant weight state, you can find out its moisture content. The formula for calculating the moisture content is:   Corrugated Board Thickness and its Influencing Factors Corrugated board thickness is also one of the export carton appearance heavy defect inspection items. Corrugated board thickness index, directly affects the cardboard edge compression strength, puncture strength and compressive strength and other properties. And the impact of corrugated board thickness index has a variety of reasons, For example, corrugated roller tooth tip (top) part becomes low after wearing, the guide paper is not adjusted, the speed of the single-side machine is too fast, excessive external pressure and the corrugated roller temperature is low. If the corrugated board thickness is too thin, its edge compression strength, puncture strength and compressive strength and other properties, will also decline. Corrugated board thickness refers to the vertical distance between up and low surface under certain pressure, usually use corrugated board thickness gauge in the experiment to detect the thickness of the cardboard, when doing measure, choose a number of parts on cardboard without damage, scoring, collapse ( not less than 50 mm from the edge) as a testing point, respectively measured between the measuring head and anvil, and read the dial indicator measuring value respectively. The sample quantity is generally 10, and finally, the average value is obtained, which is the test result. Flute shape is different , so is the thickness. According to the standard provisions of corrugated board: type A flute height is 4.5mm ~ 5.0mm:  type C flute height is 3.5mm ~ 4.0mm;Type B flute height is 2.5mm ~ 3.0mm: type E flute height is 1.1mm ~ 2.0mm: type F flute height is 0.6mm ~ 0.9mm.The test results show that the thickness of corrugated cardboard is high, then there is high probability that cardboard box vertical compression and plane compression performance is also relatively high .However, if the use of high physical indicators of the base paper to make a little thin corrugated board, the production of the carton vertical compression and surface compression resistance will be higher than the thickness of the carton. Therefore, if corrugated roll wear and make corrugated board thickness thinner, so that the corrugated layer of the base paper consumption is correspondingly reduced, it can be considered to appropriately improve the technical indicators of the base paper strength, to make up for the adjustment of cardboard performance, so that the quality of cartons and production costs are effectively taken into account. Corrugated Board Edge Compression Strength and its Influencing Factors Corrugated board edge compression strength is to take a certain width of the sample for testing, and to see its pressure holding within unit length, if also refers to the technical performance that bear pressure paralleled to the direction of corrugation. In accordance with the relevant inspection rules, samples for the test should be qualified as at least 10 specimens with no signs of mechanical or man-made damage, including those without printing marks and appearance defects.The corrugated direction of the cut sample shall be short side, the sample size shall be 25mmX100mm, and the error shall be plus or minus 0.5mm. To meet the basic requirements, on the basis of the test conducted by the author, the knife edge of the sampler should maintain absolute sharp , blade that on a holder should be installed in right position, the mouth of blade and slot into the angle can be adjusted to 45 for fitness, and when installing a blade its tip should be avoid touching the bottom of the groove, so as to prevent blade bending deformation, in that way,  edge corrugated of the sample will not appear damage and fluffiness. The conversion formula of the detected edge-pressure strength is: R=F/LX10 cubed. R is the compressive strength of corrugated board sample edge, represented by N/m; F is the force value  when the sample is crushed: L is the size of the long side of the sample in mm. Corrugated board edge compression strength standards is varied due to the different minimum comprehensive quantitative , reference to GB/t6544-2008 on corrugated board standards for details. Marginal pressure strength is the important technical indexes of the corrugated carton strength, stiffness of the base paper, quantitative, folding, burst index and ring crush strength of corrugated paper and carton board, white board stiffness of corrugated linerboard, the stiffness of the adhesive quality of the corrugated cardboard, and indicators such as the moisture content of base paper and corrugated board of corrugated cardboard marginal pressure strength will produce certain effect.In order to control the edge compression strength of corrugated board, it is necessary to check and control from these related technical indicators. Corrugated Board Adhesion Strength and its Influencing FactorsFlute peak adhesion degree of linerboard, inner linerboard, medium and corrugated paper in a certain unit of length by applying the test that withstand the maximum peeling force, called corrugated board adhesion strength. According to GB/t6544-2008 corrugated board standard provisions, adhesive strength of any adhesive layer of corrugated board should not be less than 400N/m. Adhesion strength test, mainly to test the corrugated board adhesion, mounting fastness. A type of corrugated board testing, thrusting needle of the stripping frame should useφ3mm, while corrugated hole of B, C type corrugated board is relatively thin, thrusting needle should use φ2mm . Each thrusting needle on the stripping frame should be exactly aligned with the center of the corrugated groove, and adjust separation distance equally , then tighten and fix each screw.  10 single corrugated board, 20 double corrugated board or 30 three-layer corrugated board (25mm + 0.5mm) samples are required for the test of adhesive strength. The corrugated direction is short side (i.e., 25mm). The material should be intact without degumming or foaming.The sample size is 25mmX80mm, with an error of + / - 1.0mm, so as to better ensure the accuracy of detection. The conversion formula of adhesive strength is: P=F/(n-1)XL. P is the adhesion strength of corrugated board sample, unit is newtons per meter, represented by N/m: F is the force value  when the sample is separated, N is the number of needles inserted into the sample: L is the length of the short side of the sample, that is, 0.025m. The quality of adhesives, formula, the moisture content of the base paper, as well as equipment, operating process and other factors are appropriate or not, determines the adhesion strength of cardboard, and the adhesion strength of cardboard, and to a large extent affects the strength of corrugated board properties, such as compressive strength, breaking strength and puncture strength and other properties. Therefore, the control of corrugated board bonding strength quality, has a crucial role. Corrugated Board Puncture Strength and its Influencing FactorsThe work done through corrugated board with a certain shape of angle cone, the energy shown is called corrugated board puncture strength, its unit is: The index of puncture strength is tested by the puncture strength tester. During detection, 3 sample boxes with good appearance are selected, and 4 pieces of cardboard without damage, watermark, scoring and other appearance defects are taken from the wall of each sample box, 12 pieces of test samples with the specification of 175mmX175mm are taken. When cutting samples, the starting line should be parallel to corrugated.The instrument shall be zeroed and calibrated every time before test, followed by:(1) After the hammer and sample splint removal, put the pointer to the maximum value of the pendulum in the starting position of the test, press the release device of the pendulum, swing pendulum should make the pointer pointing to the "O" position, otherwise, it is necessary to adjust the adjustment screw:(2) According to the general strength of the sample,the appropriate weight hammer, so that the measurement value in the measurement range of 20% ~ 80% :(3) The sample is firmly clamped in the middle of the test board, the pointer is set to the highest scale value, the friction ring is set behind the corner cone, the pendulum is locked to the starting position of the test:(4) Press the release device, so that the pendulum arm to push the cone through the sample, and then read the detection value:(5) Positive, negative, vertical, horizontal and other detection values, find the arithmetic average, retain three significant digits.During the test, it should be noted that: the sample should be clamped tightly. If slip occurs, the test value should be regarded as invalid. Corrugated board puncture strength index, GB/t6544-2008 corrugated board standard has not been included in the test items, and only export commodity transport packaging is included in the test items.The fiber toughness, hardness, tightness, moisture content, quantitative and cardboard adhesion strength and thickness of cardboard, has a direct impact on the puncture strength of a corrugated board.Corrugated Board of Burst Strength and its Influencing FactorsCorrugated board in a certain test conditions, the maximum vertical pressure uniformly increased that bear within its unit area is the corrugated board burst strength, its unit is expressed in KPa. When sampling, we should pay attention to cut 12 pieces samples with no watermark, folds, wrinkles, damage, specifications of 140mm x 140mm , that is, take 4 pieces respectively from 3 sample boxes, one side of the sample should be parallel to fluting. In the detection of burst strength, the samples were divided into two groups. One group was tested with the rubber film affixed to the front, and the other group was tested with the rubber film affixed to the back. When the samples were crushed, the test values were read.The sum of the detection values of each sample is divided by the number of samples to obtain the detection results. The fiber toughness, hardness and paper thickness, quantitative, compactness, moisture content and cardboard adhesion strength, etc., have a certain impact on corrugated board burst strength.Folding Strength of Base Paper and Corrugated Board and its Influencing FactorsCarton as a kind of packaging container, its shaking cover needs to be opened frequently, which requires the base paper should have a certain folding strength, so as to improve the folding strength of carton shaking cover. Transverse folding strength is the test to base paper under the condition of a certain tension, speed and angle made by samples in the specifications of 150 mm * 15 mm repeated folding test over 135°angle , when the pattern breaks, it is the number of tests of folding strength. The method of carton cover detection is, shake cover after 5 rounds of manual inspection over 180°, no crack on the linerboard layer and inner layer,then the test result is qualified . The paste properties , moisture content of base paper, compactness, fiber length and gluing fastness of the box board paper and whiteboard paper, as well as the storage time and temperature of the base paper that affected by factors, largely determine the folding strength of base paper. Therefore, to improve the folding strength of cartons, we should first pay attention to the quality of control base paper.The Ring Crust Index of Base Paper and its Influencing FactorsThe test of column strength of base paper ring is toa sample of a certain size into a circular tray to form a circular ring on the side of the sample, and then put it into the pressure plate of the compression meter for electric uniform compression, the value shown is the compression strength of the ring crust when the sample is crushed . The standard sample size should be: 152.0mm in length (longitudinal) + / - 0.2mm, 12.7mm in width + / - 0.1mm. 10 pieces are taken for testing, 5 pieces of which are front facing outwards for testing, and the other 5 pieces of which are opposite facing outwards for testing in a circular tray. After that, an average value of the 10 pieces of test results is calculated for conversion.Because the calculation formula of ring crust index requires the quantitative data of samples, according to the author's understanding and testing experience, the quantitative test value has a direct impact on the results of ring crust index conversion. Therefore, in order to improve the accuracy of detection, it is necessary to pay attention to the accurate quantitative detection, which requires the quantitative detection of samples should have a certain representativeness, for this reason, it is best to take 10 samples from different parts of the horizontal paper cylinder for detection, to find the average value, so that the detection data is relatively accurate. If 10 samples are taken from a certain longitudinal part of the paper cylinder, the detection value is usually not representative, because the error of transverse thickness is relatively larger than the longitudinal error. In addition, the accuracy of specimen thickness measurement is related to the test results of column strength. Because of the thickness of the specimen is different, the diameter of the tray core used to measure the column strength is also different. Therefore, the thickness detection should also use several points of different parts of the test, and use its average value as the final test results. The measurement of thickness index has to be  accurate, so that the clearance of sample in the tray is suitable, and the accuracy of column strength can be ensured. This requires that the selection of the corresponding pallet specifications (diameter) must be strictly in accordance with the thickness of the sample .The compactness of the base paper, the quantitative, to a large extent, affects its column strength index. Paper with good column strength, its ring crust index is also high; Only by measuring the column strength value can the ring crust index value be obtained. The following is the conversion formula of column strength and ring crust index:(1 ) Column Strength: R=F / 152.Where: R represents the column strength, unit KN/m; F is the force value when the sample is crushed, unit N;152 is the length of the sample in mm.(2) Ring Crust Index: Rd=1000R/W.Where, Rd represents the ring crust index, unit Nm/g: R represents the ring crust intensity, unit KN/m; W is the quantity of the sample, unit g/m2. The Tensile Strength of Base Paper and its Influencing FactorsBecause the drum corrugated paper on the single-sided machine paper rack and cardboard paper must withstand a certain tension in the process of transportation, so as to prevent the emergence of broken paper, this requires that the base paper should have good tensile properties, that is to say, the base paper tensile strength index should meet the requirements of production. Though the standards for the production of corrugated paper, cardboard or white paper board do not include the tensile strength, the factory can develop the corresponding enterprise standards according to actual production situation, and it’s conducive for production to control the technical indicators of the tensile strength of the base paper. Tensile strength is generally measured by the tensile strength of a sample of with a certain width stretched to the fracture under constant speed loading. The width of tensile strength specimen is 15mm and the length is greater than 180mm, which can be detected by pendulum tension tester.When testing, the standard sample is clamped between the upper and lower clamps. Driven by the tranission device, the lower chuck decreases at a certain constant speed and is transferred to the upper chuck through the sample. The upper chuck deflected the pendulum by a certain angle through the chain. When the specimen breaks, the tensile value can be read from the scale . DLS liquid crystal display electronic tensile testing machine is now used to detect the tensile strength of the base paper, so that the efficiency and accuracy of detection are more competitive. There are many factors influencing tensile strength, such as the quality of papermaking materials and the effect of papermaking technology on the fiber bonding fastness. The quantitative, thickness, rupture resistance, column strength and other indicators of the base paper also have a  greater impact on tensile strength.To sum up, base paper and corrugated board not only are the basic materials to make the cartons, but is the source control links of the carton quality. If the purchasing quality of the base paper as well as the quality of corrugated board production controls well, it means that the quality of carton production base will be more reliable guaranteed. Therefore, as long as to correctly  understand the knowledge of base paper,the scientific and reasonable detection methods, and better control of corrugated board production, then solid foundation will be laid to improve the production efficiency and product quality of carton , it is also the deep feeling of  the author after a long-term working in front-line of carton production.   --If there is Copyright Dispute about the content, please Contact us to Delete.

