Training BHS

Training Nanual
for
BHS-Corrugator
10[97
Training Manual
01.10.1997 1
1. Content
1 Type of machines chapter 1 page 1
1 Description of Equipment chapter 1 page 2-3S
General Description of Component
Functional Principle
Safety
2 Process Knowledge chapter 2 page 1-96
Paper page 2
Starch page 9
Steam page 2S
Personnel page 33
Preparing the Corrugator page 36
Running Flat Board page 4S
Instructions for Production and Maintenance Personnel page 64
3 Troubleshooting chapter 3 page 1-19
4 Knowledge Review chapter 4 page 1-67
Theoretical Part page 3
Practical Part page 4S
5 Certificate
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 succeeding
machines and installed in a facility for the production of
corrugated board (corrugator).
The job of the machine is to unwind paper rolls, with the
web tension being generated by the succeeding machine.
Brakes attached on the roll pickup arms tension the paper
between roll and succeeding machine.
The roll stand is supplied in different working widths to
suit the layout of the corrugator. Relative to the specific
working width, refer to chapter Technical Data in the
Operating Instructions.
Functional Principle: The roll stand is operated hydraulically and controlled
electrically. The control panel is located on the operating
side 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 roll
loading arms or of the paper roll is controlled via
hydraulically operated cylinders. Maximum roll lifting weight
is limited by a pressure switch.
Maximum possible lifting height of the roll is controlled by a
limit switch installed on the transverse bar (drive side). The
lowest position of the roll loading arms is adjusted and
limited mechanically by the lifting cylinder. Furthermore, a
pressure switch locks against unintended release of the roll
when being lifted (if weight exceeds 180 kgs/396 lb).
The process of unwinding is effected by the succeeding
machine pulling the paper web, with the possibility of
continuously adjusting the paper web tension via
adjustable, pneumatic brakes installed on the roll loading
arms.
Options include an automatic roll loading system
Training Manual
(ARA). This system allows automatic roll loading,
centering and core ejection. The system is designed to
allow the operator to handle more and more frequent
roll changes in time.
Safety: The use of two-piece cores is strictly forbidden!
In case of vibration occurring by rolls running untrue, the
unwinding speed is to be reduced
Unwinding of paper rolls with winding cores of aluminum or
steel is not allowed.
After loading a paper roll, make sure that the roll loading
cones are fully inserted in the core ends.
If hydraulic pressure is lost, the loading arms holding the
paper 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 which
calculates how much web is remaining on the running
paper 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 certain
preset value. After switching ON or at the beginning of a
new roll, the computer on the average requires 3 complete
measurements until the measured values have stabilised.
During this time, it is not possible to automatically release
the splice. Once the measured values have stabilised, an
automatic mode display lights up. From now on, the
computer uses these measurements as a basis for
continuous measurement.
If an error occurs during measuring, it is not possible to
automatically release the splice. In this case the automatic
mode display disappears. Once the measured values have
re-stabilised, the automatic mode appears again
automatically.
With the automatic splice release facility being switched
ON, the amount of remaining paper web is updated every
meter from approx. 150 m/492 ft before the splice is
released.
When the splice is released manually, the current value of
the remaining web is stored (it can later be viewed in the
menu and recorded on the removed paper roll) As an
option, a label printer can be supplied.
To obtain a correct measurement, the roll core diameter of
the paper roll must be entered exactly (a difference of 1mm
may 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 being
released too early; a value which is too low may possibly
allow the board web to unwind completely (thus, rather a
value which is too large is to be preferred).
Training Manual
Type of Machine:
Splicer ARW-M
General Description of Component: The job of the new BHS splicer ARW-M is to join a paper
roll running low and traveling in machine direction from a
roll stand (e.g. an ASR-M) to a new prepared paper roll in a
way 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 run
at continuously high speed
corrugator speed does not have to be reduced during
the splicing process or has to be reduced only slightly
danger of a paper break or a faulty splice is extremely
low (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, mounted
above the roll stand for the respectively following machine
(single facer or double facer). Operation of the splicer is
independent of paper going. BHS can supply splicers with
paper evacuation on the right or on the left side and for a
right-hand or a left-hand drive machine.
Due to the integrated web tension control (Dual
Control), a constant web tension is maintained
throughout the splicing operation and at all other times.
This system monitors and controls the web tension
continuously according to the exiting paper, the double
festoon loading and the roll diameter. Web tension can
be adjusted by the operator at all times. A separate
web tension control unit is not required.
Functional Principle: The splicer is operated pneumatically and controlled
electrically. Only the double festoon roll (dancer) carriage is
operated via a servo drive.
With a splicer ARW-M 240, designed for right-hand
operation, the paper runs as follows:
when the paper web runs from the left roll stand, it runs
over the left deflection roll (movable)
Training Manual
then it continues running nearly horizontally over the
top side of the clamping bar positioned inside
then it is turned by 180 by the left pressure roll and
runs into the double storage (2 storage rolls on a
movable storage carriage)
finally, the paper web leaves the splicer via inner
storage roll to exit on the right side
With a splicer ARW-M 300/400, designed for right-hand
operation, 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 load
cell)
finally, the paper web leaves the splicer via inner
storage roll to exit on the right side
While one paper roll is unwinding on one side of the roll
stand, a new roll is prepared for splicing on the other side.
The loading of the pressure roll to the rubberized splice roll
during splicing ensures perfect splice adhesion. The new
paper roll is gradually accelerated to match the running
speed, 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 roll
stand and transports away remaining rolls that are no
longer required from the roll stands.
This is done by roll trolleys that run in tracks embedded in
the concrete floor.
In accordance with the standards, the electric control is
integrated in the control panel of the roll stand or in the
automatic roll loading system (ARA, option).
Functional Principle: The movement of the trolley is achieved via a chain that is
driven by a geared electric motor. Via a rotary switch, the
operator moves the roll trolley to the corresponding position
for loading or unloading. Limit switches at both ends of the
track limit the operating range.The trolley may be operated
only if it is ensured that the paper roll has been placed
centrically on the trolley.
Training Manual
Type of Machine:
Modul Facer
MF-Bandleader
General Description of Component: The BHS Modul Facer (single facer) is a component in a
facility (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-faced
corrugated board.
Heart of the machine are two pivoted corrugating roll
modules. They can be equipped with different corrugating
roll flute configurations. The advantage is a fast change in
production to another flute without wasting too much time.
A fast replacement of a complete module by a third
cassette is possible by means of a system for quick change
of corrugating rolls (option).
Operation of the machine is controlled on the attached
control panels and/or on an external control desk, by means
of a screen operation, version "Touch Screen".
Functional Principle: For preparation, the medium (fluting) is guided over a
steam-heated preconditioner. Then it is guided over the
steam moistener to the loaded corrugating rolls. During
operation, the fluted web is held in the contour of the upper
corrugating roll by means of a pressure system.
Together with the two pressure chambers lower and
upper 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 is
formed according to the corrugating roll profile. Then the
glue is applied onto the flute tips of the medium. The liner is
guided over the steam-heated preheater to increase the
temperature. Finally, the fluting is glued together with the
liner. In order to create the necessary pressure system,
required to glue together fluting and liner, the Modul Facer
can be equipped with the BHS Bandleader System or with a
pressure 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 roll
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01.10.1997 chapter 1 page 10
When only one module is installed in a Modul Facer, it is
referred to as a mono facer. The Modul Cassette Facer is a
compact 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 glue
level control system. An automatic glue dam control system
ensures that the glue dams inside the glue unit are correctly
positioned relative to the width of the medium paper. This
prevents starch build-up on the corrugating rolls beyond
paper width, which affects runnability. At low speeds,
correction of paper shrinkage is possible by entering an
offset value.
The glue gap is the gap between doctor roll and glue
applicator roll. The glue gap is preset via the Touch Screen
to the desired nominal value. In automatic operation, the
actual glue gap is the result of nominal value plus automatic
glue gap stages. These auto glue gap stages are preset in
the Touch Screen, using the Parameter Menu. The effect
is that, when the speed of the machine is automatically
reduced to predetermined speeds, additional glue is applied
(i.e. the glue gap opens up gradually).
The glue application gap is the the gap between glue
applicator roll and upper corrugating roll. The glue
applicator gap is preset via the Touch Screen to the desired
nominal value. In automatic operation, the actual glue
application gap is continuously monitored by two eddy
current sensors (one on drive and one on operating side). If
nominal and actual value vary, the automatic control makes
a correction. This ensures that over the complete speed
operating range the glue gap is adjusted to the nominal
value.
Safety: On lubriation of the bearing points with "KRYTOX" grease,
the safety regulations on the enclosed data sheet (from the
supplier) 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 tobacco
products!
wear impermeable gloves!
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01.10.1997 chapter 1 page 11
before smoking, wash hands thoroughly after having
used KRYTOX!
wear goggles!
danger of skin and eye irritation and impairment of
lungs!
Utmost caution is advised while staying at the guide roll to
the paper evacuation (catwalk preconditioner) and at the
entrance of the belt drive at the inclined belt conveyor!
danger of getting caught by the machine
danger of burning by hot corrugated board
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01.10.1997 chapter 1 page 12
Type of Machine:
Preheater VZR-M
General Description of Component: In connection with further preceding and succeeding
machines, preheater VZR-M is part of a facility for the
production of corrugated board (corrugator).
The job of the machine is to optimise temperature and
moisture contents of the running paper webs prior to gluing.
There is a basic module which, relative to the different
requirements, can be extended in several steps.
Functional Principle: The paper web is placed on the outer surface of a rotating
cylinder, which is heated up by steam to approx. 200C/
392 F.
The required heat transfer to the paper web is achieved by
increasing or decreasing paper wrap around the heated
cylinder. Paper wrap is set by adjusting the wrap roll arms,
which are moved by means of geared motor via a full-width
shaft and chains.
The size of the wrap angle can be increased/reduced by
manual control or by the automatic system (speed-related).
In case of an automatic system, the wrap is determined
relative to paper grade and speed of single facer or double
facer. By changing the rotation direction of the wrap, you
may choose between heating of inner or outer paper
surface (option). The machine is operated on the attached
operating panel or on an external control desk with
integrated color graphics terminal (Touch Screen).
Safety: On lubrication of the bearing points with "KRYTOX" grease,
the safety regulations on the enclosed data sheet of the
supplier are to be strictly observed!
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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 to
prepare it for forming between the corrugating rolls. It is
directly positioned at the paper infeed of the machine and is
fixed to the concrete floor. It comprises a frame and a
preconditioner drum. The drum is driven directly. It is
positioned on bearings lubricated by grease. Its interior
space is heated by steam. The intensity of temperature that
is applied to the fluting can be varied by adjustable wrap
rolls.
Safety: On lubriation of the bearing points with "KRYTOX" grease,
the safety regulations on the enclosed data sheet of the
supplier are to be strictly observed!
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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, Duplex
or Triplex, relative to the number of single facers available.
This equipment is a compact steel construction which is
screwed down and partially welded. The main functions of
the 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 immediately
after the single facer (inclined belt conveyor); this part is
described as transport section. At the beginning of this
section, there is a tensioning station (to tighten the belt); at
the end, the fixed station with the drive is installed. The belt
station runs at a ratio of 10:1 to the speed of the corrugator,
which enables festoons of single-faced corrugated board to
be formed. After the transport section, there is the
accumulation section.
Further supplies of single-faced corrugated board can
be directed to the bridge web guide. At the bridge web
guide, the web is flattened by festoon damping so that
at the Corraligner, web center can be adjusted to
corrugator centerline. After it, a rubberized brake roll
with servo drive is installed, which ensures a tightened
web. On the operator side, there is a foot bridge with
safety rails along the entire length of the bridge. This
unit can be reached by a ladder and is used as
operating and maintenance platform. The operation is
done by means of a control box on the machine and/or
on 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!
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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 used
for both BHS corrugators and non-BHS corrugators.
Relative to the respective number of existing single
facers, it is supplied in Simplex, Duplex or Triplex
design.
Functional Principle: On start of production, the bridge level control is switched
on, and the actual value of the paper quantity on the bridge
is calculated automatically. Via an absolute encoder on
single facer and double facer, paper speed and storage of
paper web on the bridge are measured:
by means of absolute encoder 1, single facer speed
and the paper quantity conveyed onto the bridge can
be calculated
by means of absolute encoder 4, double facer speed
and the paper quantity removed from the bridge can be
detected
by means of measuring wheels 2 and 3 at the lower
side of the bridge, the point where the festoon loops are
pulled out in a web can be detected
When the point where the festoon loops are pulled out in a
web reaches measuring wheel 3, the bridge storage is
synchronised. As soon as the paper storage on the bridge
is running out, i.e. the point where the festoon loops are
pulled out in a web arrives at measuring wheel 2, the
double facer speed is lowered below the speed of the single
facer. Thus paper break is avoided. In case a certain
minimum value is fallen below (e.g. in case of single facer
stoppage), the double facer is switched off.
In order to have sufficient storage availabe on the bridge for
splicing, it is possible to switch over to increased demand.
The increased demand is to be preset by key input.
Increased demand: LED of the increased
demand key is on
Normal demand: LED of the increased
demand key is off
All operations of the bridge level control are controlled via
the Siemens Operator Panel OP 15. Relative to the
respective design of the corrugator, the operating
panel/bridge level control is located in the operating desk of
the single facer or in a separate operating box.
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01.10.1997 chapter 1 page 16
Speed Memory:
The Speed Memory is a special function of the bridge level
control. In case it becomes necessary to slow down the
double facer due to a lack of paper, the operating mode
Speed Memory is activated automatically:
The single facer controls the double facer; display in menu
field Production: active Modul Facer
After splicing has been completed, the bridge level control
is automatically activated again, and the modul facer/single
facer speed relative to double facer is increased, until
nominal storage has been reached again:
The double facer controls the single facer; display in menu
field Production: active double facer
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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 uniform
glue application to the flute tips of the single-faced
corrugated board web. This single-faced web is then glued
together with the lower web in the double facer to form
single-, double- or triple-wall corrugated board.
On the modular principle, the glue unit can be
extended from a simplex to a duplex or from a duplex
to 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 runs
underneath the machine. Each station is driven by a
servomotor, 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 a
guide. Standard equipment means that the glue dams can
be adjusted manually.
The applicator roll dips into the glue of the glue pan, limited
by the glue dams. Relative to the individual customer, the
glue applicator roll has a chromium-plated surface with an
engraved 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 is
uniformly pressed against the applicator roll. Optionally, a
rider roll can be used as well.
The glue pan is manufactured of corrosion-proof
special steel and can be lowered pneumatically for
purposes of maintenance and cleaning. There is good
accessibility between the preheaters and the double
facer.
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
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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
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01.10.1997 chapter 1 page 19
Type of Machine:
Double Facer DWR
General Description of Component: The BHS double facer, type DWR, is integrated in a BHS
corrugator between glue unit, type LWR-M, and rotary
shear, tpye KQM or KR (old). The machine basically
comprises:
a front, middle and rear belt drum stand
a heating section
a traction section
an Airtrol or Chaintrol or Bartrol system
and the main drives
Its job is to glue together at least one single-faced
corrugated board web covered with glue on its flute tips with
a double facer liner, to dry them and transport them to the
succeeding machines.
Main part of the machines are the hot plates, the number of
which is relative to the quality of the board to be produced.
For transport of the board through the machine, transport
belts are used.
The machine is operated via installed operating panels
and/or from an external desk via the Touch Screen.
Functional Principle: In the front belt drum stand, a double facer liner is guided
and heated via a preheating cylinder or a heated infeed
plate. At least on single-faced fluting, bonded at the flute
tips, is connected to the double facer liner in the area of the
front belt drum stand. The webs on top of the other are
transported by an upper belt via hot plates.
The respective pressure system loads the upper belt and
presses the webs onto the hot plates, ensuring effective
heating and drying of the webs. Now the board webs are
guided through the traction section, where upper belt, one
lower belt and the board webs are connected, to be able to
transmit the necessary tensile loads to the board web.
These loads are necessary to ensure correct infeed
into the following machines.
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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!
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01.10.1997 chapter 1 page 21
Type of Machine:
Rotary Shear KQM
General Description of Component: Rotary shear, type KQM, is used to separate the web
running through the machine on order change (conventional
order change) and to cut out faulty board (rejects). The
sheets are removed from the current production via a
pivotable flap.
The KQM is mounted inside the corrugator between
double facer and slitter scorer.
Functional Principle: The rotary shear is operated from the control panel on the
machine. Occurring faults on the KQM are displayed by
collective fault message on the control panel; localised fault
areas are displayed on the fault panel on the main switch
cabinet.
Cutting operation is released manually by the operator from
the control panel on the machine, automatically by the order
change system (AFW) or by the option remote release from
the double facer infeed.
If the corrugator speed is too fast for order change, the
corrugator speed is automatically reduced to cutting speed.
During cutting, the warning lamp on top of the control panel
is on.The pivotable flap is controlled during order change.
The rotary shear is equipped with several
EMERGENCY-STOP buttons. The protective doors as
well have stop functions. If, during operation, one of the
two doors at the infeed of the rotary shear is opened,
this action releases a stop. If, during cutting, the
protective door at the outfeed is opened, the knife
stops cutting. An EMERGENCY-STOP on the rotary
shear stops the knife and the complete corrugator
immediately (single facer(s) excluded).
Safety: Knives:
Both upper and lower knife bar are equipped with one knife
each. When carrying out any kind of maintenance work or
when 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 falling
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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 that
piece of board in which the order change takes place. It
works together with the order change system and the Swing
Changer (shearless order change). The sheets are
removed from the current production via a pivotable flap. In
case of a wet-end quality change controlled by the splice
synchronisation system, that piece of board in which the
splice tapes are collected is cut out as well.
The KQF is installed inside the corrugator between
Swing Changer and web diverter.
Functional Principle: The shear order change is operated from the control panel
on the machine. Occurring faults on the KQF are displayed
by collective fault message on the control panel. Localised
faults are displayed on the panel of the main switch cabinet.
Cutting operation is released manually by the operator from
the control panel on the machine, automatically by the order
change system.
If the corrugator speed is too fast for order change, the
corrugator 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 several
EMERGENCY-STOP buttons. The protective doors
have stop functions as well. An EMERGENCY-STOP
on the KQF stops the knife and the complete
corrugator immediately (single facer(s) excluded).
Safety: Knives:
Both upper and lower knife bar are equipped with one knife
each. When carrying out any kind of maintenance work or
when 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 and
score corrugated board webs during continuous operation.
The concept of the SRA-M is modular, allowing the
customer to produce a flexible product range. The machine
is designed for installation in corrugators of any
manufacturer.
Usually, the machine is installed at the end of the
corrugator (dry-end) between rotary shear and cutoff.
Functional Principle: The Automatic slitter scorer is available in three different
modular versions, i. e. as single machine, tandem machine
and as tandem compact machine.
The single machine is equipped with one slitter section
and with either one or more scorer sections. With this
machine, the tools required for the next order are set in the
order change gap.
The tandem machine is used for high-speed order
change. With this version, two machines are arranged in
series at a certain distance. While one unit is engaged, the
tools of the second machine are positioned for the next
order. The tool beds of the respective machine are engaged
or disengaged in the order change gap.
The tandem compact machine works in the same way as
the tandem version, but is installed in corrugators with little
space for installation. The machine and all its various
functions are controlled by a Siemens PLC (Programmable
Logic Controller). This ensures a continuous sequence of
operations and optimum coordination of the machine with
the cutoff (NQ or HQM), the rotary shear (KR or KQM), the
shear order change (KQF), the Swing Changer, the double
facer (DWR) and with the Automatic Order Change Control
(AFW).
All data for web slitting distances, scoring distances, scoring
depth and scoring profile for the orders to be run are input
into the respective screen menu Order Processing of the
SRA-computer.
As an option, the SRA-control can be supplied with the
order 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 central
control desk Teltrol.
Each slitter and scorer section comprises one upper and
one lower tool body. All tool bodies are on both sides
supported on two guide shafts. The tool bodies can swivel
in and out of the engaged position via lifting spindles. The
tools are positioned laterally in pairs via ball thread spindles
and toothed belts by separate motors (servo drives).
The side-trim pickup on drive and operating side in the
evacuation area is also positioned automatically in
accordance with the nominal value of the edge slitters. The
side-trim pickup also has a manual possibility for
adjustment on the machine iteself.
As for the Swing Changer, the side-trim pickup moves
together with the Swing Changer knives, which serve as
edge slitters. To ensure a clean trim quality, 20 mm per side
is considered to be the minimum edge trim.
Also the scoring depth is adjusted automatically in
accordance with the order data. A three-digit display on the
machine shows the actual value of the scoring depth in
1/10 mm. Manual change of the scoring depth is always
possible directly on the machine. At any time during the
order change in operation, the scoring depth can be altered.
A decrease of the value will result in a heavier score and an
increase in a lighter one.
The tool shafts for slitters and scorers are driven separately
by a geared servomotor over cardan shafts.
An edge control system (E & L) controls the complete
machine laterally to operating and drive side, ensuring that
edge trim on both sides is uniform. This adjustment is also
possible by manual control on the machine itself. The
complete machine rests on rollers which allow movement
over a guide rail. This enables lateral repositioning.
All control and operating elements as well as indicators
are located on the machine control panels and on the
central 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 this
purpose, 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 machine
stoppage, the engines are still hot.
danger of fire and burning
Residual board:
Residual board on the hall floor has to be removed
immediately.
--> 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 of
the board web. The characteristic feature of this cutting
principle is the use of only one knife cutting in a slitting
table.
Circumferential knife speed is a great deal higher than web
speed. This advance can be adjusted on the operating desk
(SRA-M terminal) of the machine within a range of 100 % to
250 % ; the maximum advance linearly falls to a maximum
advance of 220 %, relative to the speed limit of the knife
drive.
In order to maintain a clean cut, the knives can be reground
separately by means of the grinding device, installed on the
knife 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 only
ground when it is in operation, and the speed exceeds
30 m/min. / 98 ft/min. The computer records the running
and regrinding meters for each knife individually.
The knives are lubricated by means of the installed knife
lubrication device, relative to the produced linear meters.
This is to prevent adherent glue on the knives and to
reduce 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 for
this purpose, have to be worn.
Only authorised and trained specialists are allowed to carry
out any cleaning work on this machine. All regulations and
prohibitions, as required by law, must be strictly observed to
prevent serious injury to personnel. Prior to any machine
cleaning, make absolutely sure that the master switch is
locked in its OFF-position.
When working on the electric control system, the fuses of
the power circuit have to be removed by an expert.
When removing the fuses, observe the local safety
regulations of the users country!
Training Manual
01.10.1997 chapter 1 page 27
When using compressed air or steam for cleaning, make
sure that the used equipment is in proper condition in terms
of safety.
For cleaning, wear specified protective equipment,
such as protective gloves, face shields, ear protectors
or 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 and
pneumatic equipment. The web guide table is installed
between slitter scorer and cutoff (NQM or HQM).
Apart from the guide tables, it comprises web diverter
tubes, a supporting frame and pneumatic cylinders.
The pneumatic equipment comprises a complete
pneumatic control for control valves, cylinders and a
maintenance unit for compressed air. The pneumatic
cylinders control the tubes (slats) which divert the web.
Training Manual
01.10.1997 chapter 1 page 29
Type of Machine:
Cutoff NQM/HQM
General Description of Component: The cutoff NQM/HQM is used to cut corrugated board webs
to a certain sheet length. Cutting is done automatically during
continuous running operation. The machine is normally
installed at the end of a corrugator between slitter scorer and
stacker unit. Generally, installation in a corrugator of any
manufacturer is possible.
Functional Principle: In addition to the basic unit, the machine is equipped with
web 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 the
sheet counter processor, is completed within one revolution,
during continuous operation.
At the time of cutting, both knife bars rotate at approximately
the same speed as the web. Both upper and lower knife bar
are equipped with a one-piece knife blade.
Due to the helical installation, a jerking cut across the entire
working width is avoided.
The cutting process resulting from this can be described as a
shear cut. By lubricating the cut edge, the serviceable lifetime
of the knives is significantly increased. A thyristor unit
regulates the knife bar speed and/or any slowdown or
acceleration. In case of board jams, the photocells in the
infeed and evacuation areas of the knife bars are released
and the drives are automatically switched off.
The bearings and cogwheels are lubricated by an oil pump
force-feed. This circulating oil lubrication is monitored by a
flow control instrument, and any fault is indicated by a
collective fault light; at the same time, all drives are switched
off. All control switches and pilot lamps are located on the
control panel of the basic machine and the central control
desk (Teltrol).
n Web infeed
Each infeed section has a transport roll and a special
generator roll for residual web. The infeed gap is adjusted
automatically by the swiveling generator roll for residual web,
independently of the total width of out.
Training Manual
01.10.1997 chapter 1 page 30
The built-on pulse generator measures the length of the web
end, cut off between shear and cutoff. Moreover, when board
jams occur, this roll can be lifted pneumatically by manual
control. The transport rolls are driven individually by a
servomotor via a synchronous belt with a specified lead to the
incoming board web. During maintenance work, board jams
and cleaning, the entire machine group is move outward
manually. Outward or inward travel is restricted by limit stops.
n Sheet evacuation
The evacuation unit is mounted on both sides on machine
stands. Each evacuation level consists of two lower and two
upper roll units. Both the lower rolls at each level are driven
by a servomotor via synchronous belts. The lead is adjusted
by the master regulator unit. The gap between the lower
transport rolls and the upper anti-crush rollers is automatically
adjusted by the anti-crush rollers on the web. During board
jams and for cleaning, both rolls can be lifted at the same
time via pneumatic cylinders by manual control.
Safety: Knives:
Upper and lower knife bar are equipped with one knife
each.
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 be
worn.
--> danger of cutting
Drives:
When entering the safety area of the drive, after having
stopped the machine, the drives are still hot.
--> danger of fire and injury
Residual board:
Residual corrugated board has to be immediately removed
from the hall floor.
--> danger of tripping and falling
Training Manual
01.10.1997 chapter 1 page 31
Type of Machine:
Stacker AAR
General Description of Component:
The Automatic Stacker, type AAR, at the end of the
cutoff, forms stacks of cut sheets. The BHS modular
design provides the ideal combination of stacking units
for all sheet sizes and spatial conditions.
Functional Principle: The complete stacker, which means all individual
operations and units, is controlled by a PLC-system
(Programmable Logical Controller), ensuring both
continuous operating sequence and optimum cooperation
of all individual units. The evacuation unit of the cutoff
delivers the cut sheets onto the shingling belt, running at
lower speed. Sheet braking and alignment are effected by
brush units, the engagement of which is automatically
regulated according to sheet length and corrugator running
speed. The shingling factor (ratio of shingling corrugator
running speed) can be preselected from 1:5 to 1:15. The
shingling belt stacks the sheets continuously onto the side
transport section; this stacking operation is possible as both
upstacking or downstacking. The Upstacker method means
that stacking is done by continuous lifting of the shingling
belt, whereas downstacking is achieved by continuous
lowering of the side table conveyor. The lifting speed is
controlled by means of a light barrier/photo eye sensor
(*beginning from 09/1995 stack height detection by means
of infrared light curtain), scanning stack height and
regulating the operation hydraulically.
A special evacuation system above the last belt unit
ensures perfect evacuation of the shingled sheets onto the
side transport unit. Counting of the stacked sheets allows
accurate observance of the number of sheets per stack
height, preset by the overriding computer or preselected
manually.
With the signal for stack change, a venetian blind, installed
below the second belt unit, moves up to cover this belt unit
and takes over the transport of the shingled sheets. This
operation is controlled in a way that the first venetian blind
slat accurately meets the first sheet of the next stack to be
formed and lifts the oncoming sheets of the new stack to be
formed.
Training Manual
01.10.1997 chapter 1 page 32
At the same time, the following belts are switched over to a
higher speed (evacuation speed), and the remaining sheets
of the old stack are removed from these belts. During this
removal operation, the venetian blind carries on the sheets
for the next stack at the preset shingling speed.
Due to the varying belt speeds, the space and time gap
necessary for changing stacks is created in the
shingling board web. As soon as this gap is created,
the venetian blind moves back again to its stand-by
position below the conveyor, and the following belt,
being cleared now, is switched back again from
evacuation speed to normal speed.The rolls of the side
transport section, driven by a flat belt, ensure reliable
evacuation of the sheet stacks.
Safety:
Entering of the lifting platform, the lifting belts, the belts
and of the area below the lifting platform and the lifting belts
during machine operation is strictly forbidden!
--> caution, danger!
Entering of the roller conveyor with the drive being
switched on is strictly forbidden!
--> danger of falling, danger to life!
In case the above-mentioned machine components have to
be entered during machine stoppage, e.g. in order
to clean them, a person must be positioned at the next
EMERGENCY-STOP button during this kind of work.
Before entering the area below the lifting platform and the
lifting belts during machine stoppage, e.g. in order to
clean them, the four bolt safety devices have to be
placed in the provided drill holes in the frame.
Training Manual
01.10.1997 chapter 1 page 33
Type of Machine:
Corrugator Control
Center FDM/PDM
General Description of Component: The BHS-CCC is the data processing center of the
corrugator. It is based on a Siemens PC. Operating system:
MS-DOS and MS-Windows or WinCC (from the beginning
of 1997).
The CCC comprises the following modules:
FDM
Input and administration of corrugator
orders
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 the
machines
Storage and administration of actual
values
Order protocol
Quality protocol
Shift protocol
Stop code protocol
Transfer of data to the customer data
processing system
Training Manual
01.10.1997 chapter 1 page 34
Type of Machine:
Quality Data
Management QDM
General Description of Component: The BHS-QDM comprises a database for wet-end quality
and order data.
In combination with the splice synchronisation, it can be
considered 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 and
Automatic 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 machinery
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 area
between the 1st and the last splice joint is waste. To
minimise this waste, the splice joints must be located as
closely together as possible. This is done by the splice
synchronisation.
Change of Machine Parameters
When a quality change takes place, the used paper
grades or paper widths change. To ensure perfect
production, the machine parameters must be
altered. The Automatic Quality Change (AQW)
provides the required changeover signals.
Functional Principle: The basic sequence of a splice synchronisation is as
follows:
Evaluation of Orders
You can see from the order data, on which splicers
the paper changes. These splicers are included in
the synchronisation. On flute change, no
synchronisation is effected.
