ZERO DEFECTS GROUP 2010: Eric Yergeau - Cascades SPG Kirk Kind Pregis Tim Olson Multi-Wall Wes Montague - ITW Danelle Ramsey Newpage

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2 HONEYCOMB The Right Product for the Right Application ZERO DEFECTS GROUP 2010: Eric Yergeau - Cascades SPG Kirk Kind Pregis Tim Olson Multi-Wall Wes Montague - ITW Danelle Ramsey Newpage

3 Railcar Inspection and Preparation

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6 Railcar Quality Awareness It is the railroad s responsibility to supply cars which are clean, have sound roofs, sides and square end walls, smooth floors and snug fitting doors. The shipper has the responsibility to inspect interiors of cars to see that they are suitable to carry lading safely and damagefree. Any exception is cause for rejection.

7 Equipment Inspection Water No visible holes that would allow outside elements to enter car and damage the paper

8 Equipment Inspection Reject any temporary patches Inspect door seals reject any that do not seal properly

9 Equipment Inspection Clean no debris No protuding nails or objects Sweep equipment and remove any debris

10 Equipment Inspection Bowed walls? Severely Bowed walls? Remove steel straps from doorposts or sidewalls prior to loading Leaving steel straps in cars leading to roll damage

11 How to home shop a damaged railcar Home shop is a term the rail industry uses to describe the process of reporting a damaged railcar. If you receive a damaged railcar: Contact your local rail carrier and ask them to homeshop the railcar. Provide them with an accurate description of what the problem is and where it s located in the car. The railroad will then place billing on the car to return it to its owner. The car will not be permitted to carry any freight until the owner acknowledges the issue and it is fixed. If possible, please circle problem area on trailer/car with a permanent marker. Include notation and date as well

12 Cushioned Cars verses Rigid Cars Cushioned cars have a built in shock absorbing system in the undercarriage of the car. Rigid cars have no force dampening system. A 15 inch cushioned car can reduce a 4G force to 1G. That means 3G s of force that is not allowed to go into the paper. Fine Paper, Newsprint, and Printing paper should only be loaded in cushioned cars.

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14 The Right Product for the Right Application!

15 HONEYCOMB The Right Product for the Right Application Wall Protector Railcar Container Truck

16 HONEYCOMB The Right Product for the Right Application Improves squaring of bowed sidewalls and protects from wall s defects. Reduce chaffing and scuffing Reduce flat spot Reduce usage of void filler Prevent spinning by increasing contact surface with the roll Wall Protector

17 HONEYCOMB The Right Product for the Right Application Critical Contact surface optimisation Pressure from the airbag Critical Wall Protector

18 HONEYCOMB The Right Product for the Right Application Raising the wall pad six inches off the floor will reduce the pressure point at the floor level. Wall pads should be one inch thick and a strong cell. Pads with over 55 psi crush are best.

19 HONEYCOMB The Right Product for the Right Application Critical Contact surface optimisation Pressure from the airbag Critical Wall Protector

20 HONEYCOMB The Right Product for the Right Application Riser Block

21 HONEYCOMB The Right Product for the Right Application There are different types of risers on the market for different applications: Stick: Cannot be stack and need proper qty for different roll weight. Square: Different size for different diameter. (Optimisation of surface and stability) Octogonal: Stability. Rising in the doorway. Round: Stability. Rising in the doorway Riser Block

22 HONEYCOMB The Right Product for the Right Application Riser Block Riser Stick Square Octogonal Round Riser Block

23 HONEYCOMB The Right Product for the Right Application Breaking the Strata Line Different width rolls 6 riser Riser Block

24 HONEYCOMB The Right Product for the Right Application Block minimum of 6 with strapping. In compliance with AAR regulations Riser Block

25 HONEYCOMB The Right Product for the Right Application In compliance with AAR regulations Block 50% width of second layer rolls. Riser Block

26 HONEYCOMB The Right Product for the Right Application Optimisation of airbags efficiency (S.O.C) for small diameter roll in vertical position. Buffer Pads Optimisation of the stability when combined with void filler

27 HONEYCOMB The Right Product for the Right Application Void Filler Void fillers are used to fill voids when roll diameters vary.

28 HONEYCOMB The Right Product for the Right Application Never put a void filler in direct contact with an airbag. Except for vertical usage. Manufactured to covered a maximum of contact surface. Void Filler

29 HONEYCOMB The Right Product for the Right Application Positioning Examples Void Filler

30 Correct Methods of Intermodal Shipping Loading Method E

31 Intermodal approved Strapping Non Metallic Strapping Better known as Plastic cord strapping. Must use one of approved products and it must be marked with the Strap ID. Typical 1.25 wide with ASTM type 1A-Grade 4 or 1.5 wide with ASTM type 1A-Grade 5 Must have minimum break strength of 3,285 lbs. Joined strapping is to have minimum of 2,135 Lbs of break strength. It is important the the buckle be applied properly. Use strap hangers or tape while staging to maintain proper strap position. Polyester Plastic 5/8 x ASTM Type IV Heat Seal must be used w/joint strength of 900 Lbs. Minimum break strength of 1,200 Lbs with a joint strength of 900 Lbs minimum break strength Strap must also be clearly marked with the strap I.D.

32 Rubber Matting 3mm thick on all loading methods and 2mm thick on select loads approved? Follow exact mat roll loading requirments to the diameter of load and method number. Roll Width is required to be 2, 3, or 4 depending on loading method. Cannot Reuse rubber mats if they have been torn or damaged. Depending on load mat overhang behind rolls is required to meet or exceed 8. Mats must be AAR approved. In question contact the AAR or refer to the Intermodal Loading Guide

33 50 diameter loading methods

34 58 diameter loading drawing

35 Nose block, Void Fillers If three rolls in the nose of the trailer it is imperative to center the first roll into the nose and block it from side to side. Materials can be Honeycomb, Corrugated, and Lumber as approved methods. It is also important that on all loads a minimum of 3 void is required between the lading and the trailer door. Void Fillers can also be used at the sides of the container as a method of tightening the load. This can save many Roll Headers in 1-1 offset loading patterns.

36 Cut sheet or Palletized flat stock

37 Product Performance Profile for Pneumatic Dunnage TAPPI Shipping, Receiving and Warehousing April 2010

38 Levels 2-52 Level 2 - Intended for Loads Less Than 75K. Level 3 - Intended for Loads 75K 160K Level 4 - Intended for Loads 160K 205K.

39 Performance Levels Level 5 Pneumatic Dunnage used as Lengthwise Void Fillers in Horizontal Application Between Concave Surfaces. Level 4 The following railroads have agreed to allow Level 4 air Bags to be used in horizontal application in rolls of paper in boxcars. BNSF CN CSX NS UP KCS

40 Level 5 FOR HORIZONTAL APLICATION. Max void allowable in rail shipment is 12 not void for verification test only. Most of RRs allow Level 4 bag in horizontal applications.

41 Placement of Airbags Airbag should cover 2/3 of the load height when used in horizontal or vertical position Level 4 & 5 Operating pressure is between 8-10 PSI. Level 4 & 5 up to 205,000 lb loads for most carriers.

42 AIR BAGS Side View Vertical Air Bag Top View Horizontal Air Bag

43 Airbags Center line Peanut Shape! Air pocket

44 Bags to support each layer

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48 HONEYCOMB The Right Product for the Right Application Use the proper technique to reduce risk of damage on the roll.

49 Thoughts on Success "Every successful enterprise requires three men a dreamer, a businessman, and a son-of-a-bitch." Peter McArthur "Few great men would have got past personnel." Paul Goodman...