56668158 Training BHS

7UDLQLQJ0DQXDOIRU

%+6&RUUXJDWRU

Training Manual

01.10.1997 1

1. &RQWHQW

7\SHRIPDFKLQHV FKDSWHUSDJH

HVFULSWLRQRI(TXLSPHQW FKDSWHUSDJH *HQHUDOHVFULSWLRQRI&RPSRQHQW

)XQFWLRQDO3ULQFLSOH

6DIHW\

3URFHVV.QRZOHGJH FKDSWHUSDJH

3DSHU SDJH

6WDUFK SDJH

6WHDP SDJH

3HUVRQQHO SDJH

3UHSDULQJWKH&RUUXJDWRU SDJH

5XQQLQJ)ODW%RDUG SDJH

,QVWUXFWLRQVIRU3URGXFWLRQDQG0DLQWHQDQFH3HUVRQQHO SDJH

7URXEOHVKRRWLQJ FKDSWHUSDJH

.QRZOHGJH5HYLHZ FKDSWHUSDJH

7KHRUHWLFDO3DUW SDJH

3UDFWLFDO3DUW SDJH

&HUWLILFDWH

Training Manual

01.10.1997 chapter 1 page 1

Type of machines

ROLL STAND ASR-M ................................................................................................................................... 3

BUTT ROLL COMPUTER ............................................................................................................................. 5

RRR ............................................................................................................................................................... 5

SPLICER ARW-M.......................................................................................................................................... 6

UNDER/ABOVE FLOOR TROLLEY ............................................................................................................. 8

FB/UFB ....................................................................................................................................................... 8

MODUL FACER............................................................................................................................................. 9

MF-BANDLEADER........................................................................................................................................ 9

PREHEATER VZR-M................................................................................................................................... 12

PRECONDITIONER VBR-M........................................................................................................................ 13

BRIDGE B.................................................................................................................................................... 14

BRIDGE LEVEL CONTROL BMR .............................................................................................................. 15

GLUE UNIT LWR-M .................................................................................................................................... 17

DOUBLE FACER DWR............................................................................................................................... 19

ROTARY SHEAR KQM............................................................................................................................... 21

SHEAR ORDER CHANGE.......................................................................................................................... 22

KQF.............................................................................................................................................................. 22

SLITTER SCORER SRA-M......................................................................................................................... 23

DISC CUT .................................................................................................................................................... 26

WEB DIVERTER.......................................................................................................................................... 28

CUTOFF NQM/HQM.................................................................................................................................... 29

STACKER AAR........................................................................................................................................... 31

CORRUGATOR CONTROL........................................................................................................................ 33

Training Manual


CENTER FDM/PDM..................................................................................................................................... 33

QUALITY DATA .......................................................................................................................................... 34

MANAGEMENT QDM................................................................................................................................. 34

SPLICE SYNCHRONISATION.................................................................................................................... 35

SYSTEM SSS ........................................................................................................................................... 35

MACHINE CONTROL CENTER.................................................................................................................. 37

MCC ............................................................................................................................................................. 37

Training Manual


Description of Equipment

Type of Machine: Roll Stand ASR-M

General Description of Component: Roll stand ASR-M is connected to further succeedingmachines and installed in a facility for the production ofcorrugated board (corrugator).The job of the machine is to unwind paper rolls, with theweb tension being generated by the succeeding machine.Brakes attached on the roll pickup arms tension the paperbetween roll and succeeding machine.

The roll stand is supplied in different working widths tosuit the layout of the corrugator. Relative to the specificworking width, refer to chapter Technical Data in theOperating Instructions.

Functional Principle: The roll stand is operated hydraulically and controlledelectrically. The control panel is located on the operatingside of the machine below the splicer control panel.The roll is loaded within pivot range of the roll loading arms.Clamping, lifting, lowering and lateral positioning of the rollloading arms or of the paper roll is controlled viahydraulically operated cylinders. Maximum roll lifting weightis limited by a pressure switch.Maximum possible lifting height of the roll is controlled by alimit switch installed on the transverse bar (drive side). Thelowest position of the roll loading arms is adjusted andlimited mechanically by the lifting cylinder. Furthermore, apressure switch locks against unintended release of the rollwhen being lifted (if weight exceeds 180 kgs/396 lb).The process of unwinding is effected by the succeedingmachine pulling the paper web, with the possibility ofcontinuously adjusting the paper web tension viaadjustable, pneumatic brakes installed on the roll loadingarms.

Options include an automatic roll loading system

Training Manual


(ARA). This system allows automatic roll loading,centering and core ejection. The system is designed toallow the operator to handle more and more frequentroll changes in time.

Safety: The use of two-piece cores is strictly forbidden!In case of vibration occurring by rolls running untrue, theunwinding speed is to be reducedUnwinding of paper rolls with winding cores of aluminum orsteel is not allowed.After loading a paper roll, make sure that the roll loadingcones are fully inserted in the core ends.

If hydraulic pressure is lost, the loading arms holding thepaper roll are held firmly closed, in lifted position.

Training Manual


Type of Machine: Butt Roll Computer RRR

General Description of Component: The butt roll computer is a measuring device whichcalculates how much web is remaining on the runningpaper roll. This value is updated after every measurement,which the computer requires 48 revolutions of the roll for.

Functional Principle: The butt roll computer automatically releases a splice,whenever the web remaining on the roll falls below a certainpreset value. After switching ON or at the beginning of anew roll, the computer on the average requires 3 completemeasurements until the measured values have stabilised.During this time, it is not possible to automatically releasethe splice. Once the measured values have stabilised, anautomatic mode display lights up. From now on, thecomputer uses these measurements as a basis forcontinuous measurement.

If an error occurs during measuring, it is not possible toautomatically release the splice. In this case the automaticmode display disappears. Once the measured values havere-stabilised, the automatic mode appears againautomatically.With the automatic splice release facility being switchedON, the amount of remaining paper web is updated everymeter from approx. 150 m/492 ft before the splice isreleased.When the splice is released manually, the current value ofthe remaining web is stored (it can later be viewed in themenu and recorded on the removed paper roll) As anoption, a label printer can be supplied.To obtain a correct measurement, the roll core diameter ofthe paper roll must be entered exactly (a difference of 1mmmay result in a an error of measurement of 5m/16 ft,relative to paper grade!!).A value which is too high may lead to the splice beingreleased too early; a value which is too low may possiblyallow the board web to unwind completely (thus, rather avalue which is too large is to be preferred).

Training Manual

01.10.1997

Type of Machine: Splicer ARW-M

General Description of Component: The job of the new BHS splicer ARW-M is to join a paperroll running low and traveling in machine direction from aroll stand (e.g. an ASR-M) to a new prepared paper roll in away that the splice is firm and reliable the splice joint displays zero tail so that no paper tails

pass through the machine, allowing the wet end to runat continuously high speed

corrugator speed does not have to be reduced duringthe splicing process or has to be reduced only slightly

danger of a paper break or a faulty splice is extremelylow (i.e. a high degree of splice reliability!)

web tension hardly changes during splicing all common paper grades can be used splicing can be done fully automatically

Splicer ARW-M is, suspended on the bridge, mountedabove the roll stand for the respectively following machine(single facer or double facer). Operation of the splicer isindependent of paper going. BHS can supply splicers withpaper evacuation on the right or on the left side and for aright-hand or a left-hand drive machine.

Due to the integrated web tension control (DualControl), a constant web tension is maintainedthroughout the splicing operation and at all other times.This system monitors and controls the web tensioncontinuously according to the exiting paper, the doublefestoon loading and the roll diameter. Web tension canbe adjusted by the operator at all times. A separateweb tension control unit is not required.

Functional Principle: The splicer is operated pneumatically and controlledelectrically. Only the double festoon roll (dancer) carriage isoperated via a servo drive.With a splicer ARW-M 240, designed for right-handoperation, the paper runs as follows: when the paper web runs from the left roll stand, it runs

over the left deflection roll (movable)chapter 1 page 6

Training Manual


then it continues running nearly horizontally over thetop side of the clamping bar positioned inside

then it is turned by 180 by the left pressure roll andruns into the double storage (2 storage rolls on amovable storage carriage)

finally, the paper web leaves the splicer via innerstorage roll to exit on the right side

With a splicer ARW-M 300/400, designed for right-handoperation, the paper runs as follows: when the paper web runs from the left roll stand, it runs

over the deflection roll (movable) then it continues running nearly horizontally over the

top side of the clamping bar positioned inside it continues running underneath the left pressure roll

and over the right pressure roll the web is turned by 180 over the fixed deflection roll then it runs into the double storage (2 storage rolls on a

movable storage carriage and a guide roll with loadcell)

finally, the paper web leaves the splicer via innerstorage roll to exit on the right side

While one paper roll is unwinding on one side of the rollstand, a new roll is prepared for splicing on the other side.The loading of the pressure roll to the rubberized splice rollduring splicing ensures perfect splice adhesion. The newpaper roll is gradually accelerated to match the runningspeed, and the old web is rapidly and securely braked.Thus roll overrun and paper break are avoided.Splice release is possible either: manually, by the operator automatically, at a preselected minimum diameter,

using ultrasonic sensors automatically, by the butt roll computer (option) automatically, by the Splice Synchronisation System

(option)

Training Manual


Type of Machine: Under/Above Floor Trolley FB/UFB

General Description of Component: The roll transport system supplies the paper to the rollstand and transports away remaining rolls that are nolonger required from the roll stands.This is done by roll trolleys that run in tracks embedded inthe concrete floor.In accordance with the standards, the electric control isintegrated in the control panel of the roll stand or in theautomatic roll loading system (ARA, option).