Active Display
Approx. 984 ft (300 m) before the order ends, the
warning light is activated to signalise that the splice
synchronisation is in operation now.
Increased Demand
If required, the bridge quantity of the relevant single
facers is increased.
Bridge Detection
The exact bridge quantity is detected. For this
purpose, the fluting in the inclined belt conveyor is
marked with a color stain, and this stain is detected
at 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 may
be the case that the bridge quantity can no longer be
detected. Nonetheless it is possible to carry through
the synchronisation, but it is highly probable that
accuracy is affected.
Speed Reduction to Splice Speed
Braking of the single facers and of the double facer
to splice speed, if required.
Splice Warning and Release of Splicers
All splicers on which the paper changes are
released in a way that the splice joints are located
as closely together as possible. An optical warning
is released on each splicer. If required, release can
be locked by a button on the splicer.
On Automatic Quality Change : Change of Machine
Parameters
Single facers and double facer receive changeover
signals. The required machine parameters were
already transmitted by the Quality Data
Management via data concentrator.
Speed Reduction to Cutting Speed
Braking of double facer to cutting speed, if required.
Order Change with Removal of Splice Joints
Order change is started by the splice
synchronisation, with the splice joints being
removed by the rotary shear. If the splice joints are
to be removed in a different place, e.g. by the
cutoff, the Automatic Order Change suppresses the
release of the rotary shear, and the Automatic
Order 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 forms
the "order administration" of the corrugator. It is based on
a Siemens PC-RI 25.
The program MCC runs under the operating system
Microsoft Windows NT 4.0. It offers a graphical surface
with all possibilities known under MS-Windows.
Training Manual
Process Knowledge
INTRODUCTION
General purpose
To 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 general
agreement as how to use the equipment the best and most efficient way. It is, however, not a
complete machine description as this was not the intention. The machine manuals provided
with the units should take care of that.
CONTROLLING THE PRODUCTS and BASIC MATERIALS.
1. PAPER..................................................................................................................2
2. STARCH................................................................................................................9
3. STEAM................................................................................................................28
4. PERSONNEL ......................................................................................................33
5. PREPARING THE CORRUGATOR....................................................................36
6. RUNNING FLAT BOARD....................................................................................48
7. INSTRUCTIONS FOR PRODUCTION AND MAINTENANCE PERSONNEL .....64
8. THE CORRUGATOR MAINTENANCE ...............................................................86
Training Manual
1. PAPER
Several types of paper are used in the corrugated board industry. They are divided in 2 different
types 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 bottom
liner at the double facer. There is also a middle liner when running double-double, but in some
cases, fluting or medium is also used as middle liner. Liner paper differs from fluting or medium
paper, mainly through the different fibre length, and through the fabrication methods, it is also
mostly more expensive.
Different types of liner are used on the corrugate, such as: KRAFTPAPER , SCHRENZ or
WASTEPAPER, DUPLEX or TEST LINER.
Different types of fluting: SCHRENZ or WASTEPAPER, SEMI-CHEMICAL, a combination of
both, and STRAW or BOGUS PAPER. All of these papers are available in different grades and
qualitys, 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 of
the corrugator. We will look further into the different demands which will decide what makes a
certain 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 these
country'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. Is
therefore 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 is
essential that we heat the paper sufficiently to reach the correct temperature. Use the
preconditioner to achieve this.
SEMI-CHEMICAL. The name semi-chemical is mostly used to indicate cellulose and less for
paper, as it is nearly always used to mix with wastepaper or old paper. This paper has been
developed especially for the corrugated board industry, and has the advantage to create a very
stiff, strong fluting.
Some scandinavian papers have also a small percentage of Kraft fibre mixed in it, what
increases even more the strength of the fluting, but also makes it more difficult to run! The fibres
are very short and hard, are mainly positioned in length direction and causes therefore a rather
difficult fluting to run. It is nearly impossible to run semi chemical without the steam showers and
without conditioning the paper with the preconditioner.
Training Manual
1.1 Caliper
Caliper means the thickness of the paper. It is very important that the caliper of the paper is
even over the full width, as it may cause wrinkling, bad gluing, warp and twist on the sheets.
1.2 Humidity
Humidity means the moisture contents of the paper. It is essential that the moisture content is
even, 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 however
essential that the papers are in "balance", meaning that when your top-liner has a humidity of
5%, and your bottom-liner 10%, you will have the greatest problems to run flat board. From this
it is obvious that the moisture content of your paper will greatly decide the flatness of your
board.
Important Note: There are many different types of moisture meters, but most of them give a
very inaccurate moisture content of the paper. To check the humidity over the width, these
meters are very useful, but to determine the moisture content, the best way is to use a proper
moisture 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 can
be properly obtained. This method is also useful to check the humidity content of the board.
1.3 Even structure
Even structure, without streaks, caused by the papermachine. When the paper runs into the
machine, it should be straight, evenly tensioned. When not, the streaks will be lower in
temperature, due to bad contact with the preheaters, therefore will cause bad gluing at higher
speeds and cause warp.
1.4 Winding
Winding of the paper is very important too, plus the general condition of the reel. Badly
wounded reels can cause problems at higher speeds, due to the "jumping" of the paper going
into the machine.
Most liners have a smooth and a ruff side, especially the Kraft qualitys This depends on the
calendring of the paper, therefore, most rolls have direction indicators on the sides of the reel. It
is 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 Grammage
Weight or grammage. Wrong or uneven weight will cause trouble at a further stage of the
boxmaking, as the demands for strength of your finished box will mainly depend on the
grammage of your paper. Extreme big grammage differences will show up on the board as weak
spots, due to the fact that it is mostly combined with caliper loss. Note: It is an important part of
the foreman job to keep a close check at the paper at all times, and keep a record of all defects
and or abnormalitys which occurs during the production. It is a good habit to do this, even if in
most cases you have to run the bad reel anyway. When it comes to the point where heavy
production losses occurs due to the paper, it is always handy to have these records.
1.6 Schrinkage
Shrinkage of paper is always present, due to the fact that paper is heated when used on the
corrugator. Heating means reducing the moisture content of the paper, and by doing so, the
paper "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 very
rare phenomena, as this is usually a serious paper machine fault, therefore mostly cured on the
paper machine after detection!. This fault can also be detected by observing the even structure
of the paper, very large, loose bands over the paper width with no higher moisture content will
indicate this problem.
From the above remark, it is easily deducted , that fluting paper has less schrinkage due to the
fact 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 of
heating used on the machine, the type of paper used and the speed of the machine. It is
obvious that when running slow, more moisture is removed from the paper, therefore schrinkage
is more important.
However, the more moisture in the paper, the more moisture can be removed, thus causing
more schrinkage. Schrinkage should not exceed 0.3 to 0.5 % of the paperwidth, as more
schrinkage will cause problems maintaining the correct trim at the Slitter Scorer. Schrinkage will
also cause problems on the SF, when running slow. The edges will show streaks, noticeable
because of the width difference between fluting and medium.
Training Manual
1.7 Aging of Petra
Paper freshly produced on the paper machine can cause trouble on the corrugator. It is
generally 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 the
absorption time with the aging.
It is generally accepted that the absorbtivity decreases , thus absorption time increases with
aging. This is caused by oxidation of the paper. Outside layers of a roll increase in absorption
time 25-fold in the initial stage(an increase in penetration time!)while inner layers did not change
in a 10 month period!. Therefore, to compensate for those expected changes, many mills induce
artificial aging Usually some form of elevated temperatures constitutes the artificial aging
process. Ex: One laboratory found that 2-8 Hrs at 221 F (105 C) gave age equivalent of one
month 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 FEFCO
for 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 time
running 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 of
paper
Weigth
in #/msf
(g/m)
Caliper in
inch (mm)
Gurley
value
Droptest
inch sec
Surface
struct.
Humidity
inch %
Cobb
value
Wellenstof 22.5
(110)
0.0067
(0.17)
25-30 18-50
Testliner 30.7
(150)
40-20 50-100 22< 71 150-200
Schrenz 33,3
(160)
0.01
(0.26)
40-20 20-50 22 < 71 100-200
w. Starch 30-60
Semi-Chem 23
(112)
0.007
(0.18)
30-15 18-50 71
26
(127)
0.01
(0.25)
20-50
32.7
(160)
0.01
(0.26)
Kraft 35.8
(175)
30-10 50 22 < 71 20-35
Explanations:
Drop test: Time needed for a drop of water with a 3% NaOH solution to penetrate inch the
paper surface.
Water absorption or Cobb test:
The Cobb test illustrates the ability of the paper to absorb water.
The values that are indicated are the amount of water, absorbed by 10 sgF (1m) of paper inch
a certain time period. The paper is brought inch contact with a water column. By weighing the
paper before and after the test, the Cobb value is fixed.
Humidity test:
Humidity is measured by means of a Doser or equal instrument. However, the most accurate
way of determining the humidity is with a balance. The paper is put on a (electronic)fine
balance. The weight is determined, then the paper is dried-out. The difference inch weight of a
fixed surface 0.01 sgF (10 cm) gives a very accurate humidity content of the paper.
Training Manual
1.9 Roll length in meter - feet
g/m
2
200
mm
300
mm
400
mm
500
mm
600
mm
700
mm
800
mm
900
mm
1000
mm
1100
mm
1200
mm
112 190 425 760 1240 1700 2320 3050 3850 4750 5700 6800
120 175 400 710 1100 1600 2150 2850 3600 4350 5350 6400
125 170 380 680 1050 1550 2075 2750 3450 4250 5100 6100
127 165 375 665 1030 1500 2040 2675 3350 4175 5025 6000
130 160 370 650 1010 1460 2000 2620 3310 4100 4950 5900
140 150 335 600 930 1350 1820 2400 3000 3725 4500 5200
150 140 310 530 860 1250 1700 2200 2800 3450 4200 5000
175 120 270 480 750 1075 1475 1900 2450 3000 3620 4350
180 115 260 465 720 1050 1420 1850 2350 2900 3500 4200
200 100 230 410 640 920 1250 1650 2050 2550 3100 3700
225 95 215 385 600 860 1180 1520 1950 2400 2900 3450
250 80 190 330 510 720 1000 1300 1700 2050 2500 3000
300 70 160 280 440 640 860 1120 1420 1750 2320 2520
350 60 140 250 390 530 770 1000 1280 1570 1900 2250
#/msf 8
inch
12
inch
16
inch
20
inch
24
inch
28
inch
32
inch
35
inch
39
inch
43
inch
47
inch
23 623 1394 2493 4067 5576 7610 10004 12628 15580 18696 22304
24.6 574 1312 2329 3608 5248 7052 9348 11808 14268 17548 20992
25.6 558 1246 2230 3444 5084 6806 9020 11316 13940 16728 20008
26 541 1230 2181 3378 4920 6691 8774 10988 13694 16482 19680
26.6 525 1214 2132 3313 4789 6560 8594 10857 13448 16236 19352
28.7 492 1099 1968 3050 4428 5970 7872 9840 12218 14760 17056
30.7 459 1017 1738 2821 4100 5576 7216 9184 11316 13776 16400
35.8 394 886 1902 2460 3526 4838 6232 8036 9840 11874 14268
36.9 377 853 1525 2362 3444 4658 6068 7708 9512 11480 13776
41 328 754 1345 2099 3018 4100 5412 6724 8364 10168 12136
46 312 705 1263 1968 2821 3870 4986 6396 7872 9512 11316
51.2 262 623 1082 1673 2362 3280 4264 5576 6724 8200 9840
61.4 230 525 918 1443 2099 2821 3674 4658 5740 7610 8266
71.7 197 459 820 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 them
Clay Coated White top. (Kemiart)
This is a transcript in short version from Mr Pertti Kaasalainen, Metsa Serla, Finland. Many of
the remarks in this article are also valid for other papers, therefore to be used in most cases
where 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 this
paper.
A minimum amount of glue should be used,0.8-1.0 #/msf (4-5 g/m) on the SF and
1,0-1,23 #/msf (5-6 g/m) on the glue unit at the DB is recommended. Excessive use of glue
is the main reason for washboarding!.
Glue line should be approx. 0.08 ft (2mm) wide, and there should be no visible starch
between the flutes. Check that the rider roll is smooth and parallel. A smooth and slightly
extended 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 the
hotplates. The glue bond must not be too quick on the first hotplate section. A major
reduction of heat on the hotplate sections is therefore very important. Higher running speed is
another 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 understood
from the previous remarks. Too much steam, too much heat and too much starch are the
three main factors that cause washboarding on lightweight liners. Leaving the DB, the
temperatures of the board should be approx. 194-203 F (90-95 C) at the bottom liner, and
179.6-186.8 F (82-86 C) at the top (SF) liner. Checks should be done with infra red
thermometers to obtain these temperatures.
The use of papers with good moisture profile on the SF is recommended. We recommend
minimum use of steamshower on the SF for a proper flute formation. Excessive steam gets
trapped in the sheets and as these liners are very closed, the steam can only escape through
the flute channels. This causes bonding problems, blistering and is also partly responsible for
washboarding.
For the right bonding on the corrugator and for warpcontrol it is useful to know that the
primary fibre is coated. White top liners shrink in cross direction about 0.5% at temperatures
of 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 grades
being run now on overheated corugators!
Training Manual
2. STARCH
2.1 Generalities
In the early stages of the corrugated boxmaking, the first ways of gluing the paper together was
by 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 also
tended to eat the machine away due to its chemical properties, and above all, it was extremely
difficult to keep the machine in good running condition(extreme long cleaning times). It became
also problematic to recycle the board, as its starch was practically impossible to separate from
the paperpaste, causing the newly made paper to become famous for its corrugator roll wear, as
the silicate starch was a very abrasive material. Starch is used to glue the different layers of
paper to together. The specific demands on starch to be able to run fast, cost efficient and good
quality board at the same time, are Gel temperature and a stable viscosity of a predetermined
value. 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 to
measure 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 types
of viscosity. However, the most commonly known cup is the Stein Hall, and from here on we will
always refer to this type of viscosity.
2.2 Basic properties of starch
Since starch is the main raw material in most adhesive formulations, it is helpful to understand
the 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.
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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, one
has to work in the liquid phase. The water is necessary for the swelling of the starch granules
and therefore has to be in sufficient quantity to allow complete swelling. The remaining water will
have 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 % Amylose
Waxy Maize 3
Tapioca 17
Potato 20
Maize 24
Wheat 25
High Amylose Maize 50
High Amylose Maize 70
0
10
20
30
40
50
60
70
% Amylose
Waxy maize
Tapioca
Potato
Maize
Wheat
H.A.Maize
H.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 bond
formation takes place at a lower temperature on the machine, meaning increased speeds and
energy savings.
Beside producing more stable adhesive, caustic soda also helps penetration of the adhesive into
the 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 Steinhall
process 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 when
circulating 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 a
faster 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 the
reaction 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 add
a small quantity of preservative, to prevent any loss in viscosity. In good conditions of
temperature and medium, one bacteria would lead to a one million bacteria population after 10
hours.(It doubles every 30 min!)
2.3.8 Slurring
A starch slurry can easily be prepared by adding starch to water while stirring continuously. If
not continuously agitated, the starch readily settles out, forming a dense sludge on the bottom of
the mixing vessel, which is difficult to re-slurry.(think of your kitchen, when trying to make sauce
with flower and you forget to stir!) Starch slurries can be prepared with concentrations up to
40%, and have a thin, watery consistency.
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01.10.1997 chapter 2 page 12
2.3.9 Adhesive nature
A starch slurry has no adhesive properties whatsoever. However, on heating, water migrates
into the granules, causing them to swell, and eventually burst to produce the familiar cooked
starch paste. This starch paste now has a very high viscosity and behaves as an adhesive. The
increase in viscosity is due to the reduction in mobility of the starch as a result of the swelling
action. 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 gel
has been formed. In contact with the paper, this will give rise to a strong glue bond
For 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, such
as caustic soda, will reduce the temperature at which the starch granules begin to swell and
finally burst. With a sufficient high level of caustic soda, a starch slurry can be gelatised without
any 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 water
that is used to heat up the adhesive who is put in the glass inside the bowl. The adhesive is
stirred and heated on an electric stove. The electronic thermometer is fitted inside a small tube
from glass. This keeps its position fixed and constant. During operation the temperature will rise
quickly and constantly. At the gelatinisation temperature, the water will be heated further but not
so 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 the
indication that the gel temperature has been reached. This test is simple, accurate , and very
effective. It is good practice to introduce this test on a regular basis, an increase of a few
degrees in gel temperature can make an enormous difference in the running speed of the
corrugator. 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 very
difficult to pump through the pipes and trays. Above 15% starch solid contents, the cooked
paste on cooling forms an immobile rubbery mass. If a cooked starch paste is required to give a
low enough viscosity for convenient pumping at a higher solids content than 7%, then it has to
be 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" or
looses his viscosity. The degree of viscosity loss will depend upon the rate and duration of
pumping, 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 one
bottom mixer. The top mixer is called the carrier or primary mix and the bottom mixer slurry or
secondary mix. We will now study such a formula and discuss the pro and contras of this type
of 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(primary
mix, and adding to this the uncooked slurry in a bottom tank. (secondary mixer) A typical
formulation follows. The mixers need to be of good construction and the agitators need to be
powerful 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. For
routine monitoring of the adhesive, the Steinhall Cup is the most widely used. The time, in
seconds, needed for the escaping fluid (100 cc.)to flow from the top wire to the bottom wire is
the stein hall viscosity. The value for clear water is 15 Sec.
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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 an
employee from Stein Hall!) except for the thickness of the bottom plate of the cup. Although the
orifice diameter is also 0.1 inch (2.65 mm), the thickness of the bottom plate for the Steinhall
Cup 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 Bauer
60 Sec Stein Hall 42 Sec Bauer
65 Sec. Stein Hall 46 Sec Bauer
80 Sec. Stein Hall 52 Sec Bauer
100 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 coupled
with an unpleasant odour. To prevent such spoilage, all areas of the plant where starch
adhesives are handled and used should be kept clean. In addition, a small amount of a suitable
preservative should be added to the adhesive, particularly the carrier portion. A carrier starch is
usually only present at about 5 or 6% starch solution and it is very susceptible to attack by
bacteria even at the very high alkalinity which exist in corrugated formulas. Particularly
disconcerting is the fact that these bacteria can attack the carrier starch before causing any
objectionable odor or otherwise making their presence obvious. Formaldehyde or other
equivalent materials, such as sodium pentachlorphenol or sodium orthophenylphenate is
normally 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 carrier
adhesive. In the process, a solution of caustic soda is added to a slurry of starch to swell all the
starch granules uniformly until they reach the required adhesive viscosity. An acid(usually alum
solution)is then added to stop this swelling process short of gelatinisation. Finally borax is
added. A recent improvement is the use of boric acid to stop the swelling reaction. In reacting
with the caustic soda, the necessary borax is formed.
Advantages of "no carrier compared to Stein Hall Adhesives.(This is claimed by CPC, the
maker 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
Collys TCF 2205 lb (1000 Kg)
Drop caustic soda tank content
into 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 in
handling, choice of solids content and gel temperature, easy process-automation and high
glueabillity performance-especially with heavy weight or multi wall board.
They contain all the necessary ingredients for the formulation of Stein Hall adhesives. Excellent
quality glues can be prepared by simply blending with water.
A range of one-bag-mix products is available for production of adhesives with various solids
contents (20-28%)and gelatinisation temperatures122-144 F (50-62 C)in order to meet specific
application requirements. In addition, one-bag-mix adhesives are supplied with special
ingredients to improve adhesive wet-bond strength. The special nature of the pre-gelatines cold
water 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 a
carrier starch. The latter is made by gelatinising a portion of the mix with, eventually,
subsequent oxidative degradation for superior visco-stability and excellent penetration
performance. It is however a very expensive starch to use, as the product itself is rather
expensive 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, a
reactive material has to be added to the starch to create the necessary impermeable bonds. The
adhesive is rendered moisture resistant or water resistant by addition of materials such as
ketone aldehydes. These materials cross-link the starch molecules making it more difficult oft
water to dissolve the starch. Different suppliers use different methods, but nearly all have some
peculiar 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 be
mixed with normal starch, and further used in the production process. Care has to be taken
however, that the speed is watched at which the machine is run, as these starches do
usually 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 adhesive
temperature 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 to
obtain good bonding.
5. Good, water-resistant board can only be made if the paper properties allow the formation of
strong 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 as
possible. 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" applies
literally, the majority still require some heat to achieve required throughput rates. At present
these adhesives are regarded as a supplement to the standard starch adhesives and they are
mainly recommended for use on the heavyweight multiply boards on double facer glue
application, or where coated liners, such as waxed liners, are being used.
2.4.13 Other Additives
Defoamers
The presence of excessive amounts of foam in the adhesive can lead to problems, such as
overflowing of adhesive from pans, affect application, etc. Some of the causes of foam are the
pumps, adhesive applicator roll surface, pan configuration, contamination, etc.
Sometimes the addition of a small amount of defoamer such as corn oil makes the bubbles to
break up more easily which usually eliminates foam. The starch supplier can suggest other
additives or approaches if the problem persists.
Colorants
Occasionally it is useful to color the starch to help ensure that the changeover from the domestic
adhesive has been completed at the machine. The addition of a very small amount of pigment
usually suffices.
Wetting agents
Additives are occasionally added to the adhesive with the purpose of increasing the rate of
wettabillity of the liner. Improvement in wettabillity has occasionally been noted by this practice.
However, caution must be exercised, because when the shipment of "hard to wet" paper has
been used, the wetting agent may still be in the adhesive. The next lot of paper may be
relatively easy to wet. This might allow the water in the adhesive to literally rush into the
medium, leaving insufficient water to gelatinize all of the raw starch. This would result in a white
glue line and possibly brittle bonds, loose back, etc.
Urea
Another additive has been noted to improve bonds, particularly at the single facer. The Urea
appears to help hold moisture at the glue line. The amount usually added is about 22-33 lb
(10-15 Kg) per 793 gal (3000 lt) batch.
Training Manual
01.10.1997 chapter 2 page 20
2.5 Application of Adhesives
2.5.1 Mechanism involved in the formation of the adhesive bond
All of us are familiar with the typical starch based corrugating adhesive as it is used in the typical
box plant. Most of us are familiar with it in its final dry form as it bonds the corrugated paper
components. However, few understand the complex sequence of events through which the
corrugating adhesive must pass as it is transformed from the liquid state of its application 4ton
the dry solid state. The process itself consist of the following sequence that most occur in this
order in the presence of adequate heat.
2.5.2 Ideal sequence of events
1. Application-Transfer from glue roll to flute tip.
2. Pre-adhesion dynamics.
a) Wetting of the paper surface by the adhesive-water and caustic soda soften the paper
fibers or "bite into them"
b) Diffusion or penetration-the liquid adhesive is absorbed or strikes into the paper (note:
water moves in very rapidly taking dissolved materials especially carrier starch with it)
c) Absorption or specific adhesion-the starch is strongly attracted to the cellulose of the
paper.
3. Raw Starch Gelatinization-the raw starch of the corrugating adhesive begins gelatinization
causing a rapid viscosity increase in the adhesive.
4. Green bond or Initial Bond Formation.
5. Drying of the adhesive-the heat present in the corrugating process evaporates the water
from the adhesive. A larger portion of the water diffuses from the adhesive into the paper
components and is actually evaporated from the paper
The pre-adhesion dynamics represent a very critical stage in the dynamic process of the
corrugated bond formation. Since these events occur first at the flute tip of the corrugated
medium, which by its nature is highly absorbent, one would expect that a significant
proportion of the water in the adhesive would be lost or separated from the starch solids of
the adhesive. This diffused water also brings a portion of the cooked carrier starch with it, so
that the proportion of the raw starch to carrier at the flute tip is greater than it was in the
adhesive at the moment of application. This separation of the water and carrier components
lowers the overall efficiency of the adhesive.
d) Water loss. The un-gelatinised starch granule has the capacity to absorb about 20 times
its own weight of water and expands to about 100 times its original volume. The relatively
high solids of the corrugating adhesive raw starch, therefore, allows only a partial
swelling of the raw starch granules. The identity of these granules exist in the final dried
glue line and their ability to form the continuous film required of the adhesive is at best
limited.
Training Manual
01.10.1997 chapter 2 page 21
e) Carrier loss. The carrier starch is the true adhesive because it is "dissolved" and
capable of forming a continuous film. The carrier starch is analogous to the Portland
Cement that binds the aggregate (the raw starch) in the concrete. To the extend that
carrier is lost in the paper, the proportion of aggregate to cement increases and the
quality of the "concrete"is reduced.
2.5.3 Competing events - the great race
The corrugating bonding process is a highly dynamic one that is occurring on very hot moist
medium that is an ideal absorbent. After adhesive application, wetting, diffusion, and absorption
to the cellulose fibre, raw starch gelatinisation must occur very rapidly or the "Great Race" might
be lost. The competing events of 1) Water loss,2) carrier loss,3) adhesive components
separation discussed before also occur very rapidly. If they have progressed to too large an
extend, the bond at best will be marginal and the glue line will show white, ungelatinised starch.
On the other hand, if gelatinisation of the raw starch takes place to rapidly, insufficient wetting
and adhesive penetration will occur. This ultimately yields a dry crystalline surface bond and the
"popcorn" board with which, unfortunately, we are all familiar.
2.5.4 Multiple sequence
The sequence of application, wetting, diffusion, and absorption actually occurs twice at every
glue line. It first occurs on the flute tips of the medium, as weve discussed before, but it also
occurs again when the adhesive at the flute tip comes in contact with the liner which is to be
bonded. The adhesive has the ability to wet the liner and form an adhesive bond even if the raw
starch portion is completely gelatinized, provided a significant amount of drying of the adhesive
has not occurred.
Very dry corrugated medium can present a significant problem due to premature drying of the
adhesive. Excessive wet components on the other hand, also cause major difficulties by
maintaining a high moisture level in the adhesive and allowing diffusion and penetration of the
adhesive into the components to continue.
There are enormous differences in the time allowed for the bond formation process described
before to take place at the Single Facer and the Double facer.
At the Single Facer, flutes are being formed and bonded at rates approaching 600 flutes per
second with high temperatures and high pressures. At normal operating speeds, as the web
emerges from the Single Facer, at best a tenuous green bond" usually exist so that drying and
final bond formation must be effected on the bridge.
In addition, the adhesive is "killed" at the tip of the flute. That is, little or no adhesive bond exist
at the flute tip because the dwell time of the components in the nip of the pressure and
corrugating rolls is too short to allow the sequence of wetting, diffusion, absorption, and raw
starch gelatinization to occur before drying.
At the Double facer the situation differs entirely. There, the time between the application of the
adhesive to the flute tip and final green bond formulation may be hundreds or times greater than
at the Single Facer. The Double facer conditions demands the ultimate of the adhesive in terms
of water holding ability and wet tack development. This is why specialty starches invariable allow
Training Manual
01.10.1997 chapter 2 page 22
higher running speeds than do simple corn starch adhesives. The same properties allow
increased running speeds and improved bond quality at the Single Facer because they can be
run wetter and with less total heat from the machine and the preheaters. In addition, there is
evidence that suggest that less "killing" at the Single Facer flute tips exists with specialties than
with simple corn starch
Ex: Number of flutes per minute and second at 250 m/min.
Flute Dist. Fl. Nr Flutes Fl/min Fl/sec
K 11.7 101 21.367 356
A 8.66 136 28.868 481
C 7.95 148 31.446 524
B 6.5 181 38.461 641
E 3.25 362 76.923 1285
F 2.4 490 104.166 1736
2.5.5 Wheat Starch
Lately, the use of wheat as a component to make starch in the corrugated industry has
increased dramatically, specially in Europe because of the ready availability of wheat against
corn.
Several advantages are claimed against corn such as:
Energy savings up to 25 %, due to the use of lower steam pressure.
Reduced consumption (approx. 10 %)
More stable viscosity
Retrogradation lesser than for corn, lesser Thixotroop.
Better quality, due to the use of reduced temperatures.
2.5.6 Typical wheat starch Formula. (Stein Hall) AMYLUM
Primary tank
Meriwit AA(Wheat) 220 lb (100 Kg)
NaOH SF 20 lb (9 Kg)
DB 26 lb (12 Kg)
Mixing 15 Min.
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01.10.1997 chapter 2 page 23
Secondary tank
Meriwit AA 1323 lb (600 Kg)
Borax SF 13 lb (6 Kg)
DB 20 (9 Kg)
Mixing 15 Min.
Viscosity 35" Bauer
Temperature 82-86 F (28-30 C)
2.5.7 Potato Starch.
Potato starch has become rather popular today, because of his low gelpoint possibilities.
Especially when running Triple or Double wall, this starch can give spectacular results!.
It has to be said that very often, the carrier is a mix of potato and maize starch, to increase the
stability and reduce the splashing effect of the potato starch.
Advantages and disadvantages of potato starch:
Advantages
Low gelpoint
Very high tack after gluing
A relative high solid content
A carrier system who has a good water absorption retention
These specifications are the reason for several positive advantages against other starches,
such as
Increased machine speed (increases of up to 50% have been achieved!)
Easier to run flat board(lower temperatures !)
Reduced dry board (lower temperatures !)
Possibility to run pre-printed, or with thermoplastic resins laminated paper, where the
blocking point is approx. 248 F (120C).
Much easier gluing process, less badly glued board.
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01.10.1997 chapter 2 page 24
Disadvantages:
Not always price friendly
One need two separate lines towards DB
Splashing due to shorter fiber
Some potato starch specifications.:
(Emsland Emcol VPK 300/50 HE)
1. Viscosity:
2. pH value:
3. Gelpoint:
4. Solid
content:
5. Humidity:
40-70 sec steinhall
ca 12
203 F (50C)
ca.27% lutro
18.4% 0,5 %
Cerestar C*GUM 30065:
1. Viscosity:
2. pH value:
3. Gelpoint:
4. Solidcontent:
5. Humidity:
40-60 sec steinhall
ca 12
122 F (50C)
19-28% lutro
14-16 %
Training Manual
01.10.1997 chapter 2 page 25
2.6 Trouble Shooting Starch Problems
Viscosity
Breakdown or loss of viscosity.
