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Type of machines ROLL STAND ASR-M ................................................................................................................................... 3 BUTT ROLL COMPUTER ............................................................................................................................. 5 RRR ............................................................................................................................................................... 5 SPLICER ARW-M.......................................................................................................................................... 6 UNDER/ABOVE FLOOR TROLLEY ............................................................................................................. 8 ÜFB/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

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CENTER FDM/PDM..................................................................................................................................... 33 QUALITY DATA .......................................................................................................................................... 34 MANAGEMENT QDM................................................................................................................................. 34 SPLICE SYNCHRONISATION .................................................................................................................... 35 SYSTEM – SSS ........................................................................................................................................... 35 MACHINE CONTROL CENTER.................................................................................................................. 37 MCC ............................................................................................................................................................. 37

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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

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(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.

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Type of Machine: Butt Roll Computer RRR


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.


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).

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Type of Machine: Splicer ARW-M


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!)

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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.


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: •

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when the paper web runs from the left roll stand, it runs over the left deflection roll (movable)

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•

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:

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manually, by the operator

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automatically, at a preselected minimum diameter, using ultrasonic sensors

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automatically, by the butt roll computer (option)

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automatically, by the Splice Synchronisation System (option)

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


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).


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.

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Type of Machine: Modul Facer MF-Bandleader


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".


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:

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Modul Facer (MF) with Bandleader System

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Modul Facer (MF) with pressure roll

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Modul Cassette Facer (MCF) with Bandleader System

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Modul Cassette Facer (MCF) with pressure roll

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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:

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only to be used in well-ventilated rooms!

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avoid inhalation of fumes if temperatures exceed 260°C /500°F!

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keep away flames to avoid formation of toxic fumes!

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avoid contact with eyes or mucous membranes!

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avoid inhalation of toxic decomposition products evolving from the burning down of impure tobacco products!

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wear impermeable gloves!

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before smoking, wash hands thoroughly after having used KRYTOX!

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wear goggles!

Í 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! Í danger of getting caught by the machine Í danger of burning by hot corrugated board

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Type of Machine: Preheater VZR-M


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.


The paper web is placed on the outer surface of a rotating cylinder, which is heated up by steam to approx. 200°C/ 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:

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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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Type of Machine: Preconditioner VBR-M


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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Type of Machine: Bridge B


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

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

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Tensioning of the single-faced corrugated board web/s for the succeeding machines (bridge brake)


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. Í danger of tripping and falling! When cutting out unbonded single-faced corrugated board, there is Í danger of falling on drive side!

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Type of Machine: Bridge Level Control BMR

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.



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: Normal demand:

LED of the increased demand key is on 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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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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Type of Machine: Glue Unit LWR-M


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 chromiumplated. 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 Å danger of contusion

Remedy: Lift glue pan by means of control valve „Lift glue pan“ 2)

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Lowering of the pressure device on the applicator roll

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Å danger of contusion Remedy: Operate key „Lift pressure system“

3)

Lifting of the glue pan between glue dams and applicator roll Å 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 Å 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 Ådanger of getting caught

Remedy: Change glue gap by means of key „glue gap minus“ or „glue gap plus“

6)

Drive applicator and doctor roll Å danger of getting caught and contusion

Remedy: Operate EMERGENCY-STOP button, if necessary

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Type of Machine: Double Facer DWR


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

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a heating section

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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.


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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Instructions on Further Sources of Danger 1)

Feed paper web between infeed plate and belt (front belt drum stand) Å

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! Å

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danger of getting caught by the machine / danger of burning!

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Type of Machine: Rotary Shear KQM


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.


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. Å danger of cutting

Residual board: 1)

Residual corrugated board has to be immediately removed from the hall floor. Å

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danger of tripping and falling

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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.


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 Å

Residual board: 1)

Residual board has to be removed immediately from the hall floor. Å

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danger of tripping and falling

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Type of Machine: Slitter Scorer SRA-M


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.


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

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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. Í danger of cuts

Drives:

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When entering the safety area of the drive after machine stoppage, the engines are still hot. Í danger of fire and burning Residual board: Residual board on the hall floor has to be removed immediately. --> danger of tripping and falling

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Type of Machine: Disc Cut


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 user’s country!

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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.

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Type of Machine: Web Diverter


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.

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Type of Machine: Cutoff NQM/HQM


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.


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.

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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 replacing 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

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Type of Machine: Stacker AAR



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. 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.

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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.

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Type of Machine: Corrugator Control Center FDM/PDM


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

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Type of Machine: Quality Data Management QDM


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):

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•

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

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Type of Machine: Splice Synchronisation System – SSS


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.


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.

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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.

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Type of Machine: Machine Control Center MCC


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.

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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

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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 quality’s, 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 country’s, 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.

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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 quality’s 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.

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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 abnormality’s 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.

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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: ½ "Jumping” rolls. ½ Freshly made rolls, coming straight from papermachine. ½ (Between 2/3 weeks storage is recommended!). ½ Extreme cold paper rolls. ½ Badly winded rolls, irregular winding. ½ Smooth, stricken paper. ½ Extremely high concentration of starch. ½ Excessive schrinkage.

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Some paper specifications:

Type of paper

Weigth Caliper in in #/msf inch (mm) (g/m²)

Wellenstof

22.5 (110)

Testliner

30.7 (150)

Schrenz

33,3 (160)

0.0067 (0.17)

0.01 (0.26)

Gurley value

Droptest inch sec

25-30

18-50

40-20

50-100

22<°

7±1

150-200

40-20

20-50

22 <°

7±1

100-200

w. Starch Semi-Chem

Kraft

Surface Humidity struct. inch %

Cobb value

30-60 23 (112)

0.007 (0.18)

30-15

26 (127)

0.01 (0.25)

20-50

32.7 (160)

0.01 (0.26)

35.8 (175)

30-10

18-50

50

7±1

22 <°

7±1

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 (1m²) 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 cm²) gives a very accurate humidity content of the paper.