Functional Principle: The movement of the trolley is achieved via a chain that isdriven by a geared electric motor. Via a rotary switch, theoperator moves the roll trolley to the corresponding positionfor loading or unloading. Limit switches at both ends of thetrack limit the operating range.The trolley may be operatedonly if it is ensured that the paper roll has been placedcentrically on the trolley.

Training Manual

01.10.1997

Type of Machine: Modul Facer MF-Bandleader

General Description of Component: The BHS Modul Facer (single facer) is a component in afacility (corrugator) for the production of corrugated board.The job of the machine is to process two paper webs,supplied separately from each other, to single-facedcorrugated board.Heart of the machine are two pivoted corrugating rollmodules. They can be equipped with different corrugatingroll flute configurations. The advantage is a fast change inproduction to another flute without wasting too much time.A fast replacement of a complete module by a thirdcassette is possible by means of a system for quick changeof corrugating rolls (option).Operation of the machine is controlled on the attachedcontrol panels and/or on an external control desk, by meansof a screen operation, version "Touch Screen".

Functional Principle: For preparation, the medium (fluting) is guided over asteam-heated preconditioner. Then it is guided over thesteam moistener to the loaded corrugating rolls. Duringoperation, the fluted web is held in the contour of the uppercorrugating roll by means of a pressure system.Together with the two pressure chambers lower andupper one - the glue unit represents the pressure system.The glue unit is not fixed and only in working position(moved in), it is pressurized and sealed. The fluting isformed according to the corrugating roll profile. Then theglue is applied onto the flute tips of the medium. The liner isguided over the steam-heated preheater to increase thetemperature. Finally, the fluting is glued together with theliner. In order to create the necessary pressure system,required to glue together fluting and liner, the Modul Facercan be equipped with the BHS Bandleader System or with apressure roll.The following BHS single facers are available: Modul Facer (MF) with Bandleader System Modul Facer (MF) with pressure roll Modul Cassette Facer (MCF) with Bandleader System Modul Cassette Facer (MCF) with pressure rollchapter 1 page 9

Training Manual

01.10.1997 chapter 1 page 10

When only one module is installed in a Modul Facer, it isreferred to as a mono facer. The Modul Cassette Facer is acompact machine with a system for quick cassette change,allowing only one cassette to be installed at a time.Moreover, the machine is equipped with an automatic gluelevel control system. An automatic glue dam control systemensures that the glue dams inside the glue unit are correctlypositioned relative to the width of the medium paper. Thisprevents starch build-up on the corrugating rolls beyondpaper width, which affects runnability. At low speeds,correction of paper shrinkage is possible by entering anoffset value.The glue gap is the gap between doctor roll and glueapplicator roll. The glue gap is preset via the Touch Screento the desired nominal value. In automatic operation, theactual glue gap is the result of nominal value plus automaticglue gap stages. These auto glue gap stages are preset inthe Touch Screen, using the Parameter Menu. The effectis that, when the speed of the machine is automaticallyreduced to predetermined speeds, additional glue is applied(i.e. the glue gap opens up gradually).The glue application gap is the the gap between glueapplicator roll and upper corrugating roll. The glueapplicator gap is preset via the Touch Screen to the desirednominal value. In automatic operation, the actual glueapplication gap is continuously monitored by two eddycurrent sensors (one on drive and one on operating side). Ifnominal and actual value vary, the automatic control makesa correction. This ensures that over the complete speedoperating range the glue gap is adjusted to the nominalvalue.

Safety: On lubriation of the bearing points with "KRYTOX" grease,the safety regulations on the enclosed data sheet (from thesupplier) are to be strictly observed!Particularly important is the following: only to be used in well-ventilated rooms! avoid inhalation of fumes if temperatures exceed

260C /500F! keep away flames to avoid formation of toxic fumes! avoid contact with eyes or mucous membranes! avoid inhalation of toxic decomposition products

evolving from the burning down of impure tobaccoproducts!

wear impermeable gloves!

Training Manual

01.10.1997 chapter 1 page 11

before smoking, wash hands thoroughly after havingused KRYTOX!

wear goggles! danger of skin and eye irritation and impairment of

lungs!

Utmost caution is advised while staying at the guide roll tothe paper evacuation (catwalk preconditioner) and at theentrance of the belt drive at the inclined belt conveyor! danger of getting caught by the machine danger of burning by hot corrugated board

Training Manual

01.10.1997 c

Type of Machine: Preheater VZR-M

General Description of Component: In connection with further preceding and succeedingmachines, preheater VZR-M is part of a facility for theproduction of corrugated board (corrugator).The job of the machine is to optimise temperature andmoisture contents of the running paper webs prior to gluing.There is a basic module which, relative to the differentrequirements, can be extended in several steps.

Functional Principle: The paper web is placed on the outer surface of a rotatingcylinder, which is heated up by steam to approx. 200C/392 F.The required heat transfer to the paper web is achieved byincreasing or decreasing paper wrap around the heatedcylinder. Paper wrap is set by adjusting the wrap roll arms,which are moved by means of geared motor via a full-widthshaft and chains.The size of the wrap angle can be increased/reduced bymanual control or by the automatic system (speed-related).In case of an automatic system, the wrap is determinedrelative to paper grade and speed of single facer or doublefacer. By changing the rotation direction of the wrap, youmay choose between heating of inner or outer papersurface (option). The machine is operated on the attachedoperating panel or on an external control desk withintegrated color graphics terminal (Touch Screen).

Safety: On lubrication of the bearing points with "KRYTOX" grease,the safety regulations on the enclosed data sheet of thesupplier are to be strictly observed!hapter 1 page 12

Training Manual

01.10.1997 chapter 1 page 13

Type of Machine: Preconditioner VBR-M

General Description of Component: The job of the preconditioner is to heat the fluting and toprepare it for forming between the corrugating rolls. It isdirectly positioned at the paper infeed of the machine and isfixed to the concrete floor. It comprises a frame and apreconditioner drum. The drum is driven directly. It ispositioned on bearings lubricated by grease. Its interiorspace is heated by steam. The intensity of temperature thatis applied to the fluting can be varied by adjustable wraprolls.

Safety: On lubriation of the bearing points with "KRYTOX" grease,the safety regulations on the enclosed data sheet of thesupplier are to be strictly observed!

Training Manual

01.10.1997 chapter 1 page 14

Type of Machine: Bridge B

General Description of Component: The bridge can be supplied in the versions Simplex, Duplexor Triplex, relative to the number of single facers available.This equipment is a compact steel construction which isscrewed down and partially welded. The main functions ofthe bridge are as follows: Infeed of the single-faced corrugated board web/s Storage of the single-faced corrugated board web/s Guiding of the sides of the single-faced corrugated

board web/s (*Corraligner/web aligner) Tensioning of the single-faced corrugated board web/s

for the succeeding machines (bridge brake)

Functional Principle: The bridge is fitted with a conveyor belt station immediatelyafter the single facer (inclined belt conveyor); this part isdescribed as transport section. At the beginning of thissection, there is a tensioning station (to tighten the belt); atthe end, the fixed station with the drive is installed. The beltstation runs at a ratio of 10:1 to the speed of the corrugator,which enables festoons of single-faced corrugated board tobe formed. After the transport section, there is theaccumulation section.

Further supplies of single-faced corrugated board canbe directed to the bridge web guide. At the bridge webguide, the web is flattened by festoon damping so thatat the Corraligner, web center can be adjusted tocorrugator centerline. After it, a rubberized brake rollwith servo drive is installed, which ensures a tightenedweb. On the operator side, there is a foot bridge withsafety rails along the entire length of the bridge. Thisunit can be reached by a ladder and is used asoperating and maintenance platform. The operation isdone by means of a control box on the machine and/oron a control panel in front of the machine.

Safety: The footpath has to be kept clear of residual paper. danger of tripping and falling!

When cutting out unbonded single-faced corrugated board,there is

danger of falling on drive side!

Training Manual

01.10.1997 chapter 1 page 15

Type of Machine: Bridge Level Control BMR

General Description of Component: The bridge level control is a system which can be usedfor both BHS corrugators and non-BHS corrugators.Relative to the respective number of existing singlefacers, it is supplied in Simplex, Duplex or Triplexdesign.