Professional! The most detailed using and maintenance terms for corrugating rolls

Corrugating roller is a key component in corrugated carton production. The  of corrugating roller is to process corrugating medium paper into the required flute, and fixed medium paper to complete the gluing and surface operation. In order to improve wear resistance and reduce wear, the roller surface must be both strong and durable. Strong but not durable will cause mechanical damage (breakage or peeling) to the surface of the roll. This damage will accelerate roller wear. In the daily use of corrugating roller, service life can be extended through some simple ways : Polishing Because corrugating rollers will be worn, the surface of the rollers will obviously appear ladder like pattern. Wear is the most serious in the middle of the roller, especially in the paper edge through the part of the roller surface is the most obvious. This will result in uneven pressure on the pressure roller clamps and difficulty in aligning the glue on the floor. When this wear affects the quality of the board, even if the thickness is still within the acceptable range, then it is necessary to replace the roller. In order to overcome this problem, diamond paste can be used to grind or a all amount of material can be removed from the flute point at the journal (0.O5mm).This operation is very difficult and requires a high level of skill in order not to rub off the important coating on the corrugating form. As with many maintenance methods, there is no need to maintain badly worn rollers with this method. Some factories produce all fixtures that can be mounted on a single-sided machine to make grinding more accurate and easy. The service life of the uncoated roller can be extended significantly by careful grinding. Adjust Regularly The pressure of the corrugating roll can be adjusted by changing the paper frame or core paper grade (the pressure should be appropriately reduced to prevent metal and metal contact at the shaft neck).When required, correct adjustments can reduce journal damage and extend roll life. More important is to ensure that the rollers are placed in parallel in the machine. This can be detected by the electric newspaper, the electric newspaper into the roller, can show the relative position of the upper pressure roller and the lower pressure roller, when the roller is first installed, you can also use this electric newspaper. In order to ensure the service life of rollers, they must be placed in parallel. In future checks, any shift indicates a potential problem with the machine.  Clean Regularly The presence of metal particles larger than 0.5mm will cause damage to the roll. The roller and single-side machine should be kept clean enough to avoid unnecessary large particles of impurities passing between the rollers. Internal Monitoring of Roll Wear Reinforced steel roll wear is linear, so it is necessary to regularly detect the corrugation height, accurately infer the life expectancy of the roll and replacement date. A dial scale or traditional depth micrometer may be used in conjunction with a all pin (radian less than the radian of the valley) for measurement. Rollers should be checked periodically to detect wear rates between each fixed paper frame.If running normally, the wear rate of the roll should correspond to the percentage of each fixed paper frame running on the roll.Different coating rollers (chrome or tungsten carbide) are tested slightly differently.Coating roll wear rate is much aller than the steel base roll.In this way, in the absence of specific equipment, this all wear rate in a single machine is difficult to accurately measure. This means that coating integrity is an important guide to roll life.The integrity of the coating can be detected by applying copper sulfide to the surface of the roll (which is available from the laboratory supplies supplier).If the coating is complete, copper sulfide will remain blue.If the stainless steel is exposed, the copper sulfide will turn brown after two minutes and stain the surface of the stainless steel.The first wear on the coating should be at the edge of the groove in the middle of the roll.Other ways to improve roll life include optimizing the Angle arc, which is the best compromise between wear and shrinkage, and improving surface oothness to minimize friction coefficient between paper and roll and continuous paper tension.The last factor that affects the life of the roll is the ooth running performance of the roll itself at any running speed.Vibration or unstable operation of the roller will increase the impact of hammer tip at both ends of the roller, and lead to premature fracture of the surface of the roller, greatly reducing the service life of the roller. Inspection of Corrugating Roll During Installation and Commissioning;1. Inspection and maintenance of corrugating roll during installation and commissioning;2. Inspection and maintenance items before installation;3. Clean and inspect corrugating surface appearance of corrugating roller (including plating quality);4. Clean and inspect fastening parts of connection (including internal and external threads);5. Check the outer diameter and middle height of corrugating roller(the whole roll surface is divided into more than five measuring points from both ends to the middle).The detection points of middle and high rollers must be odd, and the data of middle and high rollers should be symmetrical on both sides.With the corresponding specifications of the outside micrometer measurement (outside micrometer can be bought from general mechanical and electrical companies );6. Check the height of corrugating roller. Needle type depth dial meter measurement.7. Clean and check the outer diameter and appearance of each shaft of corrugating roller. Measure the outer diameter with the corresponding micrometer.8. Check the paralleli of the upper and lower corrugating rollers (generally, corrugating rollers in contact with the pressure rollers are not of medium or high height, so they are the reference rollers for installation.The corrugating roll with the middle height has an eccentric adjustment mechani to adjust the two rollers parallel).Pressure sensitive paper, carbon paper or fuse can be used to determine and adjust the corrugating shape and side indentation of the corrugating shape of the two layers of cardboard during production operation;9. Check the paralleli between the upper and lower corrugating rollers and the pressure rollers. During the operation of the upper and lower corrugating rollers and the pressure rollers, the axis of the three rollers should be parallel and the line pressure should be uniform. It can be judged according to the indentation of two layer corrugating board linerboard that being composited , and adjust the pressure at both ends of the pressure system;10. Check the paralleli of corrugating roller and glue roller, according to the gap requirements of different corrugating type on the amount of glue, check and adjust the gap between corrugating roller and glue roller with a plug gauge or corrugating paper from both ends;11. Check and adjust the corrugating roller and guide paper coated device, the relative position of a positive pressure paper guide or a negative pressure paper guide, vacuum adsorption device or  clearance between positive pressure cavity with corrugating roller and pressure roller seal can be adjusted according to the testing requirements of the production line , to control air pressure and leak, in order to ensure that the ironing corrugating paper can be closely sticky to the corrugating roller to complete gluing and composite drying process:12. The above items must be fixed with their limit devices after debugging;13. Bearings of corrugating roller and pressure roller and other roller must meet the requirements of accuracy, high temperature grease must be selected high quality, oil seal to seal well.14. Daily inspection and maintenance of corrugating roller during normal production and operation;15. Before operation and production;16. Check and ensure the cleanliness of each roll surface;17. Check and ensure the correct position of each roller;18. Check and ensure that the relevant devices (paper guide copper plate device, positive pressure paper guide device or negative pressure paper guide device, etc.) are in the correct position, Check the wear condition and adjust it;19. Check and ensure proper position of adhesive system and good preparation of adhesive;20. Check and ensure the lubrication oil supply preparation is normal;21. Check and ensure the normal pressure and hydraulic system;22. Check and ensure the heating system is normal; During Operation and Production:1. Check and control the temperature, those vaper-heated should prevent condensation water from being discharged and pipe valve leakage, we should also patrol and ensure steam supply pressure;2. Check and control the humidity of corrugating medium and linerboard;3. Check and control the operation position of corrugating medium and linerboard, both ends of the edge is neat;4. Check and control flute shape accuracy of corrugating board , no high or low flute and flute collapse ;5. Check and control the composite strength and the evenness of gluing of corrugating medium and linerboard ;6. Check and control indentation of linerboard;7. Check and control the ooth circulation of glue supply system;8. Patrol inspection, ensure the ooth operation of machinery, no abnormal impact noise;9. Inspect each lubrication oil supply system to ensure normal operation;10. Inspect the air pressure and hydraulic system to ensure that the work is normal and there is no leakage.When Production is Stopped;1. Close the heating system of the roller;2. Close the pressure at which the roller is pressurized or hydraulic system;3. Stop glue circulation, glue system separated from corrugating roller.Clean gluing system (including glue-feeding system);4. Stop corrugating roller running whencorrugating roller cooling below 40 ℃, cleaning roller surface and leading paper coins and confetti trash inside positive pressure or negative pressure device ;5. Keep good lubrication and refueling.6. Above is the general principles of qualified corrugating rollers in the correct use and daily maintenance, and the basic environmental conditions affecting the service life of corrugating rollers. In corrugating board production industry, many enterprises has accumulated a lot of scientific management experience which is worth learning and promoting, companies can learn from each other. As long as to continuous monitoring and improving the use environment and conditions of corrugating roller in the daily production process and production gap, and carry out strictly daily maintenance scientifically and seriously, corrugating roller will certainly play its due role for the high yield and low consumption of corrugating board production enterprises.Due to the structure and forms of corrugating board production line is different, some concrete and detailed use and maintenance of corrugating rollers and debugging methods need to be told to professional production maintenance services company, according to the actual condition of corrugating board production line and the corrugating roller concrete usage, so as to get satisfactory response and timely service and help.     --If there is Copyright Dispute about the content, please Contact us to Delete.