Loss of viscosity of starch can cause serious problems, such as scrap, loss of speed, brittle
bonds, low glue application, bad starch penetration, etc. and can be caused by a number of
problems, such as:
excessive water
Shear
Bacteria
The carrier starch
temperature rise.
2.6.1 Viscosity Breakdown-Water
The addition of extra water is an obvious cause of loss of viscosity. Possible causes:
Wash-up water (Cleaning!)
Water jacket at SF leaking.
Water meter inaccurate, loss of calibration, inaccurate
Excessive condensate in steamlines to heat the batch.
Starch mix equipment, leaks.
Even more important than the loss of viscosity is the loss of total solids for a given volume of
adhesive. The solids of the corrugating adhesive, usually expressed in percent, are very
important to the quality of the finished product. Higher solids may increase the total cost of a
batch of starch, but are often used today in a corrugating plant.
2.6.2 Viscosity Breakdown-Shear
This type of viscosity loss is caused by intense mechanical action and friction. Breakdown by
this cause is lessened the better the adhesive is mixed or pre-sheared while still in the mixing
tank. Specific causes are:
Agitation. The agitators in the storage tanks.
Pump and lines. Supply and return pumps, specially the gear type pumps.
Glue-metering roll gap. The squeeze through the gap.
Friction in the piping, tees, etc. Especially if the storage tanks are located at considerable
distance from the corrugator.
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01.10.1997 chapter 2 page 26
2.6.3 Viscosity Breakdown-Bacteria.
The cooked starch is attacked by bacteria, which convert in to sugars which dissolve in the
water causing a lowering of viscosity. This can usually be prevented by periodically cleaning the
whole system, with Trisodium Phosphate(TSP) and Chlorine containing compounds like Clorox
or swimming pool chemicals, and adding preservatives to domestic corrugating adhesives.
Weekend storage requires additional preservatives.
Some common sources of bacteria are: dirty storage tanks and mixers, dirty circulating lines,
water, air, sweat, etc.
2.6.4 Viscosity Breakdown-Carrier
The carrier is the cooked portion of the adhesive and is the major contributor in determining the
viscosity. The type of carrier may influence the viscosity stability of the adhesive.
viscosity breakdown or initial low viscosity may be caused by a number of factors. These include
excessive shear and inadequate carrier dry weight. Excessive temperature in the carrier may
also lead to viscosity breakdown.
2.6.5 Viscosity Breakdown-Temperature Rise
Adhesive viscosity will vary, predictably, with changes in temperature. As temperature
increases, the viscosity will decrease, the opposite is also true.
An increase in temperature causes the adhesive to become thinner, much like oil becomes
thinner when it gets warmer. It has been determined that the viscosity changes approximately
10% if the temperature changes 35.2 F (1.8 C). For instance, if the viscosity measured 40
SteinHall seconds at 100 F (38C) . It would measure about 36 Sec. At 102 F (39 C) and 32
Sec. At 104 F (40 C)
Follows a chart with temperature/viscosity relation.
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01.10.1997 chapter 2 page 27
TEMPERATURE IN F
S 90 91 93 95 97 100 102 104 106 108 110 F
T 42 38 34 31 28 25 23 21 19 17 15 Sec.
E 44 40 36 32 29 26 23 21 19 17 15 Sec.
I 46 41 37 33 30 27 24 22 20 18 16 Sec.
N 48 43 39 35 32 29 26 23 21 19 17 Sec.
H 50 45 41 37 33 30 27 24 22 20 18 Sec.
A 52 47 42 38 34 31 28 25 23 21 19 Sec.
L 54 49 44 40 36 32 29 26 23 21 19 Sec.
L 56 50 45 41 37 33 30 27 24 22 20 Sec.
58 52 47 42 38 34 31 28 25 23 21 Sec.
V 60 54 49 44 40 36 32 29 26 23 21 Sec.
I 62 56 50 45 41 37 33 30 27 24 22 Sec.
S 64 58 52 47 42 38 34 31 28 25 23 Sec.
C, 66 60 54 49 44 40 36 32 29 26 23 Sec.
in 68 61 55 50 45 41 37 33 30 27 24 Sec.
Sec. 70 63 57 51 46 41 37 33 30 27 24 Sec.
Viscosity bre a kdown
T e mpe ra ture
0
10
20
30
40
50
60
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01.10.1997 chapter 2 page 28
3. STEAM
3.1 General
Dry saturated steam is used to heat the surfaces of the heater drums, the corrugator rolls , the
pressure roll and the hotplates. It is also used to humidify the paper. Pressure is usually
between 174 and 203 psi (12 and 14 bar) at the machine, which means that the boiler should
run with approx. 232 psi (16 bar). Maximum steam consumption varies but a 5 to 6 ton/hr
capacity is usually recommended, as peak consumption for very heavy quality board can be
rather high.
3.2 System description
The boiler produces saturated steam at 203 psi (14 bar), which is fed direct into the Single
Facers, preheaters, glue unit heater drums and first hotplate section.
The condensate of these units is collected in the pressurized condensate tank Nr 1.
The condensate from hotplate section 2 is collected in the flash tank. The flash steam is used to
feed the 3 th hotplate section, and the condensate is directed to condensate tank 2. The
condensate of the 3 th hotplate section flows through the steam trap in to tank 2.
The individual machines have steam valves in the main and condensate lines, and steam traps
in the condensate lines.
The flash steam in condensate tank 1 and 2 is used for the steam showers. This is done through
a self acting pressure reducer who reduces the pressure to approx. 45 psi (3 bar)
The first section consists of usually between 5 and 8 hotplates.
The first hotplate section is sometimes uncontrolled, and works at line pressure. However, the
possibility to control even the first hotplate section becomes more and more practical. Especially
in case of E and F Flute, it is a must to reduce the first section as well. It is also the case for
special qualitys, such as pvc coated liners, who can only sustain certain temperatures.
The second section consist generally of 5 to 6 hotplates as well as the third section. The
pressure in these plates is regulated by means of a motorized valve, and can generally be
maintained within 1.5-3 psi (0.1 to 0.2 bar) pressure. Most of the machines today have also
temperature indicators. This gives the operators a much more realistic picture of the actual
temperature in the plates.
Far too often it is thought that a pressure difference of 29-44 psi (2 to 3 bar) gives big
temperature differences, but generally speaking, 14.7 psi (1 bar) pressure equals approx. 40 F
(4.5C) temperature. The other advantage is that a problem in the steam system, filling up the
plates with water, will be detected much quicker than with pressure indicators only.
Always regulate the sections downwards, i. O. W start with the highest pressure/temperature in
the first section, and gradually reduce the pressure/temperature in the next sections.
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01.10.1997 chapter 2 page 29
3.3 How to set pressure for different qualitys and grades
Pressure is regulated in the hotplates according the type of board run, the type of starch used, i.
O. W. gel point, and the qualitys.
As a general rule, settings have to be done following two parameters:
1. The heat has to be in descending order, i. O. W. The highest pressure or temperature has to
be in the first section, and
2. The lighter the quality, the lower the pressure.
Some examples:
Type of board Section 1. Section 2. Section 3
Single Wall
E/F Flute
72/102 psi
5/7bar
44/58 psi
3/4 bar
14.7/29 psi
1/2 bar
Light grade
Single wall B/C
87/116 psi
6/8 bar
58/87 psi
4/6 bar
29/58 psi
2/4 bar
Heavy grade
Single Wall B/C
145/174 psi
10/12 bar
131/145 psi
9/10 bar
131/145 psi
9/10 bar
Normal grade DD C+B
or A+B
160/174 psi
11/12 bar
160/145 psi
11/10 bar
145/131 psi
10/9 bar
Heavy grade DD
C+B, a+B, triple
203/189 psi
14/13 bar
189/174 psi
13/12 bar
174/160 psi
12/11bar
Relation Pressure/Temperature.
bar Temp C bar Temp C bar Temp C bar Temp C bar Temp C
16 204 10 184 7 170 4 152 1 120
15 201 9.5 182 6.5 168 3.5 148 0.8 117
14 198 9 180 6 165 3 144 0.6 114
13 195 8.5 178 5.5 162 2.5 139 0.4 110
12 192 8 175 5 159 2 134 0.2 105
11 188 7.5 173 4.5 156 1.5 128 0.0 100
psi Temp F psi Temp F psi Temp F psi Temp F psi Temp F
232 400 145 363 102 338 58 306 14.5 248
217 394 138 360 94 334 51 298 11.6 243
203 388 131 356 87 329 44 291 8.7 237
189 383 123 352 80 324 36 282 5.8 230
174 378 116 347 73 318 29 273 2.9 221
160 370 109 343 65 313 22 262 0 212
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01.10.1997 chapter 2 page 30
3.4 Checking siphon pipes in corrugator rolls
1-2 mm = 0.04-0.08 inch
2-3 mm = 0.08-0.12 inch
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01.10.1997 chapter 2 page 31
As already mentioned in previous chapters, it is essential that the siphon pipes are set very
accurately in the corrugator and pressure rolls.
Consequences of inaccurate setting:
Too far from bottom:
When the machine is started after even a short (5 min) stop, the web will show big, oval blisters
in the middle. This is caused by water lagging in the rolls.
Too close to bottom:
Siphon will turn away from position, thus causing bad condensate removal.
In order to set these siphon pipes accurately, set the siphon pipes to following distance of the
bottom corrugator roll or pressure roll.
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01.10.1997 chapter 2 page 32
3.5 Checking steam traps
As well as siphon pipes, steam traps who are not functioning satisfactory, can cause serious
trouble on the corrugator. It was found on several occasions, that the malfunctioning of a steam
trap caused heavy production losses, due to lack of heat in the vessel.
To check the steam trap, check the temperature just before the trap. A small temperature
difference with the main pressure should be measured, but certainly not more than 50 F
(10 C).
Another way to check the steam traps is with an ultrasonic meter. This instrument indicates the
functioning of the trap by means of a sonar system. There are several types on the market, who
are also useful for other purposes, such as checking the functioning of hydraulic valves, finding
air leaks or water leaks, etc...
It is good practice to check the traps once a month. At the same time, strainers, filters etc..
Should also be checked.
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01.10.1997 chapter 2 page 33
4. PERSONNEL
4.1 General
Very often, the question is put forwards who shall we put on the new machine"? The answer is
not always easy ! The modern corrugator has completely different demands from the operators
than 10-15 years ago. In principle everybody who has the interest and the willingness to accept
the fact that a corrugator puts special demands on people. Because of the ever increasing
speed and the use of modern technology such as computers, micro processors, faultfinding
systems etc.. It is absolutely essential that the operator on the corrugator has the condition to
react quick and precise whenever the need for such action is occurring. Although age is an
important factor, it is however not the most important factor. Over the years, it was proven that
although young people tend to learn quicker, in many cases, it turned out that it was worth to
show some patience with the so-called older people, as very often, they turned out to be the
best ones after a somewhat longer learning period. The main problem when a new machine bas
been bought, is usually the fact, that so many things have been said and showed to the
interested people, that they become scared of the machine before it even started! Therefore, it
is very important to create confidence and take away the fear, by explaining to the people that
one advantage working with sophisticated, computerized machines is, that no matter what
mistake they make, the computer will tell them, and at the same time refuse to do whatever it
was told to do, or the wrong command will create such a jam-up, that the person in question will
not likely forget his mistake. In both cases, it would be extremely rare to have a breakdown
caused by wrong operation of the machine.
4.2 Prepare for production
1. Check if all necessary personnel is available and ready for running.
2. Make sure everybody knows the program, avoid mistakes before you even start! (Briefing!)
3. Control the individual jobs, making certain that the different tasks have been well understood
by everybody.
4.3 Job Description
Every plant has different working methods, and different machine combinations, therefore, it is
rather difficult to decide who should do what. We will however, summarize certain
responsibilitys which under normal circumstances are done by the respective operators.
Ex:More and more, the foremans job is combined, with the teltrol operators job, as the loading of
orders in the respective units, is done by on-line connections with the planning department. In
many cases however, it remains the key figure at the machine..
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01.10.1997 chapter 2 page 34
4.3.1 TELTROL DESK OPERATOR, or MACHINE LEADER
He controls the process of making flat board, all the necessary adjustments to obtain flat
board are in his hands, therefore he must have knowledge of the complete range of
adjustments to obtain flat board.
He is responsible for quality, all defects are reported to him by the stacker operator, and he
regularly checks the quality himself. He corrects the fault himself if he can, but also
communicate the problems to the different operators.
He is responsible for quantity, which means he runs the machine at maximum speed, still
obtaining perfect board.
He keeps all operators continuously informed about possible changes in program, paper,
orders, etc...
He fills in the necessary documents, so that production supervisors are constantly kept
informed about the production data.
He checks the sheets for measurements.
He can operate the complete dry-end units.
He keeps the machine in good condition, i. O. W, he reports possible defects, gets his
operators(stacker) to clean the machine and assist himself on the proper cleaning of the
machine.
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01.10.1997 chapter 2 page 35
4.3.2 WET-END OPERATOR or SINGLE -MODULFACER OPERATOR
He makes sure he has the right paper in his machine for the right order.
Checks his planning and makes sure he has the correct order of run.
Checks if his machine is operational, and ready to run.
Lines-up his paper correctly, regarding width.
starts the machine, and assist on readying the complete wet-end.
Knows the complete operation of the units (Modulfacer or Single Facer, bridge, glue Unit,
double facer.
Corrects settings which are in his reach only
(glue roll/corr. Roll gap, pressure roll gap).
Adjust paper tension, checks that the web is perfect.
Zeros his meter counter on bridge control and switches in AUTO.
Reports any anomalys to the foreman or the machine leader.
Inspects visually the good function of the machine on regular intervals.
Keeps his machine in good condition, and cleans thoroughly.
4.3.3 DOUBLE FACER OPERATOR
This job consists of controlling the bridge, bridge guides, bridge brakes, preheaters, glue unit,
hotplates.
Although it looks a complicated job, it is probably the easiest part of the machine to control,
because of the highly automated remote controls available on the modern machines.
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01.10.1997 chapter 2 page 36
5. PREPARING THE CORRUGATOR
General
CHECKLIST FOR CORRUGATORS
5.1 Different factors which can cause problems during
production..
1. Paper
2. Starch
3. Steam
4. Machine
5. Personnel
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01.10.1997 chapter 2 page 37
5.1.1 Recognizing and detecting paper faults
Humidity(generally 8 %)
Loose edges, bad winding
Absorption
Starch penetration.(drop test!)
Caliber
Calandering, smooth surface
5.1.2 Recognizing starch faults
Viscosity
Gelpoint
Solid contents and consequences
Starch temperature and consequences
Bacteriological problems
Waterproof starch
Adhesion (pin adhesion test)
Starch film:
- too much
- not enough
- Splashing
- glue line too wide, too small)examples
Starch penetration (absorption) Borax, caustic soda
5.1.3 Steamfaults
Check:
Pressure regulating for different quality
Single Flute
Double-Double
Triple
Pressure setting on different hotplate sections
(see list in Trainings program)
Condensate return
Syphon pipes and how to check if correct
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01.10.1997 chapter 2 page 38
Complete steam system by using scheme
Regulating valves for accurate regulation 7.25 psi (0.5 bar)
Temperature of all pre heaters preconditioners. Check top and bottom temperatures
5.1.4 Recognizing operational faults
Wrong operation
Operator recognizes fault: correcting the fault
Operator denies fault: investigating fault by checking cause
- machine or operation
Fault is not recognized or is not repeated: search for cause from start, and if too late, wait for
repetition
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01.10.1997 chapter 2 page 39
5.2 Checklists
5.2.1 Modulfacer group
All systems function as described
Visual faults, damage, malfunctioning systems such as:
- Doctor roll, scraper working OK (no starch on doctor roll)
- Glue dams working OK (no glue at wrong side of dams.)
- Airpressure in glue unit is OK (0.36 psi / min.25 mb)
- All hydraulic pressures OK
- Steam pressure is OK, set pressure is reached, no more than 14.7 psi (1 bar) fluctuation
- Condensate return system is working, check manometers
- Starch flow is correct, overflow is set at correct level
- Airpressure is OK (87 psi / min. 6 bar)
- All cooling systems are working.(cooling rib at glue unit, hydraulic cooler)
- All belts are running correctly, no loose hooks, no damage on edges, etc...
Visual faults, paper defects
Check paper for loose edges
Search for causes for loose edges such as:
Rolls not parallel in splicer
Rolls not parallel in pre heater and pre conditioner
All adjustable rolls must have a central position inscription. Occasional adjustments have to
be returned to original position later
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01.10.1997 chapter 2 page 40
5.2.2 EWR-VT Fingerless Single Facer
Visual faults, damage, malfunctioning systems such as:
- Doctor roll, scraper working OK(no starch on doctor roll)
- Glue dams working OK(no glue at wrong side of dams.)
- Vacuum is correct, all tubes are correctly positioned
- All hydraulic pressures OK
- Steam pressure is OK, set pressure is reached, no more than 14.7 psi (1 bar) fluctuation
- Condensate return system is working, check manometers
- Starch flow is correct, overflow is set at correct level
- Airpressure is OK (87 psi / min.6 bar)
- All cooling systems are working.(cooling rib at glue unit, hydraulic cooler)
- All belts are running correctly, no loose hooks, no damage on edges, etc...
Visual faults, paper defects
Check paper for loose edges
Search for causes for loose edges such as:
Rolls not parallel in pre heater and pre conditioner
All adjustable rolls must have a central position inscription. Occasional adjustments have to
be returned to original position later
5.2.3 Splicers
On many occasions, the accumulator rolls (speicherwagen) have been found out of parallel,
caused by the occasional forward movement at full speed, thus stopping against the forward
part of the splicer..
Missed Splices. Listen to comments from oparators and search for reason for missed splices:
- Bad splice preparation?
- Too much heat from preheaters
- (operator must learn to reduce wrap before splicing
- Mechanical fault splicer. (see possible splicer failures in manual)
- Electronic splicer fault. (see possible splicer failures in manual)
- Brake problems. Check brakepads for wear
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01.10.1997 chapter 2 page 41
5.2.4 Bridge
Check automatic bridge guiding system
Check all belts, bearings and other mechanical parts from bridge and bridge conveyor belts
Check web loops on bridge, if necessary, correct bridge belt speed
Check web for damage
Check belts for correct tensioning and correct if necessary
Check web entrance at web guides, bridge brakes en preheaters, see that width indicators
are correct and see that web is in good contact with the pre heaters
5.2.5 Glue Unit LW
Check:
All rolls for parallelism
Distance glue roll/idler roll (caliper)
Distance glue roll/doctor roll (glue film)
Scraper doctor roll, roll should be dry, no starch on doctor roll
Scraper in front of glue roll
Function and correct adjustment of the glue dams
Glue roll speed against board speed (-4%)
5.2.6 Double facer
Function and correct adjustment of :
- Chaintrol
- Airtrol
- Steam pressure and temperature in the different sections
Belt condition: edge wear, caliper, gelled starch at sides, causing board damage, belt guiding
Roller condition.:dirt on rollers (tar!), broken bearings, stopped rollers
Hotplate condition: check at regular intervals for dirt building up at edges of hotplates:
- dirt between the hotplates
- dirt on the hotplates
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01.10.1997 chapter 2 page 42
- setting of the hotplates
- lifting bars, dirt on the bars
- steam and water leakages
5.2.7 Rotary shear KR/KQM
Cutting condition: cuts all types of board up to wet paper
Correct functioning of single cut at the indicated speed
Wooden shells in good condition
Evacuation belts and rollers functioning correctly
Remote. Control is functioning correctly
5.2.8 Automatic Slitter Scorer, SRA-T and SRA-M
Precision setting up to 0.04 inch (1 mm)
Precision tandem setting
Rill depth setting over full width is correct
Knives are cutting correctly, no bad edges with correct air pressure
If available, correct functioning of the E&L system
5.2.9 Guide tables and paddle unit PE
Board line is perfect (no board jumping, board is supported everywhere)
Measuring wheel is correctly adjusted, runs parallel with the bottom roller and causes no
marking of the board, no movement when running, no jumping and the wheel surface is kept
clean. (no tar or double sided paper or any other objects at wheel run surface)
paddles setting is correct, movement is correct speedwise and are adjusted at correct height
Board is not jumping when cut with NQM occurs
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5.2.10 Cut-off knives NQS-D/NQM
Precision cutting: 0.04 inch (1 mm) for 95%
Perfect boardline: Board runs correctly into pull rolls and is supported by the tables(no
jumping when the knife cuts!)
Pull rolls are set perfectly parallel
Board runs exactly between top and bottom knife bars
Exit conveyors are set at correct height and at correct caliper
Board moves correctly onto stacker
Knives are cutting cleanly, no ragged edges. Board is separated at all speeds
5.2.11 Automatic stacker AAR
Board does not show any damage when transferred from Knife to stacker
Brush program is set correctly, and pressure is adjusted
Belts are running correctly and without damage
Venetian blind functions correctly
Stacks are neat and have the correct count
Board runs through the stacker correctly, and without jams
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01.10.1997 chapter 2 page 44
5.3 Preparing the start-up
Always start at the beginning and work your way down:
1. Put the paper in the roll stand, make sure the unwind direction is correct
2. Thread the paper into the splicer making certain that it is done correctly
3. Prepare the single facer for running
4. Prepare double facer for running
5. Check slitter scorer
6. Start trim suction
7. Set the paddles
8. Set the pull roll gap
9. Set the cut-off knifes
10. Check if all settings are in auto
11. Set the stacker:
- -brushes
- -backstop
- -shingling program
12. Start automatic conveyor system
5.3.1 Threading the splicers
1. Switch on the splicers and roll stand electrics
2. "Zero" the splicers, i. O. W, make sure the correct paper is threaded through the splicer. If
necessary, change splicer roll position by making a splice without paper, or with the ARW-M
by pushing the Homeposition button.
3. Feed the paper through, following the thread-up sketch shown at the side of the machine.
Before you do so, switch splicer electrics "off" to avoid any accident, caused by automatically
moving rolls.
4. Thread the paper through the auto tensioning unit, and through the preheater and
preconditioner. Note: Zeroing" the splicer simply means that the splicer carriage should be
at the right position, it will show very quickly if this is correctly done, as it will be impossible to
make a splice if the carriage is in the wrong position
5. Do not forget to bring the accumulator to its end position, by pushing the
- button, otherwise, the splicer will not function.
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01.10.1997 chapter 2 page 45
5.3.2 Starting the single facer
1. Check if all systems are switched on: Oilpump, vacuum pump, auxiliary glue roll drive
2. Put pressure on corrugator rolls
3. Open pressure roll
4. Put glue unit in auto-position, clamps in vertical position.
5. Make sure starch level is correct
6. Set glue-dams at approx. Correct width, and switch to auto when machine is running with
paper.
7. Set glue-film at correct gap
8. Thread paper into machine
9. Note: there are 2 different ways of threading the S. F:
10. Check if all systems are sw
5.3.3 Fluting first (Only for EWR-VT)
Paper is threaded through splicer, preconditioner and into the S. F. The paper is run through the
machine, until the complete corrugator roll is covered with paper, the machine is then stopped,
the pressure roll closed, the glue unit is closed, the machine restarted, and the paper fed into
the take-up conveyors. This way of threading in the paper is particularly interesting for fingerless
single facers running with vacuum systems, as it prevents glue being picked up by the suction
system if glue unit is switched in to quickly. This way of threading up does not apply for
pressurized Single Facers.
5.3.4 Liner first
This is the most common way, and was always used on normal single facers. Open pressure
roll, put pressure on the corrugator roll Start the machine, thread paper through machine, pull
the paper straight, and feed the liner into the take-up conveyors. Stop the machine, close
pressure roll, insert the fluting, start the machine. When the corrugator roll is fully covered with
paper, switch the glue roll "in"and guide the paper through the take-up conveyors.
Cut a point diagonally across the machine, to prepare the web for threading through the double
facer. Switch the bridge control into automatic. Switch the paperbreak system "on", and check
your board.
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01.10.1997 chapter 2 page 46
5.3.5 Starting the double facer
1. Set the web-guides at the correct width
2. Set the wrap arms at the threading-up position
3. Make sure the brake-roll on the -bridge turns freely, i. O. W. take the brakes off.
4. Set the correct flute height at the correct station, (C or A flute to the top station, b flute to
the bottom)
5. Set the glue film (gap between glue-roll and doctor roll)
6. Make sure the glue pan is in the up position.
7. Set the glue dams at the correct position, and switch to auto if system is available.
8. Check splicer for correct position of the carriage, put the accumulator roll forwards, and
thread paper through. Warning: Never thread the splicer with the power on the machine,
always switch-off when you have to go into the machine.
9. Feed paper through the auto-tensioning unit, making sure the balance roll is in the down
position, check that the brakes are "off" and in "manual"
10. Feed paper over preheater
11. Start double facer, put the liner into the hotplates and let
it pull straight, then stop the machine.
12. Thread the web into the unit
13. Start machine, introduce the web, put brake on bottom liner and web.
14. Check alignment and correct if necessary. Note: it is important to run the board in the center
of the machine, the good functioning of the order-change will depend also greatly from the
correct centering of your board, as the automatic slitter-scorer is working in the center also.
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01.10.1997 chapter 2 page 47
5.3.6 Starting the dry-end
Checks to be made before production start, make sure everything is in correct position:
1. Rotary shear if ready for cutting
2. Slitter scorer is ready: are the doors closed, no red indicators on the unit such as
emergency stops, air pressure should be minimum 87 psi (6 bar).
3. Paddles are set correctly if in manual mode.
Note: paddle setting causes more stoptimes than anything, mainly due to the fact, that very
often, one or two paddles are in the "up" position, whereas they should have been "down". Make
sure that there are always enough paddles "down".
4. Check trim suction for correct setting, if 2 units are being used (sra-t), check if change over
valve is at the right position.
5. Check if cut-off is ready.
6. Check if automatic take-off is ready: backstop setting, brushes, belt speed program is
correct .
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6. RUNNING FLAT BOARD
6.1 Types of warp
Warp is defined in three stages:
a. Direction in relation to the machine
b. Shape of the warp
c. Where is it observed, which stage in the production process at the corrugator, or later
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a) Direction in relation to the machine
- Machine direction, otherwise known as end to end warp
- Cross machine direction, otherwise known as side -to -side warp
- A combination of both a.1 and a.2 is called "Twist warp"
b) The shape of the warp refers to its curved profile. This can be:
- Normal warp or "up" warp, with its edges turned up
- Reverse warp or down" warp, with its edges turned down
- S-warp, which is a combination of b.1 and b.2
c) The final classification results from where the board is actually observed for warp. This can
either be:
- Directly at the corrugator, usually at the take off
- At any given time after the board left the machine, whereby it is important to record the
timelapses between the different warp checks
6.2 Causes and Remedies
Warp is caused by imbalanced forces, either created by the machine, operator, or paper faults.
We will look into these possible causes, and discuss what we can do to improve the board
flatness and where the limits are before we have to accept that we can under certain
circumstances, no longer guarantee flat board.
6.3 Machine direction or length warp
This is mainly due to imbalanced forces in the machine direction. There is some dimensional
change(shrinkage) due to moisture effects which will be explained later, but generally speaking,
this type of warp is mainly due to uneven tension in the liners, after leaving the double facer.
Therefore, the solution is usually easy. Too much tension on the SF Liner can also cause length
warp.
Down warp:
Too much brake at the bottom liner, not enough at the web.
Action:
- Release the brake at the roll stand
- Increase the bridge brake
- Decrease the liner brake
- Decrease the tension on the SF Liner
A good functioning bridge brake is the best tool to prevent this type of warp.
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Up warp:
- Too much brake at the bridge brake, not enough at the liner
- Too much pressure between rider roll and glue roll
Note: Because the glue roll is running slower than the board, in many cases this excessive
pressure between rider roll and glue roll is the sole reason for upwarp. This can also cause twist
warp if the rider roll is not perfectly parallel with the glue roll!.
Action:
- Release the bridge brake
- Increase the liner brake
- Adjust the rider roll on the glue unit
Note: Preheaters can cause a lot of brake in the paper, due to friction. Many machines, if not
most have their preheaters blocked either because of technical problems, such as bearing
broken or blocked, or oil or grease systems out of order due to the use of wrong oil or grease.
Remember to use high temperature oil or grease, as this is the main reason for faulty bearings.
Once a preheater has been blocked for an extended period, it will be very difficult to make the
preheater to turn again. For light qualitys, this can have disastrous consequences regarding
length warp. Blocking a preheater is in most cases absolutely not necessary, and can only
cause trouble. It has to be remembered that the preheaters have mainly a braking system, not a
blocking system. Only when running very heavy liners 61.5-82 #/msf (300-400 gr/m2) can a
brake help to increase the temperature or even out the paper
6.4 Cross machine directional warp
The main reason that up or down warp occurs is shrinkage. This is due to a property of paper
called "hygroexpansivity". Which means that when moisture is put in the paper through starch or
other means, the paper will expand, but when this moisture is driven out, it will contract to a
smaller size than it was originally. In other words, the result is shrinkage. The effect is more
noticeable if the bond is formed whilst a liner is in the WETTED stage, when sufficient moisture
has been driven off. In this and similar cases, the warp may not become apparent immediately
after the board leaves the machine, but only after the board has been aged in storage. By
contrast to length warp, since there is little if any web tension across the machine, warpage
more frequently occurs in this direction. It can be said that cross machine direction warp (up or
down warp) is mainly due to moisture differences between the liners, particularly at the point of
firm double facer bonding.
It is probable that the single face liner will be wetter than the double facer liner, due to the
amount of moisture that has been added to it before it reaches this point. The moisture is added
by the water in the single facer adhesive which has not been driven off; by steam absorbed into
the S. F web during its time spent on the bridge, absorbing in addition that moisture driven off
from the double face glue line whilst in the double facer. Also whilst losing moisture from its glue
line, the double facer liner between the flute tips is being dried out considerably within the
double facer. On leaving the double facer the two liners will undergo moisture equalization with
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the surrounding atmosphere. This will involve the S. F liner in losing moisture and shrinking, and
the D. F liner in gaining moisture and expanding, therefore causing normal warp.
