ZERO DEFECTS GROUP 2010 - TAPPI · Cushioned Cars verses Rigid Cars • Cushioned cars have a built...

ZERO DEFECTS GROUP 2010:

Eric Yergeau - Cascades SPG

Kirk Kind – Pregis

Tim Olson – Multi-Wall

Wes Montague - ITW

Danelle Ramsey – Newpage

HONEYCOMB…The Right Product for the Right ApplicationHONEYCOMB…The Right Product for the Right Application

Railcar Inspection and Preparation

Railcar Quality Awareness

• It is the railroad’s responsibility to supply cars which are clean, have sound roofs, sides and square end walls, smooth floors and snug fitting doors.

• The shipper has the responsibility to inspect interiors of cars to see that they are suitable to carry lading safely and damage-free.

• Any exception is cause for rejection.

No visible holes that would allow outside elements  to enter car and damage the paper

Equipment Inspection ‐Water

Equipment Inspection

Reject any temporary patches

Inspect door seals – reject any that do not seal properly 

Equipment InspectionClean – no debrisNo protuding nails or objects

Sweep equipment and remove any debris

Equipment Inspection

Bowed walls? Severely Bowed walls?Remove steel straps from doorposts or sidewalls prior to loading

Leaving steel straps in cars –leading to roll damage

How to home‐shopa damaged railcar

Contact your local rail carrier and ask them to homeshop the railcar.Provide them with an accurate description of what the 

problem is and where it’s located in the car.The railroad will then place billing on the car to return 

it to its owner.The car will not be permitted to carry any freight until 

the owner acknowledges the issue and it is fixed.If possible, please circle problem area on trailer/car 

with a permanent marker. Include notation and date as well

“Home‐shop” is a term the rail industry uses to describethe process of reporting a damaged railcar. If you receive adamaged railcar:

Cushioned Cars verses Rigid Cars

• Cushioned cars have a built in shock absorbing system in the undercarriage of the car.

• Rigid cars have no force dampening system.

• A 15 inch cushioned car can reduce a 4G force to 1G.

• That means – 3G’s of force that is not allowed to go into the paper.

• Fine Paper, Newsprint, and Printing paper should only be loaded in cushioned cars.

The Right Product for the Right Application!

Wall Protector

HONEYCOMB…The Right Product for the Right ApplicationHONEYCOMB…The Right Product for the Right Application

Railcar Container Truck

Improves squaring of bowed sidewalls and protects fromwall’s defects.

• Reduce chaffing and scuffing

• Reduce flat spot

• Reduce usage of void filler

• Prevent spinning by increasing contact surface with the roll

Wall Protector

HONEYCOMB…The Right Product for the Right ApplicationHONEYCOMB…The Right Product for the Right Application

Critical

Critical

Contact surface optimisation

Pressure from the airbag

HONEYCOMB…The Right Product for the Right ApplicationHONEYCOMB…The Right Product for the Right Application

Wall Protector

HONEYCOMB…The Right Product for the Right ApplicationHONEYCOMB…The Right Product for the Right Application

Raising the wall pad six inches off the floor will reduce the pressure point at the floor level. Wall pads should be one inch thick and a strong cell. Pads with over 55 psi crush are best.

Critical

Critical

Contact surface optimisation

Pressure from the airbag

HONEYCOMB…The Right Product for the Right ApplicationHONEYCOMB…The Right Product for the Right Application

Wall Protector

HONEYCOMB…The Right Product for the Right ApplicationHONEYCOMB…The Right Product for the Right Application

Riser Block

There are different types of risers on the market for differentapplications:

Stick: Cannot be stack and need proper qty for different roll weight.

Square: Different size for different diameter.(Optimisation of surface and stability)

Octogonal: Stability. Rising in the doorway.

Round: Stability. Rising in the doorway

HONEYCOMB…The Right Product for the Right ApplicationHONEYCOMB…The Right Product for the Right Application

Riser Block

Riser Block

Square Octogonal RoundRiser Stick

HONEYCOMB…The Right Product for the Right ApplicationHONEYCOMB…The Right Product for the Right Application

Riser Block

Breaking the Strata Line

6’’ riserDifferent width rolls

HONEYCOMB…The Right Product for the Right ApplicationHONEYCOMB…The Right Product for the Right Application

Riser Block

Block minimum of 6’’with strapping.

In compliance with AAR regulations

HONEYCOMB…The Right Product for the Right ApplicationHONEYCOMB…The Right Product for the Right Application

Riser Block

Block 50% width of second layer rolls.