Two-steps Starch Glue Adhesive Performance of Corrugated Board

 Two-step starch adhesive has been widely used in corrugated board assembly line. A large number of production practices show that the adaptability of this adhesive to large production line greatly affects the production efficiency, product quality and energy consumption of corrugated board assembly line. Performance of corrugated paper adhesive are mainly included viscosity (liquid), the drying speed, gelatinization temperature, viscosity, film forming performance, etc., at present, these properties are still has certain problem, such as slow drying speed, high gelatinization temperature, poor initial viscosity ect. How to improve the corrugated board production line adhesive has been a vital research subject. The viscosity of adhesive is one of the key indexes to evaluate the adhesive used in corrugated board assembly line. If viscosity is too big, it is easy to get roller gelatinized, failed to coated, and cause waste; If viscosity is too all, the initial viscosity is not good, resulting in collapsed flute, board crack, and board drying speed is slow, so a proper viscosity is the key.In this article, we analyzed the effect under different reagent dosage on the viscosity of two-step starch adhesive through carrier starch oxidation modification .The Experimental Methods1.1  Carrier StarchAfter mix the water (40 + 2) ℃ with corn starch, slowly add about a quarter of the total NaOH (no more than a quarter, with PH value between 11 ~ 12), then adding catalyst FeSO4, after that adding H202 for a few times.Oxidation for 1.5 ~ 2 h, after oxidation, adding the rest NaOH, stirring it while keeping the temperature not to exceed 50 ℃.1.2  Main starchAdding borax solution that dissolved in hot water before into water(40±2)℃, stir evenly, and add corn starch, keep stirring until completely dispersed evenly.1.3  MixtureSlowly add the carrier starch while keep stirring into the main starch, mix it thoroughly for 20-30min, and keep it warm for another 10-30min.The change of powder water ratio in the experiment was controlled by changing the water consumption. The amount of starch in the carrier: the amount of starch used is about 1:3.5.Discussions on Influencing Factors2.1  Influence of Powder Water RatioLow powder water ratio means less water needs to be evaporated in the drying process, in order to achieve a faster drying speed, the water content in the adhesive should be lower, that is to say, in the premise of meeting other performance requirements, low powder water ratio is good.However, too low powder water ratio is not conducive to the fluidity of adhesive, corrugated board production line has a high liquidity requirements on the adhesive, high fluidity can meet the requirements of rapid, uniform and appropriate coating, obviously, large power water ratio is conducive to decrease the adhesive viscosity. Therefore, we need to find a better water powder ratioin actual production, so as to get a proper viscosity.Table 1 is the influence of water-powder ratio on the viscosity under experimental conditions. The viscosity in the table is determined by the coated 4-cup method.As can be seen from the table, the powder water ratio is better between 1:4.4 and 1:4.8.At this point the viscosity of 37 ~ 53S is more suitable for coating. 2.2 Influence of Oxidant (H202)Oxidation modification mainly through oxidation, so that the glycosidic bond of starch glucose is partially broken and degraded, resulting in depolymerization, molecular weightreduced, and  water solubility and affinityincreased, thus, adhesive with high solid content and low viscosity can be prepared, which enhanced drying capacity, and enables oxidation converts the hydroxyl group in starch to an aldehyde group, this will increase the the number of carboxyl groupcombined with paper fibre, as a result,the adhesive force of oxidized starch is greatly improved. In addition, the aldehyde group produced after oxidation has anti-corrosive effect, which improves the anti-corrosive ability of the adhesive, and the carboxyl group significantly improved the stability of the adhesive.The oxidants commonly used in starch adhesives are mainly KMn04, NaCLO and H202. Through comparison, this article selects H202, which has strong oxidation capacity, low dosage, non-toxic, tasteless and colorless, and does not bring impurity ions into the reaction during the oxidation process, as the oxidant of starch carrier.Under the action of H202, the hydroxyl group on the starch glucose unit is transformed into aldehyde group, ketone group, and then oxidized into carboxyl group. The glycosidic bond of the molecule breaks, thus hinders the molecular association, reduces the degree of polymerization, macromolecular degradation, and molecular weight of starch reduced, thus endows the glue liquid with certain fluidity.The oxidized starch obtained by proper control of oxidation degree has good water solubility, affinity, penetrability and adhesion.If the amount of H202 is too much, instead of oxidization, starch will be oxidized too much, which will lead to starch excessive degradation, low viscosity of adhesive, even reduce the bearing capacity and adhesion capacity of the main starch.Table 2 shows the relationship between the viscosity of adhesive and the amount of H202 under experimental conditions.As can be seen from table 2, the viscosity of adhesive changes significantly with the amount of H202. At the beginning, the viscosity decreases rapidly. When the amount of H202 changes around 2.0% (accounting for the total amount of starch), the viscosity of adhesive changes slightly. When the content of H202 exceeds 24%, the viscosity decreases with the increase of oxidant. When H202 is used as oxidant, the viscosity is appropriate from 40 to 46S, so the optimal dosage is 1.6% to 2.4%.In general, the change of H202 dosage between 0.8% and 2.8% does not have obvious influence on the viscosity of adhesive, which is mainly related to the all proportion of carrier starch in the total starch.  2.3 Influence of NaOH DosageNa0H, as a gelatinizer, has three main s: one is to adjust PH value and ensure alkaline oxidation conditions; the other is to combine with hydroxyl group in corn starch, destroying part of hydrogen bond, reducing starch intermolecular forces and lowering gelatinization temperature. The third is to change carboxyl group of oxidized starch into sodium salt and increase hydrophilic and solubility.In fact, oxidized starch itself is insoluble in water, and no adhesion, which needs sodium hydroxide to promote gelatinization, sodium hydroxide integrated with starch molecules in the hydroxyl group, preventing the starch between the hydrogen bond from associating, at the same time, starch swelling and gelatinizing, viscosity largen ,adhesion improved, liquidity stabilized , and storage time being long.Table 3 shows the change of adhesive viscosity with the amount of Na0H.As can be seen from the table, the viscosity of glue liquid almost keeps increasing with the increase of Na0H dosage. When the dosage is 55%, the viscosity has reached 53S; when the dosage continues to increase to 12%, the viscosity is 131S.When the amount of Na0H exceeds 12%, the viscosity shows a downward trend. The reason is that when the alkali solution is added to a certain amount, the starch particles are swollen to a certain extent, and then break up, and become thinner after better dissolution with the alkali solution.From the perspective of fluidity, it is appropriate to control the amount of Na0H at 4.4% ~ 5.5% of the total starch.  2.4 Influence of Borax Amount on ViscosityBorax, as a crosslinking agent, can increase the viscosity of glue solution and enhance the initial viscosity, which is because borax can combine with the aldehyde group and carboxyl group of fully expanded oxidized starch as ligands to form polynuclear ligand compounds.Borax dosage is too much, will lead to product with high cohesion , and produce gel;If the dosage is too little, the complexation effect and the initial viscosity cannot be reached.Table 4 shows the increasing relationship between borax content and viscosity under the experimental conditions.As can be seen from the table, with the increase in the amount of borax, the viscosity has been on an upward trend, when the amount of borax is within the range of 0.8% ~ 1.4%, the viscosity between 40 ~ 49S is the usable range. 2.5  Influence of Catalyst Addition on Viscosity2.5.1  Influence of Catalyst Addition Order on ViscosityThe order in which the catalyst and a all amount of Na0H were added to adjust the PH value had different effects on the experimental results.It was found in the experiment that when adding a all amount of Na0H and then FeS04, the color of glue produced was light yellow, and the viscosity was 4~6S higher than that when adding a all amount of Na0H added after the ferrous sulfate, while adding a all amount of FeS04 and then Na0H, the color of glue produced was milky white.The reason may be that when Na0H was added first, most of Na0H was involved in the gelatinization of starch, and a very all amount of OH- and Fe2+ formed Fe(OH)2 precipitation. The extra amount of Fe2+ caused partial ineffective decomposition of H2O2, and the amount of H2O2 involved in oxidation was reduced. The oxidation was not more sufficient than that when FeS04 was added first, resulting in a higher viscosity than that when FeS04 was added first.When FeS04 is added first and then Na0H, Fe2+ and OH- precipitate immediately. PH value decreased as H2O2 added, Fe(0H)2 has a certain degree of solubility, and slowly enters the role of catalyst, so that H2O2 can more fully achieve the purpose of oxidizing starch, thus reducing the viscosity of glue. In addition, H2O2 itself has bleaching effect, so the color of glue solution is good.Therefore, the effect of catalyst FeS04 was better if first added than that being added after Na0H .2.5.2  Influence of Catalyst Dosage on ViscosityTable 5 shows the influence of the amount of catalyst ferrous sulfate on the viscosity. With the increase of the amount of catalyst, the viscosity decreases, but the amount of catalyst increases to a certain extent, and the viscosity of adhesive slowly increases.This indicates that Fe2+ can catalyze the oxidation of H2O2 on starch, leading to degradation of starch molecular chain and decrease of viscosity. However, with the increase of Fe2+ dosage, the viscosity increases to a certain extent, possibly because Fe2+ has a certain complexation effect on starch molecular chain. 2.6  Influence of Oxidation Time on ViscosityTable 6 is the effect of oxidation time on adhesive viscosity.Oxidation time is long, oxidation depth is large, viscosity will also decrease.However, if oxidation time is too long, starch molecular chain is too all and short, liquidity is too large, resulting in insufficient coating, poor initial viscosity ,and the cardboard is easy to debonding, strength is not good as well. If oxidation time is too short, it will make starch molecular chain fracture degree insufficiently , cause big viscosity, and the oxidation modification effect is not good enough.  3 . Conclusion3.1 Water powder ratio has a great influence on viscosity of two-step starch adhesive.Considering the viscosity alone, the suitable powder water ratio is 1:4.4 ~ 1:4.7.3.2 Using H2O2 to oxidize starch carrier to improve the carrying capacity and solid content of the main starch , the viscosity of starch adhesive obtained is in the range of 40-50s with a good fluidity, with the amount of H2O2 is 1.6% ~ 2.4%, the amount of Na0H is 4.4% ~ 5% of the total amount of starch, and the amount of borax is 0.8% ~ 1.4%.3.3 Catalyst FeS04 was added before a all amount of Na0H for PH regulation, would make he oxidation reaction more complete and the appropriate oxidation time was 1.5-2h.    --If there is Copyright Dispute about the content, please Contact us to Delete.

How to Plan Corrugated Carton Production Factory-Waste Paper& Wastewater Treatment

Outline of Manufacturing Process and Materials UtilizedThe manufacture of corrugated packaging can be roughly classified into two processes: the containerboard combining process, which glues one or more sheets of fluted corrugating medium to one or more flat facings of linerboard; and the box manufacturing process, which is used to assemble the corrugated sheets into boxes. Figure 1 depicts the typical manufacturing process flow and the auxiliary facilities that are used at a corrugated packaging plant.Figure 1 Overview of Manufacturing Process Flow for Corrugated Packaging Wastewater Treatment Process(1) Discharge Routes for Wastewater and WastesAlthough actual discharge routes for wastewater and wastes from the containerboard combining process (corrugator) and the box-manufacturing process (printing / gluing processes only) will vary, depending upon the facilities and geographic conditions available to each particular corrugated packaging manufacturer (discharge into rivers or sewers), a typical flow is shown in Figure 5.Figure 5 Discharge Routes for Wastewater and Wastes    * “Glue balls” are lumps of gelatinized combining adhesive within the glue vat, caused by excessive ambient heat. (2) Wastewater Treatment MethodsThe wastewater generated by plants that manufacture corrugated packaging can be classified into the following categories: household wastewater /domestic wastewater; rainwater; wastewater from clean up of combining adhesive (corrugator and glue making machine) and wastewater from cleanup of printing ink and joint adhesive. Household wastewater / domestic wastewater and wastewater from processes containing substances designated by the PRTR system, except for rainwater, are generally treated through a combination of several methods listed in Table 3.Table 3 Types of Wastewater Treatment Methods2. Class I Designated Chemical Substances Contained within Materials andEnergies Utilized in the Corrugated Packaging IndustryTable 4 indicates the major Class I Designated Chemical Substances contained in the materials and energies utilized for the manufacture of corrugated packaging, which have been investigated by the member companies of Japan Corrugated Case Association (JCCA).                                                                                                  Table 4 Major Class I Designated Chemical Substances Contained in Materials and  Energies  3.  Corresponding Class I Designated Chemical SubstancesThe list of Class I Designated Chemical Substances shown in Table 5, below, was prepared from the general usage examples obtained as a result of an investigation conducted at 121 of JCCA member companies’ plants. These chemical substances comprise 1% or greater of the particular product, which itself is handled in annual quantities that may exceed 1 ton. In addition, these chemical substances may result in the release of dioxins from designated facilities, as stipulated by the Law Concerning Special Measures against Dioxins(for corrugated packaging plants, such designated facilities would be all incinerators). For chemical substances other than those listed in the table, the MSDS should be obtained, in order to confirm whether such chemical substances are subject to reporting. Table 5 List of Corresponding Class I Designated Chemical SubstancesIn addition, there are certain types of flexo inks (currently, flexo inks are utilized most commonly) that contain approximately 2% of the Class I Designated Chemical Substances shown in the aforementioned Table 4. However, as the quantities of these particular inks used (10 kg and less) are far less than the quantities specified by the law (1 t or more), these flexo inks are not subject to reporting. Quick drying inks have been designated as products that are subject to reporting. Regardless of the particular type or color of these inks, they all contain a relatively large percentage of ethylene glycol, which is a Class I Designated Chemical Substance, as a primary ingredient in the solvent. In addition, there is a strong possibility that the annual quantities handled will exceed 1 ton.  --If there is Copyright Dispute about the content, please Contact us to Delete.