Note: Since the introduction of heavy concentrated starch, the above effect has become less
apparent, mainly because of the reduced amount of water in the starch. Also since the
introduction of the fingerless single facer, glue films can be set much more accurately. At the
same time, we have to conclude that the paper humidity content becomes much more of a
problem. On several occasions, tests where carried out on high speed machines 820 ft/min
(250 m/min and more) by using scanners across the machine, it was found that the warp
diagrams obtained from moisture readings, coincided completely with the warp profile at the end
of the corrugator, hence the need for extremely accurately balanced liners in cross machine
direction.
6.5 What can we do to control warp?
Within the corrugator there are several units and parts of units which can influence the moisture
content or the tension of the paper passing through them. Some, such as preheaters or showers
or water sprays can be used directly as control elements, and the careful monitoring of others
such as glue gap and paper temperature can lead to the reduction eventually the disappearance
of warp all together. Modern, high speed machines have much more possibilities and are much
easier to handle. It depends very often mainly from a very attentive and quality conscience
operator how good the quality of the board will be that is produced. When we talk about quality,
warp is a major factor in it. The following sections will discuss what variables in the corrugator
can be used to limit the warp to an acceptable degree, if there is such thing as an acceptable
degree" of warp
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6.6 Warp and solutions to cure
1. DOWN WARP. 2. UP WARP. 3. S or TWIST WARP
SINGLE FACER
Check and adjust (-) Glue gap at
DB if possible.
Check and adjust (-) glue gap at
SF if possible
Check for glue roll/
corrugator roll parallelism at
SF
Reduce wrap at SF Preheater. Increase wrap at preheater SF. Check for glue roll/ doctor
roll parallelism
Reduce bridge loading to
minimum.
Increase bridge loading to
maximum
Check vacuum in tubes and
flexibles.
DOUBLE FACER
Reduce wrap at DB web
preheater
Increase wrap at DB web
preheater
Check for glue roll/ rider roll
parallelism
Increase wrap at DB Bottom
liner preheater
Reduce wrap at DB Bottom liner
preheater
Check for wrap arm
parallelism at all
preheaters.
Increase Chaintrol/ Airtrol Reduce heat in hotplates. Check glue roll/ doctor roll
parallelism
Increase heat in hotplates. Reduce Chaintrol/ Airtrol Check that paper is tight
against all heating
surfaces.
Paper too wet at DB. Change
paper.
Paper too wet at SF. Change
paper.
Uneven humidity over
width of reel, change
paper.
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1. DOWN WARP 2. UP WARP
1. Increase Bridge brake tension. 1. Decrease Bridge brake tension.
2. Reduce Bottom liner tension. 2. Increase Bottom liner tension.
3. Check and correct web temperature 3. Check and correct web temperature
4. Check glue roll/rider roll parallelism 4. Check glue roll/rider roll parallelism
5. Check glue rol speed 5. Check glue roll speed.
6.7 Preheaters and preconditioners
6.7.1 Preheater
The function of the preheater is two fold:
- To heat the paper
- To control warp
When controlling the warp with a preheater, a few rules have to be observed to avoid problems
with the S. F.
As mentioned before, the function of the preheater is not only to control the warp, but in the first
place to heat the paper. To often, since the appearance of machines operated from a central
control desk, operators tend to forget this primary function, and sometimes remove the wrap
completely to adjust for warp, at the same time running badly glued board due to lack of heat.
This can be detected easily at the glue line appearance, they will be white, whereas in normal
glued board, they should always look yellow. On most modern machines, another feature is
included in the system. During the speed-up of the machine, the wrap arms do not move, the
machine has to run steady before the wrap arms start moving. This also means that speeding
up the machine from zero to maximum speed, will inevitably cause bad board, due to the fact
that the wrap will not have the time to react.
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Another consequence from not using the preheater can be very badly twisted board. It is
therefore essential to check the paper going into the different machines for temperature, as this
might help you by detecting faults on the machine.
Wrapping the paper
Incorrect wrapping Correct wrapping
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How to thread the liner and why
There are two ways to thread the liner into the preheater. We can thread the paper over or
under, thus heating the inside or outside of the liner. There have always been numerous
discussions why we should use one way or the other. Lets look at the reasons why we thread
differently towards different conditions.
As a general rule, we always heat the opposite side of the glue line, i. O. W. we heat against the
side where the glue is applied. This makes the moisture to be forced through the paper, thus
wetting the side where the glue is applied. This means that the S. F paper is threaded under,
and the D. B is threaded over. This way of threading assures us the best starch penetration into
the paper.
However, in reality we should really test the paper for its glueability. With a good absorbent
paper, it could be more efficient if we heat the bonding side or the side who comes in contact
with the glue.
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Examples of Wrapping Preheaters.
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We also have to look at the closeness of the paper. A closed paper which is difficult to humidify
by the glue, should not be heated to much, because this will accelerate the gelatinisation of the
glueline and disadvantage the humidification.
Heavy liners 61.5 #/msf (300 g/m2 and above)are usually run better when heating the bonding
side. However, most of the modern Single Facers have the possibility to heat both sides, as the
small liner preheater directly at the front of the Single Facer is used, or the machine is
equipped with a double Preheater. It is certainly worth to consider the introduction of a second
preheater when running a lot of heavy board.
Again as a general rule, we should be very careful to heat the bonding side, as this might cause
very brittle gluelines, and will show very bad pin adhesion test figures, especially when running
very light qualitys, such as white 25.6 #/msf (125 g/m2) Kraft as a liner
Another point of discussion is the fact that some people run with stopped preheaters against
running preheaters. The main disadvantage of stopped preheaters is the fact that the reason
they are usually stopped, is waterlagging, i. O. W. The siphon pipes in the preheaters are not
correctly fitted, or broken, and when the preheater is used, the bottom half is sometimes filled
with water, reducing the effectiveness of the preheater to a bare minimum. Especially when
starting on a Monday, this could have very serious consequences for the production. The only
time that stopped preheaters can give you good results, is when you need extra tension on the
paper, for ex. when there is space over the paperwidth, causing blisters, or when the roll stand
brakes are too weak to apply sufficient brake on the paper, or when the bridge brake is not
functioning properly.
Also when running very heavy liners a stopped preheater can improve the quality, again due to
the ironing effect of the preheater. In any case, a preheater should be running as much as
possible, because if stopped for longer periods the drum might not rotate at all any more,
causing most of the time too much brake on the liners.
6.7.2 Preconditioner
It is extremely important that we recognize the difference between a preconditioner and a
preheater. A pre conditioner makes sure our fluting enters the single facer in the best possible
condition, thus ensuring we have the best possible flute formation. Most of the time, it is
necessary to heat the fluting to assure that the paper becomes soft, due to the fact that the
moisture is brought to the outside of the paper. Especially at higher speeds, a preconditioner
becomes extremely important. Also it should be made clear that a preconditioner must be
driven, because if stopped, it creates to much brake into the fluting and therefore can cause
broken flutes and in case of fingerless Single Facers, the fluting can be pulled out of the
corrugator rolls into the glue pan. The speed of the preconditioner should be slightly higher than
the paper (1-2%) to assure the pulling effect onto the fluting.
It is generally accepted that the preconditioner has very little effect on warp, and therefore
should be mainly used to pre condition the fluting. Only a very wild moisture profile of the
medium can sometimes cause warp board, especially S-warp
If the preconditioner is equipped with an additional shower, we should make sure that this
shower is in good condition, and that we can use the shower when ever we need to use it.
Especially with dry Semi-Chemical flutings, it might be very useful. On the other hand, when the
shower is not functioning well, for ex. if water is put into the paper instead of wet steam, this
might cause considerable stoptimes, due to paper sticking into the corrugator rolls.
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6.8 Glueability potential of paper.
It is well known that paper should have an open surface in order to allow formation of strong
glue bonds during production of corrugated board.
ECP laboratories have developed a procedure to evaluate the surface porosity of paper. It is
based on the determination of the glue uptake on a laboratory size press.
The procedures are as follows:
1. Preparation of the adhesive.
0.66 lb (300 g) one bag mix product (c. B.) are added to 0.24 gal (900 ml) water while
agitating with a propeller stirrer at 750 rpm. Subsequently agitation proceeds for another two
hours at 1450 rpm. The end viscosity should be approx. 50 SH seconds.
2. Preparation of the paper.
A plastic layer is glued on one side of the paper, the side not under investigation. The
sample is cut, 4 inch (10 cm) wide and 5.5 inch (14 cm) long. The weight is determined.
3. Determination of the glue uptake
The adhesive is added to the laboratory size press (see fig.)and the paper sample is allowed
to run between the rolls, with the side under investigation directed to the rubber roll(plastic
side to the ceramic roll)
The pressure between the rolls should be kept constant and the running speed low. The
paper samples are immediately weighted again. The difference in weight before and after
the experiment indicates the glue uptake
4. Conclusions.
Experiments with hundreds of paper samples show the following:
*The minimum and the maximum value obtained is 0.8 #/msf (4 g/m
2
) and 6.1 #/msf
(30 g/m
2
), respectively.
*Papers with a value above 3.1 #/msf (15 g/m
2
) have an open surface, allowing strong
bonding.
*The surface of the paper with a value at or below 2.3 #/msf (11 g/m
2
) is difficult to penetrate
from the adhesive, strong bonding is not self-evident. Contrary to traditional methods, such
as Cobb-test and Bendtsen porosity measurements, the so called glue pick-up test allows
evaluation of one of the paper properties of major importance. The method is quick, allows
easy handling and can be used on a frequent basis as quality control procedure.
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6.9 The Golden Rules of Running Good Board.
6.9.1 How to thread paper.
Performance liners should be wrapped with the smooth felt side against the preheaters. This
drives the moisture toward the wire side that will be bonded, thus improving the pin adhesion.
Exceptions: certain duplex papers (testliners can be very difficult to heat, thus demanding the
reverse.)
6.9.2 Paper tensioning
All medium and web liners should have equal tension across their entire widths as they wrap
around a preheater or any other heated roll. Uneven tension will result in the formation of heat,
moisture streaks, as well as uneven stretch streaks in the liners or medium. Therefore, it should
be checked if every roll, preheater or preconditioner is well aligned in the machine and easily
adjustable web idler rolls should be installed before preheaters and preconditioners, and these
should be continuously used to keep the web tensions as balanced as possible.
Whenever installing these rolls, make sure the central or parallel position of these rolls are well
marked!
6.9.3 Heating the paper.
Because performance liners heat faster, great care should be taken to use as little wrap as possible
at the preheaters. Ideally, an optical infra red Pyrometer should be used to measure and control the
temperatures of the Single Face liner and the medium before it reaches the corrugating rolls,
insuring that both papers have reached the necessary temperature for bonding, and have not
seriously exceeded it.
The temperature will vary slightly depending on the adhesive and other variables, but usually will be
around 194-230 F (90-110 C) for the liner, and about 176 F (80 C) for the medium. Across-the-
web temperature measurements are also an excellent method for ensuring that the entire web is
uniform and constant. Continuously monitoring with infra red sensors across the web and reacting
accordingly is the ideal way of ensuring top quality board.
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6.9.4 Conditioning the fluting
A good performance medium in order to flute properly without damage, needs to be temporarily
softened by both heat and moisture. Depending on the condition of the paper, the amount of
wrap is decided towards the temperature of the outgoing paper and the humidity contained in
the paper before reaching the preheater, i. O. W. It is absolutely nonsense to put excessive
amount of shower steam in the paper without heating the surface, hence bringing the moisture
at the outside of the paper. The correct amount of wrap will result in a perfect bonding and an
ideal flute formation, preventing fluff-out after being glued. Bad preconditioning will result in
reduced flat crush, e. C. T and pin adhesion strength.
Correct tensioning of the paper will ensure a good heat transfer and even temperature over full
width
6.9.5 Correct glue lines.
The width of the glue line is very important to obtain good bonding. The Single Facer glue line
should have a width of approx. 0.1-0.11 inch (2.5-2.8 mm). If the glue line is substantially below
this value, reduced (insufficient) pin adhesion strength will result. If much wider lines are
observed, wash boarding will result. This width should be checked over the machine width, to
ensure even glue lines at different speeds.
6.9.6 Parallelism of rolls.
At least once each month, non carbon required (N. C. R.) impression patterns should be made
of the corrugating rolls, checking for uniform loading pressures and crown, as well as the
parallelism of the corrugating rolls. N. C. R. Patterns should also be taken between bottom
corrugating roll and pressure roll. This can be done with a running SF across the full width of the
machine.
Equally important is the parallelism between applicator roll/doctor roll and corrugator
roll/applicator roll. These checks will assure that corrugator rolls are parallel, and that applicator
roll/doctor roll and corrugator roll/applicator roll settings are correct.
6.9.7 Running the Double back (DB) liner
The DB liner should also be run with the felt side against the preheater (heating against the
glue-side)to drive the moisture toward the side to be glued, and with as little wrap as practical.
Again an Optical Infrared Pyrometer can be used to adjust the wrap to a target temperature of
approx. 176-194 F (80-90 C)on the side of the paper to be glued as it begins to enter the hot
plates. Web alignment and even web temperature are equally important as on the SF liner.
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6.9.8 Gluing the Double back (DB) liner
The width of the DB glue line should be approx.0.08 inch (2mm). If this width is exceeded,
unnecessary wash boarding will result, and if this width is too small, reduced pin adhesion
strength will occur. Here again, checks across the machine width should be made to ensure
parallelism of applicator roll/doctor roll and applicator roll/pressure roll. Check that caliper is set
correctly!.
6.9.9 Controlling the finished board
By monitoring the combined board temperature with an Optical Infrared Pyrometer leaving the
Double facer, you should be able to ensure that enough heat is present to obtain good bonding,
without overdrying the board. This temperature is usually between 176-194 F (80-90 C) at the
SF side and between 194-230 F (90-100 C) at the DB side. Keeping control of the temperature
at all times, will prevent potential problems with your board quality.
All these figures are guides, small variations can occur depending on the quality and the weight
of the papers, but these figures can help you in resolving quality problems.
6.9.10 Starch adhesive
Particularly for high performance board machines, starch is important for the overall picture.
High solids combined with low viscosity will undoubtedly increase the speed and quality of the
gluing process. Dual or even triple starch viscosity will give you the possibility to obtain optimum
condition to run your machine as best as possible. Contact your starch supplier at regular
intervals to ensure you have the best conditions at all times. Ex. The gel temperature for the SF
can be set quite high to allow greater penetration, should be quite low for the DB for faster
running speeds.
6.9.11 Steam
Good functioning of the steam system is of utmost importance for your speed and quality of the
board.
Check at least once a month for :
Proper functioning of steam traps
Correct positioning of the siphon pipes. This can easily be done by checking the roll or drum
surfaces at the top and compare with the bottom. Temperature differences should be
minimal, if not, water lagging will occur in the drums or/and rolls.
Clean filters. Particularly with new installations, it can take up to one year to get rid of all the
dirt in the pipes, rolls caused by welding, cutting etc...
Check regulating valves for good functioning. Especially with machines running a big variety
in quality's (ex: from E-Flute up to heavy grade Double Wall).Good regulation of heat in your
machine will prevent warp and waste.
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6.9.12 Lining up paper in Corrugator rolls!
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7. INSTRUCTIONS FOR PRODUCTION AND
MAINTENANCE PERSONNEL
7.1 SINGLE FACER BHS EWR-VT
7.1.1 Production
Start-up Single Facer
Switch on Main Panel
Switch on oil pump, and open cooling water circuit
Start S. F, run at idling speed
Open Main Steam valve progressively
Place glue dams in glue tray
Open starch valve and start return pump
Start Idling motor glue roll
Start Vacuum pump, if necessary, open cooling circuit
Advance glue roll in automatic position, and lock unit
Use of the different settings. Stopped and running SF
Glue Film setting
Distance Glue roll-Corrugator rolls
Distance Pressure roll-Corrugator roll
Set hydraulic pressure Corrugator rolls
Set hydraulic pressure at Pressure roll
Set glue dams for correct paper width
Set Vacuum Tubes for correct paper width if necessary
Set wrap arms in automatic if possible
Set steam shower
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Starting the S. F with paper
Check if all systems are switched on (oil pump, vacuum pump, auxiliary glue roll drive)
Put pressure on Corrugator rolls
Open pressure roll
Put glue unit in auto position, clamps vertically
Make sure starch level is correct
Set glue dams at approx. correct width and switch in "auto when paper is in machine
Set glue film at correct gap (approx. 0.30-0.35) and switch in "auto"
Thread paper in the machine
Checks during production runs
Cooling system (pumps and water jacket)
Feed and return lines starch system, level in glue tray
Vacuum system (flutes are held in corr. Rolls.)
Glue film is correct
Distance Glue roll-Corrugator roll is correct (check regularly with splice tape, specially in
morning when frames are still cold
Check vacuum tubes for position after replacement (Tubes only need readjustment when
problems where encountered!)
Constant check if paper is running well into machine. (make sure the paper runs correct
between slots or tubes.)
Line up of paper is correct. (liner should always be in center of fluting and glue is not
transferred onto corrugator rolls.)
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7.1.2 Cleaning instructions at end of production
1. Switch off bridge control, paper break, and glue dam automatic
2. Slow down machine to idling speed and cut the paper, making sure the glue roll is away
from the corrugator rolls before the fluting is out of the rolls!
3. Shut off pressures, corrugator rolls and pressure roll
4. Shut off starch lines, empty glue tray
5. Bring glue trolley out of machine
6. Switch on automatic cleaning of the suction nozzles
7. Stop vacuum pump, close cooling water system
8. Clean the glue roll and glue tray with water and stop the idling roll. (Once a week, take out
the glue dams and clean completely)
9. Clean the complete machine with steam jet
10. Clean surroundings and outside of the machine, take special care for the glue dam guides
11. Clean filters(motors, panel etc.)
12. Close steam lines and stop machine
13. Switch off main panel
7.1.3 Safety and Maintenance instructions
Production
During every long stop time.:
- Retract glue trolley to avoid starch heating and gelling
- Clean the suction nozzles in "auto, always make sure the glue trolle
- is out of the machine.
Caution: Before starting the cleaning sequence, make sure nobody is in the machine!
- Switch off all hydraulic pressures
- Stop the vacuum pump
- Run the machine at idling speed
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Maintenance
During every long stop time.:
Oiling the glue tray rails (a few drops of oil will do)
Grease the Glue Dam guides
Make sure the limit switches are clean and work properly
Maintenance Safety instructions when working at SF
Before fore switching on main panel, make sure nobody or nothing is in the machine
Before starting the machine, warn all the people concerned (operator or supervisor)
Never interfere with running machine(example: setting nozzles!)
Always put on gloves for heat protection. Never work on the nozzles with short sleeve shirts!
When using the steam jet or automatic nozzle cleaning, take maximum precautions: never
direct the steam (live 189 psi/13 bar steam) to other people
Read carefully the instruction manuals delivered with the machine
Never bridge out or disconnect the safety devices on the machine!
Take care not to fall on to the preheaters or preconditioner when carrying out work on the
machine. Cover up the drums with sheets of board
Always look after youre own and your colleges safety
7.1.4 Maintenance and grease instructions
Follow instructions as described in the manual
List of grease and oil points for periodic maintenance can be found in the manual
Instructions and translations of the electronic schemas are given during the start and training
period
If these should prove to be inadequate, supplementary courses can be arranged at
Weiherhammer for electricians, mechanics and electronic engineers
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7.2 BHS MODULFACER. (PRESSURE)
7.2.1 Instructions for start-up
Following conditions must be met to start MODUL FACER:
EMERGENCY STOP key has been released
Main drive ventilator must be in operation
All interlocks such as Thermal protection, over current, Fuse control and Main drive Thyristor
set Thermal protection have not been activated
Control voltage is present
Scraper limit switch has not been activated
Motor protecting switches for ventilators have not been activated
Stop command bridge control, splicers and machine stops have not been activated
Wrap-up control corrugator rolls is active
Water flow detector for gearbox lubrication has not been activated
Note: All of these checks can be made through the screen diagnostic system delivered
with the machine!.
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7.2.2 To start machine
Visual checks for obstructions and notes, left by personnel
Switch main panel ""ON"
Switch:
- Pressure roll pressure OFF
- Corrugator roll pressure ON
- Glue roll pressure OFF
Start Modul Facer
- Switch ON oil pump
- Switch ON take-up conveyors
- Slowly open steam valves
Start starch pumps and open valves (feed and return lines.)
Start glue roll motor.(switch ON coupling.) Switch ON auxiliary motor
Note: Never switch ON glue roll without starch being fed between the rolls. Running the glue roll
dry can cause damage to the scraper blade and the glue dams!
Feed liner into machine:
- Close pressurized glue roll compartment
- Switch glue unit into auto position by pushing the glue roll "IN" button until light on left side
comes ON. (This can only be done from the glue unit side, and not from the preconditioner
side for safety reasons.)
- Bring wrap arm pressure roll fully down
- Bring wrap arm preheater fully down
- Thread paper into machine and into take up conveyors
Feed fluting into machine:
- Start Blower motor
- . Apply a small piece of double sided tape to point of paper
- Switch pressure roll UP
- Feed point into corrugator roll nip
- Switch glue unit ON
- Cut point onto the web
Training Manual
01.10.1997 chapter 2 page 70
7.2.3 Conditions to speed up machine
Before speeding-up, check following
Blower is running correctly(triangular)
Lubrication pump is running (green pilot light is steady, if not, check for clogged filters and
min. and max. Pressure.)
Progressive oil distributor protection has not been activated
Slow commands are not activated
Glue roll idling motor is switched "ON"
Transmission lubricating oil pump is running
Coupling glue-unit is engaged
Nominal/real values control has not been activated
7.2.4 Second set of corrugator rolls
When not in use, close steam valves and stop rolls. Clean rolls with steam jet delivered with the
machine. If necessary remove all residues from rolls. Make sure no foreign material or dents or
other damages are present. If so, report to maintenance personnel immediately.
Do not spray cold water onto heated corrugator rolls! This might result in cracks or
distortion of the rolls!
Do not use cleaning agents which contain abrasive material! Seriously reduced roll
lifetime will result.
When it is necessary to use, start rolls ONE HOUR PRIOR TO OPERATION, and open steam
valve slowly.
Training Manual
01.10.1997 chapter 2 page 71
7.2.5 Instructions to stop the Modul Facer.
Slow down machine to bottom speed
Cut fluting.(liner can stay in machine!)
Switch:
- Glue unit OUT
- Pressure roll UP
- Take up conveyors OFF
- Stop Blower
Bring glue unit fully OUT
Open cover glue unit, and close starch lines
Clean glue roll abundantly with water. When clean stop roll. Clean rest of machine with
steam jet
When machine has been cleaned:
- Stop auxiliary motor
- Switch clutch OUT
Close steam and condensate valves
After approx. 15 min. Sop Modulfacer
Switch corrugator roll pressure OFF Switch main panel OFF
7.2.6 Changing Modules
Slow down machine to minimum speed
Cut fluting out of Modul Facer
Bring Glue unit out to Auto-position
Stop Blower
Stop machine
Switch glue unit to fully out
Switch change over switch to position as required.(Yellow flash light starts flashing!)
Select correct Modules. Bring one OUT, bring other IN
Push buttons in correct order. Follow the automatic sequence, the lights are pulsing in the
correct order. Push button until light is steady
Feed fluting paper back in machine as explained before
Training Manual
01.10.1997 chapter 2 page 72
7.2.7 Cleaning the Modul Facer.
In order to maintain continuous operation of the Modul Facer, it is essential that the machine is
kept clean. The following instructions have to be followed when cleaning the MF.
Before starting the cleaning, make sure all safety precautions have been taken!
Safety provisions for cleaning.
Prior to any work carried out on the MF, machine and blower must be switched OFF. Make sure
all movements have ceased.
If, for any reason, work has to be carried out on a running machine, the utmost care has
to be taken, such as:
Wear no loose or suspending clothing
Long hair has to be covered!
Suspending jewelry, rings as well as other personal items, which might be entangled by the
machine have to be removed!
No work may be performed in the immediate vicinity of roll intake, swivel range or moving
mechanisms with machine running
It has to be ascertained that machine is running at bottom speed, and that a qualified person
is positioned at the EMERGENCY STOP switch
Be careful when working at heated machine, wear protective clothing and/or close off steam
valves
For machine protection!
Make sure:
- the glue-unit is fully retracted
- that the pressure roll does not touch the top corrugator roll
- the pressure on all rolls is zero ("0")
- not to spray water onto the corrugator rolls or other heated parts
Caution: Heat shock might result in cracks or distortion of heated parts!
Training Manual
01.10.1997 chapter 2 page 73
7.2.8 Cleaning of both corrugator rolls and pressure roll
Clean rolls with steam jet delivered with the machine
Caution: Do not blow dirt against side frames!
Check rolls over the full width, if necessary remove all residues from rolls. Make sure no
foreign material or dents or other damages are present. If so, report to maintenance
personnel immediately.
Clean pressure roll scraper with steam jet, and if necessary, remove gelled starch and paper
with plastic spatula
Check if scraper blade is in good condition
Do not spray cold water onto heated corrugator rolls! This might result in cracks or distortion of
the rolls!
Do not use cleaning agents which contain abrasive material! Seriously reduced roll lifetime will
result.
7.2.9 Cleaning the glue unit.
Fully retract glue unit
Drain starch from unit
Thoroughly clean glue pan, glue roll, doctor roll, scraper, glue dams, cooling jacket with
water. Gelled starch and other foreign materials to be removed with steam jet
All loose parts to be cleaned with water
Check glue dams and scraper blade for wear or damage.(when not correct, maintenance to
replace with new ones!
Main drive filter cleaning.
The main drive motor filter mat has to be cleaned daily.
The best way to do this is to beat the mat against the wall or pillar(at a safe distance from the
motor, to avoid the dust being sucked up again by the fan!)
7.2.10 General
Clean the machine surroundings completely and remove all paper rests, gelled starch and
other foreign materials
Clean gangway, steps and floor. Remove any oil or other liquids from operational and
maintenance range to avoid accidents caused by slippery surfaces!
Look after your and others safety at all times!
Training Manual
01.10.1997 chapter 2 page 74
7.2.11 Daily Cleaning.
Checklist for the MF operator
1. Clean MF with steam jet(swivel out Modules)
2. Wash complete glue unit with water jet
3. Check free movement and wear of glue dam seals and readjust or replace if necessary
4. Check spray cleaner at applicator roll
5. Check and clean sealing elements(doctor roll)
6. Check glue supply and return
7. Check and lubricate rails of glue unit
8. Check pressure roll and doctor roll scrapers
(Visual check of doctor roll can only be made if glue level is at least 30 mm higher than the
scraper blade
9. Clean Teflon seals on sealing bar/corrugator roll and check wear(minimum thickness 2mm!)
10. Check smooth running and wear of sealing roll and felt packing
11. Clean all glue unit seals
12. Clean backstops and wedges on each corrugator roll set
13. Check groove cleaning fingers on each corrugator roll set and replace or adjust if necessary
14. Check filters of switch cabinet fans and motors
15. Check oil levels of hydraulic and lubrication system
16. Ensure functioning of cooling water circulation
17. Maintenance most be informed immediately of any damage
OBSERVE ALL SAFETY REGULATIONS!
Training Manual
01.10.1997 chapter 2 page 75
7.3 Splicer ARW-N
7.3.1 Production
Splicer Start up
Always check first that the unit is free and nobody is in the machine.
Threading the splicer
1. Switch on the splicer and roll stand electrics
2. "Zero" the splicers. I. O. W. Make sure the correct paper is threaded through the splicer. If
necessary, change splice roll position by making a dummy splice
3. Bring accumulator roll forward by pushing the <--- button
4. Check that the paper is correctly put in the roll stand
5. Check line-up
6. Switch off the electrics on the splicer by turning the main switch to "off Never climb
into the splicer with the power "on. Automatic sequences in the splicer could set off
without warning and causing serious accidents!
7. Feed the paper through the splicer, following the instruction sketch at side of the splicer
8. Thread paper through the auto tensioning unit and preheater or preconditioner
9. Switch on the splicer electronic
10. When machine is running, bring accumulator back in the correct position for splicing by
pushing the --->button
Note: When accumulator is in the forward position, splicing is not possible!
11. Prepare the next reel for splicing
12. Follow the directives as given by the BHS specialist
13. Check paper unwind direction and select the correct drive direction at the auxiliary air drive
motor
14. Switch the Fintrol system(Auto-splice) on
15. Set Photo cells onto edges of the paper
Maintenance Checks:
Condition of the Knife.
Condition of the rubber suction plates in the splice roll, replace damaged ones to maintain
correct suction. If too many are damaged, the paper will fall down easy.
Check if accumulator roll is parallel(when roll is at locked splice position, the distance between
the roll carriage and the rubber stops indicate if roll is parallel
Condition of the brake pads, replace when necessary.
Check correct movement of the reel transporters and clean if necessary.
Training Manual
01.10.1997 chapter 2 page 76
7.4 Roll stand ASR-N
Always check that the roll stand has clearly defined markings of the paper widths. Markings
should be on the floor, so that no matter what the positions of the reel stand arms are, the
paper reel should always be in the correct position. Make sure the hydraulics are not leaking,
the paper reel should not drop!.
7.5 Automatic tensioning Unit ABR-N
7.5.1 Operation.
1. Bring tensioning roll in thread up position
2. Thread paper through
3. When SF is running, apply slowly hand brake with manual valve
4. Increase the setting on the Tension Gauge by pushing the button (roll will start going
upwards with approx. 29 psi /2 bar Tension)
5. When the roll starts the upwards movement switch to Automatic
6. Adjust to the required tension
Training Manual
01.10.1997 chapter 2 page 77
7.5.2 Cleaning instructions
1. Bring Tensioning roll in bottom position, by reducing the pressure at the tension gauge
Below 29 psi (2 bar), the roll will start to descend
2. Put accumulator in threading position (forward)
3. Take paper out of the roll stands
4. Switch off power at the main panels
5. Close air valve at the splicer
6. Clean the machines completely with air or steam jet
7. Clean all filters
7.5.3 Safety and Maintenance instructions to be carried out by operators and
maintenance personnel.
Instructions for extended stoptimes.
Switch off vacuum pumps to avoid unnecessary wear
Safety and Maintenance instructions.