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1.9

Roll length in meter - feet

g/m2

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

12 inch

16 inch

20 inch

28 inch

32 inch

35 inch

39 inch

43 inch

47 inch

#/msf

8 inch

24 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

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½ These are approximate figures, and are meant to be of help for the operators.

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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.. ½ 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. ½ A minimum amount of glue should be used,0.8-1.0 #/msf (4-5 g/m²) on the SF and 1,0-1,23 #/msf (5-6 g/m²) on the glue unit at the DB is recommended. Excessive use of glue is the main reason for washboarding!. ½ 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. ½ 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. ½ 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. ½ 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 afterwarpage. Adhering to these recommendations will also improve the quality of many regular grades being run now on overheated corugators!

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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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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

70

Waxy maize

60

Tapioca

50

Potato

40

Maize

30

Wheat H.A.Maize

20

H.A.Maize

10 0 % Amylose

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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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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.

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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 contra’s 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.

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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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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

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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) ½ It requires less heat for the bond formation as the starch granules are already partially swollen. ½ There is less free water. This is because the water in the adhesive is bound up inside the swollen starch granules. Follows: ½ Increased machine speed-especially with double wall boards and the heavier single wall boards. ½ Reduction in warped board production resulting in considerable savings ½ Superior storage and shear stability.

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2.4.9

Typical No Carrier formula.(Roquette)

CAUSTIC SODA TANK.

Water

150 gal (570 lt)

Caustic soda

62 lb (28 Kg)

Temperature

124 °F (51 °C)

MIXING TANK

Water

740 gal (2800 lt)

Collys TCF

2205 lb (1000 Kg)

Temperature

97 °F (36 °C)

Drop caustic soda tank 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.

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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

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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.

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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.

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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 we’ve 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

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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.

2.5.5

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

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: ½ Energy savings up to 25 %, due to the use of lower steam pressure. ½ Reduced consumption (approx. 10 %) ½ More stable viscosity ½ Retrogradation lesser than for corn, lesser Thixotroop. ½ Better quality, due to the use of reduced temperatures.

2.5.6

Typical wheat starch Formula. (Stein Hall) AMYLUM

Primary tank Water

264 gal (1000 lt)

Meriwit AA(Wheat)

220 lb (100 Kg)

Temperature

104 °F (40 °C)

NaOH

SF 20 lb (9 Kg) DB 26 lb (12 Kg)

Mixing

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Secondary tank Water

396 gal (1500 lt)

Meriwit AA

1323 lb (600 Kg)

Borax

SF 13 lb (6 Kg) DB 20 (9 Kg)

2.5.7

Mixing

15 Min.

Viscosity

35" Bauer

Temperature

82-86 °F (28-30 °C)

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 ½ Low gelpoint ½ Very high tack after gluing ½ A relative high solid content ½ A carrier system who has a good water absorption retention These specifications are the reason for several positive advantages against other starches, such as ½ Increased machine speed (increases of up to 50% have been achieved!) ½ Easier to run flat board(lower temperatures !) ½ Reduced dry board (lower temperatures !) ½ Possibility to run pre-printed, or with thermoplastic resins laminated paper, where the blocking point is approx. 248 °F (120°C). ½ Much easier gluing process, less badly glued board.

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Disadvantages: ½ Not always price friendly ½ One need two separate lines towards DB ½ Splashing due to shorter fiber Some potato starch specifications.:

(Emsland Emcol VPK 300/50 HE) 1. Viscosity:

40-70 sec steinhall

2. pH value:

ca 12

3. Gelpoint:

203 °F (50°C)

4. Solid content:

ca.27% lutro 18.4% ± 0,5 %

5. Humidity:

Cerestar C*GUM 30065: 1. Viscosity:

40-60 sec steinhall

2. pH value:

ca 12

3. Gelpoint:

122 °F (50°C)

4. Solidcontent:

19-28% lutro

5. Humidity:

14-16 %

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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!) ½ Water jacket at SF leaking. ½ Water meter inaccurate, loss of calibration, inaccurate ½ Excessive condensate in steamlines to heat the batch. ½ 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: ½ Agitation. The agitators in the storage tanks. ½ Pump and lines. Supply and return pumps, specially the gear type pumps. ½ Glue-metering roll gap. The squeeze through the gap.

½ Friction in the piping, tees, etc. Especially if the storage tanks are located at considerable distance from the corrugator.

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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 (38°C) . 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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TEMPERATURE IN ºF

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.

V isc o s ity b re a kd o wn 60 50 40 30 20 10 0 T e mp e ra ture

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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 quality’s, 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 (4.5°C) 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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3.3

How to set pressure for different quality’s 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 quality’s. 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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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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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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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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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 responsibility’s 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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4.3.1

TELTROL DESK OPERATOR, or MACHINE LEADER

½ 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. ½ 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. ½ He is responsible for quantity, which means he runs the machine at maximum speed, still obtaining perfect board. ½ He keeps all operators continuously informed about possible changes in program, paper, orders, etc... ½ He fills in the necessary documents, so that production supervisors are constantly kept informed about the production data. ½ He checks the sheets for measurements. ½ He can operate the complete dry-end units. ½ 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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4.3.2

WET-END OPERATOR or SINGLE -MODULFACER OPERATOR

½ He makes sure he has the right paper in his machine for the right order. ½ Checks his planning and makes sure he has the correct order of run. ½ Checks if his machine is operational, and ready to run. ½ Lines-up his paper correctly, regarding width. ½ starts the machine, and assist on readying the complete wet-end. ½ Knows the complete operation of the units (Modulfacer or Single Facer, bridge, glue Unit, double facer. ½ Corrects settings which are in his reach only (glue roll/corr. Roll gap, pressure roll gap). ½ Adjust paper tension, checks that the web is perfect. ½ Zero’s his meter counter on bridge control and switches in AUTO. ½ Reports any anomaly’s to the foreman or the machine leader. ½ Inspects visually the good function of the machine on regular intervals. ½ 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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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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5.1.1

