KEEP AN EYE ON Lightweight Paper
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1 KEEP AN EYE ON Lightweight Paper TAPPI/AICC SuperCorr Orlando 2016 BHS Corrugated Greg Grdinich Redesigning the Corrugator
2 2 Table of Contents Availability of Lightweight Corrugated Case Material (CCM) in Our Industry. Paper Specific Values and Technical Features of Lightweight CCM Material What Do We As A Machine Manufacturer - Contribute to Process Lightweight Material with Best Quality and Strength? As an OEM, we work on: industrial solutions and improvements for your product "corrugated board" on runability and printability on design of corrugating roll profiles on new flute combinations on reduction of wash-boarding on sustainable usage of energy
3 3 Definition for Lightweight CCM Paper 100 gr/m² (21lb.) and all lower medium and liner papers
4 6 Paper Strength (SCT Short Span Crush Test) (SCT index = SCT CD/ ma) SCT Index (specification over the years) Basic weight [g/m²] Source: Lab. BHS
5 7 Paper Strength CMT (Concora Medium Test) CMT and paper weight (medium paper) for different flute profiles 350,00 300,00 CMT [N] 250,00 200,00 150, ,0 0 50,00 0, Paper w eight [g/m²] A Flute C Flute B Flute Source: Lab. BHS
6 8 Paper Strength CMT (Concora Medium Test) (CMT index = CMT / ma) CMT Index for different flute profiles 3,50 3,00 2,50 2,00 1,50 Index A Index C Index B 1,00 0,50 0, P aper weight [g/ m²]
7 7 Corrugating Roll Profiles for Light-Weight Papers
8 10 Corrugating Roll Profiles for Light-Weight Papers Caliber PAPER CALIPER of paper 200 Caliber of paper [µm] belt version belt version Paper weight [g/m²]
9 11 Corrugating Roll Profiles for Light-Weight Papers Spec. density 0,75 Spec. density [kg/m³] 0,7 0,65 0,6 0,55 0,5 0,45 0, Paper weight [g/m²]
10 12 Corrugating Roll Profiles for Light-Weight Papers Flute formation on the flute tips
11 13 Corrugating Roll Profiles for Light-Weight Papers CMT improvement with smaller head radius of a B-flute profile head radius CMT test for 100g/m² Medium 335 N (+15%) R = N (+10%) R = N R = 1.35 Head radius
12 14 Profile Criteria in Strength for Light-Weight Papers small pitch large FCT -- low height high FCT + ECT + BCT ++ Take Up -- FCT ++ ECT ++ BCT - Take Up + pitch height ECT -- BCT + Take Up - FCT - ECT - BCT Take Up ++ + good ++ very good - bad -- very bad
13 13 Board Strength with Light-Weight Papers reduce medium weight 100 % reduce pitch
14 14 ECT Values with Light-Weight Papers test quality B 26 B BM 4 Flute 6,50x2,6 B 12 Flute 6,20x2,6 SCT [kn/m] take-up SCT [kn/m] take-up TL white medium TL ECT nom % ECT LAB %
15 15 ECT Values with Light-Weight Papers Increase of ECT value: 1 15 Flute - BM4 6,50 x 2,6 rh 1.14 rf 1.45 take-up glue lines per 100 mm Flute - B12 6,20 x 2,6 rh 1.10 rf 1.41 take-up glue lines per 100 mm 15
![16 Box Compression Test BCT [N]](/docs-images/77/76068349/images/16-0.jpg "Bending stiffness Stronger Liner on")
16 16 Box Compression Test BCT [N] Bending stiffness Stronger Liner on inside
17 17 BCT [N] Box 450*300*300 BCT Value Box Design for E/B or B/E 2500 B/E +25% E/E E/B TL / 75 Medium 110 TL / 75 Medium 110 TL = 480 g/m² height of board [mm]
18 18 BCT [N] Box 450*300*300 BCT Value Box Design for B/C or B/B B/B C/B B/C 3000 Why is the printability for BC flute and the 2000 EB flute not good anymore? KL / 110 Med. 90 Med. / 110 Med. 135 KL = 580g/m² height of board [mm]
19 19 Printability of Light-Weight Double Wall BC flute with conventional division ratio 11/9 BHS patent pending mm
20 20 Printability of Light-Weight Double Wall BC flute with conventional division ratio 11/9 BHS patent pending mm BC flute with adapted division ratio: here 4/ mm
21 21 Printability of Light-Weight Double Wall BC flute with conventional division ratio 11/9 BHS Patent mm BC flute with adapted division ratio: here 4/ mm
22 22 Printability of Light-Weight Double Wall Conclusion 1: The smaller the division ratio of the flutes is, the better the quality (surface) and the stiffness of the respective double wall corrugated board. Conclusion 2: Higher material stiffness for light-weight papers is reached by a smaller pitch and a higher flute height.
23 23 Lightweight Paper and The Corrugator Corrugating Roll Profiles The Single Facer (Design) Glue Application Temperature / Heat Control Process Control
24 24 Single Facer and Lightweight Paper Single Facer with Pressure Roll Single Facer with Belt
25 25 Glue Application
26 Light-Weight Bottom Liner Paper 26 Conditioning of bottom liners Improving surface Reducing wash-board
27 27 Process Control for the Corrugator Locations of temperature and moisture sensors: M M T SF 2 T T M T T T SF 1 T T T T PH 3 GU T DF T T
28 28 Thank You *Special Thanks to Paul Roier for all his research
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