New glue machine in action International Paper Board · that fuel consumption was reduced by some...

printing and die-cutting accuracy. Thesystem also produces board that is muchsmoother than that produced by mostconventional systems. Smooth board withvirtually no washboarding provides asuperior printing surface that can demandpremium prices.

With the system, operators canconsistently maintain precision glue filmthicknesses across the full width andcircumference of the roll, regardless ofoperating speed or speed fluctuations.Kohler’s patented Pressure Gap ControlSystem maintains a constant pressure onthe flutes even with changes in machinespeed, flute size or web width. As easy tooperate as a contact bar, the operatorsimply enters the flute specifications intothe control system.

The ISO-BAR TFM control makes iteasy to adjust and maintain both glue filmthickness and applied glue weight, on-the-fly and with precision. Through thetouch screen control panel, the operatoruses the graphically driven user friendlyinterface to make easy and accurateadjustments.

Glue film thickness can be adjusted inincrements of 0.0025mm allowingoptimum and precise application for allmanufacturing requirements. Setting andadjusting the applied glue weight is just aseasy. The operator simply changes thespeed of the applicator roll through thetouch screen control. It’s no longernecessary to play the hit and miss game ofadjusting roll nips to fine tune the glueweight, only to have it go out ofadjustment when the corrugator speed orweb width changes.

Other adjustments

While the TFM glue machine model iswell suited to running lightweight papers,other aspects of the corrugator need to belooked at. For example, with the machinerunning faster, thanks to precise gluemetering, web wander needs to be keptto a minimum. To solve this problem, aweb alignment roll system is needed. Lessweb wander from the single facer to thedouble backer ensures accurate lay downon the web and reduces edge trim waste.

New glue machine in action

Quick PaybackLeading Spanish integrated group,

SAICA, owns many boxmaking sites in

its domestic market. One of their

plants in Barcelona, Embalajes Y Cajas

SA, has been utilising this new ISO-BAR

technology for over 12 months – this

happens to be the first such unit in

Spain. “To say we have been delighted

with the results would be an

understatement,” explains Jesus Vaca,

Production Manager at the plant.

“SAICA is well known in the European

market for the production of

lightweight corrugated casemaking

raw materials and we are working hard

to produce true lightweight packaging.

For example, we are currently running

fluting in a basis weight range from

75gsm to 90gsm – to do this

successfully we needed to make

changes to our corrugator. We needed

a glue machine that would apply

precise amounts of starch, without

making the paper too wet. When the

paper is too moist and then dried too

quickly, it leads to brittle board and

with lightweight packaging, we can not

risk this.

“We have seen significant

reductions in energy costs at the plant,

reduction in steam production, an

increase in integral board strength and

improved speeds when running

lightweight papers. In addition to this,

we have seen a dramatic reduction in

waste, all of which means that the

return on our initial investment will be

less than 12 months.”

…rest assured that the machine will be capable ofrunning at maximumspeeds while reducingenergy consumptionand waste

“With boxmakers in Europe – andincreasingly in America – seeking theperfect lightweight packaging solution, itbecomes critical that they are able tomanufacture flat, well formed sheets,”concludes Mr Kohler. “Using lightweightliners and fluting places pressure on theoperators to ensure the corrugator is up tothe job in hand. With a thin film meteringglue machine like ours, operators can restassured that the machine will be capableof running at maximum speeds whilereducing energy consumption and waste– both from the corrugator and in theconverting department.”

InternationalPaper BoardIndustryA Brunton Business Publication

An article reprinted from the September 2006 issue of International Paper Board Industry

CHASINGLIGHTWEIGHT

…AND A COOLERCORRUGATOR

WITH A THIN FILM METERINGGLUE MACHINE LIKE OURS,

OPERATORS CAN REST ASSURED THATTHE MACHINE WILL BE CAPABLE OFRUNNING AT MAXIMUM SPEEDSWHILE REDUCING ENERGYCONSUMPTION AND WASTE – BOTHFROM THE CORRUGATOR AND IN THECONVERTING DEPARTMENT,” SAYSHERB KOHLER.

that fuel consumption was reduced bysome 40 per cent. Based on this figurealone, the payback on the new, moreaccurate glue machine, has beencalculated at between 12 and 14 months.