Recognizing and detecting paper faults

½ Humidity(generally ±8 %) ½ Loose edges, bad winding ½ Absorption ½ Starch penetration.(drop test!) ½ Caliber ½ Calandering, smooth surface

5.1.2

Recognizing starch faults

½ Viscosity ½ Gelpoint ½ Solid contents and consequences ½ Starch temperature and consequences ½ Bacteriological problems ½ Waterproof starch ½ Adhesion (pin adhesion test) ½ Starch film: - too much - not enough Splashing - glue line too wide, too small)examples ½ Starch penetration (absorption) Borax, caustic soda

5.1.3

Steamfaults

Check: ½ Pressure regulating for different quality ½ Single Flute ½ Double-Double ½ Triple ½ Pressure setting on different hotplate sections (see list in Training’s program) ½ Condensate return ½ Syphon pipes and how to check if correct

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½ Complete steam system by using scheme ½ Regulating valves for accurate regulation 7.25 psi (±0.5 bar) ½ Temperature of all pre heaters preconditioners. Check top and bottom temperatures

5.1.4

Recognizing operational faults

½ Wrong operation ½ Operator recognizes fault: correcting the fault ½ 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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5.2

Checklists

5.2.1

Modulfacer group

½ All systems function as described ½ 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... ½ Visual faults, paper defects ½ Check paper for loose edges ½ Search for causes for loose edges such as: ½ Rolls not parallel in splicer ½ Rolls not parallel in pre heater and pre conditioner ½ All adjustable rolls must have a central position inscription. Occasional adjustments have to be returned to original position later

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5.2.2

EWR-VT Fingerless Single Facer

½ All systems function as described ½ 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... ½ Visual faults, paper defects ½ Check paper for loose edges ½ Search for causes for loose edges such as: ½ Rolls not parallel in splicer ½ Rolls not parallel in pre heater and pre conditioner ½ All adjustable rolls must have a central position inscription. Occasional adjustments have to be returned to original position later

5.2.3

Splicers

½ All systems function as described ½ Rolls not parallel in splicer 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.. ½ 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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5.2.4

Bridge

½ All systems function as described ½ Check automatic bridge guiding system ½ Check all belts, bearings and other mechanical parts from bridge and bridge conveyor belts ½ Check web loops on bridge, if necessary, correct bridge belt speed ½ Check web for damage ½ Check belts for correct tensioning and correct if necessary ½ 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

½ All systems function as described ½ Check: ½ All rolls for parallelism ½ Distance glue roll/idler roll (caliper) ½ Distance glue roll/doctor roll (glue film) ½ Scraper doctor roll, roll should be dry, no starch on doctor roll ½ Scraper in front of glue roll ½ Function and correct adjustment of the glue dams ½ Glue roll speed against board speed (-4%)

5.2.6

Double facer

½ All systems function as described ½ Function and correct adjustment of : - Chaintrol - Airtrol - Steam pressure and temperature in the different sections ½ Belt condition: edge wear, caliper, gelled starch at sides, causing board damage, belt guiding ½ Roller condition.:dirt on rollers (tar!), broken bearings, stopped rollers ½ 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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-

5.2.7

setting of the hotplates lifting bars, dirt on the bars steam and water leakage’s

Rotary shear KR/KQM

½ All systems function as described ½ Cutting condition: cuts all types of board up to wet paper ½ Correct functioning of single cut at the indicated speed ½ Wooden shells in good condition ½ Evacuation belts and rollers functioning correctly ½ Remote. Control is functioning correctly

5.2.8

Automatic Slitter Scorer, SRA-T and SRA-M

½ All systems function as described ½ Precision setting up to ± 0.04 inch (1 mm) ½ Precision tandem setting ½ Rill depth setting over full width is correct ½ Knives are cutting correctly, no bad edges with correct air pressure ½ If available, correct functioning of the E&L system

5.2.9

Guide tables and paddle unit PE

½ All systems function as described ½ Board line is perfect (no board jumping, board is supported everywhere) ½ 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) ½ paddles setting is correct, movement is correct speedwise and are adjusted at correct height ½ Board is not jumping when cut with NQM occurs

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5.2.10 Cut-off knives NQS-D/NQM ½ All systems function as described ½ Precision cutting:± 0.04 inch (1 mm) for 95% ½ Perfect boardline: Board runs correctly into pull rolls and is supported by the tables(no jumping when the knife cuts!) ½ Pull rolls are set perfectly parallel ½ Board runs exactly between top and bottom knife bars ½ Exit conveyors are set at correct height and at correct caliper ½ Board moves correctly onto stacker ½ Knives are cutting cleanly, no ragged edges. Board is separated at all speeds

5.2.11 Automatic stacker AAR ½ All systems function as described ½ Board does not show any damage when transferred from Knife to stacker ½ Brush program is set correctly, and pressure is adjusted ½ Belts are running correctly and without damage ½ Venetian blind functions correctly ½ Stacks are neat and have the correct count ½ Board runs through the stacker correctly, and without jams

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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 electric’s 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 «Home»position button. 3. Feed the paper through, following the thread-up sketch shown at the side of the machine. Before you do so, switch splicer electric’s "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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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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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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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 quality’s, 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 Check and adjust (-) glue gap at Check for glue roll/ SF if possible corrugator roll parallelism at DB if possible. 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

Increase wrap at DB Bottom liner preheater

Reduce wrap at DB Bottom liner Check for wrap arm preheater 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