Functional Principle: On start of production, the bridge level control is switchedon, and the actual value of the paper quantity on the bridgeis calculated automatically. Via an absolute encoder onsingle facer and double facer, paper speed and storage ofpaper web on the bridge are measured: by means of absolute encoder 1, single facer speed

and the paper quantity conveyed onto the bridge canbe calculated

by means of absolute encoder 4, double facer speedand the paper quantity removed from the bridge can bedetected

by means of measuring wheels 2 and 3 at the lowerside of the bridge, the point where the festoon loops arepulled out in a web can be detected

When the point where the festoon loops are pulled out in aweb reaches measuring wheel 3, the bridge storage issynchronised. As soon as the paper storage on the bridgeis running out, i.e. the point where the festoon loops arepulled out in a web arrives at measuring wheel 2, thedouble facer speed is lowered below the speed of the singlefacer. Thus paper break is avoided. In case a certainminimum value is fallen below (e.g. in case of single facerstoppage), the double facer is switched off.In order to have sufficient storage availabe on the bridge forsplicing, it is possible to switch over to increased demand.The increased demand is to be preset by key input.

Increased demand: LED of the increaseddemand key is on

Normal demand: LED of the increaseddemand key is off

All operations of the bridge level control are controlled viathe Siemens Operator Panel OP 15. Relative to therespective design of the corrugator, the operatingpanel/bridge level control is located in the operating desk ofthe single facer or in a separate operating box.

Training Manual

01.10.1997 chapter 1 page 16

Speed Memory: The Speed Memory is a special function of the bridge levelcontrol. In case it becomes necessary to slow down thedouble facer due to a lack of paper, the operating modeSpeed Memory is activated automatically:The single facer controls the double facer; display in menufield Production: active Modul FacerAfter splicing has been completed, the bridge level controlis automatically activated again, and the modul facer/singlefacer speed relative to double facer is increased, untilnominal storage has been reached again:The double facer controls the single facer; display in menufield Production: active double facer

Training Manual

01.10.1997 chapter 1 page 17

Type of Machine: Glue Unit LWR-M

General Description of Component: The glue unit, type LWR, serves the purpose of uniformglue application to the flute tips of the single-facedcorrugated board web. This single-faced web is then gluedtogether with the lower web in the double facer to formsingle-, double- or triple-wall corrugated board.

On the modular principle, the glue unit can beextended from a simplex to a duplex or from a duplexto a triplex glue unit, one above the other.

Functional Principle: The machine comprises individual bonding stations,assembled vertically as simplex, duplex or triplex version.Guided by 2 (3) guide rolls, the double facer liner runsunderneath the machine. Each station is driven by aservomotor, running at base speed on machine stoppage.

Glue dam follow-up can be done automatically by motor,with the outer edges of the double facer liner serving as aguide. Standard equipment means that the glue dams canbe adjusted manually.

The applicator roll dips into the glue of the glue pan, limitedby the glue dams. Relative to the individual customer, theglue applicator roll has a chromium-plated surface with anengraved screen, the doctor roll is smooth and chromium-plated. The gap can be adjusted by motor.

By means of the BHS pressure shoe system, the fluting isuniformly pressed against the applicator roll. Optionally, arider roll can be used as well.

The glue pan is manufactured of corrosion-proofspecial steel and can be lowered pneumatically forpurposes of maintenance and cleaning. There is goodaccessibility between the preheaters and the doublefacer.

Safety: 1) Lowering of the glue pan between the frames danger of contusion Remedy: Lift glue pan by means of control valve Lift glue pan 2) Lowering of the pressure device on the applicator roll

Training Manual

01.10.1997 chapter 1 page 18

danger of contusion

Remedy: Operate key Lift pressure system

3) Lifting of the glue pan between glue dams and applicator roll

danger of contusion Remedy: Lower glue pan by means of control valve

4) At the limit stops of the glue gap adjustment on drive side

danger of contusion Remedy: Change glue gap by means of key glue gap minus or glue gap plus

5) At the toothed wheels gap adjustment/doctor roll danger of getting caught Remedy: Change glue gap by means of key glue gap minus or glue gap plus

6) Drive applicator and doctor roll danger of getting caught and contusion Remedy: Operate EMERGENCY-STOP button, if necessary

Training Manual

01.10.1997

Type of Machine: Double Facer DWR

General Description of Component: The BHS double facer, type DWR, is integrated in a BHScorrugator between glue unit, type LWR-M, and rotaryshear, tpye KQM or KR (old). The machine basicallycomprises: a front, middle and rear belt drum stand a heating section a traction section

an Airtrol or Chaintrol or Bartrol system and the main drivesIts job is to glue together at least one single-facedcorrugated board web covered with glue on its flute tips witha double facer liner, to dry them and transport them to thesucceeding machines.Main part of the machines are the hot plates, the number ofwhich is relative to the quality of the board to be produced.For transport of the board through the machine, transportbelts are used.

The machine is operated via installed operating panelsand/or from an external desk via the Touch Screen.

Functional Principle: In the front belt drum stand, a double facer liner is guidedand heated via a preheating cylinder or a heated infeedplate. At least on single-faced fluting, bonded at the flutetips, is connected to the double facer liner in the area of thefront belt drum stand. The webs on top of the other aretransported by an upper belt via hot plates.The respective pressure system loads the upper belt andpresses the webs onto the hot plates, ensuring effectiveheating and drying of the webs. Now the board webs areguided through the traction section, where upper belt, onelower belt and the board webs are connected, to be able totransmit the necessary tensile loads to the board web.

These loads are necessary to ensure correct infeedinto the following machines.chapter 1 page 19

Training Manual

01.10.1997 chapter 1 page 20

Instructions on Further Sources of Danger 1) Feed paper web between infeed plate and belt (front

belt drum stand) danger of getting caught by the machine /

danger of burning!

Remedy: Operate EMERGENCY-STOP button; lift pressure system.2) Touching rotary steam joint on front stand before

sufficient cooling has taken place, is strictly forbitten! danger of getting caught by the machine /

danger of burning!

Training Manual

01.10.1997

Type of Machine: Rotary Shear KQM

General Description of Component: Rotary shear, type KQM, is used to separate the webrunning through the machine on order change (conventionalorder change) and to cut out faulty board (rejects). Thesheets are removed from the current production via apivotable flap.

The KQM is mounted inside the corrugator betweendouble facer and slitter scorer.

Functional Principle: The rotary shear is operated from the control panel on themachine. Occurring faults on the KQM are displayed bycollective fault message on the control panel; localised faultareas are displayed on the fault panel on the main switchcabinet.Cutting operation is released manually by the operator fromthe control panel on the machine, automatically by the orderchange system (AFW) or by the option remote release fromthe double facer infeed.If the corrugator speed is too fast for order change, thecorrugator speed is automatically reduced to cutting speed.During cutting, the warning lamp on top of the control panelis on.The pivotable flap is controlled during order change.

The rotary shear is equipped with severalEMERGENCY-STOP buttons. The protective doors aswell have stop functions. If, during operation, one of thetwo doors at the infeed of the rotary shear is opened,this action releases a stop. If, during cutting, theprotective door at the outfeed is opened, the knifestops cutting. An EMERGENCY-STOP on the rotaryshear stops the knife and the complete corrugatorimmediately (single facer(s) excluded).

Safety: Knives: Both upper and lower knife bar are equipped with one knifeeach. When carrying out any kind of maintenance work orwhen replacing the knives, utmost caution is advised.

1) Safety gloves, appropriate for this purpose, have to be worn. danger of cutting

Residual board: 1) Residual corrugated board has to be immediately

removed from the hall floor. danger of tripping and fallingchapter 1 page 21

Training Manual

01.10.1997 chapter 1 page 22

Type of Machine:Shear Order Change

KQF

General Description of Component: Shear order change, type KQF, is used to remove thatpiece of board in which the order change takes place. Itworks together with the order change system and the SwingChanger (shearless order change). The sheets areremoved from the current production via a pivotable flap. Incase of a wet-end quality change controlled by the splicesynchronisation system, that piece of board in which thesplice tapes are collected is cut out as well.

The KQF is installed inside the corrugator betweenSwing Changer and web diverter.

Functional Principle: The shear order change is operated from the control panelon the machine. Occurring faults on the KQF are displayedby collective fault message on the control panel. Localisedfaults are displayed on the panel of the main switch cabinet.Cutting operation is released manually by the operator fromthe control panel on the machine, automatically by the orderchange system.If the corrugator speed is too fast for order change, thecorrugator speed is automatically reduced to cutting speed.During cutting, the warning lamp on the control panel lights.The pivotable flap is controlled during order change.

The shear order change is equipped with severalEMERGENCY-STOP buttons. The protective doorshave stop functions as well. An EMERGENCY-STOPon the KQF stops the knife and the completecorrugator immediately (single facer(s) excluded).

Safety: Knives: Both upper and lower knife bar are equipped with one knifeeach. When carrying out any kind of maintenance work orwhen replacing the knives, utmost caution is advised.

1) Safety gloves, appropriate for this purpose, have to be worn. danger of cutting

Residual board: 1) Residual board has to be removed immediately from

the hall floor. danger of tripping and falling

Training Manual

01.10.1997 chapter 1 page 23

Type of Machine: Slitter Scorer SRA-M

General Description of Component: The Automatic Slitter Scorer SRA-M is used to slit andscore corrugated board webs during continuous operation.The concept of the SRA-M is modular, allowing the customer to produce a flexible product range. The machineis designed for installation in corrugators of anymanufacturer.