Starch Viscosity and Quality of Corrugated Board

?Abstract: viscosity is one of the important indexes to measure the quality of starch gum, which directly affects the quality of corrugated board. Therefore, in production, relevant personnel should observe different production conditions at any time, adjust the required viscosity in time, and make the production process reach the best state.Viscosity refers to the degree of liquid flow of starch glue and also the expression of initial viscosity of starch glue. The optimal range is 20 ~ 40 s. In this range of viscosity, the degree of glue liquid oxygenation is appropriate, no flow, no wire drawing; The amount of glue is easy to control. Long storage life. Whether single face, glue unit, or corrugated board production line are in good operation.Factors affecting starch viscosity 1. 1 Type and Quality of StarchStarch variety, fineness, protein and fat content can affect the viscosity of starch gum, especially protein. If the content of protein and fat in starch is too high (more than 1.1%) and the fineness is lower than 98 mesh (100 mesh screen filtration), even if the degree of oxidation is very high at the time of making, the viscosity at the time of discharging is only 20 seconds. After five to seven days of storage, starch glue will naturally thicken, lose fluidity, and be like jelly, affecting the bonding quality . As long as the degree of oxidation and gelatinization is appropriate, the viscosity of the prepared starch adhesive will be 40 + or 10 s. The viscosity will not change much during the storage period, only the color will be dark. The commonly used tapioca starch, potato starch than corn starch, wheat starch viscosity is higher. The dosage of starch varies according to the specific requirements of the adhesive object. 1. 2 Dosage of Oxidant and Oxidation Time For certain starch, the product performance is different due to different degree of oxidation. The content of sodium hydroxide, water ratio and borax remains unchanged. Under any oxidation time condition, the viscosity of starch gum decreases with the increase of oxidant dosage. This is because the larger the amount of oxidant, the larger the degree of oxidation of starch, the aller the molecules, and the aller the viscosity. When the amount of oxidant is less than 2%, the viscosity is not only affected by the amount of oxidant, but also affected by the oxidation time. When the amount of oxidant was more than 2.5%, the viscosity was less affected by the amount of oxidant, and the viscosity was very all, which may be because the oxidation of starch tends to be complete. The results showed that when the oxidant dosage was between 1.8% ~ 2.5% (measured by the percentage content of starch quality), the viscosity was not only suitable for the production of corrugated board, but also high bonding strength, and its viscosity was less affected by the oxidation time. The specific dosage of oxidant depends on the type and quality of starch. Sodium hypochlorite (10%) is about 28% of starch, hydrogen peroxide (27.5%) is about 4% of starch, and potassium permanganate is about 2% of starch. If excessive oxidant is added in operation, strong reducing agent (such as sodium sulfite, baking soda, etc.) should be added to reduce excessive oxidant and prevent excessive oxidation. For the self-use of all and medium-sized factories, it can be used to oxidize at night to prolong the oxidation time, reduce the dosage of oxidant, reduce the consumption of raw materials, so as to reduce the cost.1.3 Oxidation Temperature The effects of temperature on oxidation reactions are manifold: On the one hand, it can increase the speed and degree of oxidation reaction. The higher the temperature is, the faster the oxidation reaction will be. Under the same conditions, the lower the viscosity of starch adhesive produced will be. On the other hand, it can make starch gelatinize and increase the evaporation of water, make starch glue thicken and do not go against the diffusion and oxidation of oxidant, thus increase the viscosity of starch gum. Appropriate oxidation temperature of 20 ~ 30 ℃.1. 4 Dosage of the Gelatinizer NaOHKeep the dosage of oxidant, water ratio and borax unchanged. Under different oxidation time conditions, the viscosity increases with the increase of NaOH dosage. This is because starch particles have a strong cohesive force, and the water molecules must be introduced into starch particles with the help of NaOH, so that starch particles can expand, generate viscosity, and reduce the gelatinization temperature. The dosage of NaOH has a great influence on the viscosity of starch gum. Therefore, the dosage and temperature should be strictly controlled. The dosage is too all, the gelatinization is not complete, the viscosity is poor, the glue fluid is turbid, the fluidity is poor, not easy to store, affects the starch glue performance. If the dosage is too large, which exceeds all the required amount in the pasting process, the starch molecules will swell and pasting, which is not conducive to the diffusion of oxidants, thus affecting the degree of oxidation of starch. The dosage of NaOH should be observed in practice, generally about 12% of starch is more appropriate. On the other hand, the concentration of NaOH cannot be too high. High concentration, strong reaction when gelatinization, easy to saccharify, so that the gluing machine to shake the gum, the phenomenon of flower glue on corrugated peaks, resulting in unglued cardboard and difficult to dry.1. 5  Dosage of BoraxBorax, as a cross-linking agent, can thicken and improve viscosity, but the dosage should be strictly controlled, usually 1% ~ 2% of starch content.If exceeded, gel will be produced, resulting in high cohesion, which is characterized by high viscosity, poor viscosity and fluidity, difficulty in gluing and brittle adhesive layer.Less dosage, making starch glue thin which is easy to infiltrate into the paper, resulting in low viscosity, poor adhesion force, that caused deflected flute, collapse and degelatinize. 1.6 Water  RatioWith the increase of water ratio, while Keeping the dosage and concentration of oxidant, sodium hydroxide and borax as well as oxidation time unchanged, the viscosity of starch glue decreases rapidly. However, when the water ratio exceeds 6, the viscosity is less affected by the water ratio. This is because the viscosity is already low, which almost close to the viscosity of water. The size of water ratio  depends on the type and use of adhesive board, usually should be controlled between 4. 5 and 5. 5.1. 7  Storage Temperature , Time and Storage EnvironmentAs the storage temperature increases, the viscosity decreases rapidly. When the starch glue is stored in an airtight container, its viscosity changes very little with the extension of storage time. When stored in an open container, the viscosity is greatly affected by the storage time [3]. This is because the starch glue in the open container is oxidized by the oxygen in the air, while the moisture keeps evaporating, which makes the starch glue more viscous. 2 .  Effect of Starch Viscosity on Board QualityWhen the viscosity is high, the fluidity of starch glue is poor, which not only increases the amount of glue consumption, but also causes the paper where on paper deflector of the single-sided machine to have pasting points and other problems such as discontinuous debonding, starch glue lateral ejection, cardboard warping, washboard, corrugated height reduced, and cardboard compression strength reduction, etc.When the viscosity is low and the speed is slow, the gumming roller is not gluing. It is not only easy to lose the paste, which makes the starch glue permeate into the corrugated medium and cardboard too much, resulting in poor adhesion; but also cause problems like washboard (the lighter the weight of liner, the more serious it is), longitudinal warping, cardboard too moist, loose linerboard , linerboard and corrugated medium separate after initial bonding ,which leads to delamination, cardboard adhesion strength is relatively low, blank edge compression strength and cardboard compressive strength reduced accordingly.Low viscosity of starch glue and fast speed of gluing will cause low viscosity starch glue where in the shape of water on the double-sided machine having insufficient gluing amount, and glue liquid deviating from the corrugated direction will be lateral ejection .If it is serious, it may cause the cardboard warping or high humidity, and the adhesive strength, side pressure strength and the compressive strength of the carton will be correspondingly reduced. And there may be a pull chain adhesive cardboard or linerboard layered. Too high or too low viscosity will lead to the  linerboard or inner linerboard debonding; Slitting edge single face corrugated board loose; The shape of single-sided paper starch glue In the longitudinal will appear blank traces which is consistent with the shape of finger, unglued and without of starch glue. Cardboard moisture is too high; single face corrugated board sheet edge loose. 3 . Regulation of starch viscosityThe viscosity of starch should be adjusted according to the performance of the paper, the object used and the speed of the corrugated machine, heating capacity and other factors. Generally, the viscosity of starch glue used in production line is within the range of 50 ~ 90 s, and that used in single machine production is between 20 ~ 50 s. The bonding strength of high strength corrugated paper, single side corrugated board and thinner flute color board  is about 30 + or 5The bonding strength of normal corrugated paper is about 40 + / 10 s. If the viscosity is too high, the content of starch in the carrier can be reduced or a vat of starch glue with low viscosity can be prepared. If NaOH is excessive, some viscosity stabilizer can be added to inhibit the increase of starch viscosity. The amount of NaOH should be reduced when making new paste at the same time. When the phenomenon of glue thrown appeared due to high viscosity or glue machine failed to use (normal use of starch glue viscosity is related to the speed of glue machine, when speed is slow, viscosity can be moderately higher, and vice versa. with no glue thrown as the principle), some moderate amount of oxidant can be added so as to oxidizing again. Don't add water to dilute, lest appear degelatinize and glue thrown . If the viscosity is too low (below 20 s), borax solution can be added or a vat of starch glue with higher viscosity can be prepared. Moderate starch paste (starch + water) can be added to starch glue, and then stirring evenly, but not long-term storage. If the amount of NaOH is insufficient, add some volume to avoid the viscosity reduced. Starch glue should be sealed in storage, not exposed to the air, to avoid scaling, thickening or frozen. 4 . ConclusionAdhesion is one of the most critical processes of corrugated paperboard production, which has the greatest impact on the quality of paperboard. The quality of adhesion ultimately depends on the quality of starch glue. The viscosity is an important index of starch glue and the volume of viscosity directly affect adhesion performance of corrugated board. Only with stable viscosity can the adhesion quality of starch glue be guaranteed. --If there is Copyright Dispute about the content, please Contact us to Delete.

