KEEP AN EYE ON Lightweight Paper TAPPI/AICC SuperCorr Orlando 2016 BHS Corrugated Greg Grdinich Redesigning the Corrugator
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 Definition for Lightweight CCM Paper 100 gr/m² (21lb.) and all lower medium and liner papers
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
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 10 0,0 0 50,00 0,00 60 80 100 120 140 160 Paper w eight [g/m²] A Flute C Flute B Flute Source: Lab. BHS
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 0,00 60 75 80 100 120 140 160 P aper weight [g/ m²]
7 Corrugating Roll Profiles for Light-Weight Papers
10 Corrugating Roll Profiles for Light-Weight Papers Caliber PAPER CALIPER of paper 200 Caliber of paper [µm] 180 160 140 120 100 belt version belt version 80 60 70 80 90 100 110 120 130 140 Paper weight [g/m²]
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 0,4 60 70 80 90 100 110 120 130 140 Paper weight [g/m²]
12 Corrugating Roll Profiles for Light-Weight Papers Flute formation on the flute tips
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 = 1.00 320 N (+10%) R = 1.16 290 N R = 1.35 Head radius
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 Board Strength with Light-Weight Papers reduce medium weight 100 % reduce pitch
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 1.333 SCT [kn/m] take-up 1.364 125 TL white 2.05 2.05 90 medium 2.16 2.2 105 TL 1.45 1.45 ECT nom. 4.02 4.05 + 0.7 % ECT LAB. 3.92 4.13 + 5 %
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 1.333 15.3 glue lines per 100 mm 1 14 16 Flute - B12 6,20 x 2,6 rh 1.10 rf 1.41 take-up 1.363 16.2 glue lines per 100 mm 15
16 Box Compression Test BCT [N] Bending stiffness Stronger Liner on inside
17 BCT [N] Box 450*300*300 BCT Value Box Design for E/B or B/E 2500 B/E +25% 2000 1500 E/E E/B 1000 1 2 3 4 110 TL / 75 Medium 110 TL / 75 Medium 110 TL = 480 g/m² height of board [mm]
18 BCT [N] Box 450*300*300 BCT Value Box Design for B/C or B/B 5000 4000 B/B C/B B/C 3000 Why is the printability for BC flute and the 2000 EB flute not good anymore? 2 4 6 8 135 KL / 110 Med. 90 Med. / 110 Med. 135 KL = 580g/m² height of board [mm]
19 Printability of Light-Weight Double Wall BC flute with conventional division ratio 11/9 BHS patent pending 71.55 mm
20 Printability of Light-Weight Double Wall BC flute with conventional division ratio 11/9 BHS patent pending 71.55 mm BC flute with adapted division ratio: here 4/3 23.85 mm
21 Printability of Light-Weight Double Wall BC flute with conventional division ratio 11/9 BHS Patent 71.55 mm BC flute with adapted division ratio: here 4/3 23.85 mm
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 Lightweight Paper and The Corrugator Corrugating Roll Profiles The Single Facer (Design) Glue Application Temperature / Heat Control Process Control
24 Single Facer and Lightweight Paper Single Facer with Pressure Roll Single Facer with Belt
25 Glue Application
Light-Weight Bottom Liner Paper 26 Conditioning of bottom liners Improving surface Reducing wash-board
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 Thank You *Special Thanks to Paul Roier for all his research