Usually, the machine is installed at the end of thecorrugator (dry-end) between rotary shear and cutoff.

Functional Principle: The Automatic slitter scorer is available in three differentmodular versions, i. e. as single machine, tandem machineand as tandem compact machine.The single machine is equipped with one slitter sectionand with either one or more scorer sections. With thismachine, the tools required for the next order are set in theorder change gap.The tandem machine is used for high-speed orderchange. With this version, two machines are arranged inseries at a certain distance. While one unit is engaged, thetools of the second machine are positioned for the nextorder. The tool beds of the respective machine are engagedor disengaged in the order change gap.The tandem compact machine works in the same way asthe tandem version, but is installed in corrugators with littlespace for installation. The machine and all its variousfunctions are controlled by a Siemens PLC (ProgrammableLogic Controller). This ensures a continuous sequence ofoperations and optimum coordination of the machine withthe cutoff (NQ or HQM), the rotary shear (KR or KQM), theshear order change (KQF), the Swing Changer, the doublefacer (DWR) and with the Automatic Order Change Control(AFW).All data for web slitting distances, scoring distances, scoringdepth and scoring profile for the orders to be run are inputinto the respective screen menu Order Processing of theSRA-computer.As an option, the SRA-control can be supplied with theorder data from an overriding computer system (FDM Format Data Management).

The FDM can be supplied with data via an on-line

Training Manual

01.10.1997 chapter 1 page 24

connection or manually, via a keyboard at the centralcontrol desk Teltrol.

Each slitter and scorer section comprises one upper andone lower tool body. All tool bodies are on both sidessupported on two guide shafts. The tool bodies can swivelin and out of the engaged position via lifting spindles. Thetools are positioned laterally in pairs via ball thread spindlesand toothed belts by separate motors (servo drives).The side-trim pickup on drive and operating side in theevacuation area is also positioned automatically inaccordance with the nominal value of the edge slitters. Theside-trim pickup also has a manual possibility foradjustment on the machine iteself.As for the Swing Changer, the side-trim pickup movestogether with the Swing Changer knives, which serve asedge slitters. To ensure a clean trim quality, 20 mm per sideis considered to be the minimum edge trim.Also the scoring depth is adjusted automatically inaccordance with the order data. A three-digit display on themachine shows the actual value of the scoring depth in1/10 mm. Manual change of the scoring depth is alwayspossible directly on the machine. At any time during theorder change in operation, the scoring depth can be altered.A decrease of the value will result in a heavier score and anincrease in a lighter one.The tool shafts for slitters and scorers are driven separatelyby a geared servomotor over cardan shafts.An edge control system (E & L) controls the completemachine laterally to operating and drive side, ensuring thatedge trim on both sides is uniform. This adjustment is alsopossible by manual control on the machine itself. Thecomplete machine rests on rollers which allow movementover a guide rail. This enables lateral repositioning.

All control and operating elements as well as indicatorsare located on the machine control panels and on thecentral control desk in the Teltrol.

Safety: Slitter knives: In case of maintenance work or when replacing the knives,utmost caution is advised.Safety gloves, appropriate for thispurpose, have to be worn. danger of cuts

Drives:

Training Manual

01.10.1997 chapter 1 page 25

When entering the safety area of the drive after machinestoppage, the engines are still hot. danger of fire and burning

Residual board: Residual board on the hall floor has to be removedimmediately.--> danger of tripping and falling

Training Manual

01.10.1997 chapter 1 page 26

Type of Machine: Disc Cut

General Description of Component: The BHS DISC CUT is designed for longitudinal cutting ofthe board web. The characteristic feature of this cuttingprinciple is the use of only one knife cutting in a slittingtable.Circumferential knife speed is a great deal higher than webspeed. This advance can be adjusted on the operating desk(SRA-M terminal) of the machine within a range of 100 % to250 % ; the maximum advance linearly falls to a maximumadvance of 220 %, relative to the speed limit of the knifedrive.In order to maintain a clean cut, the knives can be regroundseparately by means of the grinding device, installed on theknife tool body. Grinding is controlled automatically,separately for each knife, by the computer. On the machine,it is also possible to grind an individual knife manually.Maximum grinding time is five seconds. A knife is onlyground when it is in operation, and the speed exceeds30 m/min. / 98 ft/min. The computer records the runningand regrinding meters for each knife individually.The knives are lubricated by means of the installed knifelubrication device, relative to the produced linear meters.This is to prevent adherent glue on the knives and toreduce friction during cutting (cooling).

A toothed belt transmission, installed in the tool body,makes it possible to run high web speeds.

Safety: Slitter knives:In case of maintenance work or when replacing the knives,utmost caution is advised. Safety gloves, appropriate forthis purpose, have to be worn.Only authorised and trained specialists are allowed to carryout any cleaning work on this machine. All regulations andprohibitions, as required by law, must be strictly observed toprevent serious injury to personnel. Prior to any machinecleaning, make absolutely sure that the master switch islocked in its OFF-position.When working on the electric control system, the fuses ofthe power circuit have to be removed by an expert.When removing the fuses, observe the local safetyregulations of the users country!

Training Manual

01.10.1997 chapter 1 page 27

When using compressed air or steam for cleaning, makesure that the used equipment is in proper condition in termsof safety.

For cleaning, wear specified protective equipment,such as protective gloves, face shields, ear protectorsor any other equipment that may be required.

Training Manual

01.10.1997 chapter 1 page 28

Type of Machine: Web Diverter

General Description of Component: The web diverter comprises web guide tables andpneumatic equipment. The web guide table is installedbetween slitter scorer and cutoff (NQM or HQM).Apart from the guide tables, it comprises web divertertubes, a supporting frame and pneumatic cylinders.

The pneumatic equipment comprises a completepneumatic control for control valves, cylinders and amaintenance unit for compressed air. The pneumaticcylinders control the tubes (slats) which divert the web.

Training Manual

01.10.1997

Type of Machine: Cutoff NQM/HQM

General Description of Component: The cutoff NQM/HQM is used to cut corrugated board websto a certain sheet length. Cutting is done automatically duringcontinuous running operation. The machine is normallyinstalled at the end of a corrugator between slitter scorer andstacker unit. Generally, installation in a corrugator of anymanufacturer is possible.

Functional Principle: In addition to the basic unit, the machine is equipped withweb infeed and sheet evacuation.n Basic machine

Alternatively, each pair of knife bars is driven via a coupling,by one or two drive motors. Order change, released by thesheet counter processor, is completed within one revolution,during continuous operation.At the time of cutting, both knife bars rotate at approximatelythe same speed as the web. Both upper and lower knife barare equipped with a one-piece knife blade.Due to the helical installation, a jerking cut across the entireworking width is avoided.The cutting process resulting from this can be described as ashear cut. By lubricating the cut edge, the serviceable lifetimeof the knives is significantly increased. A thyristor unitregulates the knife bar speed and/or any slowdown oracceleration. In case of board jams, the photocells in theinfeed and evacuation areas of the knife bars are releasedand the drives are automatically switched off.The bearings and cogwheels are lubricated by an oil pumpforce-feed. This circulating oil lubrication is monitored by aflow control instrument, and any fault is indicated by acollective fault light; at the same time, all drives are switchedoff. All control switches and pilot lamps are located on thecontrol panel of the basic machine and the central controldesk (Teltrol).n Web infeed Each infeed section has a transport roll and a specialgenerator roll for residual web. The infeed gap is adjustedautomatically by the swiveling generator roll for residual web,independently of the total width of out.chapter 1 page 29

Training Manual

01.10.1997 chapter 1 page 30

The built-on pulse generator measures the length of the webend, cut off between shear and cutoff. Moreover, when boardjams occur, this roll can be lifted pneumatically by manualcontrol. The transport rolls are driven individually by aservomotor via a synchronous belt with a specified lead to theincoming board web. During maintenance work, board jamsand cleaning, the entire machine group is move outwardmanually. Outward or inward travel is restricted by limit stops.n Sheet evacuation The evacuation unit is mounted on both sides on machinestands. Each evacuation level consists of two lower and twoupper roll units. Both the lower rolls at each level are drivenby a servomotor via synchronous belts. The lead is adjustedby the master regulator unit. The gap between the lowertransport rolls and the upper anti-crush rollers is automaticallyadjusted by the anti-crush rollers on the web. During boardjams and for cleaning, both rolls can be lifted at the sametime via pneumatic cylinders by manual control.

Safety: Knives: Upper and lower knife bar are equipped with one knifeeach.

When effecting any kind of maintenance work or when re-placing the knives, utmost caution is advised.Safety gloves, appropriate for this purpose, have to beworn.

--> danger of cutting

Drives: When entering the safety area of the drive, after havingstopped the machine, the drives are still hot.--> danger of fire and injury

Residual board: Residual corrugated board has to be immediately removedfrom the hall floor.--> danger of tripping and falling

Training Manual

01.10.1997

Type of Machine: Stacker AAR

General Description of Component: The Automatic Stacker, type AAR, at the end of thecutoff, forms stacks of cut sheets. The BHS modulardesign provides the ideal combination of stacking unitsfor all sheet sizes and spatial conditions.