Effect of Starch Gelatinization Temperature on the Quality of Corrugated Board

                                                                                                                                                                                                                                                                                                                                                                                 Gelatinization temperature is one of the important technical indexes of starch glue quality and the standard of gelatinization temperature is 58 + 2 ℃. Generally, the temperature of starch glue in summer is relatively high, paper and mechanical has enough heat to laminating. When gelatinization temperature is high (57-59 ℃), viscosity is relatively stable. The temperature is rather low in winter, so is starch glue. In order to reduce heat that starch glue gelatinization demand, gelatinization temperature should be lowered(55-57℃) to laminating.1. The process of Starch Glue Gelatinization     Starch particles were stirred fully under the action of a certain temperature of water, and expanded gradually under the action of the gelatinizer to reach the gelatinization temperature. As the temperature rises, starch particles begin to collapse and gradually disperse into all pieces. When soaked to the inside of linerboard and corrugated medium, they start to bond which require a certain initial viscosity (mainly due to NaOH solution and borax solution). As the temperature rises, the moisture content of starch particles will evaporate, and some of them will be absorbed by linerboard and corrugated medium, so that the initial adhesion will be carried out rapidly. The starch glue will connect inner liner, corrugated medium, flute and linerboard  into a whole, so as to achieve the purpose of adhesion. 2. Factors Affecting Gelatinization Temperature of Starch GlueWhen starch glue starts to thicken and the gelatinization temperature is that showing the bonding property due to raw starch gradually gelatinizing among all the starch glue raw materials.There are many factors affecting the gelatinization temperature, mainly in the following aspects.2.1 The Dosage of the Gelatinizer NaOH             ① The Effect of the GelatinizerStarch particles itself has a strong cohesive force, water molecules are not easy to infiltrate, so water molecules must be brought into starch particles with the help of gelatinizer, which can weaken the interaction between starch macromolecules and reduce the gelatinization temperature. Secondly, when gelatinizer dissolves in starch solution, it will give out certain heat, making starch particles expand, producing viscosity, and also make starch glue having better fluidity, and not moldy easily.In the carton industry, sodium hydroxide (NaOH) is generally selected as the gelatinizer. The dosage is usually controlled below 1% of the quality of starch glue. It is appropriate to add the oxidized starch solution and stir the starch solution into a translucent paste for 20min.②The Amount of NaOH has a great influence on the Gelatinization Temperature of Starch GlueThe higher the amount of NaOH, the lower the gelatinization temperature with a better infiltration. However, if the weather is too hot, the temperature of starch glue will rise, and the activity of NaOH will increase as well, which will easily cause viscosity rising. Therefore, the amount of NaOH should be slightly adjusted to reach the appropriate gelatinization temperature. Generally, the amount of NaOH should be adjusted with the second amount of NaOH. Large amount of NaOH will cause swelling and gelatinization of starch molecules, resulting in thickening and increase of viscosity (higher than that of 80s). It is not conducive to the diffusion of oxidants, and it is not easy to glue or glue vague.The dosage of NaOH should be reduced according to the situation, and measures should be taken to dilute.If the amount of NaOH is too large, which exceeds all the required amount in the gelatinization process, the glue solution is in high fluidity, which will reduce the viscosity of starch glue and increase the pH value, resulting in yellowing corrugated box and the ink color shifted on the surface of corrugated box. The dosage of NaOH is relatively all., it is white or milky paste 20min after being added, opaque and non-sticky, which under this circumstances is not conducive to the oxidation of starch. The gelatinization is not complete. Glue solution is turbid with a poor fluidity and difficult to storage. If the dosage is too all, characterized by the amount of heat released is less, the gelatinization effect is not sufficient, the viscosity is too low (viscosity is below 20s), and the adhesion force is poor, then the amount of NaOH should be added appropriately according to the situation (the net amount of NaOH used should be clarified). When adding NaOH, fill a certain amount of NaOH with 5-10 times cold water, slowly add it to the container, and continue to stir. In addition, the concentration of NaOH cannot be too high, if so, the gelatinization reaction will be too strong, easy to saccharifying, resulting in glue thrown, and vague glue will be generated on the framed corrugated peak. It will cause debonding and destroy paper fiber and is difficult to dry. when air humidity is large, easy to absorb moisture and yellowing, which generally should be controlled in 10%-13% . The dosage of NaOH should be depended on the actual use, generally about 12% of starch is  appropriate.2 . 2 The Type and Quality of Starch                 Starch is the main adhesive, insoluble in water, expands and gelatinizes with the increase of water temperature. When it acts with NaOH solution, it expands sufficiently and its viscosity increases.The commonly used starch mainly includes corn starch, wheat starch, tapioca starch and potato starch. The variation of gelatinization temperature is due to different producing areas, production climate, brands or quality of starch. The gelatinization temperature of different starch is referred to table 1. Therefore, in practices, combined with the actual situation of each place, choose the lower price starch to produce starch glue. The gelatinization temperature can be adjusted mailnly by changing the amount of sodium hydroxide, and it can be increased by reducing the amount of sodium hydroxide, and vice versa. But remember not to add sodium hydroxide to the prepared starch glue. The gelatinization temperature of starch gum in double corrugated board is lower than that of single ones. This is because the heat transfer of double-sided machine is not as good as single-sided machine, but too low gelatinization temperature often makes the adhesive layer brittle and form surface adhesion.                                                           Table 1 Gelatinization Temperature of Different Starch                   At present, expanding gelatinization is adopted in making various starch gels. The expanded maize starch has loose structure and is spongy and soluble in water. In water, the infiltration, expansion, viscosity, initial viscosity and adhesive strength are enhanced, which makes the expanded corn starch can be directly used as starch adhesive.2.3  TemperatureThe higher the water temperature, the stronger the activity of NaOH, the faster the starch glue viscosity increases, and therefore the lower the gelatinization temperature is. In this case, the amount of secondary NaOH must be reduced to achieve a stable gelatinization temperature, while the lower the water temperature is, the opposite is true.2.4  The Process of Configuration CraftAfter the first addition of NaOH, it should be stirred for 25 + / 5min to have sufficient time to evenly expand and get the correct gelatinization temperature. If the gelatinization temperature is too low, some starch particles will overexpand, while some are not yet expanded, and the viscosity changes greatly, in this case, the amount of NaOH must be reduced. If the gelatinization temperature is too high, the viscosity will be decreased in the text of shear cut during the use, and the amount of NaOH needs to be increased. 3. Effect of Gelatinization Temperature on the Storage Performance of Starch GlueThe biggest defect of starch glue is that it is easy to corrupt and deteriorate, the storage period is short, the service performance is not stable, and the reason why is related to gelatinization temperature. When gelatinization temperature is low, it is easy to cause insufficient gelatinization reaction. The more complete the gelatinization reaction, the longer the storage time of the glue. If starch glue deteriorates during storage from 3 days to 6 months, the reason for the insufficient gelatinization reaction is that ungelatinized starch molecules are more susceptible to bacterial erosion than gelatinized starch molecules.4. Effect of Gelatinization Temperature on the Quality of Corrugated Board         When gelatinization temperature is too high, starch glue is not curing, flute tip paste is in white powder, resulting in poor bonding of linerboard, or linerboard loose, linerboard and corrugated medium seperate after preliminary adhesion. When a single-sided machine is running at high speed, continuous unbonded areas, usually spherical swelling, appear in the center of the single-sided web or on a substantial portion of the cross-sectional web, causing the board bubbled.Low gelatinization temperature makes board gelatinized before getting into heating plate , flute tips starch glue blackening and glistening, which cause linerboard in poor laminating. The gelatinization temperature is too high or too low, resulting in poor laminating of inner liner and its sheet edge , flute A and B; as well as in loose slitting edge single face blank linerboard and web edge single face blank.  5 . ConclusionAdhesion is one of the most critical processes in producing corrugated board, which has the greatest impact on the quality of board. The quality of adhesion ultimately depends on the quality of starch glue. Gelatinization temperature is one of the important indexes of starch glue, which directly affects the adhesive performance of corrugated board. Only with stable gelatinization temperature, the bonding quality of corrugated board can be guaranteed.  --If there is Copyright Dispute about the content, please Contact us to Delete. 

Function Analysis on Stacker in Multi-order stacking

Output conveyor belt in terms of cardboard specifications is an important part of the stacker, especially for E flute, aller flute or even B flute.Roller conveyor belt will cause the bottom of the cardboard movement that is called "cardboard move" or "elephant foot" phenomenon, especially when the cardboard warped downward.The wider the roll hole, the more serious the phenomenon.Therefore, conveyors and/or output conveyors usually use plate chain conveyors, plastic link conveyors, or even rollers covered by common conveyors to solve this problem.Vibration or impact board is usually located below the conveyor belt output, impact against the cardboard on the back baffle, so that the cardboard stacked neatly.Some suppliers also offer optional side baffles.When order changing, the rear baffle stacker is the main adjustment components.The position of the rear baffle can be adjusted according to the length of the board, and the rear baffle also defines the back edge of the stack.Since the purpose of stacking is to form a neat stack of cardboard, the design of all components of the stacker, its accessories and optional parts should be able to adjust and control the cardboard delivered from the cross cutter to the stacking place so that it is well aligned, regardless of whether a new stacking has been started or the order has been changed.At present, there is a cardboard stacker differential single device on the market, its characteristics are: the paper conveyor belt is grille shape, adjacent grille between the lower than the paper conveyor belt and the transfer of cardboard under the surface is not in contact with the paper acceleration belt;Paper conveyor belt and paper pushing acceleration belt are mutually spaced in the same direction;The outer side of the paper pushing acceleration belt is connected with the paper pushing convex and fixed, and is controlled by the speed control device of the conveyor belt, or stops moving and is in the state of reset, or accelerates synchronously with the paper feeding conveyor belt.The positive effect of the device is: Once the front cross cutter signals the number of sheets (or pieces) per piece of cardboard, the push feeding belt accelerating, pushing feeding crib bump with a specified points before the end of the last a piece of cardboard, cardboard slip back to prevent stated, and a specify the last piece of cardboard to accelerate before stacking, gapoccurs between the falling position of the first piece of cardboard after the stacking to achieve the purpose of accurate stacking count (or sheet).Refer to table 2 for analysis of stacker in multiple order stacking.Table2: Analysis of Stacker inMultiple OrderStackingIn addition, folding cardboard for large household appliances (such as refrigerators) and furniture transport can play a certain role in protecting.This folding board is continuously folded into piles, rather than cut into single pieces of cardboard.Carton factories in the industry are more likely to use scoring roll than crossing cutters to process folded cardboard.The scoring roll presses the line horizontally on the board to reach the specified length.The cardboard is delivered to the stacking site and then drops almost vertically into the stacking site.Place the cardboard horizontally and fold left and right alternately until it reaches the specified height or quantity.This operation is much slower and more complex than normal operations.  --If there is copyright dispute, please contact us to delete.