HONEYCOMB…The Right Product for the Right ApplicationHONEYCOMB…The Right Product for the Right Application

In compliance with AAR regulations

Riser Block

Optimisation of airbags efficiency(S.O.C) for small diameter roll in vertical position.

Optimisation of the stability whencombined with void filler

HONEYCOMB…The Right Product for the Right ApplicationHONEYCOMB…The Right Product for the Right Application

Buffer Pads

Void Filler

HONEYCOMB…The Right Product for the Right ApplicationHONEYCOMB…The Right Product for the Right Application

• Void fillers are used to fill voidswhen roll diameters vary.

• Never put a void filler in direct contact with an airbag. Except for vertical usage.

• Manufactured to covered a maximum of contact surface.

Void Filler

HONEYCOMB…The Right Product for the Right ApplicationHONEYCOMB…The Right Product for the Right Application

HONEYCOMB…The Right Product for the Right ApplicationHONEYCOMB…The Right Product for the Right Application

Void Filler

Positioning Examples

Correct Methods of Intermodal Shipping Loading Method E

Intermodal approved StrappingNon Metallic Strapping

• Better known as Plastic cord strapping.

• Must use one of approved products and it must be marked with the Strap ID.

• Typical 1.25” wide with ASTM type 1A-Grade 4 or 1.5” wide with ASTM type 1A-Grade 5

• Must have minimum break strength of 3,285 lbs. Joined strapping is to have minimum of 2,135 Lbs of break strength.

• It is important the the buckle be applied properly. Use strap hangers or tape while staging to maintain proper strap position.

Polyester Plastic• 5/8 x 0.040 ASTM Type IV• Heat Seal must be used w/joint

strength of 900 Lbs.• Minimum break strength of

1,200 Lbs with a joint strength of 900 Lbs minimum break strength

• Strap must also be clearly marked with the strap I.D.

Rubber Matting• 3mm thick on all

loading methods and 2mm thick on select loads approved?

• Follow exact mat roll loading requirments to the diameter of load and method number.

• Roll Width is required to be 2’, 3’, or 4’depending on loading method.

• Cannot Reuse rubber mats if they have been torn or damaged.

• Depending on load mat overhang behind rolls is required to meet or exceed 8”.

• Mats must be AAR approved. In question contact the AAR or refer to the Intermodal Loading Guide

50” diameter loading methods

58” diameter loading drawing

Nose block, Void Fillers

• If three rolls in the nose of the trailer it is imperative to center the first roll into the nose and block it from side to side.

• Materials can be Honeycomb, Corrugated, and Lumber as approved methods.

• It is also important that on all loads a minimum of 3’ void is required between the lading and the trailer door.

• Void Fillers can also be used at the sides of the container as a method of tightening the load. This can save many Roll Headers in 1-1 offset loading patterns.

Cut sheet or Palletized flat stock

Product Performance ProfileProduct Performance Profileforfor

Pneumatic Pneumatic DunnageDunnage

TAPPI Shipping, Receiving and Warehousing April 2010

Levels 2Levels 2--55

• Level 2 - Intended for Loads Less Than

75K.

• Level 3 - Intended for Loads 75K – 160K

• Level 4 - Intended for Loads 160K –

205K.

Performance LevelsPerformance Levels• Level 5

– Pneumatic Dunnage used as Lengthwise Void Fillers in Horizontal Application Between Concave Surfaces.

• Level 4– The following railroads have agreed to allow Level 4 air Bags to

be used in horizontal application in rolls of paper in boxcars.

– BNSF– CN– CSX– NS– UP– KCS

Level 5 FOR HORIZONTAL APLICATION. Max void allowable in rail shipment is 12” not 18”. 18” void for verification test only. Most of RRs allow Level 4 bag in horizontal applications.

Placement of AirbagsPlacement of Airbags

• Airbag should cover 2/3 of the load height when used in horizontal or vertical position

• Level 4 & 5 Operating pressure is between 8-10 PSI.

• Level 4 & 5 up to 205,000 lb loads for most carriers.

AIR BAGSAIR BAGSAIR BAGS

Side ViewVertical Air Bag

Top View Horizontal Air Bag

Airbags

Peanut Shape!

Air pocket

Center line

Bags to support each layer

Use the proper technique to reduce risk of damage on the roll.

HONEYCOMB…The Right Product for the Right ApplicationHONEYCOMB…The Right Product for the Right Application

Thoughts on Success

• "Every successful enterprise requires three men – a dreamer, a businessman, and a son-of-a-bitch." – Peter McArthur

"Few great men would have got past personnel." – Paul Goodman...