Functional Principle: The complete stacker, which means all individualoperations and units, is controlled by a PLC-system(Programmable Logical Controller), ensuring bothcontinuous operating sequence and optimum cooperationof all individual units. The evacuation unit of the cutoffdelivers the cut sheets onto the shingling belt, running atlower speed. Sheet braking and alignment are effected bybrush units, the engagement of which is automaticallyregulated according to sheet length and corrugator runningspeed. The shingling factor (ratio of shingling corrugatorrunning speed) can be preselected from 1:5 to 1:15. Theshingling belt stacks the sheets continuously onto the sidetransport section; this stacking operation is possible as bothupstacking or downstacking. The Upstacker method means that stacking is done by continuous lifting of the shinglingbelt, whereas downstacking is achieved by continuous lowering of the side table conveyor. The lifting speed iscontrolled by means of a light barrier/photo eye sensor(*beginning from 09/1995 stack height detection by meansof infrared light curtain), scanning stack height andregulating the operation hydraulically.A special evacuation system above the last belt unitensures perfect evacuation of the shingled sheets onto theside transport unit. Counting of the stacked sheets allowsaccurate observance of the number of sheets per stackheight, preset by the overriding computer or preselectedmanually.With the signal for stack change, a venetian blind, installedbelow the second belt unit, moves up to cover this belt unitand takes over the transport of the shingled sheets. Thisoperation is controlled in a way that the first venetian blindslat accurately meets the first sheet of the next stack to beformed and lifts the oncoming sheets of the new stack to beformed.chapter 1 page 31

Training Manual

01.10.1997 chapter 1 page 32

At the same time, the following belts are switched over to ahigher speed (evacuation speed), and the remaining sheetsof the old stack are removed from these belts. During thisremoval operation, the venetian blind carries on the sheetsfor the next stack at the preset shingling speed.

Due to the varying belt speeds, the space and time gapnecessary for changing stacks is created in theshingling board web. As soon as this gap is created,the venetian blind moves back again to its stand-byposition below the conveyor, and the following belt,being cleared now, is switched back again fromevacuation speed to normal speed.The rolls of the sidetransport section, driven by a flat belt, ensure reliableevacuation of the sheet stacks.

Safety: Entering of the lifting platform, the lifting belts, the beltsand of the area below the lifting platform and the lifting beltsduring machine operation is strictly forbidden!

--> caution, danger!

Entering of the roller conveyor with the drive beingswitched on is strictly forbidden!

--> danger of falling, danger to life!

In case the above-mentioned machine components have tobe entered during machine stoppage, e.g. in order

to clean them, a person must be positioned at the nextEMERGENCY-STOP button during this kind of work.

Before entering the area below the lifting platform and thelifting belts during machine stoppage, e.g. in order toclean them, the four bolt safety devices have to beplaced in the provided drill holes in the frame.

Training Manual

01.10.1997

Type of Machine: Corrugator Control Center FDM/PDM

General Description of Component: The BHS-CCC is the data processing center of thecorrugator. It is based on a Siemens PC. Operating system:MS-DOS and MS-Windows or WinCC (from the beginningof 1997).The CCC comprises the following modules:

FDM

Input and administration of corrugatororders

Supply of machines with nominal values Review of data input for feasibility Display of errors in clear text Storage of the last 100 completed

orders Acceptance of data from a customer

data processing system

PDM

Acceptance of actual values from themachines

Storage and administration of actualvalues

Order protocol Quality protocol Shift protocol Stop code protocol Transfer of data to the customer data

processing systemchapter 1 page 33

Training Manual

01.10.1997

Type of Machine: Quality Data Management QDM

General Description of Component: The BHS-QDM comprises a database for wet-end qualityand order data.In combination with the splice synchronisation, it can beconsidered as wet end master.It is based on a Siemens PC.Operating system: MS-DOS and MS-Windows or WinCC(from the beginning of 1997).

The QDM comprises the following modules: Corrugator quality data entry and data

management Entered data plausibility check Client data download, using FDM Storage of up to 500 different quality and paper

descriptions

In combination with splice synchronisation andAutomatic Quality Change (AQW): Supply of wet-end machinery with quality target

data Quality-related storage of actual parameters of

wet-end machinery Quality-related setting of parameters and reset of

wet-end machinerychapter 1 page 34

Training Manual

01.10.1997 chapter 1 page 35

Type of Machine: Splice Synchronisation System SSS

General Description of Component: The Quality Change is the Order Change for the wet-end.For this purpose, the following steps have to be taken: Synchronisation of Splicers

When a quality change takes place, usually the areabetween the 1st and the last splice joint is waste. Tominimise this waste, the splice joints must be located asclosely together as possible. This is done by the splicesynchronisation.

Change of Machine ParametersWhen a quality change takes place, the used papergrades or paper widths change. To ensure perfectproduction, the machine parameters must bealtered. The Automatic Quality Change (AQW)provides the required changeover signals.

Functional Principle: The basic sequence of a splice synchronisation is asfollows:

Evaluation of OrdersYou can see from the order data, on which splicersthe paper changes. These splicers are included inthe synchronisation. On flute change, nosynchronisation is effected.

Active DisplayApprox. 984 ft (300 m) before the order ends, thewarning light is activated to signalise that the splicesynchronisation is in operation now.

Increased DemandIf required, the bridge quantity of the relevant singlefacers is increased.

Bridge DetectionThe exact bridge quantity is detected. For thispurpose, the fluting in the inclined belt conveyor ismarked with a color stain, and this stain is detectedat the bridge end.

Training Manual

01.10.1997 chapter 1 page 36

Attention :

If the quality run is shorter than 990 ft (300 m), it maybe the case that the bridge quantity can no longer bedetected. Nonetheless it is possible to carry throughthe synchronisation, but it is highly probable thataccuracy is affected.

Speed Reduction to Splice SpeedBraking of the single facers and of the double facerto splice speed, if required.

Splice Warning and Release of SplicersAll splicers on which the paper changes arereleased in a way that the splice joints are locatedas closely together as possible. An optical warningis released on each splicer. If required, release canbe locked by a button on the splicer.

On Automatic Quality Change : Change of MachineParameters

Single facers and double facer receive changeoversignals. The required machine parameters werealready transmitted by the Quality DataManagement via data concentrator.

Speed Reduction to Cutting SpeedBraking of double facer to cutting speed, if required.

Order Change with Removal of Splice JointsOrder change is started by the splicesynchronisation, with the splice joints beingremoved by the rotary shear. If the splice joints areto be removed in a different place, e.g. by thecutoff, the Automatic Order Change suppresses therelease of the rotary shear, and the AutomaticOrder Change removes the splice joints itself.

Training Manual

01.10.1997 chapter 1 page 37

Type of Machine: Machine Control Center MCC

General Description of Component: The MCC is a HMI-system (Human Machine Interface),serves as interface between man and machine and formsthe "order administration" of the corrugator. It is based ona Siemens PC-RI 25.

The program MCC runs under the operating systemMicrosoft Windows NT 4.0. It offers a graphical surfacewith all possibilities known under MS-Windows.

Training Manual


Process Knowledge

INTRODUCTION

General purposeTo help corrugator staff and personnel in the preparation and the running of the corrugator.In using this paper, especially for in-house training programs, it should create a generalagreement as how to use the equipment the best and most efficient way. It is, however, not acomplete machine description as this was not the intention. The machine manuals providedwith the units should take care of that.

CONTROLLING THE PRODUCTS and BASIC MATERIALS.

1. PAPER ..................................................................................................................22. STARCH................................................................................................................93. STEAM................................................................................................................284. PERSONNEL ......................................................................................................335. PREPARING THE CORRUGATOR ....................................................................366. RUNNING FLAT BOARD ....................................................................................487. INSTRUCTIONS FOR PRODUCTION AND MAINTENANCE PERSONNEL .....648. THE CORRUGATOR MAINTENANCE ...............................................................86

Training Manual


1. PAPERSeveral types of paper are used in the corrugated board industry. They are divided in 2 differenttypes called LINER and FLUTING or MEDIUM. Liner paper is mainly used as a "liner", i. O. W,the outside papers of the corrugated sheet. We use a top-liner on the single-facer and a bottomliner at the double facer. There is also a middle liner when running double-double, but in somecases, fluting or medium is also used as middle liner. Liner paper differs from fluting or mediumpaper, mainly through the different fibre length, and through the fabrication methods, it is alsomostly more expensive.Different types of liner are used on the corrugate, such as: KRAFTPAPER , SCHRENZ orWASTEPAPER, DUPLEX or TEST LINER.Different types of fluting: SCHRENZ or WASTEPAPER, SEMI-CHEMICAL, a combination ofboth, and STRAW or BOGUS PAPER. All of these papers are available in different grades andqualitys, one more easy to run on the corrugator than others, depending on different factors.We call this the runnabillity" of the paper. Especially the fluting plays a big part in the running ofthe corrugator. We will look further into the different demands which will decide what makes acertain paper easy to run, and another difficult.