Five Points to Consider for Cardboard Factory When Purchasing Corrugator

Corrugator line purchase is generally divided into the whole line purchase, self-selection and upgrade purchase of the original equipment.The cardboard factory that purchases whole line often has relatively certain sales volume and long-term stable customer group.Self-selection is generally considered by cardboard factory who do not want to invest more money, but also want to get the corrugator line with good quality, price, performance. In this case, the purchase generally stems from the original corrugator line which has been unable to meet the needs of production or in order to reduce the risk of investment in the new plant, the corrugator line supplier will configure each parts according to the demand.Upgrade purchase of original equipment is generally the factory who do not want to buy new corrugator line.They may purchase two or three paper splicers to increase the average speed and production efficiency, or retrofit steam pipes to quickly replenish heat and reduce energy consumption, or acquire glue making equipment to improve the adhesion of cardboard.This way of purchasing has little impact on production, less capital investment and benefits can be seen in a short time.Corrugatorpurchase is a project features long life of equipment, relatively large investment.Cardboard factory should consider a supplier with good faith, timely after-sales service, reliable equipment performance, reasonable equipment price, good reputation when purchasing corrugator.In addition to listen to the introduction by suppliers,potential buyers should also do a field trip.Before deciding to buy, cardboard factory must do a full investigation.Investigate not only the product specifications and the main flute of the surrounding potential customers, providing the basis for the decision, but to understand the equipment status, management status and customer status of the peripheral compes.There are five main factors to consider when purchasing corrugator line: 1).Door width 2).The maximum speed 3). The product direction 4). The investment scale 5).The optimization direction.1.Corrugator Width Cardboard factory running corrugator line with the door width of 1800mm and below, the biggest advantage is that the base paper is easy to purchase, the second is the speed and cardboard production process is relatively easy to master.The price of all door width corrugator line is also relatively cheap, the price of standard configuration is about $850,000, it is suitable for all-scale development of cardboard factory, as well as food packaging as the leading products of cardboard factory.Small door width corugator line also has production and operation limitations.For example, the home appliance kind of carton generally required cardboard door width are wide.More than 1800mm door width of cardboard, all door width corrugator line can not be produced.Therefore, if the cardboard factory has the order of home appliance carton, it needs to consider the purchase of 2000mm-2200mm door width corrugator line.The door width of 2000mm-2200mm is the most conventional corrugator door width, the base paper of this door width is also relatively easy to purchase, the operation process is also relatively easy to master.2000mm-2200mm door width corrugator is the most mainstream one, it is suitable for the production of most cardboard production enterprises, the price of its standard configuration is between $110,000 to $1,400,000.                  Table 1:The use range of corrugator with different door widths When cardboard factory develop to a certain stage, the size of the enterprise expanded, and orders like large furniture, home appliances refrigerator are very much needed, this kind of carton requires larger door width, in this case it is necessary to consider the configuration of 2500mm door corrugator2500mm and above corrugator line is suitable for large-scale operation of the cardboard factory, the current standard configuration price of more than $1,700,000At present, the development of wide, high-speed, automatic corrugator line, improve the operating rates are the corrugated board industry trend.The corrugator line is developing towards a wide width. On the one hand, the width of the paper machine is getting wider and wider. The paper mills are already running 6m wide paper machines or even 10m wide paper machines.On the other hand, the advantages of corugator line in the broad width are lowering trimming loss, increasing production.When purchasing corrugator, considering the factor of the door width, cardboard factory should purchase corrugator with wider door width in the case of adequate budget and superb equipment operation level.2. The Maximum Speed The selection principle for the high-speed corrugator line should take into account the degree of automation of each single machine, meanwhile, factories should pay more attention to the overall corrugated board production line matching and coordination. For instance, equipped with automatic paper splicer (according to the linear velocity, choose a suitable speed of paper splicer, equipped with quantity according to their own economic conditions), the positive pressure card cartridge single facer (roll change convenient, stable running, high speed), the production control system, internal rising collet (in order to meet the demands of safety, must choose more brakes), automatic thin knife slitter (in order to facilitate rapid change orders, equipped with 2 sets), slitter equipped with three kinds of scoring roll (convex to concave, convex, convex to the flat), spiral crossing cutter, automatic glue making system, gluer (use of touch pressure roll rather than roller pressure).The number of double facer hot plate to match the speed of the corrugator line (the drying part using a spring-type hot plate, of course, the advantages and disadvantages of condensate steam trap must be valued) and so on.At present, most domestic suppliers can produce corrugator line with a maximum speed of 200m/min and below. The price of standard configuration is about $110,000.If the speed of 200m/min-300m/min is needed, then domestic excellent suppliers and suppliers of Taiwan brand can produce. The standard configuration price is relatively high, generally between $1,400,000 and$ 2,500,000.                Table 2:Corrugator Supply in the market under Different Speed  If 300m/min and above speed is required, the corrugator line produced by a few excellent suppliers in China and Taiwan can reach this speed. While the speed 300m/min and above produced by foreign suppliers has a wider range of models. In terms of production efficiency, the higher the speed corrugator line, the better.The higher speed means that the production of higher output, and the increase in unit output and efficiency will certainly reduce the paperboard production of coal, electricity and other unit consumption and other labor, financial and other costs.However, high-speed corrugator line has two points to focus.First,corrugator line speed is too high, the variable cost of paperboard production such as raw paper purchase costs will rise, because the high-speed assembly line often put forward special requirements on paper, such as tensile strength, moisture content.Second, the high production speed of cardboard quality and scrap rate of effective control is also a challenge.Because corrugator line must be supplied with a higher steam temperature to maintain a relatively high running speed, if temperature too low cardboard will be soft.And in the production state of high temperature, once there is a speed fluctuation will inevitably lead to cardboard bending up and down warping, resulting in a waste of brittle. At the same time, at high speed, if there are breaking paper and other circumstances, it will cause loss multiplied.Therefore, before the purchase of high-speed corrugator, cardboard factory in the raw paper purchase, operator skills and other aspects to make full preparation.3.Products Orientation Cardboard industry has two main product models, one is based on cardboard production, one is based on carton production.Those who mainly based on cardboard production, generally the volumes of order are relatively high, and more disorderly, short orders are taking too much, the production of each order is relatively all, but the total number of orders is very high.In this case, when purchasing corrugator line, we need to consider the automation of order change.Otherwise, the loss of each order will directly pull up the total loss.When purchasing corrugator, it is recommended to strengthen the configuration of rectifying deviation, automatic glue control, automatic paper splicing and production control system.Under normal circumstances, the speed of 250m/min, door width of 2.2m or 2.5m corrugator line, the price of standard configuration is about $2,412,000.Those who mainly based on carton production, in general, each order has large production, but the total number of orders is relatively all.This requirements for this mode of automatic control corrugator will be relatively low.The investment saved in the automatic control part of corrugator line is recommended to be used in the configuration of printing equipment.This production mode, corrugator standard configuration of the price will be relatively low, generally $1,714,000.Table 3: Major Points for Different models of corrugator line4.Investment Scale The investment scale in the cardboard factory below $7,000,000, it is recommended to configure the corrugator line below $2,200,000.This price of corrugator line can be produced by the most domestic excellent suppliers .Corrugator line with higher price will be much advanced in many aspects like al design, material, intelligence.Cardboard factory should be in accordance with the expected use of life to evaluate the cost of corrugator line.The investment scale between $7,000,000 and $15 million, it is recommended to configure $2,200,000 to $3,500,000 of corrugator line, and consider the best choice of cost performance within 8 years.Investment of more than $22.5 million cardboard factory, it is recommended to configure more than $4,300,000 corrugator line.This price of corrugator line though can be produced by the domestic excellent suppliers, it still mainly depends on imported corrugator brand.Whether it is domestic or foreign corrugator line, in the intelligent equipment, equipment life, etc., we should consider the best choice of cost performance within 15 years. Table 4: Major Points to configuration for Different investment scale corrugator5.Optimization OrientationSome suppliers in corrugator automation performance is flawed.It is understood that the production control system of some brands of corugator line is not compatible with the ERP system, which will have a bad impact on the future development of automation equipment.When purchasing corrugator line, we should possibly choose standard spare parts. If corrugator malfunctions, emergency measures will be well implemented.Now a lot of corrugator suppliers are doing very well in this regard, the use of spare parts are universal.When purchasing corrugator line, cardboard factory should also take into account enough space.Otherwise if to upgrade the corrugator line in the future, such as adding some additional s when upgrading five ply to seven ply, there is no enough space for single machine to put. So reserving enough space for the future equipment transformation of cardboard factory will be more convenient and easier to implement.Table 5: Different Optimization Orientation of Corrugator line--If there is copyright dispute,please contact us to delete.

Conveyor Purchase System and Process Technology

Since the 1980s, companies in the U.S., Japan and some Europe countries have often referred to improved conveyor as a "third source of profit".With the development of automation equipment, the improvement of conveyor system may be related to the revolution in management of enterprises, and will also affect the production efficiency of enterprises to a great extent.So, how to choose and buy a modern conveyor system to improve their competitiveness?1. Conveyor System This paper will talk about corrugated board production line on the conveyor system.In the whole corrugated board production line, in the process of processing all kinds of raw paper into corrugated board and carton, in addition to the cooperation of workers and corrugator equipment, it also need a very important process, that is, transportation, the raw paper, cardboard, waste paper and other transport to the corresponding equipment or location requires a lot of work.In the past, this part of the work is basically done by manual, but with the development of automation, corrugated board production line conveyor system has entered the era of automation.   Corrugated board production line conveyor system mainly includes the raw paper conveyor system, cardboard conveyor system and waste paper conveyor system.The following will do a detailed introduction to each part of corrugated line conveyor system.  1). Base paper conveyor system Base paper conveyor system refers to the transport system responsible for the base paper.There are three modes of base paper conveyor:The first is a single track in and out mode, that is, a paper cylinder with a track.Each track is both in and out of the paper, this mode of investment is minimal, but is not suitable for high-speed machine production operations.Because it takes time to wait while the base paper in and out, has to wait until the inside base paper feeding out, which does not meet the needs of modern high-speed production.As a result, this pattern is relatively rare.The second mode is that you have four tracks that don't go in and one vertical track.That is, these four tracks only into, the base paper from the other end of the longitudinal rail out, the base paper from the other end after a long longitudinal rail out of the direct transport to the base paper warehouse.This model is fast, but at the same time because it takes up a lot of space, so the investment is also large.Therefore, although the layout is the most reasonable, the investment is large.The third pattern is four in and one out.That is, four tracks are only responsible for the base paper feeding in, and another track is responsible for the base paper feeding out.This is to add a track rather than the use of longitudinal track mode, that additional track specifically to let the base paper out, the base paper generally will not come out together, so this mode is relatively better, and relatively less investment and speed.So this is a relatively economical and efficient model at present.2). Cardboard Conveyor SystemCardboard conveyor system is responsible for the cardboard transport system.Cardboard conveyor system is divided into the following two forms:The first is part conveyor. This form is applied to the cardboard conveyor that needs to be packaged after coming out of the hanging basket of the production line. This form mainly requires the configuration of a trolley and multiple packaging tracks, which are converted to pallet transportation after packing.The second is the complete conveyor, this form is applied to the place where the space is big enough, and not need to pack products .This form mainly requires the configuration of automatic ground rail and transport conveyor system, its advantages are high degree of automation, less operators, can greatly reduce labor costs.However, this kind of form requires a large site area and is inconvenient to package and requires a large investment.Cardboard conveyor often used in the equipment are: electric feeding trolley, electric rotary table, non-power roll (of course, there are also dynamic roll with motor), electric induction trolley (servo control can be used) and infrared induction equipment and caterpillar plastic link.3).Waste Paper Conveyor SystemWaste paper conveyor system refers to the transport system responsible for waste paper.In the transport of waste paper in general with trench conveyor belt to transport waste paper, but also can use suction type transport.In addition, automatic paper packaging can be used to reduce the workload of paper packaging.To improve the production efficiency of the whole factory, we must do a good job in every link.Timely disposal of waste paper is an important step to ensure the normal production of corrugated line.Waste paper baling machine is mainly composed of belt feeding, belt returning, joint connecting and cutting device, tranission system, rail frame and control device.As long as the paper is sent into the automatic paper baler, it can be automatically packaged, no manual work at all.  Trench conveyor belt Automatic waste paper baler 2.Factors to consider when purchase conveyor systemBefore purchasing conveyor system, let's understand the basic  of conveyor system.The three basic s of conveyor system, there are input, conversion and output.In the corrugator production process, the conveyor system should meet the following s:1. Fast and accurate, shorten the process time2.Save manpower and material resources3. Easy to manage and identify The biggest purpose of conveyor purchase system is to improve the efficiency of paper transportation.On the basis of not damaging the paper, accurately and quickly transfer the paper to the designated location, shorten the production time will maximize production efficiency.However, no matter what kind of conveyor system is equipped, it is a prerequisite to meet the production speed.If the machine is produced at a high speed, it needs to be equipped with a high-speed conveyor system. If the production itself is very slow, then the high-speed conveyor system will make the production more disordered and disorderly, which is not conducive to the improvement of production efficiency.In addition, the biggest advantage of modern conveyor system is that automation equipment replaces manual operations, which greatly saves labor costs and facilitates factory management and system identification.In some relatively all three-level carton factories in China, workers can still see the handling of raw paper or finished products, which not only takes up labor and reduces the production speed, but also has instability, which is not conducive to the manual management of the factory.In some foreign carton factories, workers can hardly be seen. In spacious factories, cardboard runs orderly on the conveyor belt, and workers only need to set some parameters to operate the system.Purchasing conveyor system is to make the factory work more convenient, fast, stable and save manpower and material resources as much as possible.Generally speaking, the following two aspects should be paid attention to when purchasing conveyor system:1. Selection of position control mode2. Selection of tranission modeFirst, to consider the choice of position control mode.Generally speaking, there are two main ways of position control: servo motor control and electronic eye recognition.Servo control is controlled by program, not easy to damage the cardboard, cardboard protection is the most stable, but its cost is relatively high.But the electric eye automatic induction generally applies in the automatic transportation conveyor to control the cardboard position, its price is cheap.But its installation needs to be higher than the conveying surface, easy to cause cardboard bump damage.(Refer to table 1)Table 1:Comparative analysis of position control modeThen we need to consider the tranission mode of conveyor system.Generally speaking, there are several tranission modes: plastic link, roller conveyor, conveyor belt and air suction.If the caterpillar plastic link is used to transfer the cardboard, the bottom layer of the cardboard does not need the backing plate is not easy to damage, but it is not easy to maintain, because sometimes even a all part of the broken will lead to the removal of the whole piece, and its price is higher.Relatively speaking, drum transport is cheap and easy to maintain, but it is easy to damage the bottom of the cardboard, so in the transport of cardboard need to add pad.Conveyance belts and air suction belts are generally used for the conveyance of waste paper. Conveyance belts are suitable for the conveyance of larger materials, while air suction belts are suitable for the conveyance of aller materials.(Refer to table 2)Table 2:Comparative analysis of tranission mode--If there is copyright dispute, please contact us to delete.

