3 Board Quality - Kopie PDF

Board Quality
page 2
Board defects: Causes and corrections
page 3
Board defects
Warp Bonding problems Other board defects
page 4
Roll stock management
Moisture level Moisture imbalance Wet streaks Loose windings Green rolls Identify problem rolls and claim Storage
page 5
Liner moisture level
6 -10% Too high moisture, but uniform run on DB
page 6
Medium moisture level
6-8% 9.5 - 10% For semi cemical
page 7
Medium absorbency
Water drop test, Cobb test Steam shower requirement
page 8
Paper tension and alignment
Proper alignment between running papers Prevent creases Loose edges/ pendular rolls/alignment systems Paper tension should be limited to prevent problems
page 9
Paper tension too high can cause
Poor single face bonds Build up stress in the board Cause end-to-end warp Smearing of the glue lines In the DB Cutting of the medium paper Uneven corrugations
page 10
Alignment
Roll stand alignment Wrap roll alignment Level and square the equipment Prevent wrinkles in the liner, diagonal stress Pre-heaters and conditioner level and square
page 11
Wrapping pre-heaters
Light liner papers, heat the outside, drive the moisture towards the glue line Wet or heavy liner papers drive moisture away from the glue line
page 12
Wrap-control pre-heaters
Manual Automatic, speed controlled Automatic, temperature controlled (option)
page 13
Bonding requirements
Heat Pressure Starch parameters
page 14
Bonding phases
Application Wetting Penetration Gelling Drying
page 15
Why warp occurs ?
Paper expands as it absorbs moisture Paper shrinks as it looses moisture Two liner papers with different moisture level Unbalanced liners Wrong paper tensions Loose or badly wound rolls
page 16
Factors that affect the moisture differential between two liners?

Paper making process Application of glue Use of steam-shower Use of additional water-showers Moisture removed by pre-heaters
page 17
Normal or up-warp side-to-side, what action required.

Increase wrap SF internal and/or external preheater Decrease wrap double face liner pre-heater (#1) Increase wrap SF web pre-heater (triple stack #2 or #3) SF decrease glue DB glue unit increase glue
page 18
Reverse or down-warp side-toside, what action required.

Decrease wrap SF internal and/or external preheater Increase wrap double face liner pre-heater (#1) Decrease wrap SF web pre-heater (triple stack #2 or #3) SF increase glue DB glue unit decrease glue
page 19
End-to-end up-warp, what action required.

Decrease tension single face web, bridge brake Increase tension double face liner
page 20
End-to-end down-warp, what action required.

Increase tension single face web, bridge brake Decrease tension double face liner Excessive friction with hot plates
page 21
Twist or diagonal warp, what action required.

Roll stands not level Pendular rolls not functioning correctly Wrap rolls not level Dirt (tape/glue) build-up on wrap rolls/heated drums DB belt not running true and pulling web unevenly Fibre orientation problems in liner paper
page 22
Twist or diagonal warp, what action required (cont).

Loose or tight edge in one of the liner rolls Try to isolate paper or machine related problem Festoon carriage splicer not straight
page 23
S- warp, what action required.

SF glue roll/metering roll gap not parallel Doctor blade worn Wet streak in liner paper or medium (light board grades only) DB glue unit glue roll/doctor roll gap not parallel Loose paper edge , bad contact/heat transfer preheater Try to isolate paper or machine related problem
page 24
S- warp, what action required (cont).

Out of level or out of square machine components Dry streak in paper roll Moisture profile, grammage profile, calliper profile
page 25
Washboarding
More occurring on lightweight liners Too much starch application Too high moisture inside paper
page 26
Blistering
Paper Microflutes, slow running, too much heat in combination with large glue gap
page 27
Bonding problems
Loose edge bonding Zipper board/shallow Too green bond Directional pull different
page 28
Adhesive pattern.
Iodine test Application Glue transfer Even glue line Width of glue line Spraying/splashing
page 29
Flute formation problems.

Low calliper High/low flutes, uneven Fractured or cut corrugations Leaning flutes Damaged flute edge area
page 30
Low calliper
Below standard flute height, check original corroll protocol, worn corrolls Too low corroll nip pressure Flattened flute tips, wrong rider roll gap DB glue unit Medium paper too dry Too much web-tension on medium paper Low FCT and reduced stacking strength
page 31
High/low flutes, uneven

Glue transfer DB glue unit rider roll (spring loaded shoes more forgiving) Corrolls out of parallel Vibrations on corrolls Older SF dirty fingers, bent or too far away from corrolls Bad print surface
page 32
Fractured or cut corrugations

Medium roll out of round, web tension changing Too much pressure on corrolls Dirty, worn or damaged corrolls
page 33
Leaning flutes
Corrolls not parallel Uneven pressure corrolls Hot plates dirty Speed difference between DB top and bottom belt Hot plates not level Rider roll gap too small
page 34
Bonding issues
Zipper bond White bond Chrystallised bond Blistering Poor edge bond Too green bond
page 35
Zipper bond
Weak surface bond between liner and fluting Liner too heavily sized, poor starch penetration Gel. temp too low, starch formulation Hot plates dirty Too much heat used Caution low speed, excessive heat in combination with wheat starch
page 36
White bond
Board delaminates and starch lines appear white Paper moisture excessive or too absorbent Starch viscosity too low, Gel. temp too high Insufficient heat input, poor heat transfer
page 37
Chrystallised bond
Poor bond and starch lines appear glass like Paper moisture excessive or too absorbent Gel. temp too low, gelling too quickly prior to penetration Poor contact between DB liner and SF web, mechanical problems on DB, pressure loading system. Double kiss effect at DB infeed.
page 38
Blistering
Small patches of unbonded liner to the fluting Low moisture inside the liner Wet or dry streaks in liner or fluting Paper with grammage or calliper profile problem Gel. temp too high Microflutes low speed, too much starch Poor glue application, dirty raster application roll (calcium, hard water) Excessive heat on liner

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Board Quality

Board defects: Causes and corrections

Warp Bonding problems Other board defects

Roll stock management

Liner moisture level

6 -10% Too high moisture, but uniform run on DB

Medium moisture level

6-8% 9.5 - 10% For semi cemical

Water drop test, Cobb test Steam shower requirement

Paper tension and alignment

Paper tension too high can cause

Manual Automatic, speed controlled Automatic, temperature controlled (option)

Heat Pressure Starch parameters

Application Wetting Penetration Gelling Drying

Why warp occurs ?

Factors that affect the moisture differential between two liners?

Normal or up-warp side-to-side, what action required.

Reverse or down-warp side-toside, what action required.

End-to-end up-warp, what action required.

End-to-end down-warp, what action required.

Twist or diagonal warp, what action required.

Twist or diagonal warp, what action required (cont).

S- warp, what action required.

S- warp, what action required (cont).

Flute formation problems.

High/low flutes, uneven

Fractured or cut corrugations

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