SCHRENZ or WASTEPAPER. Has been widely used in most of the European countrys,especially in Holland, Germany, Belgium, Austria, France. This mainly due to the fact that thesecountry's have practically no virgin wood to be used for the paper industry, as Scandinavia has.It is a porous paper, who takes up liquid easily such as starch, but is rather weak as a paper. Istherefore mainly used as fluting paper, due to the fact that it can become a rather stiff paper.Because it is cheap , it is also widely used as an inside liner.When used as a fluting, remember that schrenz is rather difficult to take-up heat, therefore it isessential that we heat the paper sufficiently to reach the correct temperature. Use thepreconditioner to achieve this.

SEMI-CHEMICAL. The name semi-chemical is mostly used to indicate cellulose and less forpaper, as it is nearly always used to mix with wastepaper or old paper. This paper has beendeveloped especially for the corrugated board industry, and has the advantage to create a verystiff, strong fluting.Some scandinavian papers have also a small percentage of Kraft fibre mixed in it, whatincreases even more the strength of the fluting, but also makes it more difficult to run! The fibresare very short and hard, are mainly positioned in length direction and causes therefore a ratherdifficult fluting to run. It is nearly impossible to run semi chemical without the steam showers andwithout conditioning the paper with the preconditioner.

Training Manual


1.1 CaliperCaliper means the thickness of the paper. It is very important that the caliper of the paper iseven over the full width, as it may cause wrinkling, bad gluing, warp and twist on the sheets.

1.2 HumidityHumidity means the moisture contents of the paper. It is essential that the moisture content iseven, and within a restricted percentage. The moisture content of liners and fluting are different,usually liners should contain between 6 and 10%, and fluting between 4 and 8% It is howeveressential that the papers are in "balance", meaning that when your top-liner has a humidity of5%, and your bottom-liner 10%, you will have the greatest problems to run flat board. From thisit is obvious that the moisture content of your paper will greatly decide the flatness of yourboard.Important Note: There are many different types of moisture meters, but most of them give avery inaccurate moisture content of the paper. To check the humidity over the width, thesemeters are very useful, but to determine the moisture content, the best way is to use a propermoisture analyzer, whereby the paper is put on a balance, and by first weighing the paper,drying the paper out by means of heating, weighing the paper again, the moisture content canbe properly obtained. This method is also useful to check the humidity content of the board.

1.3 Even structureEven structure, without streaks, caused by the papermachine. When the paper runs into themachine, it should be straight, evenly tensioned. When not, the streaks will be lower intemperature, due to bad contact with the preheaters, therefore will cause bad gluing at higherspeeds and cause warp.

1.4 WindingWinding of the paper is very important too, plus the general condition of the reel. Badlywounded reels can cause problems at higher speeds, due to the "jumping" of the paper goinginto the machine.Most liners have a smooth and a ruff side, especially the Kraft qualitys This depends on thecalendring of the paper, therefore, most rolls have direction indicators on the sides of the reel. Itis essential to follow these indications, as severe peeling might occur at the finishing machines,or even at the hotplates if these instructions are not followed.

Training Manual


1.5 Weight or GrammageWeight or grammage. Wrong or uneven weight will cause trouble at a further stage of theboxmaking, as the demands for strength of your finished box will mainly depend on thegrammage of your paper. Extreme big grammage differences will show up on the board as weakspots, due to the fact that it is mostly combined with caliper loss. Note: It is an important part ofthe foreman job to keep a close check at the paper at all times, and keep a record of all defectsand or abnormalitys which occurs during the production. It is a good habit to do this, even if inmost cases you have to run the bad reel anyway. When it comes to the point where heavyproduction losses occurs due to the paper, it is always handy to have these records.

1.6 SchrinkageShrinkage of paper is always present, due to the fact that paper is heated when used on thecorrugator. Heating means reducing the moisture content of the paper, and by doing so, thepaper "schrinks", i. O. W. the width of the paper is reduced.The mis alignment of the fibre in the paper can also cause extreme schrinkage, but this is a veryrare phenomena, as this is usually a serious paper machine fault, therefore mostly cured on thepaper machine after detection!. This fault can also be detected by observing the even structureof the paper, very large, loose bands over the paper width with no higher moisture content willindicate this problem.From the above remark, it is easily deducted , that fluting paper has less schrinkage due to thefact that the fibre is much shorter, thus less risks of unaligned fibres!.The amount of schrinkage will depend highly on the moisture content (humidity), the amount ofheating used on the machine, the type of paper used and the speed of the machine. It isobvious that when running slow, more moisture is removed from the paper, therefore schrinkageis more important.However, the more moisture in the paper, the more moisture can be removed, thus causingmore schrinkage. Schrinkage should not exceed 0.3 to 0.5 % of the paperwidth, as moreschrinkage will cause problems maintaining the correct trim at the Slitter Scorer. Schrinkage willalso cause problems on the SF, when running slow. The edges will show streaks, noticeablebecause of the width difference between fluting and medium.

Training Manual


1.7 Aging of PetraPaper freshly produced on the paper machine can cause trouble on the corrugator. It isgenerally recommended to store paper for approx. 3 weeks before use on the corrugator.Reason for this, is usually the bad Gurley value on the fluting paper and the change of theabsorption time with the aging.It is generally accepted that the absorbtivity decreases , thus absorption time increases withaging. This is caused by oxidation of the paper. Outside layers of a roll increase in absorptiontime 25-fold in the initial stage(an increase in penetration time!)while inner layers did not changein a 10 month period!. Therefore, to compensate for those expected changes, many mills induceartificial aging Usually some form of elevated temperatures constitutes the artificial agingprocess. Ex: One laboratory found that 2-8 Hrs at 221 F (105 C) gave age equivalent of onemonth storing under normal conditions.The Gurley value is important on vacuum machines as it indicates the porosity of the paper.With too low Gurley values, the fluting tends to fall out of the corrugator rolls.

1.8 Specifications.Conditions for good quality and high speed. These specifications are recommended by FEFCOfor Liner and Fluting medium.Paperhumidity:7% in length and cross direction.Droptest: 20-30 sec for 3% solution.Runability conditions to ensure good flute formation and acceptable gluing, at the same timerunning flat board.

To avoid for smooth production: "Jumping rolls. Freshly made rolls, coming straight from papermachine. (Between 2/3 weeks storage is recommended!). Extreme cold paper rolls. Badly winded rolls, irregular winding. Smooth, stricken paper. Extremely high concentration of starch. Excessive schrinkage.

Training Manual


Some paper specifications:

Type ofpaper

Weigthin #/msf(g/m)

Caliper ininch (mm)

Gurleyvalue

Droptestinch sec

Surfacestruct.

Humidityinch %

Cobbvalue

Wellenstof 22.5(110)

0.0067(0.17)

25-30 18-50

Testliner 30.7(150)

40-20 50-100 22

Training Manual


1.9 Roll length in meter - feetg/m2 200

mm300mm

400mm

500mm

600mm

700mm

800mm

900mm

1000mm

1100mm

1200mm

112 190 425 760 1240 1700 2320 3050 3850 4750 5700 6800120 175 400 710 1100 1600 2150 2850 3600 4350 5350 6400125 170 380 680 1050 1550 2075 2750 3450 4250 5100 6100127 165 375 665 1030 1500 2040 2675 3350 4175 5025 6000130 160 370 650 1010 1460 2000 2620 3310 4100 4950 5900140 150 335 600 930 1350 1820 2400 3000 3725 4500 5200150 140 310 530 860 1250 1700 2200 2800 3450 4200 5000175 120 270 480 750 1075 1475 1900 2450 3000 3620 4350180 115 260 465 720 1050 1420 1850 2350 2900 3500 4200200 100 230 410 640 920 1250 1650 2050 2550 3100 3700225 95 215 385 600 860 1180 1520 1950 2400 2900 3450250 80 190 330 510 720 1000 1300 1700 2050 2500 3000300 70 160 280 440 640 860 1120 1420 1750 2320 2520350 60 140 250 390 530 770 1000 1280 1570 1900 2250

#/msf 8inch

12inch

16inch

20inch

24inch

28inch

32inch

35inch

39inch

43inch

47inch

23 623 1394 2493 4067 5576 7610 10004 12628 15580 18696 2230424.6 574 1312 2329 3608 5248 7052 9348 11808 14268 17548 2099225.6 558 1246 2230 3444 5084 6806 9020 11316 13940 16728 2000826 541 1230 2181 3378 4920 6691 8774 10988 13694 16482 1968026.6 525 1214 2132 3313 4789 6560 8594 10857 13448 16236 1935228.7 492 1099 1968 3050 4428 5970 7872 9840 12218 14760 1705630.7 459 1017 1738 2821 4100 5576 7216 9184 11316 13776 1640035.8 394 886 1902 2460 3526 4838 6232 8036 9840 11874 1426836.9 377 853 1525 2362 3444 4658 6068 7708 9512 11480 1377641 328 754 1345 2099 3018 4100 5412 6724 8364 10168 1213646 312 705 1263 1968 2821 3870 4986 6396 7872 9512 1131651.2 262 623 1082 1673 2362 3280 4264 5576 6724 8200 984061.4 230 525 918 1443 2099 2821 3674 4658 5740 7610 826671.7 197 459 820 1279 1738 2526 3280 4198 5150 6232 7380

These are approximate figures, and are meant to be of help for the operators.