Treatment of Contaminants - Dioxins

Fundamental Data for Calculating the Quantities of Corresponding Class IDesignated Chemical Substances Released / TransferredIn general, the quantities of corresponding Class I Designated Chemical Substances released and transferred can be calculated using either the actual values or the measured values, as obtained by each company. However, in the event that these numeric values are difficult to determine, then it is acceptable to utilize either: industry average values, nominal values or the standard values set by machine manufacturers (the numeric values in red font), as listed in Table 6.(The particular values utilized must be clearly stated.)Table 6 Fundamental Data for Calculating the Quantities of Corresponding Class IDesignated Chemical Substances Released / TransferredNote: Actual quantities for each company must be utilized for the following: quantities of wastewater produced from other processes (m3 / day); quantities of materials handled (such as adhesives and ink); number of days of operation;and number of print color change operations. Dioxins[Calculation Procedures]①Annual quantity of dioxins in exhaust gases released= quantity of exhaust gases* × measured quantity of dioxins in exhaust gases ×number of daily hours operation × number of days operation②Annual quantity of dioxins in incinerated ashes transferred= quantity of incinerated ashes released × measured quantity of dioxins inincinerated ashes[Calculation Examples]<Input Data for Calculations>*TEQ: As a variety of different dioxins are produced, the quantity of dioxins has beenconverted tothetoxicequivalencespecifiedby2,3,7,8tetrachlorinateddibenzo-para-dioxin.<Calculation Results>①Annual quantity of dioxins in exhaust gases released= 1,180×2.0×10-6  × 8 × 20 × 12 = 4.53mg-TEQ / year②Annual quantity of dioxins in exhaust gases released= 21 × 10 6 × 1.1 × 10-6  = 23.1 mg - TEQ / year--If there is Copyright Dispute about the content, please Contact us to Delete.

Treatment of Contaminants - Ethylene Glycol

Fundamental Data for Calculating the Quantities of Corresponding Class IDesignated Chemical Substances Released / TransferredIn general, the quantities of corresponding Class I Designated Chemical Substances released and transferred can be calculated using either the actual values or the measured values, as obtained by each company. However, in the event that these numeric values are difficult to determine, then it is acceptable toutilize either: industry average values, nominal values or the standard values setby machine manufacturers (the numeric values in red font), as listed in Table 6.(The particular values utilized must be clearly stated.)Table 6 Fundamental Data for Calculating the Quantities of Corresponding Class IDesignated Chemical Substances Released / Transferred Note: Actual quantities for each company must be utilized for the following: quantities of wastewater produced from other processes (m3 / day); quantities of materials handled (such as adhesives and ink); number of days of operation; and number of print color change operations.Ethylene Glycol  Shown below are the flows for the release and transfer of ethylene glycol.Ethylene glycol is contained in the quick drying inks used during the conversion process and is present in wastewater subject to treatment. The quantities both released and transferred can be calculated by following the procedures described below.Figure 10 Flows for Ethylene Glycol Released and Transferred The methods used for the cleaning and final treatment of printers that utilize quick drying inks will vary, depending upon the characteristics of the inks and the specifications of each machine. Therefore, the various treatment methods are classified as shown in (1) - (3), below.(1) Wipe-off Method: used for conventional roll transfer type printers and conventional spray type printers. After excess ink has been wiped off the printers with waste cloths, the materials used for cleaning are disposed of as industrial waste.(2) Industrial Waste Treatment Method for Waste Liquids: the waste inks resulting from color change processes and the wastewater from ink clean up are stored indrums, then disposed of as industrial waste, as is.(3) Wastewater Treatment Method: the printing process utilizes washable quick drying inks. After wastewater is treated by a standard wastewater treatments ystem, the wastewater is separated into liquid wastewater and solid waste. Inthe event that an activated sludge treatment is performed as a tertiary treatment,then the wastewater will be fully broken down into water and carbon dioxide.Therefore, the quantity of ethylene glycol released will be "0". Annual quantity handled Annual quantity released or transferred [Calculation Procedures]①Quantity of ethylene glycol handled = annual quantity of quick drying inkhandled × ethylene glycol content②Wipe-off Method: quantity of ethylene glycol transferred in waste= quantity of waste per color / cleaning operation × number of daily color changes×number of days of operation③Industrial Waste Treatment Method for Waste Liquids: quantity of ethyleneglycol transferred in waste = quantity of waste per color / cleaning operation× number of daily color changes× number of days of operation④Wastewater Treatment Method: quantity of ethylene glycol released towastewater = quantity of waste per color / cleaning operation × number ofdaily color changes × number of days of operation [Calculation Examples]<Input Data for Calculations>Note: Figures in red font represent industry average values / nominal values-  Quantity of ink handled: 6,000 kg / year (wipe-off type: 3,500 kg / year)-  Ethylene glycol content: 30%-  Quantity of ink per disposal, per color: ② 350 g / disposal; ③ 50 g / disposal;④ 126 g / disposal-  Number of color changes: 40 changes / day (wipe-off type: 20 changes / day)-  Number of days of operation: 20 days × 12 months = 240 days / year<Calculation Results>①Quantity of ethylene glycol handled = 6,000 kg / year × 0.3 (3,500× 0.3) = 1,800 kg / year (1,050 kg / year)②Wipe-off Method: quantity of ethylene glycol transferred in waste = (350 /1,000 ) × 0.3 × 20 × 20 × 12 = 504 kg / year③Industrial Waste Treatment Method for Waste Liquids: quantity of ethyleneglycol transferred in waste = (50 / 1,000 ) × 0.3 × 40 × 20 × 12 = 144kg /year④Wastewater Treatment Method: quantity of ethylene glycol released towastewater = (126 / 1,000 ) × 0.3 × 40 × 20 × 12 = 363 kg /yearNote: In the event that the wastewater from procedure ④, above, receives tertiary treatment using an activated sludge treatment method, then complete decomposition would occur. Therefore, the quantity of ethylene glycolreleased would be determined as "0". If the wastewater is not treated using an activated sludge treatment method, then a slight amount of ethylene glycolwill be transferred along with the residual water, to the dehydrated waste(although most of the ethylene glycol is released to the wastewater itself).This miniscule quantity of transferred ethylene glycol is difficult to measureand is estimated as being only a few % of the entire quantity released.Therefore, for the purposes of the calculations above, the entire quantity ofethylene glycol is considered as being released to the wastewater, with none ofit being transferred to the dehydrated waste. --If there is Copyright Dispute about the content, please Contact us to Delete. 

Treatment of Contaminants - Toluene

Fundamental Data for Calculating the Quantities of Corresponding Class IDesignated Chemical Substances Released / TransferredIn general, the quantities of corresponding Class I Designated Chemical Substances released and transferred can be calculated using either the actual values or the measured values, as obtained by each company. However, in the event that these numeric values are difficult to determine, then it is acceptable to utilize either: industry average values, nominal values or the standard values set by machine manufacturers (the numeric values in red font), as listed in Table 6.(The particular values utilized must be clearly stated.)Table 6 Fundamental Data for Calculating the Quantities of Corresponding Class IDesignated Chemical Substances Released / Transferred Note: Actual quantities for each company must be utilized for the following: quantities of wastewater produced from other processes (m3 / day); quantities of materials handled (such as adhesives and ink); number of days of operation; and number of print color change operations. Toluene   Figure 8 Flows for Toluene Released  The flow of toluene released from joint adhesives used during the conversion process is the same as the flow of xylene described in section 2, above). Annual quantity handled Annual quantity released or transferred [Calculation Procedures]①Annual quantity of toluene handled=②Quantity released to atmosphere = Annual quantity of joint adhesive handled × Toluene content[Calculation Examples]<Input Data for Calculations>Annual quantity of joint adhesive handled: 22,000 kg / yearToluene content in joint adhesive: 5%<Calculation Results>①Annual quantity of toluene handled = 22,000 kg / year × 0.05 = 1,100 kg / year=1.1 t / year②Quantity of toluene released to atmosphere = 22,000 kg / year × 0.05= 1,100 kg / year = 1.1 t / year --If there is Copyright Dispute about the content, please Contact us to Delete

Treatment of Contaminants - Xylene

Fundamental Data for Calculating the Quantities of Corresponding Class IDesignated Chemical Substances Released / TransferredIn general, the quantities of corresponding Class I Designated Chemical Substances released and transferred can be calculated using either the actual values or the measured values, as obtained by each company. However, in the event that these numeric values are difficult to determine, then it is acceptable to utilize either: industry average values, nominal values or the standard values set by machine manufacturers (the numeric values in red font), as listed in Table 6.(The particular values utilized must be clearly stated.)Table 6 Fundamental Data for Calculating the Quantities of Corresponding Class IDesignated Chemical Substances Released / Transferred Note: Actual quantities for each company must be utilized for the following: quantities of wastewater produced from other processes (m3 / day); quantities of materials handled (such as adhesives and ink); number of days of operation; and number of print color change operations. Xylene  Shown below are the flows for the xylene released. Xylene is contained in the joint adhesives used during the conversion process and is also used as an additive for boiler fuel. The quantity released can be calculated by following the procedures described below. Figure 7 Flows for Xylene Released  [Calculation Procedures] Annual quantity handled Annual quantity released or transferred ①Annual quantity of xylene handled= annual quantity of kerosene handled × density × xylene content + annual quantity of joint adhesive handled × xylene contentNote: 99.5% of xylene contained in kerosene is decomposed through combustion.The entire quantity of xylene contained in joint adhesives for combining is released to the atmosphere during the drying process.②Quantity of xylene released to atmosphere = Quantity of xylene in kerosene ×+ non-decomposition rate + annual quantity of joint adhesives handled ×xylene content[Calculation Examples]<Input Data for Calculations>  <Calculation Results>①Annual quantity of xylene handled = 9,240* + 22,000 × 0.05 = 10,340 kg②Quantity of xylene released to atmosphere = 9,240 × 0.005 + 22,000 kg / year× 0.05= 1,146 kg / year--If there is Copyright Dispute about the content, please Contact us to Delete. 