Never carry out work on a splicer while running! Ex: Knife setting!
Never carry out work on a splicer with power on the machine!
Never switch on power without having checked that nobody is in the machine
Never change a knife without switching off air and power
Read manuals carefully
Never obstruct or disengage safety switches or guards
7.5.4 Maintenance and grease instructions.
1. Follow instructions as described in the manual
2. List of grease and oil points for periodic maintenance are given in the manual
3. Instructions and translations of the electronic schemas are given during the start and
training period
4. If these should prove to be inadequate, supplementary courses can be arranged at
Weiherhammer for electricians, mechanics and electronic engineers
Training Manual
01.10.1997 chapter 2 page 78
7.6 BHS SPLICER TYPE ARW-M
7.6.1 Instructions for start-up
Following conditions must be met to start the Splicer.
1. Check for obstructions and notes left by personnel
2. Switch main panel "ON"
3. Check which side of the splicer is in use (Correct paper reel in use). Push Home" position
button, positioned at each side of the splicer
4. Switch Servo motor "ON" by pushing the green flashing button
5. Switch paper tension system to "AUTO"
6. Reduce brake power to zero (Take brake "OFF" by turning knob to "0")
7. Bring accumulator forwards to "Feed in" position.
8. Feed paper through splicer (See drawing at side of splicer)
9. Start machine
10. Regulate brake power(Tensioning power)at the Nominal value regulating knob until required
value is obtained.. After some meters running, push accumulator reverse button to obtain
"Full" position.
Training Manual
01.10.1997 chapter 2 page 79
7.6.2 Splice Preparation
1. Cut point on paper and feed between rolls and splicer carriage
2. Apply brake on paper reel
3. Pull paper straight, fold paper over cutting edge, and push the magnets onto splicer
carriage. These magnets are simplifying the cutting of the paper
4. Clamp the paper by pushing the "Clamping bar"->||<- push-button
5. Apply tape to paper. Making sure the tape is even with the cutting edge of the paper. By
doing so, the "Zero Tail" is obtained
6. Cut edges at 113 F (45 C) and cut paper over the full width
7. Remove tape cover and turn rubber roll back until pointer(visible in mirror!)is at front of the
tape
8. Reduce brake and bring prepared unit into splicing position by pushing "Forward" button
9. Tighten paper and push "Brake ON" button (approx. 14.7 psi (1 bar) brake power.)
10. Check if "Splice Start" button is illuminated
Training Manual
01.10.1997 chapter 2 page 80
TROUBLESHOOTING SPLICER ARW-M.
Splicer is not ready (Light is not on splice button)
When the splicer button is not illuminated, the splice can not be started. Several obstructions
might cause this, such as:
Emergency stop splicer is
activated.
Release button.
Accumulator is empty (in Forward
position).
Bring accumulator in "Full" position.
Splicer carriage is not in "Home)
position.
Pull carriage in home position.
Servo motor not operational(Green
light in front of machine is pulsating).
Push button.
Splicer unit is in middle position. Check proximity switch at locking
clamp.
Air pressure too low, red light is
blinking.
Increase air pressure (Min. 73 psi /
5 bar)
Splicer carriage clamping bar not in
"Splice" position. (Both proximity
switches)
Check and activate both proximity
switches.
Pivoting rolls at both ends of splicer
in "Bottom" position.
Move splicer carriage outwards and
back inwards.
Knife cylinder limit switches not
activated.
Check and activate limit switches.
Training Manual
01.10.1997 chapter 2 page 81
7.7 DUPLEX GLUE UNIT LWR/2 and TRIPLE PREHEATERS
VHZ/3
7.7.1 Production.
7.7.1.1 Preparing and starting the machine
1. Switch on the Main Panel, after having checked that nothing obstructs the machine.
2. Check that the Belt Lift is in the UP position, to avoid accidental burning of the belt.
Caution: Never leave the belt on the hotplates with a stopped machine, even when the
machine is cold, opening the steam valve and forgetting to bring the belt lift up, could cause
serious damage to the belt.
3. Open the condensate return valves and gradually open the main steam valves.
4. Raise the glue trays, and lock in position.
5. Start return pumps and open feed lines.
6. Start glue roll drive, after having checked that the level is sufficiently high.
7. Start auxiliary drive of the preheaters if available.
8. Set the wrap arms in thread-up position.
9. Set the web guides at correct width and make sure the bridge brake is Off.
10. Set the correct flute height (B for bottom station C or A for top station.
11. Set the glue gap at correct distance and switch to AUTO.
12. Set the glue dams at correct width and switch to AUTO if available (Optional)
Training Manual
01.10.1997 chapter 2 page 82
7.7.1.2 Start Double facer with Paper.
1. Check Splicer, roll stand and automatic tensioning unit (see instruction sheet splicers!)
2. Feed bottom liner (as shown per sketch on machine side) through the splicer, tensioning unit
and preheater, and into the hotplates
3. Start machine
Note: Most of the belt manufacturers will advise you to run the belts on the heated hotplates
for approx.10 min, to make sure that the belt has the same temperature over the full length.
With a new machine, it is sometimes difficult to get the liner go through the hotplates. With
most of the synthetic belts, it is possible to spray water onto the belt to make the paper go
forward.
4. Run the bottom liner into the hotplates until the paper is between the belts of the pulling
section.
Note: Although this is not absolutely necessary, you might find that if the machine is stopped
with the paper somewhere half through the plates, when restarting the DB, the paper will
stick under the hotplates. Reason is mainly the fact that when the paper is over dried, the
grip of the top belt will be insufficient to "push" the paper forwards!.
5. While the bottom liner is being pulled forwards, apply some brake, in order to pull the paper
straight
6. Feed the web through, and start the DB, making sure the other side has been warned about
the start up
7. Apply web brake, and final adjust web guides.
Note: Although the web guides have a digital very accurate width indicator, it has to be
remembered that sometimes, the paper shrinkage can be considerable, therefore a visual
check is recommended.
8. Check alignment and adjust if necessary
Note: Run the board in the center of the machine. This way , you will avoid trouble at the
dry-end. Remember that the dry end is Automatically centered after every Auto Order
Change.
9. Check if everything is correct, and switch all systems to AUTO
7.7.1.3 Use of different settings with stopped and running DB.
Glue gap setting. Although this should be controlled from the Teltrol Desk, it is good practice
to make occasional checks
Glue dam setting(If auto available, check if Auto is on)
Preheater wrap arms, check if in AUTO
When machine was stopped for any reason with the Emergency stop, restart the glue roll if
independent drive is fitted
Training Manual
01.10.1997 chapter 2 page 83
7.7.2 Cleaning instructions
Stop the machine
Close the starch lines
Remove starch tray barriers and drain all starch
Open cleaning circuit if available, or redirect return lines into drain. Make sure no water is
directed into the starch circuit, as this could cause considerable viscosity loss
Drop starch pans into cleaning position
Clean glue roll with water, taking care not to put too much water into the electronics or
electric motors
Clean the glue dams, dismantle once a week, or sooner if necessary, and clean completely
Clean glue dam guides, and remove any dried starch from the unit
Clean surroundings. Make sure all starch deposits are washed away to avoid any
bacteriological action
Clean Filters
Prepare for next run or shift
Switch off main panel
7.7.3 Safety and Maintenance instructions to be carried out by operators and
maintenance personnel.
Instruction for long stop times.
Make sure the glue roll auxiliary motor is restarted after the emergency stop has been used.
Maintenance Instructions for long stop times.;
Oil guide rails for gluedams (a few drops is sufficient)
Clean limit switches, clean dried glue from telescopic cylinders
Training Manual
01.10.1997 chapter 2 page 84
Maintenance Safety instructions working at the D. B.;
Before switching on main panel, make sure machine is clear, and nobody is in the machine
or carrying out work at the units
Read carefully the instruction manuals delivered with the machine
Never bridge out or disconnect the safety devices on the machine!
Take care not to fall on to the preheaters or preconditioner when carrying out work on the
machine. Cover up the drums with sheets of board
Always look after your own and your colleges safety
7.7.4 Maintenance and grease instructions.
Follow instructions as described in the manual
List of grease and oil points for periodic maintenance are given in the manual.
Instructions and translations of the electronic schemas are given during the start and training
period.
If these should prove to be inadequate, supplementary courses can be arranged at
Weiherhammer for electricians, mechanics and electronic engineers.
Training Manual
01.10.1997 chapter 2 page 85
7.8 AUTOMATIC SLITTER SCORER SRA-T/TC.
Prepare for production.
1. Before switching on the unit, make sure the machine is ready, i. O. W. Check if nobody is in
the machine if there are no warnings or notes left, who tell you not to switch on.
2. Remember that this unit operates on automatic signals, and it is always useful to check and
double check if nobody is in the machines before the main panel is switched on.
3. Make sure the switch hand/auto on the control panel is in hand position for both units
4. Make sure there are no red light indicators on the unit, if so, push the red buttons, the light
should disappear. If not, check for emergency stops, safetys on doors, and air
pressure(min.87 psi/6 bar) on main pressure gauge at front door.
5. Check that the photo-cell in front of the unit is clear, this photocell will prevent the unit to set,
on condition that the cell is blocked and the machine is stopped at the same time. This is to
prevent that the unit would set with stationary board in the machine, as it could damage the
machine when the board is taken with the heads.
6. Put 3way selector switch on middle of operating panel to the
position: -left position = hand setting
-middle position = sra-t screen setting
-right position = fdm or computer setting
7. Set first order on the screen, and continue with next order.
8. After having checked again if all is clear, switch to "auto" and push "S". The screen will
show SRA-, then select unit 01. Always start with unit 01, looking in board direction, as this
unit is designated by the electronics as the "leader", nr 02 unit being the "slave". This will be
of particular interest when running in tandem operation. By using"S", the order will be set
and the slitter knifes will automatically go down and close, ready for running. The orange
"Positioned" light and the green Closed light will be on.
9. Push P", the other unit (02) will set the next order, but the shafts will stay open. Warning:
the "P"or positioning operation will only work, on condition that the shafts are open, thus
green light off. After being set, the orange "ready light will lit-up, meaning the unit is ready
set. Note: Except for latest versions, (from 1990 onwards) the green and orange light will
only be "on" together when the units are set for the first time after the machine has been
switched on, all other times, the orange indicator will show unit "ready"set, but not in
production, the green indicator will show that the unit is set, closed, and ready for
production.
10. Continue setting orders in the processor, so that a sufficient queue is available for running.
11. Switch the suction nozzle setting to"auto", and select the correct unit (only for SRA-T
model). Make sure the suction is "on"
12. Set the paddles in the correct position, making sure there are sufficient paddles in
the"down"position. Remember: one paddle to many "up means a jam-up. Note: Remember
that the first order you typed into the processor will be at the operator side, the second at
the drive side. The only way to change this, is to reset the order in reverse and erase the
wrong setting.
Training Manual
01.10.1997 chapter 2 page 86
8. THE CORRUGATOR MAINTENANCE
Influence on Production
General
Why should Maintenance people understand so much about production?.
While the first can not be split from the latter
In every corrugated board plant, what counts is the quality and quantity of produced board. To
reach this goal, with a minimum amount of waste, the maintenance and production personnel
must work as a team!
Lets run through the main parts of the machine, which can cause breakdowns, at the same time
causing stop times for the production. It is, however, not possible to mention all reasons for stop
times. We hope that this is a guide to help find the faults in your units, no matter what make of
machine you have.
8.1 Roll stand
Machine problems Production Influence
Brakes not being smooth, vibrating
during braking.
Web moving off center, paper breaks,
bad flute formation.
Lifting out of parallel. Web moving off center, paper breaks,
paper flutters running into machine.
Axial movement too fast or not smooth
enough.
No smooth running, high waste figures.
Bad chucks, inaccurate clamping. Irregular paper tension, reel can turn on
chuck, high waste figures, important stub
or rest reels.
Reel preparation by operator. Cleaning and/or cutting of wet paper,
damaged and split paper.
Training Manual
01.10.1997 chapter 2 page 87
8.2 Splicer and Tensioning unit
Machine problems. Production Influence.
Rolls are not parallel Irregular paper entrance, fluttering of
paper, danger of paper break.
Splice unit not parallel. Increased splice failures.
Paper reel starts too brusque (paper reel
does not start smoothly.
Increased risks of paper break.
Increased splice failures
Paper tensioning unit respond is too
slow. Or starts bouncing.
Increased splice failures
Roll diameter too small, rolls bending. Paper entering uneven in machine
Cutting unit functions badly. Fail splices.
Inaccurate or badly positioned splice
tape.
Fail splice, sticks on preheater or rolls.
Training Manual
01.10.1997 chapter 2 page 88
8.3 Outside liner Preheater
Machine problems Production Influence.
Preheater is stopped. Too much paper tension.
Wrap or guide rolls out of parallel. Irregular entering of the paper, fluttering,
bad gluing due to lack of heat.
The wrap roll automatic does not
function or moves too fast.
Warped boards, twisted and/or S-warp.
Siphon pipes badly positioned or broken. Preheater is cold, liner not heated
adequately, warped boards
Steam valves(main or condensate lines!)
not opened enough.
Preheater is cold, liner not heated
Condensate trap malfunctioning. Preheater is cold, liner not heated
Training Manual
01.10.1997 chapter 2 page 89
8.4 Fingerless Single Facer
Corrugator rolls worn unevenly Irregular flute formation, bad line
pressure, flutes falling out of corrugator
rolls.
Sides of corrugator rolls not been
used(running small deckles)
Badly marked pressure lines on liner
side.
Uneven or changing pressure on
corrugator and pressure roll.
Bad gluing, folds and markings.
Glue roll-Corrugator roll distance out of
parallel.
Uneven or missing glue-film. Waste.
Glue film out of parallel Uneven glue film across the width,
warped and twisted board
Doctor roll scraper not scraping evenly. Uncontrollable glue film, too much or too
little glue.
Inadequate vacuum. Fluting falls out of corrugator rolls, folds
double, too much starch, waste.
Suction nozzles blocked. Fluting flutters, bad flute formation,
waste.
Roll slots, suction holes blocked. Fluting flutters, bad flute formation,
waste.
Water leaks from shower. Waste, paper breaks, paper sticks into
corrugator rolls.
Paper break control functioning badly or
not at all.
Machine stops too late when paper
break occurs, corrugator rolls full of
starch.
Bad condensate return from
Corrugator rolls or pressure roll.
Rolls running out of round, bad flute
formation, waste.
Accumulator pressure too high or too
low.
Bad flute formation. Same effect as low
or high corrugator roll pressure.
Training Manual
01.10.1997 chapter 2 page 90
Press. roll/ corr. roll stops too much
tolerance.
Irregular pressure lines.
Glue roll/doctor roll stops too much
tolerance
Uneven glue film over web width.
Eccentrics too much tolerance (worn). Corrugator roll vibration.
Glue dams not functioning properly. Starch in corrugator rolls, bad flute
formation, waste.
8.5 The Preconditioner
Preconditioner runs at wrong speed.
Too fast, too slow.
Bad flute formation. Broken Flutes due to
too much tension(too slow). Fluting
drops into glue pan.
Preconditioner too cold, due to low
steam pressure, blocked condensate
return, broken or badly positioned siphon
pipes.
Irregular heat transfer into paper due to
contact changes with drum surface.
Wrap rolls out of parallel. Paper runs into machine in angle, paper
flutters on one side.
Wrap rolls move too fast. Paper breaks.
Training Manual
01.10.1997 chapter 2 page 91
8.6 Overhead Bridge
Too much web on the bridge. Damaged liner, folds, irregular supply of
web causes warp!.
Inadequate bridge brake(different
systems!).
Badly tensioned web going into DB,
gluing problems, web movement
sideways, folds.
Inaccurate web guiding, web guides
worn.
Web movement, badly lined board
causing waste.
Unstable brake power onto web. Web breaks, length warp, sheet length
variation.
8.7 Duplex or triplex Preheater
Production Influence. Machine problems
Preheater is stopped. Too much paper tension.
Wrap or guide rolls out of parallel. Irregular entering of the paper, fluttering,
bad gluing due to lack of heat
The wrap roll automatic does not
function or moves too fast.
Siphon pipes badly positioned or
broken.
Steam valves(main or condensate
lines!) not opened enough.
Condensate trap malfunctioning.
Training Manual
01.10.1997 chapter 2 page 92
8.8 Duplex or triplex Glue Unit
Press roll/Glue roll distance out of
parallel
Damaged flutes, bad bonding. Uneven
stacks, hanging to one side.
Press roll/Glue roll distance too close Damaged flutes, board strength
inadequate("soft" board!).
Units with DC drives: length warp caused
by brake effect of glue roll.
Press roll/Glue roll distance too big. Badly glued liners, board peeling off to
easily, no pin adhesion values.
Glue roll/doctor roll distance out of
parallel.
Bad gluing, irregular glue line pattern
over web width.
Warp caused by uneven glue
application. Waste.
Scraper not scraping evenly(Wet lines
on doctor roll!)
Irregular glue application, warp.
Glue roll speed too fast or too slow. Glue line shoulders(too much glue on
one side of flute!)
Glue splashing between flutes.
Glue dams set too wide. Glue transferred onto belt and hotplates:
damaged board.
Glue unit installed out of square, glue roll
not square with board line.
Bad entrance into hot plates (one side
wavering!). Smeared glue film, s-warp,
buckles on one side of board.
Training Manual
01.10.1997 chapter 2 page 93
8.9 Double facer (Hotplates and Pulling section)
Hotplates are not adjusted evenly, crown
is inaccurate. Hotplates are "sagging".
Damaged edges, caliper loss. Too much
friction against bottom liner can cause
board stoppages under the hotplates.
Weight rolls "jumping", weight rolls out of
square.
Damaged board, vibrating machine,
noisy.
First weight roll and hotplate entrance
not set correctly, contact point of web
and liner not ideal.
Bad board entrance, smeared glue lines,
loss of glue due to "double kiss" contact,
bad gluing. Caliper loss.
Temperature in hotplates incorrect,
temperature difference in hotplates due
to blocked condensate lines or pipes.
Warped board, bad gluing, reduced
speed. Twisted boards.
Weight rolls in pulling section
jumping(broken bearings) not adjusted
correctly, or out of square
Caliper loss on sides, board stacks
"hanging".
Board line moving constantly, board line
running off-center
Bottom rolls in pulling section incorrectly
dimensioned (too thin, sagging in
middle!)
Board caliper loss at edges. Bad gluing
in middle running Double Double.
Main belt drum coating worn. Speed differences, board line
movement, board damage, problems
gluing in center running Double Double.
Belts worn, edges are thinner than
middle.
Bad gluing on edges running Double
Double, board opens up at edges, folds,
waste.
Erratic functioning belt guiding system. Belt moving , board moving
Training Manual
01.10.1997 chapter 2 page 94
8.10 Rotary Shear
Knife not stopping in correct position. Board jams in shear. Stoppages, waste.
Not cutting cleanly over full width. Order change obstruction, continuous
cutting obstructed, jam ups.
8.11 Automatic Slitter Scorer
Knife/score setting not accurate. Problems in Finishing end, waste.
Inaccurate boxes delivered to client.
Order returned.
Ragged cutting of slitting knifes. Dust created on slitter, problems on
printers due to dust going into ink
system!.
Scoring not centered. Male/female score
not centered.
Bad folding, inaccurate folding Problems
on printers.
Scoring not parallel. Board not folding equal over width
Insufficient or too much knife
overlapping.
Bad, ragged cutting, knives engaging
wrongly(on wrong side!).
Trim suction not positioning correctly. Trim jam ups, waste, stoppages.
Score speed incorrect (too slow)Jam ups when paper is
running into slitter
(too fast)Jam ups when paper is running
into knife, board being pulled out of
double facer.
Scoring distance (male/female)too close. Board cuts when running slow. Problems
on Printers.
Training Manual
01.10.1997 chapter 2 page 95
8.12 Duplex or Triplex cut-off knife.
Sheet length differences. Stacker jam-ups, bad stacks, waste.
Problems in Finishing end.
Out of square cutting. Problems on Die cutters, jam-ups,
waste.
Bad entering of knifes(pulling unit, rolls or
vacuum).
Board moving, board not running
through when cutting with rotary shear.
Jam-ups during order changes.
Sheet length differences.
Outfeed badly functioning, not adjusted
properly.
Bad shingling, board not leaving the
outfeed properly ("hanging at end of
rolls)Bad stacks.
Bad cutting. Boards not separated, causing jam-ups
in stacker and knife. Speed reduction.
Measuring wheel not running smoothly. Sheet length differences.
Pull roll speed incorrect Too slow: Board buckles when entering
the cut-off, folding double and jamming.
Too fast: Bad sheet length,
Outfeed speed incorrect. Too fast: Board leaving the knife at too
high speed, bad shingling. Board being
"pulled off instead of cutting.
Too slow: Jams in stacker, sheets hit
each other when leaving the outfeed.
Cutting speed incorrect(electronic) Board buckling, incorrect sheet length.
Training Manual
01.10.1997 chapter 2 page 96
8.13 Duplex or Triplex Stacker
Faulty braking of sheets on stacker belt
by brushes, rolls or vacuum.
Bad stacking, bad shingling(out of
square).
Creases in board. Waste.
Bad sheet transfer between stacker belt
and hopper
Bad stacking, board turning and
jamming.
Stacker belts running irregular. Bad stacking, single sheet movement.
Stacker decks not lifting
smoothly(shuddering)
Bad stacking, top sheets are
"swimming".
Stacker cycle disturbed(ex: proximity
switch moved)
Repeated problems with Auto Order
Change or stack change.
Problems with stacker belts: slipping. Bad shingling, boards coming into
hopper at angles.
Faulty drop height at outfeed cut-off
knife.
Too much: boards "swimming", bad
stacking.
Not enough: boards jamming against
each other leaving the belts.
Training Manual
Troubleshooting
1. What and how to check paper and board
1.1 Visual surface checks
Correct type and color of paper (Kraft, testliner, white Kraft etc..)
Correct winding. Ex: Running Kraft paper the wrong way can cause peeling on hotplates and
Printer Slotter pull-rolls!
Correct weight, check against specifications!
Correct flute(A, b, c, AB, AC etc..)
Smooth, flat surface, none or minimal wash boarding
Pressure lines at SF are minimal, no splitting can be done
DB side, check for dirt marks in length directions(dirty hotplates!)
Check for glue patches on SF side, belts are clean!
Edges are cleanly cut, no ragged edges
1.2 Measurements checks
Check:
Width
Length
Score distance
Score depth
Correct score alignment(top and bottom)
Caliper
Training Manual
1.3 Gluing checks
Glue lines, amount of glue, quantity and quality of glue lines
Starch penetration, good bonding
Regularly (once a week) check by means of the Iodine test the uniformity of the glue lines
1.4 General
Humidity of the board after leaving the stacker (7-9%)
1.5 Board and paper tests
Some of these tests are more important than others. We will look at these important tests and
see what can cause loss of test values on the corrugator.
1.5.1 FCT or Flat Crush Test
This test is of high importance for the final strength of your box, and can be seriously influenced
by the corrugator.
Corrugator rolls out of parallel
Over tensioning on the fluting
Rider roll on Glue Unit too low!
Too much starch on glue unit
Rolls in DB out of parallel
Too much weight at D. B. On low grade board (too many rolls or too much pressure!)
Gap infeed rolls on cut-off knife too small
Gap outfeed rolls on cut-off knife too small
These faults can be detected through the FCT Test, but only when done after the corrugator
Training Manual
Fig 1
1.5.2 ECT or Edge Crush Test
The edge crush test will in most cases be reduced by damaged fluting in length direction.
Badly adjusted fingers or suction nozzles. (Touching the paper!)
Too much suction or too much pressure in pressure chamber
Worn corrugator rolls
Uneven glue lines in length direction
Training Manual
1.5.3 BCT or Box Compression Test
Poor bonding, bad glue lines and all the same reasons as for the edge and flat crush test will
diminish the values of the Compression test.
1.5.4 BT or Burst Test
1.5.5 Mullen Test
These tests determine the strength of the paper or board for bursting strength. Can be highly
influenced by :
Pressure lines on board, due to pressure lines on SF. Cause: too much pressure on pressure
roll.
Too humid board, caused by wet paper or too heavy glue lines.
1.5.6 PAT or Pin Adhesion Test
Tests the bonding of the board. Pulling the paper apart will show fibre tearing. When starch
penetration is good, it should be impossible to tear paper off without fibre sticking on to the flute
tips.
1.5.7 T or Thickness test
Thickness of the board should be measured with a thickness gauge. A list with theoretical
caliper of the different board grades should be available at all times in the appropriate place
(most of the time, at central control desk).
This list should contain the theoretical caliper with the allowed tolerances. Very often, caliper
gets ruined because of the badly adjusted rider roll at the glue unit.
1.5.8 Drop Test
Measuring at which speed the water is absorbed into the paper. A drop of water is put onto the
paper and the time of absorption is checked.
Training Manual
1.5.9 Cobb Test
Measures the volume of water absorbed into the paper. This test is important for the gluing of
the board, and for deep freeze product, where the de-congelation causes condense water,
which will be taken-up by the paper.
Training Manual
2. What can cause Waste on the Corrugator?
Different factors which can cause waste on the corrugator are in order of appearance on the
machine:
2.1 Paper
Condition of the reels
Quality of the paper
Paper storage: inside/outside.
Transport of the paper to the plant
Internal transport
Handling of the reels on the machine
Putting reels into the reelstands and splicers
2.2 Machine
2.2.1 Single Facer
Proper threading of the paper into the machine
Correct use of the pre-heaters and pre-conditioners.
Lining up the paper correctly
Settings at the Single Facers, proper threading-up.
Correct braking power
Glue dam settings
Nip settings Pressure and Glue roll
Correct glue settings
Correct use of the steam showers
Correct order length input, i. O. W information about the work.
Double Backer
Proper use of the bridge(do not overfill!)
Training Manual
Set bridge brake guides at correct position
Use correct amount of brake at bridge brakes
Avoid "wandering of the web on the bridge
Lining up of the bottom liner and web
2.2.3 Rotary shear
Do not cut too many sheets
Keep machine going, avoid stoppages.
Cut out bad board, to avoid important jam-ups at stackers.
2.2.4 Slitter Scorer
Make sure the correct order is set at the Slitter Scorer
Correct positioning of the unit regarding the boardline
Correct positioning of the trim nozzles if not automatic
Lead-in tables correctly set (one too many down!)
2.2.5 Cut-off knife
Pull rolls are down and set to board caliper (board thickness 0.004 in/0.1mm) .
Correct length setting
The orders are going to the correct knifes
Unit cuts correctly (no ragged cutting)
Accuracy is within limits
Board is going into unit without "jumping", board line is steady
Training Manual
2.2.6 Stackers
Settings are correct (backstop, shingling, brushes)
All functions are in automatic
Bad board is taken out
Quality checks are done at regular intervals
2.2.7 ConveyorsSystem in Automatic, make sure the line is clear
Correct labels go into the stacks
Training Manual
3. Possible reasons for Waste
3.1 Paper reels
Modern high speed machines, equipped with fingerless Single Facers have the reputation of
running extremely good quality board with poor quality paper. Although this is through in many
ways, we have to consider a few important facts.
The higher the speed, the more accurate the winding has to be, because of the influence of
jumping" at the SF. So the reels have to be perfectly "round", if not, immediate speed
reductions are the consequence, if not waste!
The cores have to be of good quality, and well positioned in the reels. Due to the fact that
very heavy reels (up to 3 tons and more!) are today being run at extremely high speeds, the
forces put onto the cores by the brakes are much higher than before. The cores have to be
of a fixed diameter, preferably a solid strong quality, so as to be able to run reels until the
last meters!.
Bad or extreme thick splices in the paper cause long stoptimes and waste. The splices
should be well marked, so that the operator can react towards these bad splices.
Paper stored outside always causes more trouble than paper stored inside, again, this
shows up much more with high speed machines and this practice should be abandoned.
Transport from the store to the machine is in many occasions, very damaging. It should be
remembered that due to the higher amount of rolls in the machine, it is practically impossible
to run badly damaged paper reels through the splicers.
Handling of the paper on the machine should be carried out with the necessary caution, to
avoid missed splices or even blocked suction nozzles due to big cuts in the paper.
Training Manual
01.10.1997 chapter 3 page 10
3.2 Machine
3.2.1 Single Facer
The heat transfer is a major factor in the whole machine, therefore, regular checks of the
steam condensate system will help considerably. Bad condensate return or badly positioned
siphon pipes will cause serious trouble, not only speed wise but also regarding warp.
Considering that 14.7 psi (1 bar) of steam represents aprox. 39 F (4 C), it is sometimes
surprising to find preheaters with temperatures at the bottom part of 149-158 F (65-70 C)! This
means that the siphon pipes are not there anymore or badly positioned.
Lining up of the paper is essential for good running with a Fingerless S. F. More than a
conventional Single Facer, if the paper is not lined up properly, and glue does get into the
corrugator rolls, inevitably the flute formation will be poor, and the paper will prematurely leave
the corrugator rolls, because the vacuum will not be strong enough to hold the flutes in the
corrugator rolls.
Glue roll-Corrugator roll setting is also vital. Due to the fact that the suction does not allow for
any fluff-out, the distance between the corrugator roll and the glue roll has to be extremely
accurate. The simple fact that the side frames of the SF take aprox.3 to 4 hours to heat up,
means that during this time, regular checking has to be done, to make sure the distance is still
OK. When changing from light to heavy fluting, the same adjustment should be done, to allow
for the paper thickness.
Pressure roll setting is equally important. In this case, too much pressure will cause badly cut
liner, not enough pressure will give unglued board. It has to be remembered that although we
talk about pressure, we really mean distance. The hydraulic pressure on the Single Facer
Pressure roll should remain fixed, and the gap correction is done by adjusting the gap by means
of two independent electric motors with electronic digital indicators.
Glue Dams can cause a lot of waste if not in the correct position. Although usually equipped
with automatic positioning system with photo cells, it is always possible that the system is not
functioning properly, or the glue tray is packed with gelled starch, or the glue dams are
extremely dirty. It is good practice to check on regular intervals if the dams are still in the right
position, because if not, the machine will run waste very quickly. As soon as some glue is
running in the corrugator rolls, the nip pressure will be insufficient to form proper flutes, and the
fluting will fall out of the corrugater rolls. When running full reels, it is recommendable to switch
the automatic to manual, so that the dam can not move during the time the reel is running.