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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 quality’s, 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: 2 *The minimum and the maximum value obtained is 0.8 #/msf (4 g/m ) and 6.1 #/msf 2 (30 g/m ), respectively. 2 *Papers with a value above 3.1 #/msf (15 g/m ) have an open surface, allowing strong bonding. 2 *The surface of the paper with a value at or below 2.3 #/msf (11 g/m ) 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-theweb 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 : ½ Proper functioning of steam traps ½ 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. ½ 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... ½ 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 ½ Switch on Main Panel ½ Switch on oil pump, and open cooling water circuit ½ Start S. F, run at idling speed ½ Open Main Steam valve progressively ½ Place glue dams in glue tray ½ Open starch valve and start return pump ½ Start Idling motor glue roll ½ Start Vacuum pump, if necessary, open cooling circuit ½ Advance glue roll in automatic position, and lock unit

Use of the different settings. Stopped and running SF ½ Glue Film setting ½ Distance Glue roll-Corrugator rolls ½ Distance Pressure roll-Corrugator roll ½ Set hydraulic pressure Corrugator rolls ½ Set hydraulic pressure at Pressure roll ½ Set glue dams for correct paper width ½ Set Vacuum Tubes for correct paper width if necessary ½ Set wrap arms in automatic if possible ½ Set steam shower

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Starting the S. F with paper ½ Check if all systems are switched on (oil pump, vacuum pump, auxiliary glue roll drive) ½ Put pressure on Corrugator rolls ½ Open pressure roll ½ Put glue unit in auto position, clamps vertically ½ Make sure starch level is correct ½ Set glue dams at approx. correct width and switch in "auto” when paper is in machine ½ Set glue film at correct gap (approx. 0.30-0.35) and switch in "auto" ½ Thread paper in the machine

Checks during production runs ½ Cooling system (pumps and water jacket) ½ Feed and return lines starch system, level in glue tray ½ Vacuum system (flutes are held in corr. Rolls.) ½ Glue film is correct ½ Distance Glue roll-Corrugator roll is correct (check regularly with splice tape, specially in morning when frames are still cold ½ Check vacuum tubes for position after replacement (Tubes only need readjustment when problems where encountered!) ½ Constant check if paper is running well into machine. (make sure the paper runs correct between slots or tubes.) ½ 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.: ½ Oiling the glue tray rails (a few drops of oil will do) ½ Grease the Glue Dam guides ½ Make sure the limit switches are clean and work properly

Maintenance Safety instructions when working at SF ½ Before fore switching on main panel, make sure nobody or nothing is in the machine ½ Before starting the machine, warn all the people concerned (operator or supervisor) ½ Never interfere with running machine(example: setting nozzles!) ½ Always put on gloves for heat protection. Never work on the nozzles with short sleeve shirts! ½ 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 ½ Read carefully the instruction manuals delivered with the machine ½ Never bridge out or disconnect the safety devices on the machine! ½ 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 ½ Always look after you’re own and your colleges safety

7.1.4

Maintenance and grease instructions

½ Follow instructions as described in the manual ½ List of grease and oil points for periodic maintenance can be found in the manual ½ Instructions and translations of the electronic schema’s are given during the start and training period ½ 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: ½ EMERGENCY STOP key has been released ½ Main drive ventilator must be in operation ½ All interlocks such as Thermal protection, over current, Fuse control and Main drive Thyristor set Thermal protection have not been activated ½ Control voltage is present ½ Scraper limit switch has not been activated ½ Motor protecting switches for ventilators have not been activated ½ Stop command bridge control, splicers and machine stops have not been activated ½ Wrap-up control corrugator rolls is active ½ 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

½ Visual checks for obstructions and notes, left by personnel ½ Switch main panel ""ON" ½ Switch: - Pressure roll pressure OFF - Corrugator roll pressure ON - Glue roll pressure OFF ½ Start Modul Facer - Switch ON oil pump - Switch ON take-up conveyors - Slowly open steam valves ½ Start starch pumps and open valves (feed and return lines.) ½ 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! ½ 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 ½ 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

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7.2.3

Conditions to speed up machine

½ Before speeding-up, check following ½ Blower is running correctly(triangular) ½ Lubrication pump is running (green pilot light is steady, if not, check for clogged filters and min. and max. Pressure.) ½ Progressive oil distributor protection has not been activated ½ Slow commands are not activated ½ Glue roll idling motor is switched "ON" ½ Transmission lubricating oil pump is running ½ Coupling glue-unit is engaged ½ 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.

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7.2.5

Instructions to stop the Modul Facer.

½ Slow down machine to bottom speed ½ Cut fluting.(liner can stay in machine!) ½ Switch: - Glue unit OUT - Pressure roll UP - Take up conveyors OFF - Stop Blower ½ Bring glue unit fully OUT ½ Open cover glue unit, and close starch lines ½ Clean glue roll abundantly with water. When clean stop roll. Clean rest of machine with steam jet ½ When machine has been cleaned: - Stop auxiliary motor - Switch clutch OUT ½ Close steam and condensate valves ½ After approx. 15 min. Sop Modulfacer ½ Switch corrugator roll pressure OFF Switch main panel OFF

7.2.6

Changing Modules

½ Slow down machine to minimum speed ½ Cut fluting out of Modul Facer ½ Bring Glue unit out to Auto-position ½ Stop Blower ½ Stop machine ½ Switch glue unit to fully out ½ Switch change over switch to position as required.(Yellow flash light starts flashing!) ½ Select correct Modules. Bring one OUT, bring other IN ½ Push buttons in correct order. Follow the automatic sequence, the lights are pulsing in the correct order. Push button until light is steady ½ Feed fluting paper back in machine as explained before

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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: ½ Wear no loose or suspending clothing ½ Long hair has to be covered! ½ Suspending jewelry, rings as well as other personal items, which might be entangled by the machine have to be removed! ½ No work may be performed in the immediate vicinity of roll intake, swivel range or moving mechanisms with machine running ½ It has to be ascertained that machine is running at bottom speed, and that a qualified person is positioned at the EMERGENCY STOP switch ½ 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!

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7.2.8

Cleaning of both corrugator rolls and pressure roll

½ 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. ½ Clean pressure roll scraper with steam jet, and if necessary, remove gelled starch and paper with plastic spatula ½ 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.

