The current state of the corrugated industry is a future direction in which management needs to determine production targets, quality improvement and waste reduction, so the industry has to pay more attention to details. The carton factory currently has three support stands: one for the sales carton, one for the production of the carton, and the other for the maintenance of the machine. Removing any one of them will cause a chain reaction that will cause everything to collapse. The current problems faced by the carton factory are excessive waste; frequent flow of operators; high density of base paper and low fiber content; production trends are lightweight basis papers, micro-corrugated cardboard, wheat pulp paper, and higher-level training. Increased quality requirements; and high-speed machinery for carton plants and end-users, any failure will pay a high production cost. The more serious problems are: the incorrect view of the operation of the corrugated board production line; the operation of the corrugated board production line is more complicated than its first appearance; a new generation of operators is learning to operate the corrugated board production line from the old workers. And lack of standardization in production.
The corrugated cardboard production line not only serves as the heart of the carton plant, but it is also the quickest place to reduce waste, but it is not currently automated in the wet area. The previous design speed of a corrugated cardboard production line was approximately 35 to 210 meters per minute—the ratio of speed gaps was 1:6.
Heat and starch
The heat transfer is inversely proportional to the production speed of the corrugated board production line, so sometimes the difference in heating of the same starch paste glue on different corrugated board production lines by the carton factory is up to six times. The nature of starch production used by food starch and cartons is the same. Therefore, as with the processing of starch, we should use special equipment to measure and control the starch heating process on the corrugated board production line. The temperature control of corrugated industrial base paper is very important. If we cook our food six times as often, then we get wood charcoal and we can't eat it at all. If we deal with starch, like charcoal, how can we produce high-quality corrugated board? On three-layer corrugated paperboard, the minimum weight of paper for three-layer corrugated cardboard is generally 1.6 g/m2. After adding starch paste, the weight of paperboard is 2 g/m2. When producing highly absorbent core paper or using water-resistant starch, the weight of the paperboard will be very different. In the corrugated industry, the consumption of starch paste includes:
Current process limitations
The production speed of corrugated board production line is too wide;
As a "shock absorber" during heating, the starch is used too much.
Excessive starch may cause problems:
The cardboard is too soft and the water is too much;
Thermal stress limits the speed of production;
Layering of paperboard paste adhesive;
"Laundry" phenomenon - increasing the difficulty of printing;
As time goes by, the board warps;
Product image is wrong.
Factors associated with excessive use of starch include:
Low maintenance work quality;
The quality of the base paper is low;
Inconsistent steam supply Insufficient operator training Reduce profit
temperature control
The temperature control of the base paper on the corrugated cardboard production line includes: the noodle paper entering the single-sided machine; the single-sided paper web and the double-sided noodle paper entering the hot plate section; and the external noodle paper leaving the double-face paper. Temperature plays an important role in the production of cardboard.
The basic principle of using electronic control
Reliability - Electronic controls can do a lot of repetitive work and never get bored;
Instantaneousness - Electronic controls can respond immediately to problems that arise in production;
High speed - When the operator does not have enough time to complete the task, he will have to reduce the production speed. Electronic control can save time for the operator: it can complete a large number of operations at the same time and complete a series of operations in accordance with the correct steps each time;
Accuracy - A well-designed electronic control system will provide more accurate measurements and more consistent adjustments than the same operator.
The electronic control system can record, recall and use the variables in the process repeatedly. The electronic control system can avoid input errors and can accomplish tasks that an operator cannot and cannot accomplish.
The electronic control system can control the gap between the paste roller and the squeegee roller on the existing and new single-sided machines, adjust the other mechanical devices, monitor the thermal coupling of the steam valve, and complete the control of the load layout on the hot plate and the hot plate. The adjustment of the steam pressure on the part is suitable for the production trend of light basis heavy base paper and microvar. Use of electronic controls to ensure reliable cardboard bonding, low contact area high-strength bonding, better printing surface, elimination of overheated or underheated starch paste, elimination of corrugation cracking during crimping and enabling ISO9002 The standardization of the production process. At the same time, the electronic control system guarantees the standardization of the operation process and the training of the operating team is simpler. More importantly, the quality of the paperboard is improved: the compressive strength of the paperboard; the perfect printing surface; the reduction of warpage of the paperboard and the better appearance of the carton, and the production speed: the production speed of the corrugated board production line is increased by 10%. The production speed is increased by 10% while reducing clogging.
Corrugated paperboard production lines often suffer from web pick-ups. The lower the corrugated paperboard production line speed, the more frequent the frequency of paper web pick-up occurs. This is caused by the overheating of the web. Eliminating overheating of the web will therefore reduce web squeezing. With proper heat control, the trimming of the web will be reduced. The smaller the margin of paper repair, the more profitable the carton plant means. Other advantages include the automatic recall and use of integrated production variables, and the system warns the operator if the process is out of control due to steam or tension problems. The use of an electronic control system will provide a rapid return on investment for the carton plant – converting the packaged waste into cardboard for sale, for example: the weight of the carton (tons) - the weight of the packaged waste (tons) X tons/year X1% = minimum savings.
Ways to reduce the amount of glue
Install a modern airbag system on the hot plate to increase heat transfer while reducing crushing at the edge of the paperboard;
Repair the mechanical state of the glue supply device;
Install cardboard upturn detection device to improve the protection of glue system;
Do not use starch paste to correct board warpage;
Preparation of starch paste glue standardization;
Buy or use an optical principle thermometer;
Choose the base paper roll with the appropriate moisture content;
Check the gap and parallel state of the paste roller;
Use "LOCK-TITE" - to avoid loose and machine damage;
The whole plant is clean - very important;
Purchase synchronous speed control system at single-sided machine;
The iodine test is often used to detect the state of the paste roller;
Ensure good communication between wet and dry operators: Radio or perfect signal system.
