Low-weight base paper and low-temperature tile operation

Tile line operation usually consumes a lot of energy for steam generation. According to different production speeds, ages, operating hours, and fuel prices, energy costs range from about $250,000 to $750,000 per year.

Unfortunately, the technology and processing used by most of the gluing machines currently in operation are obsolete. Although many modern transformations have been made to these devices over the years, the major design and functions have not changed much. According to the newness of the gluing machine, it is not uncommon to apply 1.5 times to 3 times of sizing. Although operators tend to use as little paste as possible, most older machines cannot make adjustments. If you reduce the amount of paste, it is very likely that you will not be able to apply a little paste.

A popular belief is that the more paste is used, the stronger the bond strength. In fact, this is not true. Excess paste will cause many problems besides the increase in heat required for drying. Many tile welding machines work at maximum power. If it is possible to reduce the amount of paste without affecting the strength of the board, the end result is less heat for drying. If reducing the amount of paste is beneficial to the strength and quality of the reinforced paperboard, such a win-win choice will benefit tile operation.

In order to achieve this goal, the operator wants to make the sizing more uniform. The ideal state is to sizing only at the center of the tip. One way to achieve this effect is to use the Thin Film Meter (TFMTM) technology. The TFM system can accurately reduce the thickness of the paste film to less than 0.01 mm. This eliminates spills and waste of paste, reduces paste usage, and enhances bond strength.

In order to improve the performance of cardboard, Kohler Coating, an ISO-BARTM TFM gluing machine manufacturer, estimated that if they use their new gluing unit, tile line speed can be increased by approximately 40%, and paste usage can be reduced by more than 25% per steam. The steam pressure in the room can be reduced by 50% to 90%. Herb Kohler Coating Chairman, Herb Kohler, said: “This is really significant. Due to the improved accuracy of the gluing on the tip and the narrowing of the sizing gap, our gluing machine greatly improves board performance and reduces energy costs. Accurate sizing and accurate paste metering allow the corrugated sheet to stay in contact with the single-sided machine, preventing collapse of the tip."

The following table shows the actual production data of a carton company using ISO-BAR - this shows that the fuel consumption is reduced by about 40%. Based on the above data, the investment recovery period for this new, more precise gluing equipment is approximately 12 to 14 months.

As the steam pressure on the laminating machine is reduced, the corrugated box manufacturing industry is moving towards "cold" development - less heat consumption means cost savings. In addition, the use of a "cold" laminator also facilitates the production of cardboard with coated tissue. A common problem faced by many tile lines is the problem of blistering and delamination encountered in the processing of special facing papers. With the TFM system, the amount of used paste is reduced, so the less heat and steam are needed, and the blisters on the surface paper can be avoided as much as possible.

Kohler's solution

The ISO-BAR TFM system has been proven to eliminate excessive paste application, reduce paste usage by at least 30%, apply only a paste capable of achieving sufficient bond strength to the corrugated, and reduce or avoid tipping during gluing. Collapse phenomenon. This ensures the PIN and ECT values ​​while making it possible to use low-density paper and core paper. In terms of paper alone, the annual savings are substantial.

The TFM also allows the solids content to be increased in the paste so that less than 40% of the moisture can be transferred to the paperboard than conventional systems. Therefore, to eliminate excessive moisture, you only need to consume less energy and time than in the past. As a result, the fuel consumption is greatly reduced, and the operating speed is significantly increased.

High moisture content is one of the major enemies of cardboard quality. Installing ISO-BAR TFM for tile lines reduces the moisture content in the board and produces a flatter board than traditional equipment. The advantages of this system are reflected in the entire production process: the warpage of the board is reduced; the wrinkling of the paper feeding section is reduced; the downstream equipment operates more smoothly and the speed is faster; the accuracy of printing and die-cutting is enhanced. The cardboard produced is smoother. Cardboard without a washboard can provide a very good printing surface.

With the TFM system, operators can consistently maintain accurate paste film thickness and sizing roll conditions throughout the entire processing width, regardless of operating speed. Regardless of the speed of operation, the size of the corrugations and the width of the web, Kohler's patented pressure gap control system guarantees continuous pressure on the corrugations. The operator simply enters the cylithus into the control system just as easily as a contact bar.

The ISO-BAR TFM control system makes it easy to adjust and maintain paste thickness and weight. Even when the machine is running fast, it can sizing very accurately. With the touch screen control panel, the operator can easily and accurately use the graphical and user-friendly interface.

Paste thickness can be adjusted between 0.0025mm. It is also simple to set and adjust the weight of the applied paste. The operator only needs to change the speed of the gluing roller through the touch screen.

Other adjustments

In addition to being suitable for processing low basis weight papers, the TFM gluing machine has other characteristics. For example, after the speed of the machine is accelerated, with accurate paste application metering system, the deviation of the paper web requires the market to control within the minimum range. To solve this problem, a web adjustment roller system is needed. The smaller the deviation of the paper web from the single-sided machine to the double-sided machine, the less waste the trimming will be.

Kohler concluded: “Europe's carton manufacturers – and more and more US carton manufacturers – are looking for the best low-weight packaging solutions, which is their standard for producing flat cardboard. Use low weight Face and core papers put pressure on production companies, and the TFM system allows equipment to be produced at the fastest speed and can reduce energy consumption and waste including tile lines and processing equipment."

Reprinted from: "Global Corrugated Industry"