½ Fully retract glue unit ½ Drain starch from unit ½ 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 ½ All loose parts to be cleaned with water ½ 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 ½ Clean the machine surroundings completely and remove all paper rests, gelled starch and other foreign materials ½ 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!

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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!

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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 electric’s 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 electric’s 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.

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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

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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. ½ Switch off vacuum pumps to avoid unnecessary wear

Safety and Maintenance instructions. ½ Never carry out work on a splicer while running! Ex: Knife setting! ½ Never carry out work on a splicer with power on the machine! ½ Never switch on power without having checked that nobody is in the machine ½ Never change a knife without switching off air and power ½ Read manuals carefully ½ 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 schema’s 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

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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.

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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

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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.

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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)

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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. ½ Glue gap setting. Although this should be controlled from the Teltrol Desk, it is good practice to make occasional checks ½ Glue dam setting(If auto available, check if Auto is on) ½ Preheater wrap arms, check if in AUTO ½ When machine was stopped for any reason with the Emergency stop, restart the glue roll if independent drive is fitted

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7.7.2

Cleaning instructions

½ Stop the machine ½ Close the starch lines ½ Remove starch tray barriers and drain all starch ½ 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 ½ Drop starch pans into cleaning position ½ Clean glue roll with water, taking care not to put too much water into the electronics or electric motors ½ Clean the glue dams, dismantle once a week, or sooner if necessary, and clean completely ½ Clean glue dam guides, and remove any dried starch from the unit ½ Clean surroundings. Make sure all starch deposits are washed away to avoid any bacteriological action ½ Clean Filters ½ Prepare for next run or shift ½ 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

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Maintenance Safety instructions working at the D. B.; ½ Before switching on main panel, make sure machine is clear, and nobody is in the machine or carrying out work at the units ½ Read carefully the instruction manuals delivered with the machine ½ Never bridge out or disconnect the safety devices on the machine! ½ 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 ½ Always look after your own and your colleges safety

7.7.4

Maintenance and grease instructions.

½ Follow instructions as described in the manual ½ List of grease and oil points for periodic maintenance are given in the manual. ½ Instructions and translations of the electronic schema’s are given during the start and training period. ½ If these should prove to be inadequate, supplementary courses can be arranged at Weiherhammer for electricians, mechanics and electronic engineers.

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7.8

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, safety’s 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.

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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.

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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.

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8.3

Outside liner Preheater 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.

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.


Condensate trap malfunctioning.


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8.4

Fingerless Single Facer Machine problems


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.

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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 Machine problems


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.

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8.6

Overhead Bridge Machine problems


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.

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8.8

Duplex or triplex Glue Unit Machine problems


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.

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8.9

Double facer (Hotplates and Pulling section) Machine problems


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

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8.10 Rotary Shear Production Influence.

Machine problems

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 Production Influence.

Machine problems

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.

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8.12 Duplex or Triplex cut-off knife. Production Influence.

Machine problems

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.

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8.13 Duplex or Triplex Stacker Machine problems


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.

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Troubleshooting 1.

What and how to check paper and board

1.1

Visual surface checks

½ Correct type and color of paper (Kraft, testliner, white Kraft etc..) ½ Correct winding. Ex: Running Kraft paper the wrong way can cause peeling on hotplates and Printer Slotter pull-rolls! ½ Correct weight, check against specifications! ½ Correct flute(A, b, c, AB, AC etc..) ½ Smooth, flat surface, none or minimal wash boarding ½ Pressure lines at SF are minimal, no splitting can be done ½ DB side, check for dirt marks in length directions(dirty hotplates!) ½ Check for glue patches on SF side, belts are clean! ½ Edges are cleanly cut, no ragged edges

1.2

Measurements checks

Check: ½ Width ½ Length ½ Score distance ½ Score depth ½ Correct score alignment(top and bottom) ½ Caliper

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1.3

Gluing checks

½ Glue lines, amount of glue, quantity and quality of glue lines ½ Starch penetration, good bonding ½ Regularly (once a week) check by means of the Iodine test the uniformity of the glue lines

1.4

General

½ 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. ½ Corrugator rolls out of parallel ½ Over tensioning on the fluting ½ Rider roll on Glue Unit too low! ½ Too much starch on glue unit ½ Rolls in DB out of parallel ½ 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 ½ Gap outfeed rolls on cut-off knife too small ½ These faults can be detected through the FCT Test, but only when done after the corrugator

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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. ½ Badly adjusted fingers or suction nozzles. (Touching the paper!) ½ Too much suction or too much pressure in pressure chamber ½ Worn corrugator rolls ½ Uneven glue lines in length direction

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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 : ½ Pressure lines on board, due to pressure lines on SF. Cause: too much pressure on pressure roll. ½ 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.

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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.

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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

½ Condition of the reels ½ Quality of the paper ½ Paper storage: inside/outside. ½ Transport of the paper to the plant ½ Internal transport ½ Handling of the reels on the machine ½ Putting reels into the reelstands and splicers

2.2

Machine

2.2.1

Single Facer

½ Proper threading of the paper into the machine ½ Correct use of the pre-heaters and pre-conditioners. ½ Lining up the paper correctly ½ Settings at the Single Facers, proper threading-up. ½ Correct braking power ½ Glue dam settings ½ Nip settings Pressure and Glue roll ½ Correct glue settings ½ Correct use of the steam showers ½ Correct order length input, i. O. W information about the work.

Double Backer ½ Proper use of the bridge(do not overfill!)

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½ Set bridge brake guides at correct position ½ Use correct amount of brake at bridge brakes ½ Avoid "wandering” of the web on the bridge ½ Lining up of the bottom liner and web

2.2.3

Rotary shear

½ Do not cut too many sheets ½ Keep machine going, avoid stoppages. ½ Cut out bad board, to avoid important jam-ups at stackers.