Training Manual


1.10 Special papers and how to run themClay Coated White top. (Kemiart)This is a transcript in short version from Mr Pertti Kaasalainen, Metsa Serla, Finland. Many ofthe remarks in this article are also valid for other papers, therefore to be used in most caseswhere highly densified linerboard is being used.. It is essential that this paper is run with a minimum of brakepower and wrap on pre heaters

before entering the hotplates. First try all other means of warpcontrol before heating thispaper.

A minimum amount of glue should be used,0.8-1.0 #/msf (4-5 g/m) on the SF and1,0-1,23 #/msf (5-6 g/m) on the glue unit at the DB is recommended. Excessive use of glueis the main reason for washboarding!.

Glue line should be approx. 0.08 ft (2mm) wide, and there should be no visible starchbetween the flutes. Check that the rider roll is smooth and parallel. A smooth and slightlyextended contact of the web is preferable for an even cross-directional glue line.

As the thermal conductivity of the liner is very good, the starch is easily burned on thehotplates. The glue bond must not be too quick on the first hotplate section. A majorreduction of heat on the hotplate sections is therefore very important. Higher running speed isanother way not to subject the board to too much heat on the hotplates.

Temperatures are critically important to improve the runnability of this liner as understoodfrom the previous remarks. Too much steam, too much heat and too much starch are thethree main factors that cause washboarding on lightweight liners. Leaving the DB, thetemperatures of the board should be approx. 194-203 F (90-95 C) at the bottom liner, and179.6-186.8 F (82-86 C) at the top (SF) liner. Checks should be done with infra redthermometers to obtain these temperatures.

The use of papers with good moisture profile on the SF is recommended. We recommendminimum use of steamshower on the SF for a proper flute formation. Excessive steam getstrapped in the sheets and as these liners are very closed, the steam can only escape throughthe flute channels. This causes bonding problems, blistering and is also partly responsible forwashboarding.For the right bonding on the corrugator and for warpcontrol it is useful to know that theprimary fibre is coated. White top liners shrink in cross direction about 0.5% at temperaturesof about 212 F (100 C).With proper temperature control of the top and bottom liners you will be able to control after-warpage.Adhering to these recommendations will also improve the quality of many regular gradesbeing run now on overheated corugators!

Training Manual


2. STARCH

2.1 GeneralitiesIn the early stages of the corrugated boxmaking, the first ways of gluing the paper together wasby means of starch paste, quickly followed by Sodium Silicate, the so-called Water-glass starch.This type of starch however had many disadvantages, such as slow running speed, it alsotended to eat the machine away due to its chemical properties, and above all, it was extremelydifficult to keep the machine in good running condition(extreme long cleaning times). It becamealso problematic to recycle the board, as its starch was practically impossible to separate fromthe paperpaste, causing the newly made paper to become famous for its corrugator roll wear, asthe silicate starch was a very abrasive material. Starch is used to glue the different layers ofpaper to together. The specific demands on starch to be able to run fast, cost efficient and goodquality board at the same time, are Gel temperature and a stable viscosity of a predeterminedvalue. In the case of BHS fingerless single facer you need a viscosity of approx.50 to 60 Sec.Stein Hall.(Stein Hall is the name of the inventor of the Stein Hall formula, the recipient used tomeasure the viscosity is called the Stein Hall cup). Other types of viscosity cups include Bauer,ford, zahn, love, Lory, etc... Lists are available to relate the different values to the different typesof viscosity. However, the most commonly known cup is the Stein Hall, and from here on we willalways refer to this type of viscosity.

2.2 Basic properties of starchSince starch is the main raw material in most adhesive formulations, it is helpful to understandthe basic properties of this material before discussing corrugating adhesives in more details.Starch can be extracted from a wide variety of plants such as: maize, potato, wheat, sago, rice,tapioca etc.., but the most suitable and commonly used is maize.

Training Manual

01.10.1997 chapter 2 page 10

2.3 Components of a Typical Corrugating Adhesive

2.3.1 Water

The aim is to apply starch on top of the flute tips by means of glue applicators. To do this, onehas to work in the liquid phase. The water is necessary for the swelling of the starch granulesand therefore has to be in sufficient quantity to allow complete swelling. The remaining water willhave to be evaporated to cure the bond.

2.3.2 Starch

The starch referred to in this paper is corn starch, unless otherwise mentioned. Other starches,heavily influenced by geography, are Wheat, potato, tapioca etc.. It is the basis of the adhesive

2.3.3 Amylose content of starch

Source % AmyloseWaxy Maize 3

Tapioca 17Potato 20Maize 24Wheat 25

High Amylose Maize 50High Amylose Maize 70

010203040506070

% Amylose

Waxy maizeTapiocaPotatoMaizeWheatH.A.MaizeH.A.Maize

Training Manual

01.10.1997 chapter 2 page 11

2.3.4 Caustic Soda

This is used to reduce the gelatinisation temperature of the raw starch so that the bondformation takes place at a lower temperature on the machine, meaning increased speeds andenergy savings.Beside producing more stable adhesive, caustic soda also helps penetration of the adhesive intothe paper by its wetting power

2.3.5 Heat and Agitation

Heat is used in conjunction with caustic soda to cook the primary portion of the Steinhallprocess or to promote partial swelling of the starch in the no carrier process.Agitation stabilizes the glue viscosity at the preparation stage to avoid a drop in viscosity whencirculating the glue at the corrugator.

2.3.6 Borax or Boric Acid

Borax is added to promote rapid swelling of the raw starch on gelatinisation which leads to afaster adhesion by increasing the viscosity of the glue produced.Borax reacts with cooked starch and modifies the texture of the glue affecting flow properties,glue pick-up and glue penetration. Borax is normally used in the Steinhall process.Boric Acid has the same properties as Borax. Used in the no carrier process, it also stops thereaction by neutralizing part of the caustic soda when the required viscosity is reached.

2.3.7 Preservatives

As swollen granules are sensitive to bacterial or fungal degradation, one must not forget to adda small quantity of preservative, to prevent any loss in viscosity. In good conditions oftemperature and medium, one bacteria would lead to a one million bacteria population after 10hours.(It doubles every 30 min!)

2.3.8 Slurring

A starch slurry can easily be prepared by adding starch to water while stirring continuously. Ifnot continuously agitated, the starch readily settles out, forming a dense sludge on the bottom ofthe mixing vessel, which is difficult to re-slurry.(think of your kitchen, when trying to make saucewith flower and you forget to stir!) Starch slurries can be prepared with concentrations up to40%, and have a thin, watery consistency.

Training Manual

01.10.1997 chapter 2 page 12

2.3.9 Adhesive nature

A starch slurry has no adhesive properties whatsoever. However, on heating, water migratesinto the granules, causing them to swell, and eventually burst to produce the familiar cookedstarch paste. This starch paste now has a very high viscosity and behaves as an adhesive. Theincrease in viscosity is due to the reduction in mobility of the starch as a result of the swellingaction. This cooking process is often referred to as gelatinisation.

2.3.10 Gelatinisation Temperature of adhesive

The gelatinisation temperature is the level at which the adhesive will start to thicken until a gelhas been formed. In contact with the paper, this will give rise to a strong glue bondFor unmodified maize starch the temperature is about 162 F (72 C). The gelatinisation temp.of starch can be altered by adding certain chemicals. For example a small amount of alkali, suchas caustic soda, will reduce the temperature at which the starch granules begin to swell andfinally burst. With a sufficient high level of caustic soda, a starch slurry can be gelatised withoutany heating.The gel temperature is determined taking advantage of a device in glass with a double wall.(The so called "Bain Marie from mothers kitchen!)The recipient at the outside is filled with waterthat is used to heat up the adhesive who is put in the glass inside the bowl. The adhesive isstirred and heated on an electric stove. The electronic thermometer is fitted inside a small tubefrom glass. This keeps its position fixed and constant. During operation the temperature will risequickly and constantly. At the gelatinisation temperature, the water will be heated further but notso the glue. Its elevated viscosity obstruct the penetration of heat to the center of the adhesive.The thermometer will show consistently the same temperature (for 15-20 Sec.) and this is theindication that the gel temperature has been reached. This test is simple, accurate , and veryeffective. It is good practice to introduce this test on a regular basis, an increase of a fewdegrees in gel temperature can make an enormous difference in the running speed of thecorrugator. A weekly check could avoid a lot of trouble!

2.3.11 Viscosity

If the concentration of the starch is above 7% then the cooked paste is very viscous and is verydifficult to pump through the pipes and trays. Above 15% starch solid contents, the cookedpaste on cooling forms an immobile rubbery mass. If a cooked starch paste is required to give alow enough viscosity for convenient pumping at a higher solids content than 7%, then it has tobe chemically modified by the starch manufacturer.