Treatment of Contaminants - Borax

Fundamental Data for Calculating the Quantities of Corresponding Class IDesignated Chemical Substances Released / TransferredIn general, the quantities of corresponding Class I Designated Chemical Substances released and transferred can be calculated using either the actual values or the measured values, as obtained by each company. However, in the event that these numeric values are difficult to determine, then it is acceptable to utilize either: industry average values, nominal values or the standard values set by machine manufacturers (the numeric values in red font), as listed in Table 6.(The particular values utilized must be clearly stated.)                        Table 6 Fundamental Data for Calculating the Quantities of Corresponding                  Note: Actual quantities for each company must be utilized for the following: quantities of wastewater produced from other processes (m3 / day); quantities of materials handled (such as adhesives and ink); number of days of operation;and number of print color change operations.Borax*1 : Borax shall be calculated using Na2B4O7?10H2O (boron content: 11.3%) asstandard. When utilizing either Na2B4O7?5H2O (boron content: 14.8%) or boric acidH3BO3 (boron content: 17.5%), conversion to borax Na2B4O7?10H2O (boron content: 11.3%) must be performed, in accordance with the formulae shown below. Na2B4O7?10H2O= (14.8 / 11.3) ×Na2B4O7?5H2O (borax)Na2B4O7?10H2O= (17.5 / 11.3) ×H3BO3(boric acid) Example:  If 4 tons of boric acid (H3BO3) and 5 tons of borax have been handled, then what is the total quantity of boron handled? Conversion of boric acid to borax: Na2B4O7?10H2O = (17.5 / 11.3) ×H3BO3(boric acid)= 1.55 × 4t = 6.2t Thus, 4 tons of boric acid is equivalent to 6.2 tons of borax. Therefore; after conversion, the quantity of borax equivalent is calculated as: 5t + 6.2t = 11.2 tand the total quantity of boron handled is calculated as: 11.2t × 0.113 = 1.266t= 1,266 kg. *2: Regarding Boron Content in Wastewater after Wastewater Treatment has beenPerformed (reference)- The effluent standard specified by the Water Pollution Control Law: boron content in wastewater shall be no more than 10mg/l.- Example of boron measurement at a corrugated packaging manufacturer (total quantity of wastewater discharged during manufacturing processes: 10m3/day):Over the weekend, the wastewater derived from the cleaning of glue vats was13combined with wastewater derived from the clean up of ink. Flocculants and similar coagulating agents were then added to this mixture at the beginning of he subsequent week. Lastly, the sludge within this mixture was separated out through pressure floatation and filter press techniques. The wastewater was analyzed and the boron content was found to range between 1.8-7.8mg/l, with an average concentration of 4.4 mg/l.- Normally, the wastewater derived from the clean up of ink is discharged every time that the ink color is changed, during printer operation. However, glue vat sand other parts of the corrugator are cleaned no more than once a day, even at factories that perform frequent cleaning. Factories that do not perform frequent cleaning may clean these parts only once each week. During these thorough cleaning operations, overall boron concentrations are greater due to the discharge of wastewater that contains laminating glue. Therefore, this example of actual quantities measured shows a situation in which wastewater containing a significant amount of laminating glue was discharged. Therefore, with consideration for previous examples of actual measured concentrations, it is estimated that annual average boron concentrations will actually be approximately 1-2mg / l, which is less than one-half of the average concentration measured in this example.- Precautions Prior to SamplingThe actual concentration of boron can vary greatly, depending upon the adhesives for combining content of the wastewater derived from clean up operations. Therefore, it is desirable to preset the effluent condition standards, then to perform 2 – 3 point sampling in chronological order. *3: Regarding the Decomposition Rate of Xylene in Combustion Equipment (such as boilers)- The process of combustion will cause 99.5% of the xylene present to decompose into water and carbon dioxide. The remaining 0.5% is noted composed and is released unchanged to atmosphere. (Cited from page 241 inthe "Manual for Estimating Quantities of Released and Transferred Chemical Substances" prepared by the Ministry of Economy, Trade and Industry and the Ministry of the Environment, in March 2001.)Note: Actual quantities for each company must be utilized for items that are noted scribed, including: quantities of wastewater produced from other processes(m3/day); quantities of materials handled (such as adhesives and ink); number of days of operation; and number of print color change operations.number of days of operation; and number of print color change operations.  1) Boron and its compounds - Figure 6 depicts the flows involved with the release and transfer of boron contained within adhesives for combining, during the processes of glue making, combining and wastewater treatment. The quantities of boron released and transferred can be calculated by following the procedures described below.- The borax utilized in these processes (i.e., boron and its compounds) reacts with caustic soda to produce sodium borate, which itself reacts with starch to form borate ester. As well, when boric acid is utilized, it reacts with caustic soda to produce borax. Thus, boron is transformed into a variety of chemical compounds, depending upon the processes in which it is utilized. However, for calculating the quantities released and transferred, the overall quantity should be understood in terms of the mass of elemental boron.- With respect to boron, the amount that will eventually be discharged into raw wastewater is equivalent to the difference between the quantity handled and the quantity shipped out in the form of finished product and corrugated waste. The wastewater treatment process then separates the raw wastewater into wastewater (treated water) and waste. Measurements are then performed to calculate the quantity of boron in the wastewater (treated water). The quantity of boron transferred in waste is equivalent to the difference between the quantity of boron discharged into raw wastewater and the quantity of boron measured in the wastewater (treated water).                                                         Figure 6 Boron Release / Transfer Flows *1 Containerboard combining process*2 Containerboard*3Adhesives forcombining [Calculation Procedures]                                      Annual quantity handled Annual quantity released and transferred ①Annual quantity of boron handled = annual quantity of borax handled ×boron content②Quantity of boron in the product = production volume of corrugated boards×quantity of adhesives for combining applied × borax content of adhesives for combining × boron content of borax③Quantity of boron in corrugated waste = quantity of corrugated waste sold ÷average basis weight * × quantity of adhesives for combining applied ×borax content of adhesives for combining × boron content of borax④Quantity of boron in raw wastewater (untreated) released to the wastewater treatment process = ①-(②+③+⑦)⑤Quantity of boron released to bodies of water = quantity of boron in wastewater released from the wastewater treatment process = measured quantity × quantity of water released.⑥Quantity of boron in the sludge discharged from the wastewater treatment process = ④-⑤.⑦Quantity of boron in glue balls = quantity of glue balls produced× solids content × number of days of operation× borax content of adhesives for combining × boron content of borax⑧Quantity of boron transferred in waste =⑥+⑦ 1) Boron and its compounds - Figure 6 depicts the flows involved with the release and transfer of boron contained within adhesives for combining, during the processes of glue making, combining and wastewater treatment. The quantities of boron released and transferred can be calculated by following the procedures described below.- The borax utilized in these processes (i.e., boron and its compounds) reacts with caustic soda to produce sodium borate, which itself reacts with starch to form borate ester. As well, when boric acid is utilized, it reacts with caustic soda to produce borax. Thus, boron is transformed into a variety of chemical compounds, depending upon the processes in which it is utilized. However, for calculating the quantities released and transferred, the overall quantity should be understood in terms of the mass of elemental boron.- With respect to boron, the amount that will eventually be discharged into raw wastewater is equivalent to the difference between the quantity handled and the quantity shipped out in the form of finished product and corrugated waste. The wastewater treatment process then separates the raw wastewater into wastewater (treated water) and waste. Measurements are then performed to calculate the quantity of boron in the wastewater (treated water). The quantity of boron transferred in waste is equivalent to the difference between the quantity of boron discharged into raw wastewater and the quantity of boron measured in the wastewater (treated water).             Table 7 Quantities of Boron Released / Transferred for Each Method of Wastewater Treatment     [Calculation Examples]<Input Data for Calculations>Note: Figures in red font represent industry average values/nominal values-  Production volume of corrugated boards: 49,000,000 m2 / year-  Quantity of corrugated waste sold: 3,000 t / year = 3,000,000 kg / year-  Average basis weight: 647g / m2 = 0.647kg / m2-  Annual quantity of borax (Na2B4O7?10H2O) handled: 10,000 kg / year-  Boron content: 11.3%-  Quantity of  adhesives for combining applied: 9g / m2 = 0.009kg / m2-  Borax content of  adhesives for combining : 2%-  Quantity of glue balls produced: 12 kg / day-  Solids content of glue balls: 35%-  Number of days of operation: 20 days × 12 months / year-  Quantity of clean up water discharged: 10m3 / day-  Wastewater treatment facility: pressure floating + filter press method-  Released to: bodies of water-  Quantity of boron in treated wastewater: 4.4mg / l = 0.0044kg / m3 <Calculation Results>①Annual quantity of boron handled = 10,000 kg / year × 0.113 = 1,130 kg / year(Annual quantity of borax handled × boron content)②Quantity of boron in the product (corrugated boards) = 49,000,000 m2  / year ×0.009kg / m2 × 0.02 × 0.113 = 996.7kg / year(Production volume of corrugated boards × quantity of adhesive applied × borax content of adhesives for combining × boron content of borax)③Quantity of boron in corrugated waste= 3,000,000kg / year ÷ 0.647kg / m2 × 0.009kg / m2 × 0.02 × 0.113= 94.3kg / year(Quantity of corrugated waste sold ÷ basis weight × quantity of adhesive applied × borax content of adhesives for combining× boron content of borax)④Quantity of boron in raw wastewater released to the wastewater treatment process= 1,130-(996.7 + 94.3 + 2.3) = 36.7kg / year{①-(②+③+⑦)}⑤Quantity of boron released to bodies of water=quantity of boron in wastewater released to bodies of water from the wastewater treatment process= 0.0044 kg / m 3  × 10 m 3  / day × 240 days = 10.6 kg / year(Measured quantity × quantity released (daily output × number of days ofoperation))⑥Quantity of boron in the sludge discharged from the wastewater treatment process = 36.7-10.6= 26.1 kg / year(④-⑤)⑦Quantity of boron in glue balls = 12kg / day × 0.35 × 240days / year ×0.02 × 0.113 = 2.3kg / year(Quantity of glue balls produced × solids content × number of days of operation × borax content of adhesives for combining × boron content of borax)⑧Quantity of boron transferred in waste = 26.1kg / year + 2.3kg / year= 28.4kg / year(⑥ +⑦) --If there is Copyright Dispute about the content, please Contact us to Delete.