2.2.4

Slitter Scorer

½ Make sure the correct order is set at the Slitter Scorer ½ Correct positioning of the unit regarding the boardline ½ Correct positioning of the trim nozzles if not automatic ½ Lead-in tables correctly set (one too many down!)

2.2.5

Cut-off knife

½ Pull rolls are down and set to board caliper (board thickness – 0.004 in/0.1mm) . ½ Correct length setting ½ The orders are going to the correct knifes ½ Unit cuts correctly (no ragged cutting) ½ Accuracy is within limits ½ Board is going into unit without "jumping", board line is steady

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2.2.6

Stackers

½ Settings are correct (backstop, shingling, brushes) ½ All functions are in automatic ½ Bad board is taken out ½ Quality checks are done at regular intervals

2.2.7

ConveyorsSystem in Automatic, make sure the line is clear

½ Correct labels go into the stacks

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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. ½ 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! ½ 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!. ½ 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. ½ 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. ½ 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. ½ 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.

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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!.

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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 preconditioner 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.

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3.2.2

Double Backer

½ 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. ½ 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. ½ 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. ½ 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. ½ 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.

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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.

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4.1

Single Facer. Suction system (Fingerless)

No.

Fault

Cause

Remedy

1.

Wrinkles in top liner. Partly Paper tension too low. badly glued 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 Pressure roll runs too close to not run even. Sides turning corrugator roll outwards. Liner shows dark Paper humidity too high pressure lines. Bottom corrugator roll slots are clearly marked on the liner

Reset distance pressure rollcorrugator 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

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7.

Fluting drops into glue pan. To much brake at reelstand During speed-up of SF 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 Vibration in corrugator rolls. second flute is lower Worn out corrugator rolls.

Reset corrugator rolls with eccentrics. Change rolls.

11.

Top liner tears off easily. Glue lines crystallized

Run faster. Reduce steam pressure. (Between 147 & 189 psi / 10 & 13 bar.) Apply steam with shower. Reduce pre-heater wrap. Reduce wrap at liner preheater(small pre-heater before pressure roll.) Check water absorption of papers. Check and improve starch if necessary(Borax!)

12.

Fluting runs badly. Creases Pressure corrugator rolls too low. and tears at edges towards Insufficient heat. center of machine Insufficient tension

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Running too slow. Too much heat Fluting too dry. Liner too dry. Bad starch penetration in paper. Bad starch.

Increase corrugator roll pressure. Check steam pressure. Check temperature. Check condensate return, steam traps. Check and adjust paper tension.

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13.

4.2

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

Modulfacer (Pressurized)

No.

Fault

Cause

Remedy

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 rollglue 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 Pressure roll out of parallel. too slow, unbounded Pressure in glue unit too low board.

7.

Blisters at edges, badly glued liner.

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Check distance pressure roll/sealing roll . Check and reset pressure roll for parallelism

Sealing roll between Pressure roll Check distance pressure and corrugator roll too tight. roll/sealing roll and adjust if necessary.

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8.

4.3

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

Double Backer (Chaintrol)

No.

Fault

Cause

Remedy

1.

Edges not glued properly. Cause: Edges glued unevenly, bad Fluttering edges. glue lines. 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.

Check temperature. Check condensate return system Adjust weight rollers.

3.

Damaged edges, marks on Dirt between hotplates liner. 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.

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Waterlogged hotplates Badly adjusted weight rollers. Worn hotplates.

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9.

Bad surface at SF side Running with cold web into when running Double Wall. Double Backer. Twisted warp with all Not enough heat at paper surface quality’s

Heat web, increase preheater wrap. Check temperatures of paper at DB entrance.(should be between 158-194 °F (70-90°C). Check temperature of hotplates and preheaters.

10.

Uneven glue application on Too much pressure on rider-roll. flute tips.

Adjust (reduce) rider roll gap

11.

Damage at bottom liner, board shows impression in length direction

Clean hotplates. Remove paper

4.4

Slitter Scorer

No.

Fault

Dirt on hotplates, dried starch sticking on plates Paper jammed between plates

Cause

Remedy

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 0-point position. correct position against each other

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4.5

Cut-Off

No.

Fault

Cause

Remedy

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

No.

Fault

Cause

Remedy

1.

Creases in board at stacker.

Board pushed down too hard by brushes.


2.

Wrong stack height

Board pushed down too hard by brushes.


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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.

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QUESTIONNAIRE LAYOUT The theoretical part is made out of following chapters: ½ Machines in the Wet-end ½ Machines in the Dry-end ½ Starch ½ Paper ½ Steam The practical part is made out of following chapters: ½ Machines in the Wet-end ½ Machines in the Dry-end

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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)

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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.

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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.

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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.

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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.

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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.

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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 pickup 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.

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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.

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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.

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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.

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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 don’t 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.

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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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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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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? (x°C= 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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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 don’t, 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.

B.


C.


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 cutting and the Corrugator is running?

A.

Nothing happens.

B.


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.


B.


C.


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.


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?

A.


B.


C.


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.

B.


C.


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5.

What happens when we open the first security-door on the KQF , when the knife is cutting and the Corrugator is running?

A.

The Corrugator continuous running and the knife stops cutting automatically.

B.


C.


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 cutting and the Corrugator is running?

A.

Nothing happens.

B.


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.


11.

What is the maximum speed to make one single cut ? (1m/min = 3.3 ft/min)

A.


B.


C.


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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.


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)

A.


B.


C.


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

A.


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 normalformats?

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.


B.


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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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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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?

A.


B.


C.


16.

What is the function of the blue light on the downstacker?

A.


B.


C.


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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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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.

Å 1/ WettingÅ 2/ ApplicationÅ 3/ DiffusionÅ 4/ Absorption.

B.

Å 1/ ApplicationÅ 2/ WettingÅ 3/ DiffusionÅ 4/ Absorption.

C.

Å 1/ ApplicationÅ 2/ WettingÅ 3/ AbsorptionÅ 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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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 )

B.