With the steam pressure reductions onthe double backer, the industry is movingtowards a cooler corrugator – less heatequals cost savings. In addition to thisbenefit, running a cooler double backeralso helps when producing board withcoated liners. A common problem facedby many corrugator throughout the worldis blistering and delamination whenrunning speciality liners. Using a TFMsystem, less starch is applied, thereforeless heat is required to cure the bondingand therefore less likelihood of blisteringthe liner.

Kohler’s solution

Field proven to reduce starchconsumption by at least 30 per cent, theISO-BAR TFM eliminates over-application, applies only the amount ofstarch necessary to create the strongestbond and reduces flute crush duringapplication. This allows operations tomaintain PIN and ECT ratings while usinglighter basis weight liners and fluting. Theannual savings in fibre alone can make asignificant contribution toward justifyingthe investment.

TFM also allows for an increase insolids in the starch mixture, allowing forthe transfer of 40 per cent less moisture tothe paper than conventional systems.Therefore, substantially less time andenergy is required to remove excessmoisture and cure the starch. As a result, asignificant reduction in gas consumptioncan be achieved, as well as increasingoperating speeds.

Excess moisture is one of the worstenemies of board quality. By reducingexcess moisture transfer, ISO-BAR TFMequipped corrugators produce board thatis considerably flatter than conventionalsystems. The benefits are realisedthroughout the operation as, with lesswarp, downstream operations run fasterwith fewer jams and, after coming off thecorrugator, enabling greatly enhanced

uniformity and ideally only at the centreof the flute tip. One way to achieve this isusing Thin Film Metering™ (TFM™)technology. Such TFM systems providethe ability to accurately reduce starch filmthickness to below 0.01mm. In turn, thiseliminates starch splashing and waste,reduces starch consumption and as aresult, helps produce stronger board.

For an idea as to the improvements inperformance that can be achieved, KohlerCoating, manufacturers of the ISO-BAR™ TFM glue machine, estimate thatutilising their new glue unit, speed can beincreased on the corrugator by over 40per cent, starch weight can be reduced byover 25 per cent and steam pressures inthe various steam chests on the doublebacker can be reduced anywhere from 50to 90 per cent. “This is significant,”explains Herb Kohler, President of KohlerCoating. “By minimising the glue gap andwith precise application of starch to theflute tip, our glue machine cansignificantly improve board characteristicswhile also reducing energy costs. Inaddition to this, by applying precise,metered amounts of starch allows theflute formation created on the single facerto remain intact – our system preventsflute tip crushing.”

The chart above – that has beenproduced based on actual results from aboxplant utilising the ISO-BAR – indicates

Embalajes Y Cajas SA, hasbeen utilising this new ISO-BAR technology for over 12months – this happens tobe the first such unit inSpain. “To say we havebeen delighted with theresults would be anunderstatement,” explainsJesus Vaca, ProductionManager at the plant.

HOT PLATE STEAM PRESSURESBEFORE AND AFTER ISO-BAR INSTALLATIONPRESSURE ARE IN BAR & (PSI)

Paper Quality Flute 1st-B 2nd-B 3rd-B 1st-A 2nd-A 3rd-A

Standard B, C 5 7 9 0.5 1.5 0.5

(72.5) (101.5) (130.5) (7.5) (21.5) (7.5)

Heavy B, C 7 9 12 1 2 1

(101.5) (130.5) (174.0) (14.5) (29.0) (14.5)

Double Wall Std BC, EB 13 13 13 1.5 4 3

(188.5) (188.5) (188.5) (21.5) (58.0) (43.5)

Heavy DW BC 13 13 13 4 6 5

(188.5) (188.5) (188.5) (58.0) (87.0) (72.5)

E Flute E 5 5 5 0.5 1.5 0.5

(72.5) (72.5) (72.5) (7.5) (21.5) (7.5)

Unfortunately, most corrugator gluemachines in use today rely on technologyand processes that can only be describedas old fashioned. Although many changeshave been made to modernise theequipment over the years, the principledesign and function has not reallychanged much at all. Depending on theage of the glue machine, it’s not atypicalfor the application of starch to bebetween 1.5 to as much as 3 times morethan is necessary. Operators wouldlogically prefer to use less glue, but mostolder machines simply can’t be adjusted,with any degree of accuracy, to lowerlevels. Attempts to go lower using animprecise application process can easilyresult in no glue being applied at all.