Training Manual

01.10.1997 chapter 2 page 13

2.3.12 Dual viscosity Adhesive

A single viscosity adhesive can provide a good bonding on both single facer and double facer.However, to optimist performance, it is sometimes useful to run dual solids viscosity adhesive.Indeed bonding conditions are much different. The general mechanism of adhesive is as follows:a) Application.b) Pre adhesion dynamics I.e.:

- Wetting- Diffusion- Absorption

c) Raw starch gelatinisation.d) Green bond formation.e) Drying.

2.3.13 Stability

Starch paste, when mechanically moved(such as stirring or pumping, tend to "shear down" orlooses his viscosity. The degree of viscosity loss will depend upon the rate and duration ofpumping, and the way the starch has been prepared.

2.4 Preparation of Corrugating Adhesives

2.4.1 Stein hall or Carrier system

Inventors of the "carrier" system, whereby the starch is made using two mixers, one top and onebottom mixer. The top mixer is called the carrier or primary mix and the bottom mixer slurry orsecondary mix. We will now study such a formula and discuss the pro and contras of this typeof mix. Note that this is still the most used system in the field.

2.4.2 Preparation of Stein hall adhesive

The basic procedure consist of preparing the cooked (carrier) portion in the top tank(primarymix, and adding to this the uncooked slurry in a bottom tank. (secondary mixer) A typicalformulation follows. The mixers need to be of good construction and the agitators need to bepowerful for good shearing.

Training Manual

01.10.1997 chapter 2 page 14

2.4.3 Typical Stein Hall formula

Water to secondary mixer 237 gal (1035 lt)Heat to 86 F (30 C)Unmodified starch 882 lb (400 kg)Borax 35 lb (16 kg)

Water to primary mixer 95 gal (360 lt)Unmodified starch 190 lbs (86 kg)Heat to 140 F (60 C)Caustic soda, dissolved in 25 lt. 37 lb (17 kg)Heat primary mixer to 149 F (65 C)Cold water to primary mixer 95 gal (360 lt)Agitate for 15 min.

Drop contents of primary mixer into secondary mixer over a 20 min. period.Agitate bottom mixer for 30 minutes to STABILIZE the viscosity

2.4.4 Steinhall Cup.(CPC)Adhesive viscosity can be measured and controlled using different kind of viscometers. Forroutine monitoring of the adhesive, the Steinhall Cup is the most widely used. The time, inseconds, needed for the escaping fluid (100 cc.)to flow from the top wire to the bottom wire isthe stein hall viscosity. The value for clear water is 15 Sec.

Training Manual

01.10.1997 chapter 2 page 15

2.4.5 Bauer Cup.(AMYLUM)The Bauer cup is in measurements, exactly the same as the Steinhall Cup (Bauer was anemployee from Stein Hall!) except for the thickness of the bottom plate of the cup. Although theorifice diameter is also 0.1 inch (2.65 mm), the thickness of the bottom plate for the SteinhallCup is 0.13 inch (3.3 mm) and for the Bauer cup 0.06 inch (1.5 mm)

2.4.6 Conversion table Steinhall/Bauer.;

50 Sec. Stein Hall 37.5 Sec Bauer60 Sec Stein Hall 42 Sec Bauer65 Sec. Stein Hall 46 Sec Bauer80 Sec. Stein Hall 52 Sec Bauer100 Sec Steinhall 60 Sec Bauer

To check the accuracy of the cups, following test should be done:100 cc water at 59 F (15 C) runs from top wire to bottom wire in 15 Sec. for the Steinhall Cup.100 cc water at 68 F (20 C) runs from top wire to bottom wire in 15 Sec. for the Bauer cup.

2.4.7 Microbial spoilage

Starch solutions can be affected by microbial spoilage, resulting in a drop in viscosity coupledwith an unpleasant odour. To prevent such spoilage, all areas of the plant where starchadhesives are handled and used should be kept clean. In addition, a small amount of a suitablepreservative should be added to the adhesive, particularly the carrier portion. A carrier starch isusually only present at about 5 or 6% starch solution and it is very susceptible to attack bybacteria even at the very high alkalinity which exist in corrugated formulas. Particularlydisconcerting is the fact that these bacteria can attack the carrier starch before causing anyobjectionable odor or otherwise making their presence obvious. Formaldehyde or otherequivalent materials, such as sodium pentachlorphenol or sodium orthophenylphenate isnormally added to domestic batches

Training Manual

01.10.1997 chapter 2 page 16

2.4.8 No Carrier Starch

This process does away with the carrier portion of the adhesive hence the name "no carrieradhesive. In the process, a solution of caustic soda is added to a slurry of starch to swell all thestarch granules uniformly until they reach the required adhesive viscosity. An acid(usually alumsolution)is then added to stop this swelling process short of gelatinisation. Finally borax isadded. A recent improvement is the use of boric acid to stop the swelling reaction. In reactingwith the caustic soda, the necessary borax is formed.Advantages of "no carrier compared to Stein Hall Adhesives.(This is claimed by CPC, themaker of the system) It requires less heat for the bond formation as the starch granules are already partially

swollen. There is less free water. This is because the water in the adhesive is bound up inside the

swollen starch granules. Follows: Increased machine speed-especially with double wall boards and the heavier single wall

boards. Reduction in warped board production resulting in considerable savings Superior storage and shear stability.

Training Manual

01.10.1997 chapter 2 page 17

2.4.9 Typical No Carrier formula.(Roquette)CAUSTIC SODA TANK.

Water 150 gal (570 lt)Caustic soda 62 lb (28 Kg)Temperature 124 F (51 C)

MIXING TANK

Water 740 gal (2800 lt)Collys TCF 2205 lb (1000 Kg)Temperature 97 F (36 C)Drop caustic soda tank contentinto mixing tank.Reaction Temperature 100 F (38 C)Set point 70 %Reaction time 10-30 min.Boric Acid 40 lb (18 Kg)Agitation 15 min.Dry Solids 22.9 %Gel point 135-136 F (57-58 C)Final SteinHall Viscosity 35-40 Sec.

Training Manual

01.10.1997 chapter 2 page 18

2.4.10 One bag mix

One-bag-mix products offer a number of advantages: convenience, ease of use, safety inhandling, choice of solids content and gel temperature, easy process-automation and highglueabillity performance-especially with heavy weight or multi wall board.They contain all the necessary ingredients for the formulation of Stein Hall adhesives. Excellentquality glues can be prepared by simply blending with water.A range of one-bag-mix products is available for production of adhesives with various solidscontents (20-28%)and gelatinisation temperatures122-144 F (50-62 C)in order to meet specificapplication requirements. In addition, one-bag-mix adhesives are supplied with specialingredients to improve adhesive wet-bond strength. The special nature of the pre-gelatines coldwater swellable carrier portion gives water-resistant adhesives with excellent storage stability.Some one-bag-mix products contain all of the necessary ingredients with the exception of acarrier starch. The latter is made by gelatinising a portion of the mix with, eventually,subsequent oxidative degradation for superior visco-stability and excellent penetrationperformance. It is however a very expensive starch to use, as the product itself is ratherexpensive compared with the normally used starch.

2.4.11 Water-resistant adhesives

All normal starch adhesive bonds are readily soluble in water. For water-resistant applications, areactive material has to be added to the starch to create the necessary impermeable bonds. Theadhesive is rendered moisture resistant or water resistant by addition of materials such asketone aldehydes. These materials cross-link the starch molecules making it more difficult oftwater to dissolve the starch. Different suppliers use different methods, but nearly all have somepeculiar rules which have to be followed rigorously in order to obtain good results.What has to be watched for when running water-resistant glue?1. Nearly all water-resistant starch has a limited lifetime. This can vary between 6-24 hours, but

the quicker you use the starch up, the better. Most of these water-resistant starches can bemixed with normal starch, and further used in the production process. Care has to be takenhowever, that the speed is watched at which the machine is run, as these starches dousually slow down the machine.

2. For maximum effectiveness, the solids content of these adhesives should be at least 22%-and preferably 24-30%

3. To assure top performance, glue pick-up must be increased by 30-50% and the adhesivetemperature prior to the addition of the resin should not exceed 95 F (35 C).

4. Temperatures of 230-248 F (110-120 C) on the Single Facer linerside are required toobtain good bonding.

5. Good, water-resistant board can only be made if the paper properties allow the formation ofstrong glue bonds. The paper should have an open surface to allow the glue to penetrate.Best results are achieved when the papers themselves are water-resistant.

6. Finished board should be immediately stacked to keep the temperature elevated as long aspossible. The board needs additional curing time in order to assure formation of insoluble

Training Manual

01.10.1997 chapter 2 page 19

compounds. A moist, warm glue line with sufficient starch application and time in the stack(usually 12-24 hours)should enhance water resistance.

2.4.12 Synthetic cold set adhesives

Although there exist some synthetic adhesives for which the expression cold set" appliesliterally, the majority still require some heat to achieve required throughput rates. At presentthese adhesives are regarded as a supplement to the standard starch adhesives and they aremainly recommende

Documents

56668158 Training BHS