The moisture content of the two papers is even and within a certain percentage of eachother

C.

The thickness is the same.

2

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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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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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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.

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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

½ What is the function of the Roll Stand ½ What are the functions of the tensioning arms ½ How does the process of unwinding ½ What is the function of the brake-units

Initial:

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6.2

Rest Roll Computer RRR

½ What is the function of this part ½ How does it calculates the remaining meters on the roll ½ What are the parameters that we can change in the menu , and how do we have to use these parameters ½ How do we change the paper-rolls in the labelprinters ½ When is the rest length detected ½ What kindes of splicing can be chosen ½ How are values modified in the setup (cone diameter) ½ Where is the approach switch to be found for the measurement ½ How does the printer work, when does it print

Initial:

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6.3

Splicer ARW-M incl. Automatic Roll Pick-UP ARA

½ What is the purpose of this machine ½ How does the web tensioning system operates ½ What is the purpose of the accumulator rolls in the splicer ½ How do we have to tread in the paper in the splicer ½ How do we have to prepare a splice ½ What are the functions on the controls on the splicer control cabinet ½ At what speed can we splice with these splicers ½ What is the function of the Automatic Roll Pick-Up system, type ARA ½ Where are the sensors that we use to detect the different parameters for the ARA ½ In what condition does the paper-roll have to be in, in order to assure correct paper handling ½ What are the functions on the of the controls on the ARA switch-cabinet

Initial:

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6.4

Under/Above Floor Trolley ÜFB/UFB

½ What is the function of this part ½ How does it calculates the remaining meters on the roll ½ What are the parameters that we can change in the menu, and how do we have to use these parameters ½ How do we change the paper-rolls in the labelprinters

Initial:

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6.5

Modul Facer MF Bandleader

½ What is the function of the glue unit (glue rolls and glue dams) + details ½ What is the function of the Bandleader system + details ½ What is the function of the over-pressure system in the glue unit + slots + slot-cleaners ½ What is the function of the preheaters and preconditioner ½ How to operate the touchscreens ½ How to start the machine and thread up the paper ½ Explain the functions of the controls and pressure gauges of the machine ½ What to do if the bonding between fluting and liner is not good ½ How to put the correct settings on the machine (glue dams, glue film glue, application gap web-tension) ½ Checking the paper-quality on glue films with Iodine in order to detect glue problems ½ What is the function of the Quality Change menu ½ How do we have to clean the machine properly ½ How can we make a flute change (Modul change)

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6.6

Preheater VZR-M

½ What is the function of the preheaters in the Corrugator ½ How can we change the wrap on these preheaters ½ What is the difference between Manual- and Automatic- mode ½ Which sides of the paper is heated up normally

Initial:

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6.7

Bridge B

½ Why do we need a Bridgebrake on the Corrugator ½ How does the bridgebrake works and how to change the values ½ How do we have to work with the touch screens ½ What is the difference between Automatic and manual mode and when are we going to use this ½ Why do we need a web-centring system on the machine ½ How does the web-centring system (Corraligner) works and what are the possibility’s

Initial:

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6.8

Bridge Level Control BMR

½ What is the purpose of this system ½ How can we calibrate the BMR and when do we switch on the automatic mode ½ What are the parameters that we can change in this system , and how do we have to change them ½ 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 ½ How can we change the amount of paper on the bridge during normal production ½ How can we change and give increased paper demand on the bridge ½ Why do we need the function increased paper demand ½ How can we set the speed for the DWR with the BMR and when are we going to use it ½ Explain the MASTER - SLAVE relation between the MF and DWR

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6.9

Glue Unit LWR-M

½ What is the function of the LWR in the Corrugator ½ Difference of the LWR-glue pan and the glue pan of the BHS-Modul Facer (If the customer has both) ½ What are glue dams and what is their function ½ How do glue dams operate ½ What is the difference between the glue dams in Automatic- and Manual-mode ½ What is the difference between the glue-gap system in Automatic- and Manual-mode ½ What is the function of lagging on the glue-rolls ½ What can we change from glue parameters and why is this necessary ½ How to operate the touchscreens

Initial:

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6.10 Double Facer DWR 6.10.1

DWR-Airtrol

½ What is the function of the DWR in a Corrugator ½ What is Airtrol ½ How to work with the steam sections according to the paper quality ½ How to operate the Airtrol system ½ Why do we need the internal preheater in the DWR ½ How do we operate the touchscreens ½ What are the functions of the controls on the machine ½ How can we lift the belt in case of an emergency stop , and why do we have to do this ½ How can we check if we have water in the steam sections and what to do in case this happens ½ How does the speed effect the wrap of the preheaters and the Airtrol ½ Explain the air-pressure system of the Airtrol ½ How can we avoid having problems with static electricity on the DWR

Initial:

6.10.2

Date:

DWR-Chaintrol

½ What is the function of the DWR in the Corrugator ½ What is Chaintrol ½ How to work with the steam sections according to the paper quality ½ How to operate the Chaintrol system ½ Why do we need the internal preheater in the DWR ½ How do we operate the touchscreens ½ What are the functions of the controls on the machine ½ How can we lift the belt in case of a emergency stop , and why do we have to do this ½ How can we check if we have water in the steam sections and what to do in case this happens

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½ How does the speed effect the wrap of the preheaters and Chaintrol ½ How can we avoid having problems with static electricity on the DWR

Initial:

6.10.3

Date:

DWR-Airtrol-Chaintrol

½ What is the function of the DWR in the Corrugator ½ What is Airtrol and Chaintrol ½ How to work with the steam sections according to the paper quality ½ How to operate the Airtrol - Chaintrol combination ½ Why do we need the internal preheater in the DWR ½ How do we operate the touchscreens ½ What are the functions of the controls on the machine ½ How can we lift the belt in case of an emergency stop , and why do we have to do this ½ How can we check if we have water in the steam sections and what to do in case this happens ½ How does the speed effect the wrap of the preheaters , Airtrol and Chaintrol ½ Explain the air-pressure regulating-system of the Airtrol ½ How can we avoid having problems with static electricity on the DWR