Glue gap setting has to be optimal, i. O. W. The minimum glue should be applied. Too much
glue causes up warp, not enough glue causes bad gluing and dry sheets. The surface of the
board should be unmarked by the suction nozzles, on condition that the glue roll -corrugator roll
setting is correct, and the glue gap is set correctly.
Note: Check the Glue roll surface on regular intervals for cleanliness. Check also for chalk
deposits on the surface, due to excessive presence of chalk in the water used for starch making.
This can cause serious glue film problems. If necessary, clean with a solvent (ex: ARDROX
1050). Attention: This product should only be used in pure form (not mixed with water), if not,
serious damage on the chrome surface might occur!.
Training Manual
01.10.1997 chapter 3 page 11
Steam showers should only be used if necessary. To determine if it is recommended to use
shower steam, check the humidity content of the fluting by wrapping the paper around the pre-
conditioner and watch for the damp coming out of the paper. If there is much humidity in the
paper, it is better to use the pre-conditioner to prepare the paper and use the minimum amount
of shower. Remember: steam showers put water into the paper, and although it is generally
accepted that the fluting does not play a big part in warp, excessive shower could cause warp.
As a rule, waste paper fluting needs very little if no shower, semi Chemical does hardly run
without.
Keep yourself informed concerning Quality, paper, order length, etc. Very often large
stoptimes are caused due to misunderstandings regarding these factors.
Training Manual
01.10.1997 chapter 3 page 12
3.2.2 Double Backer
Proper use of the bridge. A bridge can cause waste in the sense that when misused, warp
can be created when overfilled. Also badly compressed web will cause marked sheets, thus
waste. It is important to regulate the bridge content such that a reasonable amount of web
should be stored. This is done automatically when an automatic bridge control is available,
but even so, when the D. B is stopped, it depends on the common sense of the operator not
to continue running with the SF at bottom speed until the bridge is overfilled so much that in
many instances, it is only detected when the bridge belts slip over the pulleys due to the
excessive weight loaded onto the bridge. At the same time, board which has been run at
bottom speed at the Single Facer, is too dry and therefore nearly always badly warped.
Do not try to run bad web (badly glued at SF, broken flutes, etc.) through the machine. In
most instances, again the common sense of the operator at the D. B will avoid long
stoptimes if he takes the right decision. By trying to run the bad web through the D. B it
happens very often that extreme long stoptimes are caused at the rotary shear due to
blockages, or at the next units due to jam-ups.
Set bridge guides at correct position. This unit, although very simple, causes more waste
than anything else at the D. B. When the web and the bottom liner are not lined up properly,
usually a lot of waste is the result at the Slitter Scorer. In the best case, only one side of the
board is wasted, but in many cases both sides (drive and operator sides) have to be wasted.
It is therefore very important that the D. B operator keeps a close watch at the position of the
web guides. In many instances, the best solution is to go on the bridge and check visually if
the guides are in the proper position. Web can be much smaller as required, due to
shrinkage, paper can be smaller than indicated on the reel etc.
Use correct amount of brake on the web brake unit. Running flat board in length direction
will depend mainly from proper balance between top and bottom brake units, one applied
onto the bottom liner, the other applied onto the web. A good operator will very quickly
remember the different settings of the brake values.
Correct use of the preheaters. As already described in previous chapters, the correct use
is vital for the board quality. Wrong use of the pre-heater will inevitably cause waste either
by causing bad bonding(cold) or by causing badly warped board.
Glue unit Major causes for waste are inaccurate caliper settings, causing crushed flutes and
bad length warp caused by the speed difference of the glue rolls. Wrong glue application
due to badly adjusted glue film. Too much glue causing warp, not enough causing bad
bonding. Badly adjusted glue dams, causing unglued edges.
Training Manual
01.10.1997 chapter 3 page 13
4. Board Defects, Causes and Remedies
GENERAL
One of the most difficult jobs on the corrugator is the detection of faults, to determine where it is
originated from, and to take the correct action to solve the problem. The difference between a
good running corrugator with high production figures and low waste, lies usually in the presence
of a exceptionally good foreman, crew member or operator. With the modern high speed
machines, the rapid detection of a board fault can make a huge difference in the waste figures.
It is therefore essential to organize the corrugator crew such a way, that over the full length of
the machine, every operator takes care of the quality, and report the defect to the right man. It
will then depend highly on the skill of the man, how quick and how accurate the fault will be
remedied.
In the pages, we will try to summarize the most common faults which occur at the board and
their relation towards the machine.
In the first column, we will describe the fault, the second we will try to give the reasons for the
fault, and in the third column, we will summarize the possible solutions to cure the fault.
Training Manual
01.10.1997 chapter 3 page 14
4.1 Single Facer. Suction system (Fingerless)
No. Fault Cause Remedy
1. Wrinkles in top liner. Partly
badly glued
Paper tension too low.
Space in paper through humidity.
Rolls out of parallel.
Pressure roll too close
Increase Tension on reelstand
Increase pre-heater wrap.
Regulate pressure roll gap
Check parallelism and
2. Unbounded liner at the S.
Glue lines are white!
Tension too low
Temperature too low
Starch Gel temperature too high
Paper humidity too high
Speed too high
Increase paper tension
Increase wrap on pre-heater and
pre-conditioner.
Check temperature of corrugator
and pressure rolls.
Check condensate return.
Reduce gel temperature
Slow down machine
3. Unbounded liner: Glue
lines are Yellow
Pressure roll gap too big
Starch in corrugator rolls is
causing bad flute formation,
therefore the flutes "spring back.
Paper is held into corrugator rolls
too long, causing the flutes to be
separated from liner.
Suction tubes positioned too high
Close pressure roll gap
Set glue dams 5 mm inside
paperwidth.
Make sure glue dams function
properly. If necessary, dismantle,
clean and refit.
Check rolls for free idling. Check
bearings
Reposition suction tubes
4. Web at Single Facer does
not run even. Sides turning
outwards. Liner shows dark
pressure lines. Bottom
corrugator roll slots are
clearly marked on the liner
Pressure roll runs too close to
corrugator roll
Paper humidity too high
Reset distance pressure roll-
corrugator roll, open gap until
liner is loose and close slightly.
Wrap paper around pre-heater, or
change paper
5. Liner shows very heavy
glue lines in certain areas
(in length direction where
suction nozzles are
positioned).
Suction nozzles are partly
blocked. Specially in the middle
part of the corrugator rolls
Clean suction tubes. Replace if
necessary
6. Flutes leaving corrugator
roll BEFORE reaching the
glue-roll, thus causing
unbounded flutes. Mainly at
edges
Insufficient vacuum
Blocked suction tubes
Too low pressure on corrugator
rolls.
Glue in corrugator rolls, causing
bad flute formation.
Badly lined fluting, too close to
slots.
Check vacuum at pump and on
machine
Clean suction tubes or replace
Clean dust filters in line
Increase corrugator roll pressure.
Set glue dams correctly, clean
starch from corrugator rolls.
Align paper
Training Manual
01.10.1997 chapter 3 page 15
7. Fluting drops into glue pan.
During speed-up of SF
To much brake at reelstand
brakes.
Incorrect setting of automatic
tensioning unit.
Malfunctioning of auto tension
system.
Wrong pre-conditioner speed(too
slow).
Corrugator roll pressure too low.
Bad paper reel, tension causes
paper to crack, causing vacuum
to escape through holes
Reduce brake power at reelstand
brakes.
Adjust tension setting.
Check for malfunction and correct
if necessary.
Check pre-conditioner speed and
increase speed if necessary
(+-3%more than paper speed,
NOT MACHINESPEED!)
Increase corr. Roll pressure.
Reduce tension.
Change paperreel
8. Broken Flutes.
Damaged flutes
Too much tension.
Fluting too dry.
Too much drag (pre-conditioner
speed too slow!)
Insufficient shower steam or too
dry.
Reduce tension with brakes.
Pre-condition paper. Bring
moisture to outside!
Check and adjust pre-conditioner
speed if necessary.
Increase shower steam. Increase
pressure if necessary
9. Wide slot marks on liner.
Looks like fingerlines!
Poor bonding on one side
of web.
Distance glue-roll to corrugator
roll too big
Glue roll/corrugator roll gap out of
parallel.
Corrugator rolls badly worn out
Adjust distance glue
roll/corrugator roll.
Check glue film for parallelism.
Grind corrugator rolls with paste
(see instructions in manual!)
10. High & Lows picture. Every
second flute is lower
Vibration in corrugator rolls.
Worn out corrugator rolls.
Reset corrugator rolls with
eccentrics.
Change rolls.
11. Top liner tears off easily.
Glue lines crystallized
Running too slow.
Too much heat
Fluting too dry.
Liner too dry.
Bad starch penetration in paper.
Bad starch.
Run faster.
Reduce steam pressure.
(Between 147 & 189 psi / 10 & 13
bar.)
Apply steam with shower.
Reduce pre-heater wrap.
Reduce wrap at liner pre-
heater(small pre-heater before
pressure roll.)
Check water absorption of
papers.
Check and improve starch if
necessary(Borax!)
12. Fluting runs badly. Creases
and tears at edges towards
center of machine
Pressure corrugator rolls too low.
Insufficient heat.
Insufficient tension
Increase corrugator roll pressure.
Check steam pressure. Check
temperature. Check condensate
return, steam traps.
Check and adjust paper tension.
Training Manual
01.10.1997 chapter 3 page 16
13. Unbounded liner, lines in
length direction on SF
and/or DB side
Dirt between Glue roll/doctor roll.
Dried starch in hotplates.
Dirt between belt lift mechanism
and hotplates
Clean Doctor roll/ Glue roll gap,
remove clogged starch from glue
tray.
Clean hotplates
Clean belt lift mechanism
4.2 Modulfacer (Pressurized)
1. Blisters on top liner.
Badly glued liner
Not enough tension on liner
Not enough heat.
Distance Corrugator roll-Glue roll
too big
Increase liner tension
Increase wrap at pre-heater and
pressure roll.
Adjust distance corrugator roll-
glue roll
2. Edges of board turning
upwards at stacker.
Excessive glue
Pressure corrugator rolls too low
Starch in corrugator rolls, due to
badly adjusted dams
Increase pressure on pressure
roll
Adjust glue dams and clean
starch out of corrugator rolls by
means of paraffin oil.
3. Unglued liner, white glue
lines.
Insufficient heat.
Starch gel point too high.
Starch viscosity too low.
Check steam and condensate
pressure.
Check for closed valves!
Check starch and adjust viscosity
if necessary.
4. Flutes disturbed
(falling out of corrugator
rolls)at high speeds.
Pressure in pressurized hood
(glue unit) too low.
Pressure corrugator rolls too low.
Pre-conditioner speed too high
Check pressure, adjust seals by
means of clamps.
Check all seals and adjust if
necessary.
Adjust corr. Roll pressure.
Adjust Pre-conditioner speed.
5. Badly glued edges, bad
flute formation.
Starch in corrugator rolls at
edges.
Corr. Roll pressure too low.
Temperature Corr. Rolls too low.
Check Glue dams and adjust.
Replace if necessary.
Increase corr. Roll pressure.
Increase steam pressure.
6. Machine runs irregular and
too slow, unbounded
board.
Pressure roll out of parallel.
Pressure in glue unit too low
Check distance pressure
roll/sealing roll .
Check and reset pressure roll for
parallelism
7. Blisters at edges, badly
glued liner.
Sealing roll between Pressure roll
and corrugator roll too tight.
Check distance pressure
roll/sealing roll and adjust if
necessary.
Training Manual
01.10.1997 chapter 3 page 17
8. Bad flute formation,
wrinkles at edges.
Corrugator roll pressure too low
Pressure too low in hood.
Clean-out fingers worn or
damaged
Increase pressure
Check and replace seals
Check and replace damaged
clean-out fingers
4.3 Double Backer (Chaintrol)
1. Edges not glued properly.
Edges glued unevenly, bad
glue lines.
Cause:
Fluttering edges.
Badly adjusted hot plates.
Low temperature.
Too much pressure at pressure
roll SF,
Remedy:
Adjust bridge brake
Adjust pressure at PR roll SF.
Check condensate return system
Adjust hotplates.
2. Twist warp, humid or soft
board.
Waterlogged hotplates
Badly adjusted weight rollers.
Worn hotplates.
Check temperature.
Check condensate return system
Adjust weight rollers.
3. Damaged edges, marks on
liner.
Dirt between hotplates
Belt worn at edges.
Rollers traction section not
parallel with bottom rollers.
Clean hotplates.
Change belt.
Clean rollers
Adjust rollers.
4. Caliper loss at edges. Corrugator rolls worn.
Hotplates wrongly adjusted
(sagging)
Change Corr. Rolls.
Adjust hotplates.
5. Leaning flutes. Gap between rider roll and
applicator roll too tight.
Too much weight rollers on the
board.
Adjust gap.
Reduce weight rollers
6. Length warp.
(Upwards).
Too much bridge brake.
Gap between rider roll and glue
roll too small.
Reduce bridge brake.
Increase bottom liner brake.
Adjust gap.
7. Twist warp.
S-Warp.
Paper too cold entering hotplates.
Hotplates cold.
Preheater cold.
Rider roll out of parallel at Glue
Unit.
Worn or faulty bearings at Rider
roll.
Increase preheater wrap.
Check temperature and remedy if
necessary.
Adjust rider roll parallelism.
Change bearings in rider roll.
8. Up warp cross machine
direction.
(Upwards).
Wet top liner.
Too much starch at SF.
Not enough heat at preheater SF.
Not enough heat at Triple
preheater DB.
Too much heat at hotplates.
Increase preheater wrap at SF.
Reduce glue gap.
Increase wrap at Triple deck
preheater.
Decrease bottom liner wrap.
Reduce heat in hotplate section
2&3.
Training Manual
01.10.1997 chapter 3 page 18
9. Bad surface at SF side
when running Double Wall.
Twisted warp with all
qualitys
Running with cold web into
Double Backer.
Not enough heat at paper surface
Heat web, increase preheater
wrap.
Check temperatures of paper at
DB entrance.(should be between
158-194 F (70-90C).
Check temperature of hotplates
and preheaters.
10. Uneven glue application on
flute tips.
Too much pressure on rider-roll. Adjust (reduce) rider roll gap
11. Damage at bottom liner,
board shows impression in
length direction
Dirt on hotplates, dried starch
sticking on plates
Paper jammed between plates
Clean hotplates.
Remove paper
4.4 Slitter Scorer
1. Ragged cutting at board
edges
Slitter knives worn or damaged.
Not enough air pressure on
knives.
Adjust brush pressure.
Cancel first brush in program.
2. Scores cut board Top and bottom scores not
parallel.
Score depth too small.
Adjust top and bottom scores.
Reduce score depth
3. Scores not in correct
position against knives
Synchronized 0 point not in
correct position
Correct 0-point
4. Scores not in correct
position against knives
when running in tandem'
0-point from both machines not in
correct position against each
other
Correct 0-point position.
Training Manual
01.10.1997 chapter 3 page 19
4.5 Cut-Off
1. Ragged edges at board
cutting edge
Knife blade badly adjusted.
Knife blade worn
Adjust knife blade.
Change knife blade.
2. After setting knife blade,
knife cuts occasionally
bad
Backlash setting inaccurate, too
loose
Adjust backlash.
3. Board buckling when
entering knife
Wrong pull roll speed, too slow
Worn rolls, uneven gap
Adjust speed.
Adjust gap.
Replace pull roll.
4. Sheet length incorrect
during order change (too
long)
Pull-roll gap set too big Adjust pull roll gap.
5. Stacks uneven (down at
edges)
Worn pull rolls Replace pull rolls.
4.6 Stacker
1. Creases in board at
stacker.
Board pushed down too hard by
brushes.
2. Wrong stack height Board pushed down too hard by
brushes.
Training Manual
Knowlegde Review
Introduction
This questionnaire is to help you to test your understanding of the function, control and
operation of the various BHS Corrugated machines, which make up a complete corrugator. Also
topics such as starch, paper, steam and maintenance will be addressed.
OBJECTIVE
After completing this questionnaire, participants should have:
1. A general understanding of the function, control and operation of the various machines in a
complete corrugator both in the wet-end as in the dry end.
2. A general understanding of the bonding process, which is used to make corrugated board.
Also problems with bonding will be discussed.
3. A general understanding of the various paper types, which are used in the corrugator and
the problems that can occur in this area.
4. A general understanding of the steam system used on the corrugator.
5. Some basic information about the routine maintenance on the various machines.
PREREQUISITES
The participants should have a basic understanding of running a corrugator. This can be from
experience or from pre-training.
Training Manual
QUESTIONNAIRE LAYOUT
The theoretical part is made out of following chapters:
Machines in the Wet-end
Machines in the Dry-end
Starch
Paper
Steam
The practical part is made out of following chapters:
Machines in the Wet-end
Machines in the Dry-end
Training Manual
Theoretical Part
1. Machines in the Wet end
1.1 Roll Stand ASR-M
1. What is the function of the roll stand type ASR-M?
A. To unwind the paper webs and stocking of a second roll.
B. To splice the paper running from a roll stand and coming to an end, to the new prepared roll.
C. Stores sufficient paper for splicing.
2. What is the function of the brake-units attached to the roll pick-up arms?
A. They enable tensioning of the paper web between the roll stand and the succeeding machine
(splicer).
B. Releases the brake automatically in case of an emergency stop.
C. Is only in operation when the roll is not turning.
3. What is the min. roll diameter on your roll stand? (25,4 mm. = 1 inch)
A. 4.92 inch (125 mm)
B. 12.20 inch (310 mm)
C. 29.52 inch (750 mm)
4. What is the max. roll diameter on your roll stand?
A. 29.52 inch (750 mm)
B. 78.74 inch (2000 mm)
C. 59.84 inch (1520 mm)
5. On a 110 inch (2800 mm) width machine what is the max. allowed roll weight? (1 Kg. =
2,2 lb.)
A. 6600 lb (3000 kg)
B. 8800 lb (4000 kg)
C. 11000 lb (5000 kg)
6. On a 110 inch (2800 mm) width machine what is the min. working width of a roll?
A. 63 inch (1600 mm)
B. 39.4 inch (1000 mm)
C. 86.6 inch (2200 mm)
Training Manual
7. On a 110 inch (2800 mm) width machine what is the max. working width of a roll?
A. 110.2 inch (2800 mm)
B. 98.4 inch (2500 mm)
C. 118 inch (3000 mm)
8. What are the functions of the tensioning arms?
A. They control the web tension.
B. Clamping, lifting, lowering and lateral positioning of the clamped roll.
C. Lateral positioning with these arms is not possible.
9. How are the clamping arms moved into position?
A. Pneumatically.
B. Electrically.
C. Electrically controlled, hydraulically operated.
10. When you try to lift a roll which exceeds the max. allowable weight, what happens?
A. A red warning light comes on.
B. A warning horn sounds.
C. A pressure control valve at the drive side limits the max. hydraulic pressure, when this pressure
is exceeded lifting is not possible.
11. How does the process of unwinding operate?
A. The process of unwinding is effected by the pull of the paper web of the succeeding machine
(single facer or double facer), with the possibility of continuously adjusting the web-tension via
controllable, pneumatic brakes in the tensioning arms.
B. Two electric motors drive the paper roll.
C. The paper roll is driven by the splicer.
12. Is it possible to detach a roll, when it is clamped and lifted?
A. To detach a roll is not possible, when the load exceeds 396 lb (180 kg)
B. Always.
C. Only at high speeds.
13. How is a new roll lined up with the corrugator?
A. This goes always automatically.
B. When the new roll has the same width, you can line it up flush and laterally with the already
running roll. In case different width you can refer to marking plate on the floor.
C. This is a function of the splicer.
Training Manual
14. What is the diameter of the pick-up cones?
A. 3.9 inch (100 mm)
B. 5.9 inch (150 mm)
C. 7.9 inch (200 mm)
1.2 Splicer ARW-M
1. Describe the function of the splicer type ARW-M?
A. The function of the splicer type ARW-M is to splice the paper running from a roll stand and
coming to a end, to a new prepared roll.
B. To splice liner and medium together.
C. Only controls the web tension.
2. Name a few important characteristics of a good splice?
A. The splice must be firm and reliable (high degree of splice reliability), corrugator speed does
not have to be reduced during splicing process, web tension hardly changes during splicing, all
paper qualities in common practice can be used and splicing is done fully automatic.
B. All off the above, but splice reliability is the least important.
C. It is important that at low splice speeds the splice is firm. We accept that this goes done, when
the speed goes up.
3. Name the possibilities to release a splice?
A. Manually by operator, automatically on min. diameter or by means of rest-roll computer
(option).
B. Can only be done manually by operator control
C. Automatically, when the weight of the roll comes below a predetermined level.
4. Name some important components of the splicer?
A. Web brakes, clamping bar, storage carriage with storage rolls, pressure rolls, splicing
carriages, toothed knife bars.
B. Tensioning arms, hydraulic system.
C. Rotating knife, pneumatic system.
5. What must the operator do in case a splice is not successful?
A. Report to maintenance.
B. Switch off and on the splicer.
C. Always try to determine the reason of the failed splice.
Training Manual
6. The green Splice Start luminous key does not light, what does this mean?
A. You can only splice manually
B. Splicing is not possible.
C. You can only splice automatically.
7. The red luminous key for collective fault is flashing, what could this mean?
(1 bar = 14.7 psi.)
A. The knives are both in the top position.
B. The servo drive has failed.
C. Air pressure has fallen below 73.5 psi (5 bar) or the knives are not in the top position.
8. What is the function of the marking lever above the splicing roll?
A. To line up the beginning of the adhesive tape with the end of the marking lever brings the
paper end with tape in the correct position for splicing.
B. To adjust the knives
C. Indicates that the splice carriage is in the correct position.
9. What happens when the protective covering band is not removed from the double-sided
tape and you perform a splice?
A. The splice will be less firm.
B. You can only splice at low speeds.
C. You miss the splice.
10. Name some reasons that the splicer is not ready for splicing?
A. One of the knives is not in the top position.
B. Servo motor white luminous key light on).
C. Storage is empty and second splicing carriage (which is not needed) is not in its outer position
(pull towards you).
11. Explain how the splice operation works, when you have splice release at min. diameter
selected?
A. Rotary switch selected to release on diameter. On reaching first min. diameter (approx. 7.9
inch [200 mm]) of the old paper roll orange luminous key flashes, when the second min.
diameter is reached (approx. 5.5 inch [140 mm]), automatic splice is released.
B. When the diameter of the core is reached, automatic splice is released.
C. This function can only operate if there is an optional Rest Roll Computer installed.
Training Manual
12. What must you observe, when you interrupt this operation?
A. When you interrupt the automatic release on min. diameter by pressing the flashing orange
luminous key (light off) the operator is in manual control and must therefor release the splice by
pressing the green Splice Start luminous key.
B. The green Splice Start luminous key is goes off.
C. Nothing because automatic splice takes place anyhow.
13. If a splice fails, what should be your follow-up?
A. Operate the Reset button on the control panel of the splicer.
B. Rotate the pressure roll a few turns.
C. Operate the Basic position on (Home position) key on the operating box, this moves both
splicing carriages to their outer position and the clamping bar to the opposite side.
14. How does the splicer operate?
A. With hydraulic pressure, the same as the roll stand.
B. Electrically and pneumatically.
C. Only electrically.
1.3 Modul Facer MF Bandleader
1. Why can the flute change on the BHS Modul Facer (MF2) be carried out so quickly?
A. Because the cassettes are quickly removed from the machine.
B. Because this is done with servo drives.
C. Due to the two pivoting corrugating roll modules, whereby one is in the working position and
the other is in the parking position. For easy cleaning and access also both corrugating roll
modules can be parked in the parking position.
2. What is the max. production speed of the machine? (1 m/min = approx. 3.3 ft/min)
A. Depends on the flute which is chosen, paper quality, glue type and properties, etc.
B. 495 ft/min (150 m/min)
C. 1485 ft/min (450 m/min)
3. Which rolls are heated by steam on the MF2 Bandleader?
A. One of the three cylinders of the bandleader, upper and lower corrugating roll, the second
corrugating roll module, preheater and preconditioner.
B. Only the two corrugating rolls which are in the working position in order to save on energy.
C. The three cylinders of the bandleader, upper and lower corrugating roll, the second corrugating
roll module, preheater and preconditioner.
Training Manual
4. What steam pressure is required to heat these rolls?
A. It does not really matter, any pressure between 29.4 and 117.6 psi (2 and 8 bar) will do.
B. BHS recommends between 176.4 and 205.8 psi (12 and 14 bar).
C. Not below 235.2 psi (16 bar).
5. What is the function of the inclined conveyor belt?
A. It transports the single faced web to the double facer.
B. Controls the tension of the single faced web.
C. It transports the single faced web onto the bridge.
6. What drives the corrugating roll module which is in use?
A. An hydraulic motor.
B. Electrically, through the main drive a three-phase AC motor.
C. The medium paper going through drives this module.
7. The second corrugating roll module which is not in use can also be driven, how?
A. Electrically
B. The second module in the parking position has no drive.
C. It has an auxiliary drive a hydraulic motor.
8. Why is it necessary to drive the second module?
A. For lubrication.
B. To prevent local spots which have a lower temperature as the rest. When this corrugating roll
module is required for production the rolls are heated equally.
C. Otherwise the other module is also not driven.
9. Which roll(s) are driven by the main drive?
A. The Bandleader and the two corrugating rolls.
B. The upper corrugating roll.
C. The rolls inside the glue unit and the two corrugating rolls.
10. How is the pressure in the glue unit created?
A. Through the steam system.
B. By an air compressor.
C. By a fan.
11. What is the normal working pressure in the glue unit? (1 bar = 1000 mbar)
A. Between 176.4 and 205.8 psi (12 and 14 bar).
B. Between 0.6 and 0.9 psi (40 and 60 mbar).
C. Atmospheric pressure.
Training Manual
12. On the Modul Facer with Bandleader how is the glue unit sealed, when it is loaded?
A. It is not sealed.
B. With a large rubber seal, which is inflates with air-pressure.
C. A springloaded Teflon sealing bar seals at the bottom against the lower corrugating roll, two
rubber seals one on each side of the glue unit seal against the frame of the corrugating roll
module and a felt sealing strip on top of the glue unit seals against the belt of the Bandleader.
13. Why must there be an overpressure in the glue unit pressure chamber?
A. To pressurize the glue inside the glue unit.
B. In order to keep the formed fluting medium in contact with the upper corrugating roll module.
C. To make sure that there is positive contact between liner and medium.
14. Why are there slots in the upper corrugating roll?
A. To create a differential pressure between the pressure inside the glue unit and the ambient
pressure; this keeps the fluting medium firmly in the flute profile of the upper corrugating roll.
B. To allow thermal expansion of the corrugating rolls.
C. This allows the fluting medium to come out of the profile of the corrugating rolls in order to pick-
up glue from the glue-application roll.
15. How are these slots kept clean?
A. With water-spray jets.
B. They are not kept clean on purpose.
C. They are kept clean with brass slot-cleaners.
16. What is the function of the glue dams?
A. To prevent contamination with starch on the corrugating rolls outside the width of the fluting
medium.
B. They make sure that the glue level outside the dams stays always high in order to lubricate the
scrapper blade of the doctor roll.
C. To control the glue film, which is applied onto the flute tips.
17. Which control system sets the glue dams automatically?
A. A fibre optic system at the fluting infeed before the preconditioner detects the width of the
fluting medium by detecting both paper edges.
B. The automatic glue-level control system.
C. There is no automatic system available for this.
18. Where is the control system, which sets the glue dams automatically; selected?
A. It is selected on at the Touchscreen under the Start-up menu.
B. With a switch on the control desk.
C. There is not such a system.
Training Manual
01.10.1997 chapter 4 page 10
19. Can you also set the glue dams manually and why is this function required?
A. No, this is not possible.
B. Yes, if we want some more glue on the paper edges, we can move the glue dams a little more
outward.
C. Yes, to give an offset i.e. when the width of the liner is smaller then the fluting medium the glue
dams can be moved more inward to prevent that we get starch on the corrugating rolls.
20. Describe the manual operation of the glue dam positioning, when the glue dam
automatic is on?
A. A total of four rotary switches allow manual adjustment of the glue dams. Two are located at
the operator side and two at the drive side. One selection moves the applicable glue dam
approx. 0.4 inch (10 mm) in one or the other direction.
B. Same as above, but the adjustment (offset) is only approx. 0.08 inch (2 mm)
C. As long as you select and hold one of the four switches the applicable glue dam moves.
21. How is glue applied onto the flute tips?
A. The doctor roll applies the glue onto the flute tips.
B. The applicator roll applies starch to the flute tips according to the gap adjusted between the
applicator roll and the upper corrugating roll.
C. The air-pressure inside the glue unit takes care of this.
22. What is the function of the preconditioner?
A. To heat the fluting medium, this allows proper flute formation.
B. To heat the liner.
C. To heat the single faced web, to achieve better bonding with the bottom liner.
23. What is the function of the steam shower?
A. It is used for moistening the fluting medium and thus improving the formation of the fluting. The
use of the steam shower is used when heavy grammage fluting medium, with a too low
moisture contents used or i.e. Semi-Chemical paper.
B. To increase the moisture of the fluting medium, when its own moisture content is already very
high.
C. We must always use the steam shower.
24. What is the function of the wrap roll on the preconditioner and preheater?
A. To align the paper with corrugator center line.
B. To control the tension in the paper.
C. To control the wrap around the heated drum. These adjustable guide rolls can decrease or
increase the wrap and thereby control resp. the temperature of the fluting medium and the
liner. The wrap arms move automatically in relation to corrugator speed.
Training Manual
01.10.1997 chapter 4 page 11
25. When does the Touchscreen at the control desk activate?
A. When you operate the on selector on the control desk.
B. When the main switch on the switch cabinet is in the on (1) position
C. When you switch on the PC and PLC.
26. When you start the Modul Facer, what do you thread up first the liner or the fluting
medium?