A prevalent belief has been that moreglue would create the strongest possiblebond. But, in reality, this is not true andexcessive starch application causes anumber of problems, not the least ofwhich is that the more starch, the moreheat is required to dry out the board in thedouble backer. It’s not uncommon onmany corrugators for the double backerto be operated at its maximum. If it ispossible to reduce starch application to aminimum without negatively affectingboard strength, then the end result is thatless heat is required. And if lessening theamount of starch applied actually has apositive affect on board quality andstrength, then doing so becomes a win-win situation for all aspects of corrugatoroperation.

To achieve this goal, operators need tobe able to apply starch with better

Article heading

The average corrugator consumes anenormous amount of energy for thegeneration of steam. Depending on

speed, age of machinery, hours of operation andthe price of gas, the energy bill can rangeanywhere from $250,000 to $750,000(€200,000 to € 600,000).

CHASING LIGHTWEIGHT…AND A COOLERCORRUGATOR

Herb Kohler (left) explains the GUI and operating system ofthe ISO-Bar to Dan Brunton.

Web tension systems are critical — SAICA opted for the E+L system.

WITH SEEMINGLY UNENDINGINCREASES IN ENERGY COSTS ANDTHE SUBSEQUENT KNOCK-ON EFFECTIT HAS ON THE COST OF CORRUGATEDCASEMAKING RAW MATERIALS, NOWIS THE TIME FOR BOXMAKERS TOLOOK AT WAYS IN WHICH THEY CANACTIVELY REDUCE THEIR OPERATINGCOSTS TO ENSURE PROFIT MARGINSCAN BE MAINTAINED ON BOX PRICES.DAN BRUNTON VISITED ONE OFSAICA’S PLANTS IN BARCELONA,AND, IN THE FOLLOWING ARTICLE,LOOKS AT POTENTIAL ENERGYSAVINGS ON THE CORRUGATOR, WITHPARTICULAR REFERENCE TO AFASCINATING DEVELOPMENT INSTARCH APPLICATION. WITH THEFIRST SUCH GLUE MACHINE IN SPAIN,SAICA IS PAVING THE WAY INACHIEVING A COOLER CORRUGATOR.

Kohler’s solution

Standard B, C 5 7 9 0.5 1.5 0.5

(72.5) (101.5) (130.5) (7.5) (21.5) (7.5)

Heavy B, C 7 9 12 1 2 1

(101.5) (130.5) (174.0) (14.5) (29.0) (14.5)

(188.5) (188.5) (188.5) (21.5) (58.0) (43.5)

Heavy DW BC 13 13 13 4 6 5

(188.5) (188.5) (188.5) (58.0) (87.0) (72.5)

E Flute E 5 5 5 0.5 1.5 0.5

(72.5) (72.5) (72.5) (7.5) (21.5) (7.5)

Article heading

Kohler’s solution

Standard B, C 5 7 9 0.5 1.5 0.5

(72.5) (101.5) (130.5) (7.5) (21.5) (7.5)

Heavy B, C 7 9 12 1 2 1

(101.5) (130.5) (174.0) (14.5) (29.0) (14.5)

(188.5) (188.5) (188.5) (21.5) (58.0) (43.5)

Heavy DW BC 13 13 13 4 6 5

(188.5) (188.5) (188.5) (58.0) (87.0) (72.5)

E Flute E 5 5 5 0.5 1.5 0.5

(72.5) (72.5) (72.5) (7.5) (21.5) (7.5)

Article heading

Other adjustments

risk this.

CHASINGLIGHTWEIGHT

Other adjustments

risk this.

CHASINGLIGHTWEIGHT

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