Initial:

6.10.4

Date:

DWR-Bartrol

½ What is the function of the DWR in the Corrugator ½ What is Bartrol ½ How to work with the steam sections according to the paper quality ½ How to operate the Bartrol system ½ Why do we need the internal preheater in the DWR ½ How do we operate the touchscreens

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½ What are the functions of the controls on the machine ½ How can we lift the belt in case of a emergency stop , and why do we have to do this ½ How can we check if we have water in the steam sections and what to do in case this happens ½ How does the speed effect the wrap of the preheaters ½ How do we operate the various programs of the Bartrol system ½ How can we create or own programs in the Bartrol system ½ How can we avoid having problems with static electricity on the DWR

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6.11 Rotary Shear KQM ½ What is the function of the KQM in the Corrugator ½ What is the function during an Order Change ½ What is the maximum speed during continuous cutting ½ What is the maximum speed during one single cut ½ What are the functions of the controls on the machine ½ What are the functions of the two security doors on operator side ½ What can the signal light on the KQM tell us ½ What is the function of the lower extract rolls in the KQM ½ How can we cut the paper when the Corrugator is stopped ½ How can we use the remote control-function for starting the KQM operation

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6.12 Shear Order Change KQF ½ What is the function of the KQF in the Corrugator ½ What is the function during an Order Change ½ What is the maximum speed during continuous cutting ½ What is the maximum speed during one single cut ½ What are the functions of the controls on the machine ½ What are the functions of the two security doors on operator side ½ What can the signal light on the KQF tell us ½ What is the function of the lower extract rolls in the KQF ½ How can we cut the paper when the Corrugator is stopped ½ How can we use the remote control-function for starting the KQF operation

Initial:

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6.13 Slitter Scorer SRA-M incl. Disc Cut ½ What is the function of the SRA-M in the Corrugator ½ How do we start the SRA-M ½ How do we make a reference travel on the SRA-M ½ When do we have to make such a reference travel ½ How do we enter the quality’s in the quality menu + details ½ How do we enter the orders in the order menu + details ½ How do we send the actual and next order to the machine ½ How can we see if there is an actual and a next order in the machine ½ How can we move an order or a quality ½ How can we copy an order or a quality ½ How can we cancel an order or a quality ½ What do we have to do after changing the order-list ½ How to check if the machine has positioned correctly and what to do if it is incorrect ½ How to make a correction on the SRA-tools when the machine is running ½ Disk cut system : grinding + greasing + details ½ What are the function of the Controls on the SRA-M ½ How can we make a Order Change on the SRA-M without effecting the rest of the Corrugator ½ How to open the tools in the machine and when do we have to do this ½ How to change the lubrication-felt-pads on the knifes ½ How do we have to change the grinding intervals of the knifes ½ How do we end the production

Initial:

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6.14 Paddle Unit PE ½ How to check the pressure adjustment of the maintenance unit

Initial:

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6.15 High Speed Cut-off HQM ½ What is the purpose of this machine ½ 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 ) ½ What is over-speed ½ How can we see if / when the HQM is cutting in overspeed ½ What are the functions of the controls on the machine ½ How can we program the HQM without using the FDM ½ How can we execute an order change on the HQM without affecting the rest of the machine ½ How can we change the cutting length on the HQM during production ½ How can we, empty the whole Dry-End, when the machine is stopped

Initial:

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Date:

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6.16 Stacker AAR-S/H ½ Why do we need this machine ½ How do we have to program the stacker without the use of the FDM ½ How can we do an orderchange on the stacker without affecting the other machine components ½ how can we suppress an orderchange on the stacker , an when do we need this ½ What is the purpose of the brushes on the stacker ½ How can we change the program of the brushes -

On the computer

-

Directly on the machine

½ What is the purpose of the vacuum system on the stacker ½ How can we change the value of the backstop-position during production ½ How can we adjust the dropheight on the stacker during production -

Permanently

-

Temporarily

½ How can we , in case of a machine stop , evacuate the paper -

On the stacker

-

On the whole Dry-end

½ What are the functions of the buttons on the machine ½ What is the difference between -

Stacker in manual mode

-

Stacker in automatic mode

½ How do we have to make a reference travel on the stacker

Initial:

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Date:

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6.17 Automatic Order (Format) Change AFW ½ Why do we need an Automatic Order Change system , and how does it work ½ How can we make an Order Change in manual , and when are we going to use this ½ How can we make an Automatic Order Change ½ What are the functions of the buttons on the control panel. ½ How can we determinate on witch knife we will start our Order Change , and what does this mean ½ How can we interrupt an Automatic Order Change when it is already started ½ How can we see if the machine is ready to do an Order Change ½ How can we activate the motors of the dry end ( To clean up the belt for example. )

Initial:

01.10.1997

Date:

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Training Manual

6.18 Splice Synchronization System SSS, Automatic Quality Change AQW ½ What is the function of the SSS ½ What are the conditions for a splice sysnchronization ½ From where does the SSS get the orders, what is their content and how does the evaluation take place ½ Who is allowed to suppress the splice when and where and how ½ What does an aktive SSS look like an the monitor ½ What are the mainenance work to be performed on the pump ½ How and where can I modify splice speeds ½ What numbers are displayed in the splicers/KR ½ How does a splice synchronization go off ½ Where are the pump, pistol, reflection light scanner and how do they work ½ What does the Automatic Quality Change do ½ When do the machine change-overs take place ½ Where and how are the data of production in the NOMINAL LIST ½ 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

01.10.1997

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Certificate 0U ERUQ[[[[[

HPSOR\HGE\;;; 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. :HLKHUKDPPHU[[[[[ 0U

0U

56668158 Training BHS

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