A. The liner.
B. The fluting medium.
C. Both together.
27. When you thread up the fluting medium, what must you do with the lower corrugating
roll?
A. Adjust the loading pressure to minimum.
B. The lower corrugating roll must be unloaded.
C. The lower corrugating roll must be loaded.
28. Why is it better to heat up the machine for some time before you start production?
A. To heat up the rolls equally.
B. To increase temperature of the glue inside the glue unit.
C. To make sure that condensate forms in the heated drums.
29. How do we maintain the correct glue level in the glue unit?
A. By making sure that during production the glue return pump is not running.
B. By increasing or decreasing the glue gap.
C. The automatic glue level control system takes care of this.
30. Why is it so important that the glue dams are in the correct position?
A. Otherwise the glue level goes too low.
B. Otherwise starch can contaminate the corrugating rolls, resulting into bad fluting formation.
C. If they are not in the correct position, too much glue is applied onto the flute tips.
Training Manual
01.10.1997 chapter 4 page 12
31. Describe in which order you feed in the liner?
A. First the fluting medium and then the liner.
B. Machine runs at base speed, briefly start the air pressure system and inclined conveyor. You
increase the automatic web tension on the liner roll, cut the paper to a point on the operator
side, feed the liner through the external preheater, insert the liner via the integrated preheater
into the Modul Facer, between the upper corrugating roll and the Bandleader. Pull liner though
and feed into inclined conveyor. Decrease the web tension on liner. Now stop the machine.
C. Machine runs at base speed, briefly start the air pressure system and inclined conveyor. You
reduce the automatic web tension on the liner roll to 0 psi (0 bar), cut the paper to a point on
the operator side, feed the liner through the external preheater, insert the liner via the
integrated preheater into the Modul Facer, between the upper corrugating roll and the
Bandleader. Pull liner though and feed into inclined conveyor. Increase web tension on liner.
Now stop the machine.
32. Why is the web tension of the liner roll removed prior to feeding in the web?
A. In order that the roll is not braked and the paper can be pulled more easily into the Modul
Facer.
B. This is not required.
C. To increase tension in the liner, which improves the threading up of the paper.
33. In what position is the preheater wrap arm, when you insert the liner?
A. In the thread-up position, minimum wrap position.
B. In the thread-up position, maximum wrap position.
C. Any position will do.
34. Describe in which order you thread up the fluting medium?
A. This is always done before the liner is threaded up.
B. First the liner is in. Compressed air fan off and inclined conveyor switched on. Reduce web
tension on the fluting roll to 0 psi (0 bar). Guide the fluting medium over the guide rolls into the
preconditioner and over the steam shower to just in front of the corrugating rolls. Start machine
and insert fluting medium in between corrugating rolls. Guide the fluting medium together with
the liner into the inclined conveyor. Increase web tension on fluting. Check pressure lines and
the bonding of the single faced web and make adjustments if necessary. When satisfactory cut
the web diagonally across the width below the inclined conveyor. Remove the waste from the
bridge. Now you can load the bridge.
C. First the liner is in. Compressed air fan on, inclined conveyor on and drive glue unit on. Reduce
web tension on the fluting roll to 0 psi (0 bar). Guide the fluting medium over the guide rolls into
the preconditioner and over the steam shower to just in front of the corrugating rolls. Cut the
fluting medium to a round point in the middle and apply some adhesive double-sided tape
(remove backing tape). Start machine and insert fluting medium in between corrugating rolls.
When the upper corrugating roll is completely wrapped with the fluting medium load the glue
unit. Guide the fluting medium together with the liner into the inclined conveyor. Increase web
tension on fluting. Check the pressure lines and the bonding of the single faced web and make
adjustments if necessary. When satisfactory cut the web diagonally across the width below the
inclined conveyor. Remove the waste from the bridge. Now you can load the bridge.
Training Manual
01.10.1997 chapter 4 page 13
35. At which stage do you load the glue unit, when you feed in the fluting medium?
A. When the upper corrugating roll is completely wrapped with the fluting medium.
B. After you have loaded about 33 ft (10 meters) onto the bridge.
C. Before you insert the fluting medium in between the two corrugating rolls.
36. When do you cut the single faced web and remove the bad formed single faced web
from the bridge?
A. When the pressure lines and the bonding of the single-faced web are satisfactory.
B. After you have produced at least 330 ft (100 meters) of single faced board.
C. You dont have to do this, you can collect the bad formed board at the stacker.
37. How do you cut the single faced web?
A. Cut the web diagonally across the width below the inclined conveyor.
B. Cut the web straight across the width below the inclined conveyor.
C. Cut the web with a point in the middle below the inclined conveyor.
38. What determines the web tension on the fluting medium and the liner?
A. The type of flute which is used.
B. Depends on the paper quality.
C. The width of the paper roll, diameter and weight.
39. Where do you control the alignment of the fluting medium and liner?
A. At the roll stands.
B. At the Splicers
C. At the single facer.
40. Before filling up the bridge, which other control function must you switch on at the
Touchscreen control?
A. The Quality menu.
B. The paper tear control system.
C. The glue return pump.
41. What must you check when filling up the bridge and once again when reaching
production speed?
A. The bonding.
B. The pressure lines.
C. Good alignment of liner and fluting medium, bonding and pressure lines.
Training Manual
01.10.1997 chapter 4 page 14
42. After the bridge is loaded and you have started the double facer, which switch must you
operate on the control desk of the Modul Facer?
A. The bridge brake;
B. The control switch of the Corraligner system.
C. The bridge level control (BMR) system must be switched on.
43. Where on the Modul Facer do you activate the flute change?
A. At the machine switch cabinet, operator side.
B. At the machine switch cabinet, drive side.
C. At the Touchscreen.
44. Which of the two paper webs do you cut before the flute change?
A. The fluting medium, because it runs between the two corrugating rolls.
B. The liner paper only.
C. It is necessary to cut the liner paper and the fluting medium.
45. If you want to operate the flute change sequence, in what position must the glue unit be
in?
A. The glue unit completely retracted.
B. The glue unit loaded.
C. The position of the glue unit is not important during the flute change sequence.
46. Which flute module is normally underneath the glue unit?
A. Normally the flute module which is used the least.
B. Always the C-flute.
C. The lower flute of the two.
47. How do you know which key to press in order to carry out the flute change correctly?
A. Follow the numbers on the switches on the machine switch cabinet.
B. The complete procedure is automatic.
C. The luminous key switches at the machine switch cabinet flash one by one, to indicate the
correct sequence and guide you through the flute change menu.
48. Is there a possibility to monitor the flute change sequence?
A. No
B. On the Touchscreen you can select Modul change menu, which allows you to monitor the
flute change on the screen.
C. Only by observing.
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01.10.1997 chapter 4 page 15
49. What is the function of the lamp test key switch, when you perform a flute module
change?
A. This lamp test key switch checks all lights in the other luminous key switches, which are
required to guide you through the flute change menu.
B. To test if the light inside the lamp test key switch is OK.
C. This switch informs you if you can perform a flute module change.
50. What are the advantages of the Quality menu option which is available at the
Touchscreen?
A. It tells you for each Quality the composition of papers required.
B. It tells you the recommended splice speed in relation to the Quality which is running.
C. Production experience can be saved such as, qualities, wraps, steam shower, glue gap, glue
applicator gaps and can be recalled, if required and send to the machine.
51. What assistance does the fault diagnostics system offer?
A. It rectifies the faults.
B. It shows the presence of failures, messages and maintenance items due. It has the build-in
possibility to show (photo images) these items and offer remedies.
C. All messages, failures and maintenance items are stored in the memory.
52. How often do BHS recommend you clean the glue unit?
A. Daily.
B. Monthly.
C. Every hour.
53. What do you use to clean the glue unit normally with?
A. Special cleaning solvents.
B. Water.
C. Steam pressure.
54. Which sections of the glue unit should be cleaned more thoroughly?
A. The outside of the glue unit.
B. The glue applicator roll, doctor roll scraper blade and the glue dams.
C. The doctor roll surface.
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01.10.1997 chapter 4 page 16
1.4 Preheater VZR-M
1. What is the function of the syphon pipe inside the heated drum?
A. The syphon pipe removes condensate from the top of the drum.
B. The syphon pipe removes condensate from the bottom of the drum.
C. The syphon pipe makes sure that the condensate remains inside the drum.
2. What is the function of the preheater?
A. It heats the paper webs.
B. It only heats the bottom liner.
C. To add moisture to the paper.
3. Besides heating the paper, for what other purpose do we make use of the preheater?
A. We can control the moisture and in this way we have the possibility to control warp.
B. To control the condensate level in the steam system.
C. To preheat the fluting medium.
4. How do we control the temperature of the paper web?
A. By increasing the steam pressure inside the preheater.
B. We can not control the temperature of the paper web.
C. The required heat transfer to the paper web is achieved by increasing or decreasing paper
wraps of the heated drum.
5. How is the preheater heated?
A. Electrically
B. By steam, this is a relatively cheap energy form.
C. A combination of electrically heating and steam.
6. What is the approx. temperature? (xC= 9/5x + 32 F)
A. Approx. 392 F (200 Celsius)
B. Approx. 212 F (100 Celsius).
C. Not more then 176 F (80 Celsius)
7. How is the paper wrap set?
A. By adjusting the wrap roll arm, which is moved electrically.
B. Through changing the speed of the preheater drum in relation to paper speed.
C. By adjusting the wrap roll arm, which is moved hydraulically.
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01.10.1997 chapter 4 page 17
8. Where is the wrap controlled from?
A. Normally from the Touchscreen in the external control desk.
B. From the Touchscreen in manual mode.
C. From the control desk in automatic mode.
9. When the speed changes of the succeeding machine, what occurs to the wrap?
A. When the speed changes also the wrap changes; wrap is speed dependent, when the control
is set to manual.
B. When the speed changes also the wrap changes; wrap is speed dependent, when the control
is set to automatic.
C. When the speed changes the wrap does not changes; wrap is not speed dependent.
10. What production problem could occur, when the wrap arm and heated drum are not
parallel?
A. Warp (End-to-End warp)problems; there is no even contact between the paper web and the
heated drum across the full width, resulting into uneven heat transfer.
B. Warp (down-warp)problems; there is no even contact between the paper web and the heated
drum across the full width, resulting into uneven heat transfer.
C. Warp (S warp)problems; there is no even contact between the paper web and the heated
drum across the full width, resulting into uneven heat transfer.
11. When you switch on the Modul Facer or Double Facer the preheater(s) switches on
how?
A. This happens automatically.
B. Manually by the operator.
C. After approx. 30 seconds they switch on automatically.
12. What is the recommended BHS procedure to switch on the steam supply to the
preheater(s)?
A. Heat up the preheater approx. one hour before production start up, open steam valves slowly,
check for steam leaks and run machine at base speed.
B. There is no requirement to heat up the preheater prior to production start.
C. Open the steam supply fully and leave the condensate return valve closed till you are ready for
production.
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1.5 Preconditioner VBR-N
1. What purpose serves the preconditioner?
A. To heat the liner.
B. To add moisture to the fluting medium.
C. To heat the fluting medium and to prepare it for flute formation between the corrugating rolls.
2. Where is the preconditioner located in the corrugator?
A. Between the paper outfeed of the single facer and the inclined conveyor
B. It is directly positioned at the fluting medium paper infeed of the single facer and comes just
before the steam shower.
C. After the steam shower.
3. How is the cylinder (heated drum) driven?
A. Electrically by a three phase AC motor.
B. Hydraulically.
C. There is no separate drive.
4. Which paper web is heated by the preconditioner?
A. The fluting medium.
B. The liner paper.
C. Both.
1.6 Bridge B
1. What are the main functions of the bridge?
A. Only storage of single faced corrugated board web(s).
B. It gives support to the bridge brake.
C. Infeed, guiding (Corraligner), tightening (bridge brake) and storage of single faced corrugated
board web(s).
2. How is it possible that festoons built up on the bridge?
A. The belt station runs at the same speed as the speed of the corrugator.
B. The belt station runs slower at a fixed ratio to the speed of the corrugator.
C. The belt station runs faster at a fixed ratio to the speed of the corrugator.
3. What is the function of the bridge web guide?
A. It dampens the web by flattening the festoons.
B. It keeps the web lined up with the corrugator center line
C. It controls the tension in the web.
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4. What is the function of the Corraligner?
A. To align the middle of the single faced corrugated board web to the middle of the corrugator.
B. It dampens the web by flattening the festoons.
C. It controls the tension in the web.
5. Explain the operation of the bridge brake?
A. The bridge brake operates hydraulically.
B. The bridge brake operates pneumatically.
C. A roll with a rubber surface is driven through a regulated servo drive. By adjusting the speed of
this roll at a lower speed as the corrugator gives the required brake effect and thereby
tensioning the web.
6. Explain the operation of the web-edge detection?
A. Infrared edge sensors detect the edges of the paper web and detect any width change and
movement away from the corrugator center-line.
B. This system is part of the single facer and is covered there.
C. An hydraulic actuator controls this system.
7. How do we control the bridge brake?
A. From the Touchscreen at the control desk.
B. On the bridge itself.
C. On the single facer.
8. What production problem can occur, when the bridge brake is not adjusted properly?
A. This can cause down warp over the width.
B. This can cause end-to-end warp (up or down).
C. This can cause up warp over the width.
9. Which paper web is tensioned through the bridge brake?
A. The bottom liner.
B. All paper webs which form the corrugated board.
C. The single faced corrugated board web(s).
10. When the corrugator is stopped and we want to thread-up the paper web, what can we
do?
A. Switch on the bridge brake, which will function as a thread-up help (switch to manual).
B. This goes automatically.
C. Switch off the bridge brake, which will function as a thread-up help (switch to automatic).
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1.7 Bridge Level Control BMR
1. What purpose serves the bridge level control system?
A. Detection of the quantity (storage) of single faced corrugated board on the bridge only.
B. It mainly serves the following three purposes; detection of the quantity (storage) of single faced
corrugated board on the bridge, prevents paper tear when bridge quantity is too low and
synchronizes machine speeds (single facer(s) and double facer).
C. Prevents paper tear when bridge quantity is too high and synchronizes machine speeds.
2. When is the bridge level control switched on?
A. On start of production, one or both (only with double wall).
B. It must always be on.
C. Both bridge level control systems are on when you produce single wall.
3. When producing single faced corrugated board on a duplex machine, what must be the
condition of the second bridge level control of the single facer which is not in use, on or
off?
A. Off, rotary switch below control panel in 0 (off).
B. On, rotary switch below control panel in 1 (on).
C. Does not matter.
4. How is the paper quantity on the bridge calculated?
A. Through the markings, which are sprayed onto the top liner.
B. Through calculation using the difference in the liner speed and the fluting medium speed as
parameters.
C. By calculating how much paper is conveyed onto the bridge and removed from the bridge, the
system can calculate the bridge storage (quantity)
5. What is the function of the absolute encoder on the single facer?
A. It measures the speed of the single facer, from which the paper quantity conveyed onto the
bridge is calculated.
B. This is used for the speed indication on the Touchscreen.
C. Detects if there is a paperbreak.
6. What is the function of the absolute encoder on the double facer liner infeed into the
lower preheater?
A. This is used for the speed indication on the Touchscreen.
B. Stops the corrugator in case of a paperbreak.
C. It measures the speed of the double facer liner, from which the paper quantity removed from
the bridge is calculated.
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7. What is the function of the Increased Demand?
A. When you operate this function the speed of the double facer increases.
B. In order to have sufficient storage available on the bridge for splicing, it is possible to switch
over to Increased Demand. When the increased demand key on the panel is operated the
nominal bridge quantity is increased by a preselected percentage. Example; nominal bridge
quantity of 99 ft (30 m), increased demand 100 %. When we now select the increased demand
key the single facer speeds up to 198 ft (60 m) is on the bridge. After the splice is carried out
the system switches back to normal demand (99ft / 30 m).
C. Slows down the single facer to base speed, in order to splice.
8. Explain the Speed Memory function?
A. When it is necessary to slow down the double facer due to low paper quantity, the operating
mode Speed Memory is activated automatically. Now the single facer controls the corrugator
speed. On start of splice release (lower single facer speed). the bridge level control is blocked
and when splicing has completed switches on automatically again. Single facer speed in
respect to double facer is increased, until the nominal bridge quantity is reached.
B. This function sets the double facer speed.
C. This function increases the bridge quantity to a predetermined level.
9. How is paper tear avoided by the bridge level control?
A. As soon as the paper storage on the bridge is running out, i.e. the point where the festoons pull
out into a web arrives at the first measuring point on the bridge, the speed of the double facer
is increased above the speed of the single facer.
B. As soon as the paper storage on the bridge is running out, i.e. the point where the festoons pull
out into a web arrives at the first measuring point on the bridge, the speed of the double facer
is decreased below the speed of the single facer.
C. By informing the operator with a horn, so that he can slow down the corrugator.
10. Where are the two initiators from the bridge level control located?
A. Both are on the single facer.
B. One on the single facer and the other on the double facer.
C. On measuring wheel 2 and 3, underneath the bridge.
11. What happens, when the paper storage on the bridge runs too low?
A. The double facer slows down. In case the bridge quantity drops below a certain minimum value
the double facer is switched off.
B. The bridge level control speeds up the double facer before the paper runs out.
C. Automatically the single facer slows down.
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12. Explain the Set Double Facer Speed function?
A. From the main menu by selecting F5 you get the menu graph Set Speed Double Facer. The
cursor is at the position actual value. You can only decrease this value and by selecting F1 the
new actual value is transmitted to the double facer control. nominal value follows indicating that
the double facer is speeding down.
B. This is to stop the double facer.
C. From the main menu by selecting F5 you get the menu graph Set Speed Double Facer. The
cursor is at the position nominal value. You can increase or decrease this value and by
selecting F1 the new nominal value is transmitted to the double facer control. Actual value
follows indicating that the double facer is speeding up or down.
13. In the menu graph Production, when you see active: double facer displayed, what
does this indicate?
A. It means that the double facer is guiding the machine.
B. It means that the single facer is guiding the machine.
C. It means that the double facer is stopped.
14. How do you get into the menu graph Production?
A. Main menu and then select function key F5.
B. Main menu and then select function key F1.
C. Automatically, when the bridge level control is on.
15. In the menu graph Production, what is the function of reset F1?
A. Resets the bridge level control after a fault.
B. Resets the quality linear meters to zero (used when quality change).
C. Resets the total linear meters to zero (used at shift start).
16. In the menu graph Production, what is the function of reset F4?
A. Resets the bridge level control after a fault.
B. Resets the quality linear meters to zero (used when quality change).
C. Resets the total linear meters to zero (used at shift start).
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1.8 Glue Unit LWR - M
1. What is the function of the glue unit?
A. To apply even glue application to the top liner.
B. It serves the purpose to apply even glue application to the flute tips of the single faced
corrugated web over the complete width.
C. To apply even glue application to the bottom liner.
2. What is the speed of applicator roll?
A. The applicator roll runs a preselected percentage faster as the machine speed, this improves
glue application.
B. The applicator roll runs a preselected percentage slower as the machine speed, this improves
glue application.
C. The applicator roll runs at the same speed as the machine speed, this improves glue
application.
3. Explain the difference between the applicator roll and the doctor roll?
A. The applicator roll has a chromium-plated engraved surface and the doctor roll has a smooth
surface.
B. The applicator roll has a smooth surface and the doctor roll has a chromium-plated engraved
surface.
C. They are both the same, only the diameter is different.
4. How is the fluting pressed against the applicator roll?
A. With the BHS pressure shoe system.
B. With air pressure.
C. With a rider roll.
5. How does the automatic glue dam follow-up operate?
A. Light scanners scan the edges of the bottom liner and control the position of the glue dams.
B. This only operates manually.
C. Light scanners scan the edges of the top liner and control the position of the glue dams.
7. How is the glue unit driven?
A. The rolls inside the glue unit are not driven.
B. Electrically through a servo drive.
C. The paper itself drives the rolls inside the glue unit.
8. What happens in case the corrugator is stopped?
A. The glue unit stops also.
B. The glue unit runs 20 seconds at 165 ft/min (50 m/min) and then stops.
C. The glue unit runs at base speed.
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9. Explain the operation of the glue level control?
A. Two light scanners positioned in the middle of the working area control the automatic glue level
control. One checks glue level too low (min.) and the other checks glue level too high (max.). In
case the glue level is at the max. level the supply is closed off, if consequently the glue level
drops and reaches the min. level the supply is opened again.
B. Float-operated valves control the glue level.
C. The glue level control operates on the principle that the flow in is less then the flow out, in this
case the glue unit can never overflow.
10. What is the function of the automatic glue gap stages, which can be set on the
Touchscreen in the Parameter menu?
A. When the speed of the corrugator is reduced below certain preselected speed levels
automatically a preselected additional glue gap is added to the nominal setting. This glue gap
increase in relation to speed can be set in stages. This function is only active in manual.
B. When the speed of the corrugator is reduced below certain preselected speed levels
automatically a preselected additional glue gap is added to the nominal setting. This glue gap
increase in relation to speed can be set in stages. This function is only active in automatic.
C. Answer A. and B. are both correct; it does not matter if we are in manual or automatic for the
glue gap adjustment.
1.9 Double Facer DWR
1. What is the function of the double facer?
A. To apply glue to the flute tips.
B. The double facer is used for bonding the incoming single-faced corrugated web(s) with the
bottom liner.
C. It preheats the bottom liner.
2. Can you name a few systems which can be used inside the double facer, that apply the
necessary pressure to achieve correct bonding of the paper webs?
A. BHS machines are always equipped with a chaintrol, this is the best system especially for light
quality board.
B. The bartrol system using weightrolls, the chaintrol system using shoes.
C. Bartrol, chaintrol or airtrol (combinations are also possible).
3. How are the hot plates heated?
A. With oil.
B. Electrically.
C. By steam.
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4. A double facer with 18 hot plates consists out of how many heating sections?
A. Out of one section.
B. Out of two sections.
C. Out of three sections.
5. Where is the double facer located in the complete machine?
A. Between the glue unit and the rotary shear.
B. Between the single facer and the preheater.
C. The double facer comes after the rotary shear.
6. What are the main components of the double facer?
A. Glue unit, main drive, heating section, traction section, belt and a bar-, chain- or airtrol system.
B. Main drive, heating section, traction section, belt and a bar-, chain- or airtrol system.
C. Main drive, heating section, traction section and rotary shear.
7. When the corrugator is stopped, what happens to the belt in the area of the heating
section?
A. Is lifted automatically through hydraulic cylinders.
B. Remains in the down position, to prevent it from cooling down.
C. Remains in the down position, but lifts automatically after 30 minutes.
8. What is the function of the traction section?
A. Here the bonding takes place.
B. Preheats the bottom liner.
C. It loads the upper belt and thereby carefully transporting the board between upper and lower
belt.
9. How do you control the temperature in the heating sections?
A. We dont, always the maximum steam pressure is available on the steam sections.
B. This goes automatically.
C. By controlling the steam pressure to the three heating sections independently
10. Can you describe the procedure of switching the double facer on?
A. When you operate key switch double facer on you first get an audible pre start-up warning,
after approx. 3 seconds the white luminous key switch starts flashing, then you push again and
the key switch lights.
B. When you operate key switch double facer on the key switch lights and the double facer runs.
C. When you start the single facer the double facer starts up automatically.
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2. Machines in the Dry end
2.1 Rotary Shear KQM
1. What is the function of the KQM in the Corrugator?
A. Cut out waste and create an open space in the paper so we can make an order-change.
B. Only to cut out waste.
C. Cut the paper on the , by the customer , desired length.
2. What is the function of the orange indication light on top of the machine?
A. When it is blinking this means , that there is something wrong with the electronic system of the
machine.
B. When it is blinking this means , that the Corrugator is going to do an order-change.
C. When it is blinking this means , that the machine started cutting or is going to start cutting.
3. What happens when we open the first security-door on the KQM , when the Corrugator
is not running?
A. A warning light comes on , and when we start the Corrugator it will go out.
B. The Corrugator will make an emergency stop and it is not possible to start the Corrugator up
again without closing the door first , together with this a warning light will is on.
C. We are able to start the Corrugator , but it is not possible to start cutting.
4. What happens when we open the first security-door on the KQM when the Corrugator is
running?
A. The Corrugator will continue to run but , it is not possible to start cutting.
B. The Corrugator stops.
C. The Corrugator makes an emergency-stop.
5. What happens when we open the first security-door on the KQM , when the knife is
cutting and the Corrugator is running?
A. The Corrugator continuous running and the knife stops cutting automatically.
6. What happens when we open the second security-door on the KQM when the
Corrugator is not running?
A. Nothing happens.
B. A red warning-lamp comes on but we can still start the machine.
C. A red warning-lamp comes on and we can not start the machine.
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7. What happens when we open the second security-door on the KQM when the
Corrugator is running?
A. Nothing happens.
B. A red warning-lamp comes on but the Corrugator will keeps running.
C. A red warning-lamp comes on and the Corrugator will keeps running , but we can not start the
knife.
8. What happens when we open the second security-door on the KQM , when the knife is
A. Nothing happens.
B. The Corrugator makes an emergency-stop.
C. The KQM automatically stops cutting and the Corrugator keeps on running.
9. What is the function of the button one single cut?
A. With this button we can make one cut across the paper-width.
B. With this button we can cut the paper for an order-change.
C. With this button we can cut the paper and do an order-change at the same time.
10. What is the effect of the button one single cut?
A. It cuts one time.
B. It cuts out one single piece of board.
C. It cuts out two pieces of board.
11. What is the maximum speed to make one single cut ? (1m/min = 3.3 ft/min)
A. 660 ft/min (200 m/min)
C. 990 ft/min (300 m/min)
12. What is the function of the button Continuous cutting?
A. With this button we can cut the paper across the width during an order-change.
B. With this button we can cut out paper continuously.
C. With this button we can cut out waste during an order-change.
13. What is the effect of the button Continuous cutting?
A. It cuts out one piece of board.
B. It cuts out two pieces of board.
C. It cuts out as much pieces of board as we wish.
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14. What is the maximum speed to cut continuously?
15. What is the function of the button Order-Change on the KQM?
A. With this button we can do an order-change on the SRA (Slitter Scorer).
B. With this button we can do an order-change on the whole Dry-End , when the AFW (Automatic
Order Change) is standing in Manual-mode.
C. With this button we can do an order-change on the whole Dry-End , when the AFW (Automatic
Order Change) is standing in Automatic-mode.
2.2 Slitter Scorer SRA-M
1. What is the purpose of the SRA in the Corrugator?
A. Cut the board on the desired width and put scores on the board..
B. Cut the board on the desired length
C. Make order changes.
2. Why do we need to make a reference travel on the SRA , in the morning before we start
producing?
A. To see if all the tools in the SRA are working.
B. Because the computer has to know where the machines-tools are.
C. To see if there are no used knives in the SRA.
3. How do we have to grind the disc-cut knives?
A. We have to take the knives out to grind them.
B. We can grind the knives on the machines , when the Corrugator is stopped.
C. We can grind the knives during production.
4. When do we have to grind the disc-cut-knives?
A. Every hour.
B. Every 6600ft (2000 linear meter)
C. This depends on the board quality.
5. From which parameters depends the grinding of the disc-cut-knives?
A. The board quality.
B. The board quality and the board thickness.
C. The board quality and the running-speed of the Corrugator.
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6. Do we have to grind the disc-cut-knives manually or does it happen automatically?
A. We always have to grind the knives manually.
B. The knives are always grinded automatically.
C. Normally the knives are grinded automatically , but we can also grind them manually.
7. Why do we have to lubricate the disc-cut-knives?
A. To prevent glue from deposing on the knives.
B. To cool the knives during production.
C. To cool the knives during grinding.
8. How oft do we have to lubricate the disc-cut-knives?
A. This depends on the running-speed of the knives.
B. This depends on the length of cutted board.
C. This depends on the length of cutted board and the board thickness.
9. How do we have to lubricate the disc-cut-knives?
A. This always happens automatically.
B. We always have to do this manually.
C. This happens automatically , but we can also lubricate manually.
10. What is the minimum distance between the disc-cut-knives?
A. 3,94 inch (100 mm)
B. 4,92 inch (125 mm)
C. 5,71 inch (145 mm)
11. What is the minimum distance between the scores?
A. 2,83 inch (72 mm)
B. 3,03 inch (77 mm)
C. 3,23 inch (82 mm)
12. What is swing-change?
A. A shearless order-change: This means order-change without creating a open space in the
board.
B. This is an easy to change system for the disc-cut-knives (Less than 5 minutes).
C. This system allows fast positioning , from all the disc-cut-knives , in the board during
production.
13. Why do we need the function paper-jam control?
A. The system makes sure that is impossible to have a Board-jam on the SRA.
B. The system alerts us when there is a board-jam in the SRA.
C. The system stops the Corrugator in case of a board-jam in the SRA.
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14. Why do we need the paddle unit after the SRA and KQF?
A. To put the board on to the right cut-off-knifes.
B. To dry out the board.
C. To support the board during the cut-off process.
15. Why do we need the board-following-system on the SRA?
A. This one controls the width of the side-trim and also adjusts it when necessary.
B. We need this one to follow the board in order to control the production.
C. We need this one to align the SRA on the board.
2.3 Rotary Shear KQF
1. What is the function of the KQF in the Corrugator?
A. We need the KQF in case the KQM brakes down.
B. The KQF cuts out the waste that we forgot to cut out on the KQM.
C. The KQF cuts out the waste made by a shearless order-change.
2. What is the function of the orange indication light on top of the machine?
A. When it is blinking this means , that there is something wrong with the electronic system of the
machine.
B. When it is blinking this means , that the Corrugator is going to do an order-change.
C. When it is blinking this means , that the machine started cutting or is going to start cutting.
3. What happens when we open the first security-door on the KQF , when the Corrugator
is not running?
A. A warning light comes on , and when we start the Corrugator it will go out.
B. The Corrugator will make an emergency stop and it is not possible to start the Corrugator up
again without closing the door first , together with this a warning light will is on.
C. We are able to start the Corrugator , but it is not possible to start cutting.
4. What happens when we open the first security-door on the KQF when the Corrugator is
running?