Source: Steve Schmidt
The corrugated cardboard production line not only serves as the heart of the carton plant, but it is also the quickest place to reduce waste, but it is not currently automated in the wet area. The previous design speed of a corrugated cardboard production line was approximately 35 to 210 meters per minute—the ratio of speed gaps was 1:6.
Heat and starch
The heat transfer is inversely proportional to the production speed of the corrugated board production line, so sometimes the difference in heating of the same starch paste glue on different corrugated board production lines by the carton factory is up to six times. The nature of starch production used by food starch and cartons is the same. Therefore, as with the processing of starch, we should use special equipment to measure and control the starch heating process on the corrugated board production line. The temperature control of corrugated industrial base paper is very important. If we cook our food six times as often, then we get wood charcoal and we can't eat it at all. If we deal with starch, like charcoal, how can we produce high-quality corrugated board? On three-layer corrugated paperboard, the minimum weight of paper for three-layer corrugated cardboard is generally 1.6 g/m2. After adding starch paste, the weight of paperboard is 2 g/m2. When producing highly absorbent core paper or using water-resistant starch, the weight of the paperboard will be very different. In the corrugated industry, the consumption of starch paste includes:
Current process limitations
The production speed of corrugated board production line is too wide;
As a "shock absorber" during heating, the starch is used too much.
Excessive starch may cause problems:
The cardboard is too soft and the water is too much;
Thermal stress limits the speed of production;
Layering of paperboard paste adhesive;
"Laundry" phenomenon - increasing the difficulty of printing;
As time goes by, the board warps;
Product image is wrong.
Factors associated with excessive use of starch include:
Low maintenance work quality;
The quality of the base paper is low;
Inconsistent steam supply Insufficient operator training Reduce profit
temperature control
The temperature control of the base paper on the corrugated cardboard production line includes: the noodle paper entering the single-sided machine; the single-sided paper web and the double-sided noodle paper entering the hot plate section; and the external noodle paper leaving the double-face paper. Temperature plays an important role in the production of cardboard.
The basic principle of using electronic control
Reliability - Electronic controls can do a lot of repetitive work and never get bored;
Instantaneousness - Electronic controls can respond immediately to problems that arise in production;
High speed - When the operator does not have enough time to complete the task, he will have to reduce the production speed. Electronic control can save time for the operator: it can complete a large number of operations at the same time and complete a series of operations in accordance with the correct steps each time;
Accuracy - A well-designed electronic control system will provide more accurate measurements and more consistent adjustments than the same operator.
The electronic control system can record, recall and use the variables in the process repeatedly. The electronic control system can avoid input errors and can accomplish tasks that an operator cannot and cannot accomplish.
The electronic control system can control the gap between the paste roller and the squeegee roller on the existing and new single-sided machines, adjust the other mechanical devices, monitor the thermal coupling of the steam valve, and complete the control of the load layout on the hot plate and the hot plate. The adjustment of the steam pressure on the part is suitable for the production trend of light basis heavy base paper and microvar. Use of electronic controls to ensure reliable cardboard bonding, low contact area high-strength bonding, better printing surface, elimination of overheated or underheated starch paste, elimination of corrugation cracking during crimping and enabling ISO9002 The standardization of the production process. At the same time, the electronic control system guarantees the standardization of the operation process and the training of the operating team is simpler. More importantly, the quality of the paperboard is improved: the compressive strength of the paperboard; the perfect printing surface; the reduction of warpage of the paperboard and the better appearance of the carton, and the production speed: the production speed of the corrugated board production line is increased by 10%. The production speed is increased by 10% while reducing clogging.
Corrugated paperboard production lines often suffer from web pick-ups. The lower the corrugated paperboard production line speed, the more frequent the frequency of paper web pick-up occurs. This is caused by the overheating of the web. Eliminating overheating of the web will therefore reduce web squeezing. With proper heat control, the trimming of the web will be reduced. The smaller the margin of paper repair, the more profitable the carton plant means. Other advantages include the automatic recall and use of integrated production variables, and the system warns the operator if the process is out of control due to steam or tension problems. The use of an electronic control system will provide a rapid return on investment for the carton plant – converting the packaged waste into cardboard for sale, for example: the weight of the carton (tons) - the weight of the packaged waste (tons) X tons/year X1% = minimum savings.
Ways to reduce the amount of glue
Install a modern airbag system on the hot plate to increase heat transfer while reducing crushing at the edge of the paperboard;
Repair the mechanical state of the glue supply device;
Install cardboard upturn detection device to improve the protection of glue system;
Do not use starch paste to correct board warpage;
Preparation of starch paste glue standardization;
Buy or use an optical principle thermometer;
Choose the base paper roll with the appropriate moisture content;
Check the gap and parallel state of the paste roller;
Use "LOCK-TITE" - to avoid loose and machine damage;
The whole plant is clean - very important;
Purchase synchronous speed control system at single-sided machine;
The iodine test is often used to detect the state of the paste roller;
Ensure good communication between wet and dry operators: Radio or perfect signal system.
Source: Steve Schmidt
Silicone Suction Lid,Flexible Silicone Lid,Silicone Cup Lids,Silicone Pot Lid
Feiaoda Technology Co., Ltd. , http://www.szkitchensilicone.com