A. The Corrugator will continue to run but , it is not possible to start cutting.
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5. What happens when we open the first security-door on the KQF , when the knife is
A. The Corrugator continuous running and the knife stops cutting automatically.
6. What happens when we open the second security-door on the KQF when the
Corrugator is not running?
A. Nothing happens.
B. A red warning-lamp comes on but we can still start the machine.
C. A red warning-lamp comes on and we can not start the machine.
7. What happens when we open the second security-door on the KQF when the
Corrugator is running?
A. Nothing happens.
B. A red warning-lamp comes on but the Corrugator will keeps running.
C. A red warning-lamp comes on and the Corrugator will keeps running , but we can not start the
knife.
8. What happens when we open the second security-door on the KQF , when the knife is
A. Nothing happens.
C. The KQF automatically stops cutting and the Corrugator keeps on running.
9. What is the function of the button one single cut?
A. With this button we can make one cut across the paper-width.
B. With this button we can cut the paper for an order-change.
C. With this button we can cut the paper and do an order-change at the same time.
10. What is the effect of the button one single cut?
A. It cuts one time.
B. It cuts out one single piece of board.
C. It cuts out two pieces of board.
11. What is the maximum speed to make one single cut ? (1m/min = 3.3 ft/min)
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12. What is the function of the button Continuous cutting?
A. With this button we can cut the paper across the width during an order-change.
B. With this button we can cut out paper continuously.
C. With this button we can cut out waste during an order-change.
13. What is the effect of the button Continuous cutting?
A. It cuts out one piece of board.
B. It cuts out two pieces of board.
C. It cuts out as much pieces of board as we wish.
14. What is the maximum speed to cut continuously? (1m/min = 3.3 ft/min)
15. What is the difference in use between the KQM and the KQF?
A. The KQF is being used for shearless order-change and the KQM is used to cut out waste.
B. The KQM is being used for shearless order-change and the KQF is used to cut out waste.
2.4 Cut-off Knife NQM
1. What is the function of the NQM in the Corrugator?
A. Cut out waste.
B. Cut the board on the desired length.
C. Create an open space in the paper to make an order-Change.
2. What is the minimum cutting length of the NQM?
A. There is no minimum value.
B. 14.4 inch (365 mm)
C. 19.7 inch (500 mm)
3. What is the maximum cutting length of the NQM?
A. There is no maximum length.
B. 256 inch (6500 mm)
C. 393.7 inch (9999 mm)
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4. What means : cutting on overspeed?
A. The knife is cutting so fast that the electronic control cant follow.
B. The knife is cutting on a higher speed than his maximum speed which creates an overheating
in the electronic system.
C. The paper-speed is higher than the maximum speed of the knife , so that we are cutting the
paper under a wrong angle.
5. What is the maximum cutting-speed on the NQM
B. The NQM has no maximum cutting-speed.
C. This depends on the board-length.
6. What kind of knives do we have in the NQM?
A. Steel-balk knives.
B. With steel enforced polyester-balk knives
C. Carbon-Fibre-balk knives.
7. What does the control-light Maximum cutting speed tells us?
A. That we reached the maximum cutting-speed for this board-length.
B. That we have to slow down the Corrugator because the knife is overheating.
C. That we did not achieved the maximum cutting-speed yet.
8. Which formats can we run the fastest on the Corrugator : Very short-formats or normal-
formats?
A. Very short-formats.
B. Normal-formats as long that they are not to long.
C. We can run both formats on the same maximum speed.
9. Can we do an order-change on the NQM when there is paper in this machine?
A. Yes , we can do this.
B. No , we have to create an open space in the paper.
C. Yes , but only when the board-length does not change.
10. What happens when we open one of the security-doors situated around the NQM?
A. The Corrugator stops.
C. An acoustic signal will warn you that one of the doors is open.
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11. How can we see if the NQM is cutting the board on the right length?
A. We can see the nominal- and the actual-value on the computer-screen.
B. We can see the nominal- and the actual-value on a display on the machine.
C. The only way to check this is to measure the board.
12. Can we change the cutting length during production on the NQM?
A. Yes , if the offset-value is not higher than 1 inch (25,4 mm)
B. No , this is not possible.
C. Yes , this is possible.
13. Why do we need the buttons activate dry-end?
A. To start cutting with the NQM.
B. To start the dry-end when the Corrugator is running.
C. To run the dry-end when the Corrugator is stopped.
2.5 Stacker AAR
1. What is the function of the AAR in the Corrugator?
A The function of the AAR is , transporting the board to the end of the Corrugator.
B. The function of the AAR is , putting the board on pre-determined stacks.
C. The function of the AAR is , to palletise the stacks.
2. What is the composition of the stacker?
A. 1 Upstacker and 2 downstacker.
B. 1 Upstacker , 1 downstacker and 1 sidechamber.
C. 2 Downstacker and 1 sidechamber.
3. What is the maximum length on the upstacker?
A. 197 inch (5000 mm)
B. 256 inch (6500 mm)
C. 284 inch (7200 mm)
4. What is the maximum length on the downstacker?
A. 165 inch (4200 mm)
B. 177 inch (4500 mm)
C. 197 inch (5000 mm)
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01.10.1997 chapter 4 page 35
5. What is the maximum length in the sidechamber?
A. 142 inch (3600 mm)
B. 165 inch (4200 mm)
C. 177 inch (4500 mm)
6. Why do we need the vacuum system on the AAR right after the NQM?
A. To make sure that there is no dust on the bottom-side of the board.
B. To help the board to dry out.
C. To pull the fast out-coming board on to the transport-belt of the stacker.
7. Why do we need the brushes on the AAR?
A. To make sure that there is no dust on the top-side of the board.
B. To press the out-coming board on to the transport-belt of the stacker.
C. To determinate the shingling-factor.
8. Can we change the brush parameters on the AAR?
A. Yes.
B. No.
C. Yes , but only when the machine is stopped.
9. Where can we change these brush-parameters?
A. Only the computer-screen.
B. Only on the switch-cabinet situated on the AAR.
C. On the computer-screen and on the switch-cabinet situated on the AAR.
10. What happens when a stack can not be transported out of the AAR?
A. The Corrugator slows down but stays running.
B. The Corrugator slows down and eventually stops.
C. The Corrugator stops immediately.
11. Can we change the backstop-position on the stacker during production?
A. Yes , but only on the computer-screen.
B. Yes , but only on the switch-cabinet on the AAR.
C. Yes , we can change this value on the computer-screen and on the switch-cabinet on the AAR.
12. Can we change the height of the stack during production?
A. No we can not do this.
B. Yes we can do this , but only when the new value is smaller than the old one.
C. Yes , we can do this.
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01.10.1997 chapter 4 page 36
13. How can we see if the backstop is in the right position?
A. We can see this on the computer-screen and on the switch-cabinet on the stacker.
B. We can only see this on the switch-cabinet on the AAR.
C. We can only see this on the computer-screen.
14. What is the function of the green light on the up- and down-stacker?
A. A stop-button or an emergency-stop is pushed.
B. The stack can not get out of the AAR..
C. The lifting-table is blocked by the security surveillance on the downstacker.
15. What is the function of the red light on the up- and down-stacker?
16. What is the function of the blue light on the downstacker?
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01.10.1997 chapter 4 page 37
2.6 AFW - Automatic Order Change
1. What is the function of the AFW in the Corrugator?
A We need this to carry out a quality-change.
B We need this to carry out splice synchronisation.
C We need this to carry out the order-changes automatically.
2. How can we see if the Corrugator started an order-change?
A A light-signal tells you this.
B An acoustic signal tells you this.
C A light-signal and an acoustic-signal will tell you this.
3. Can we interrupt the automatic order-change once it is started?
A Yes , as long as the KQM did not start cutting yet.
B Yes , always.
C No , we can not do this.
4. Why do we have the possibility to start an order-change from the cut-off-knife?
A Because during production we are always standing at the cut-off-knife.
B This is easier , because we can see how the order-change is running
C Because an order-change can also be an quality-change , and then we have to cut out the old
quality until the new quality is arrived , after this we can the order-change from the cut-off-knife.
5. How can we see if the dry-end is ready to do an order-change?
A We can see this on the computer-screen.
B we can see this on a control-light.
C We can not see this.
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01.10.1997 chapter 4 page 38
3. Starch
3.1 General
1. What are the major components inside the corrugating adhesive?
A. Water and starch only
B. Water, starch, caustic soda and borax or boric acid.
C. Starch, water and borax.
2. Starch can be extracted from a wide variety of plants. Can you name some?
A. Beans, carrots and potato.
B. Sunflower seeds mainly.
C. Wheat, rice, tapioca, potato and maize.
3. Which of these is the most commonly used?
A. Maize.
B. Wheat.
C. Tapioca.
4. What do we mean with the term gelatinisation temperature?
A. This is the temperature at which the starch becomes liquid.
B. This is the temperature at which the starch looses its bonding characteristics.
C. The gelatinisation temperature is the level at which the starch granules swell rapidly as they
absorb water and eventually burst to produce the familiar starch paste with its adhesive
characteristics. This process is referred to as gelatinisation.
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5. Which component in the starch formula controls the gel. temperature?
A. Caustic soda.
B. Water.
C. Starch.
6. Which component of the corrugating adhesive has the highest percentage?
A. Starch
B. Water.
C. Borax.
7. What do we mean with the term solid content?
A. Amount of caustic soda in the formula.
B. Amount of water in the formula.
C. The percentage of starch solids which are in the adhesive formula.
8. Name a few formulation processes which have been developed to prepare a corrugating
adhesive?
A. Only the steinhall system is used to prepare a corrugating adhesive.
B. Steinhall system, No-Carrier system and Minocar system.
C. The minocar system, which is a steinhall process is used to prepare a corrugating adhesive.
3.2 Bonding Process
1. What are the stages of the bonding process?
A. Application, wetting, diffusion and absorption.
B. Application and absorption.
C. Application and diffusion.
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2. What is the correct sequence of these four events?
A. 1/ Wetting 2/ Application 3/ Diffusion 4/ Absorption.
B. 1/ Application 2/ Wetting 3/ Diffusion 4/ Absorption.
C. 1/ Application 2/ Wetting 3/ Absorption 4/ Diffusion.
3. Besides these four stages, which other two elements are needed in the bonding
process?
A. Only heat.
B. Only pressure.
C. Heat and pressure.
4. What do we mean with the term diffusion?
A. Application on the flute tip.
B. Penetration of the liquid adhesive into the paper.
C. Adhesion,: the starch is strongly attracted by the cellulose of the paper.
5. What do we mean with the term absorption?
A. Adhesion,: the starch is strongly attracted by the cellulose of the paper.
B. Penetration of the liquid adhesive into the paper.
C. Application on the flute tip.
6. When corrugator running speeds go up, what adjustment is required on the gel.
temperature?
A. The gel. temperature has to be decreased.
B. The gel. temperature has to be increased.
C. The gel. temperature can remain the same.
3.3 Application Process
1. What do we mean with the term glue gap?
A. The glue gap is the gap between the doctor roll and the glue roll.
B. The glue gap is the gap between the doctor roll and the rider roll.
C. The glue gap is the gap between glue roll and the rider roll.
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2. What do we control with the glue gap?
A. The glue gap controls the application on the flute tip.
B. The bonding process.
C. The glue gap controls the thickness of the glue coating to be applied onto the flute tips.
3. Is all the glue controlled by the glue gap applied to the flute tips?
A. Yes.
B. No, a percentage remains on the glue roll and a percentage remains on the doctor roll. Only
that part which stays on the glue roll can be applied to the flute tips.
4. What happens, when the glue application roll gap is controlled too large; do we get too
much or too little starch on the flute tips?
A. If the glue application roll gap is too large, the glue roll moves closer to the flute tips and
therefor it is possible that too much glue is applied at all onto the flute tips.
B If the glue application roll gap is too large, the glue roll moves further away from the flute tips
and therefor it is possible that no glue is applied at all onto the flute tips.
5. What do we mean with the term glue application roll gap?
A. The glue application roll gap controls the gap between the glue application roll and the
corrugating roll.
B. The glue application roll gap controls the gap between the doctor roll and the glue application
roll.
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6. Why is it necessary that the glue application roll gap is made adjustable?
A. Various paper qualities have different thickness. In order to achieve the correct glue application
onto the flute tips, this gap is adjustable.
B. This depends on the viscosity of the glue applied.
C. This depends on the gel. temperature of the glue applied.
7. Why is the glue roll engraved?
A. This results in a better glue application. Due to the engraving more glue remains onto the glue
application roll as onto the doctor roll.
B. For longer lifetime.
C. Easier to keep clean.
3.4 Problems related to Bonding
1. What are some of the more common problems with the adhesive application systems
that can cause bond problems?
A. Glue application roll/corrugating roll not parallel, Glue application roll/doctor roll not parallel.
B. Out of round rolls, Rolls with non-uniform diameters, Engraving on glue application roll locally
worn, Mechanical damage, Worn bearings.
C. Glue application roll/corrugating roll not parallel, Glue application roll/doctor roll not parallel,
Out of round rolls, Rolls with non-uniform diameters, Engraving on glue application roll locally
worn, Mechanical damage, Worn bearings etc.
2. The doctor roll and glue application roll are not parallel. What is the effect on glue
application?
A. Even glue application across the width of the paper.
B. This a normal situation.
C. Uneven glue application across the width of the paper.
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3. What happens with the glue application if in a particular area on the glue application roll
the engraving wears down?
A. At that particular spot you get too much glue.
B. At that particular spot you get too little glue.
4. What do we mean with the term Zip bonding and how does this occur?
A. Too much glue application causing wet board.
B. It is caused by insufficient glue penetration, the adhesive has not remained fluid long enough to
properly penetrate the paper and so final bond has not tied itself into the fibbers of the paper
and consequently the board will pull apart with little or no sign of paper tear. This can be
caused by: Overheating of the papers, especially on lightweight board, slippage between
double facer liner and single faced web, hi-lo flutes, incorrect formulation of the adhesive or
insufficient glue penetration.
3.5 Tests
1. How can we check the viscosity of the adhesive used?
A. Heating the adhesive and check when it thickens, the time this takes tells us something about
the viscosity.
B. The viscosity is checked with an instrument known as the Stein Hall Cup.
2. Which test do you know that can show the glue lines and therefor give you an
indication of the glue application?
A. The Steinhall test
B. The iodine staining test.
C. The water absorption test.
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01.10.1997 chapter 4 page 44
4. Paper
4.1 General
1. What is Kraft liner paper?
A. This paper made from virgin wood fibbers.
B. This is paper which consists mainly out of recycled paper.
2. What is do we mean with the runnability of the paper?
A. When the runnability of the paper is good, this means that this paper is easy to run in the
corrugator.
B. With the runnability we mean the maximum speed at which the corrugator can run with a
certain paper.
3. What paper(s) is used for fluting medium?
A. Kraftliner and testliner.
B. Semi-chemical, Schrenz and Wastepaper
4.2 Paper Properties
1. What is caliper of the paper?
A. The thickness of the paper.
B. The strength of the paper.
2. What is the moisture content of fluting medium normally?
A. Normally between 4 and 8 %.
B. As low as possible.
3. What is the moisture content of liner paper normally?
A. Between 6 and 10%.
B. Between 2 and 6%.
C. Between 10 and 14%.
4. What do we mean if we say that liner and fluting medium are balanced?
A. They have the same weight per sf (m
2
)
B. The moisture content of the two papers is even and within a certain percentage of eachother
C. The thickness is the same.
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01.10.1997 chapter 4 page 45
4.3 Problems related to Paper
1. What can happen when the paper has no even structure and shows streaks caused by
the paper machine?
A. This will improve the runnability of the paper.
B. The streaks will be higher in temperature, due to excessive contact with the preheater(s)
C. The streaks will be lower in temperature, due to bad contact with the preheater(s).
2. What can we do when we run very dry fluting medium?
A. Run with steam shower off.
B. Make sure preconditioner is at minimum wrap.
C. Use steam shower and preconditioner to prepare paper for correct flute formation.
4.4 Warp Problems
1. What do we mean if the board shows down warp?
A. The sides of the board curls up.
B. The sides of the board curls down.
C. This is also called S warp.
2. What can you do on the corrugator to correct for up warp (bonding is good) running
single wall?
A. Always adjust the glue gap first.
B. Increase the wrap on the preheater for the single faced web, decrease the wrap on the
preheater for the bottom liner.
C. Decrease the wrap on the preheater for the single faced web, increase the wrap on the
preheater for the bottom liner.
3. We have warp in machine direction or end-to-end (not in cross machine direction),
what causes this?
A. Uneven humidity over the width of the rolls.
B. Tension in the single faced web higher then in the bottom liner.
C. Glue gap glue unit too large.
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01.10.1997 chapter 4 page 46
5. Steam
1. What is the required steam-pressure on the Corrugator?
A 147 psi to 176.4 psi (10 bar to 12 bar)
B 176.4 psi to 205.8 psi (12 bar to 14 bar)
C 205.8 psi to 235.2 psi (14 bar to 16 bar)
2. Why do we need the drain-pipes inside the preheaters and preconditioners?
A To get the water out of the drums.
B To put the steam in to the preheaters and -conditioners.
C To clean the drums on the inside.
3. Why can condense-water give problems on a Corrugator?
A Because it can cause rust in to the corrugating-rolls and preheaters etc. . .
B Because water is colder than steam , it cools down the (for example) corrugating-rolls.
C Because the water adds weight in to the drums , so the electro-motors can go in over-current.
4. Why do we need a pressure-difference from minimum 29.4 psi (2 bar) on the hot-plates?
A Because of the differences in temperature needed to produce good quality-board and the
condense-system.
B Because of the differences in temperature needed to produce good quality-board.
C Because of the condense-system.
5. How can we see if we have the right temperature on our hot-plates?
A We have to shoot the temperature with a temperature gun , to check if we have the right
temperatures on the hot plates.
B The temperatures are displayed on the computer-screen.
C We can see this when we are running good production.
6. How can we see if we have water in the hot-plates?
A We can see this on the computer-screens , this means that we will have a actual temperature
on the hot plates that is not corresponding with the actual pressure in the hot-plates.
B We will see this on glue-problems that are going to occur during production.
C We will see the water flowing out of the bottom side of the hot-plates.
7. What do we have to do when we have water in the hot-plates?
A We have to put the full steam-pressure on the hot plates so that the water is being pushed out.
B Open the anti-condense-valve so that the water can leak out.
C Check if the condense system is working correctly.
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01.10.1997 chapter 4 page 47
8. What are the symptoms on the modul-facer when we have condense-problems?
A We can see this on the computer-screens , this means that we will have a actual temperature
in the corrugating-rolls that is not corresponding with the actual pressure in the hot-plates.
B We will see this on glue-problems that are going to occur during production and this over the
whole width.
C We will see the water flowing out of the corrugating rolls.
9. What are the symptoms on the double-backer when we have condense-problems?
A The board is to wet when it comes out the double-backer.
B We can see this on glue-problems that are occurring during production.
C We can see the water flowing out of the bottom side of the hot-plates.
Training Manual
01.10.1997 chapter 4 page 48
Practical Part
Customer: _____________________________________________________________
Instructor: _____________________________________________________________
Student: _____________________________________________________________
My instructor has taught or explained the following to me:
6. Machines in the Wet end
6.1 Roll Stand ASR-M
What is the function of the Roll Stand
What are the functions of the tensioning arms
How does the process of unwinding
What is the function of the brake-units
Initial: Date:
Training Manual
01.10.1997 chapter 4 page 49
6.2 Rest Roll Computer RRR
What is the function of this part
How does it calculates the remaining meters on the roll
What are the parameters that we can change in the menu , and how do we have to use these
parameters
How do we change the paper-rolls in the labelprinters
When is the rest length detected
What kindes of splicing can be chosen
How are values modified in the setup (cone diameter)
Where is the approach switch to be found for the measurement
How does the printer work, when does it print
Initial: Date:
Training Manual
01.10.1997 chapter 4 page 50
6.3 Splicer ARW-M incl. Automatic Roll Pick-UP ARA
What is the purpose of this machine
How does the web tensioning system operates
What is the purpose of the accumulator rolls in the splicer
How do we have to tread in the paper in the splicer
How do we have to prepare a splice
What are the functions on the controls on the splicer control cabinet
At what speed can we splice with these splicers
What is the function of the Automatic Roll Pick-Up system, type ARA
Where are the sensors that we use to detect the different parameters for the ARA
In what condition does the paper-roll have to be in, in order to assure correct paper handling
What are the functions on the of the controls on the ARA switch-cabinet
Initial: Date:
Training Manual
01.10.1997 chapter 4 page 51
6.4 Under/Above Floor Trolley FB/UFB
What is the function of this part
How does it calculates the remaining meters on the roll
What are the parameters that we can change in the menu, and how do we have to use these
parameters
How do we change the paper-rolls in the labelprinters
Initial: Date:
Training Manual
01.10.1997 chapter 4 page 52
6.5 Modul Facer MF Bandleader
What is the function of the glue unit (glue rolls and glue dams) + details
What is the function of the Bandleader system + details
What is the function of the over-pressure system in the glue unit + slots + slot-cleaners
What is the function of the preheaters and preconditioner
How to operate the touchscreens
How to start the machine and thread up the paper
Explain the functions of the controls and pressure gauges of the machine
What to do if the bonding between fluting and liner is not good
How to put the correct settings on the machine (glue dams, glue film glue, application gap
web-tension)
Checking the paper-quality on glue films with Iodine in order to detect glue problems
What is the function of the Quality Change menu
How do we have to clean the machine properly
How can we make a flute change (Modul change)
Initial: Date:
Training Manual
01.10.1997 chapter 4 page 53
6.6 Preheater VZR-M
What is the function of the preheaters in the Corrugator
How can we change the wrap on these preheaters
What is the difference between Manual- and Automatic- mode
Which sides of the paper is heated up normally
Initial: Date:
Training Manual
01.10.1997 chapter 4 page 54
6.7 Bridge B
Why do we need a Bridgebrake on the Corrugator
How does the bridgebrake works and how to change the values
How do we have to work with the touch screens
What is the difference between Automatic and manual mode and when are we going to use
this
Why do we need a web-centring system on the machine
How does the web-centring system (Corraligner) works and what are the possibilitys
Initial: Date:
Training Manual
01.10.1997 chapter 4 page 55
6.8 Bridge Level Control BMR
What is the purpose of this system
How can we calibrate the BMR and when do we switch on the automatic mode
What are the parameters that we can change in this system , and how do we have to change
them
How can we take a look on the actual linear meters , and how do we have to reset them
a) Pro shift
b) Pro order
How can we change the amount of paper on the bridge during normal production
How can we change and give increased paper demand on the bridge
Why do we need the function increased paper demand
How can we set the speed for the DWR with the BMR and when are we going to use it
Explain the MASTER - SLAVE relation between the MF and DWR
Initial: Date:
Training Manual
01.10.1997 chapter 4 page 56
6.9 Glue Unit LWR-M
What is the function of the LWR in the Corrugator
Difference of the LWR-glue pan and the glue pan of the BHS-Modul Facer (If the customer
has both)
What are glue dams and what is their function
How do glue dams operate
What is the difference between the glue dams in Automatic- and Manual-mode
What is the difference between the glue-gap system in Automatic- and Manual-mode
What is the function of lagging on the glue-rolls
What can we change from glue parameters and why is this necessary
How to operate the touchscreens
Initial: Date:
Training Manual
01.10.1997 chapter 4 page 57
6.10 Double Facer DWR
6.10.1 DWR-Airtrol
What is the function of the DWR in a Corrugator
What is Airtrol
How to work with the steam sections according to the paper quality
How to operate the Airtrol system
Why do we need the internal preheater in the DWR
How do we operate the touchscreens
What are the functions of the controls on the machine
How can we lift the belt in case of an emergency stop , and why do we have to do this
How can we check if we have water in the steam sections and what to do in case this
happens
How does the speed effect the wrap of the preheaters and the Airtrol
Explain the air-pressure system of the Airtrol
How can we avoid having problems with static electricity on the DWR
Initial: Date:
6.10.2 DWR-Chaintrol
What is the function of the DWR in the Corrugator
What is Chaintrol
How to operate the Chaintrol system
How can we lift the belt in case of a emergency stop , and why do we have to do this
happens
Training Manual
01.10.1997 chapter 4 page 58
How does the speed effect the wrap of the preheaters and Chaintrol
Initial: Date:
6.10.3 DWR-Airtrol-Chaintrol
What is Airtrol and Chaintrol
How to operate the Airtrol - Chaintrol combination
How can we lift the belt in case of an emergency stop , and why do we have to do this
happens
How does the speed effect the wrap of the preheaters , Airtrol and Chaintrol
Explain the air-pressure regulating-system of the Airtrol
Initial: Date:
6.10.4 DWR-Bartrol
What is Bartrol
How to operate the Bartrol system
Training Manual
01.10.1997 chapter 4 page 59
How can we lift the belt in case of a emergency stop , and why do we have to do this
happens
How does the speed effect the wrap of the preheaters
How do we operate the various programs of the Bartrol system
How can we create or own programs in the Bartrol system
Initial: Date:
Training Manual
01.10.1997 chapter 4 page 60
6.11 Rotary Shear KQM
What is the function of the KQM in the Corrugator
What is the function during an Order Change
What is the maximum speed during continuous cutting
What is the maximum speed during one single cut
What are the functions of the two security doors on operator side
What can the signal light on the KQM tell us
What is the function of the lower extract rolls in the KQM
How can we cut the paper when the Corrugator is stopped
How can we use the remote control-function for starting the KQM operation
Initial: Date:
Training Manual
01.10.1997 chapter 4 page 61
6.12 Shear Order Change KQF
What is the function of the KQF in the Corrugator
What is the function during an Order Change
What is the maximum speed during continuous cutting
What is the maximum speed during one single cut
What are the functions of the two security doors on operator side
What can the signal light on the KQF tell us
What is the function of the lower extract rolls in the KQF
How can we cut the paper when the Corrugator is stopped
How can we use the remote control-function for starting the KQF operation
Initial: Date:
Training Manual
01.10.1997 chapter 4 page 62
6.13 Slitter Scorer SRA-M incl. Disc Cut
What is the function of the SRA-M in the Corrugator
How do we start the SRA-M
How do we make a reference travel on the SRA-M
When do we have to make such a reference travel
How do we enter the qualitys in the quality menu + details
How do we enter the orders in the order menu + details
How do we send the actual and next order to the machine
How can we see if there is an actual and a next order in the machine
How can we move an order or a quality
How can we copy an order or a quality
How can we cancel an order or a quality
What do we have to do after changing the order-list
How to check if the machine has positioned correctly and what to do if it is incorrect
How to make a correction on the SRA-tools when the machine is running
Disk cut system : grinding + greasing + details
What are the function of the Controls on the SRA-M
How can we make a Order Change on the SRA-M without effecting the rest of the Corrugator
How to open the tools in the machine and when do we have to do this
How to change the lubrication-felt-pads on the knifes
How do we have to change the grinding intervals of the knifes
How do we end the production
Initial: Date:
Training Manual
01.10.1997 chapter 4 page 63
6.14 Paddle Unit PE
How to check the pressure adjustment of the maintenance unit
Initial: Date:
Training Manual
01.10.1997 chapter 4 page 64
6.15 High Speed Cut-off HQM
What is the purpose of this machine
What is the maximum cutting speed , without over-speed ( Steel balk knives 990 ft/min
(300 m/min) or carbon fibre balk knives 1320 ft/min (400 m/min )
What is over-speed
How can we see if / when the HQM is cutting in overspeed
How can we program the HQM without using the FDM
How can we execute an order change on the HQM without affecting the rest of the machine
How can we change the cutting length on the HQM during production
How can we, empty the whole Dry-End, when the machine is stopped
Initial: Date:
Training Manual
01.10.1997 chapter 4 page 65
6.16 Stacker AAR-S/H
Why do we need this machine
How do we have to program the stacker without the use of the FDM
How can we do an orderchange on the stacker without affecting the other machine
components
how can we suppress an orderchange on the stacker , an when do we need this
What is the purpose of the brushes on the stacker
How can we change the program of the brushes
- On the computer
- Directly on the machine
What is the purpose of the vacuum system on the stacker
How can we change the value of the backstop-position during production
How can we adjust the dropheight on the stacker during production
- Permanently
- Temporarily
How can we , in case of a machine stop , evacuate the paper
- On the stacker
- On the whole Dry-end
What are the functions of the buttons on the machine
What is the difference between
- Stacker in manual mode
- Stacker in automatic mode
How do we have to make a reference travel on the stacker
Initial: Date:
Training Manual
01.10.1997 chapter 4 page 66
6.17 Automatic Order (Format) Change AFW
Why do we need an Automatic Order Change system , and how does it work
How can we make an Order Change in manual , and when are we going to use this
How can we make an Automatic Order Change
What are the functions of the buttons on the control panel.
How can we determinate on witch knife we will start our Order Change , and what does this
mean
How can we interrupt an Automatic Order Change when it is already started
How can we see if the machine is ready to do an Order Change
How can we activate the motors of the dry end ( To clean up the belt for example. )
Initial: Date:
Training Manual
01.10.1997 chapter 4 page 67
6.18 Splice Synchronization System SSS, Automatic Quality
Change AQW
What is the function of the SSS
What are the conditions for a splice sysnchronization
From where does the SSS get the orders, what is their content and how does the evaluation
take place
Who is allowed to suppress the splice when and where and how
What does an aktive SSS look like an the monitor
What are the mainenance work to be performed on the pump
How and where can I modify splice speeds
What numbers are displayed in the splicers/KR
How does a splice synchronization go off
Where are the pump, pistol, reflection light scanner and how do they work
What does the Automatic Quality Change do
When do the machine change-overs take place
Where and how are the data of production in the NOMINAL LIST
Where and how can I modify the Quality (FDM)
Initial: Date:
written by Sylveer Landuyt / Mark van Bosbeke / Jos Giesbers BHS Trainers
layouted by Sichelstiel Peter / Kaschel Wolfgang BHS Documentation
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Mr. ..........................
born xx.xx.199x
employed by XXX
was successfully trained by our
staff during the period from
xx.xx.-xx.xx.199x
to operate a
corrugator line
We certify that Mr. .......................
able to operate the above
mentioned machines by himself.
Weiherhammer, xx.xx.199x
Mr. ................... Mr. ......................

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