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CORRUGATOR DOUBLEBACKER

OVERVIEW

THE DOUBLEBACKER
What does it do? Holds the liner and web together with minimal pressure just to make a bond across the board and edges What is needed Starch to gel, thus tack then loose moisture Plate temperature is critical Belt speed must be synchronized wit the board speed Top and bottom belt speed must be within 5% of each Plates must be level Weight rolls must be in right order

LEAD - IN

No wave or flutter of liner or singlefaced web permitted

DOUBLEBACKER PROBLEMS
Caliper loss
Edge Bond Blisters

Temperature - Gradient and profile


Changing heat available Special flutes E flute

Special liners - preprint

HOT PLATE DEFELECTION

1.8 mm =

PLATE DEFLECTION
NEW BELT

INFUSION HEATING -3

EXPRESS - Steam Chests

TM

Single fusion cast iron Rounded internal corners on steam path for
optimal flow and elimination of vortexes

Sec A - A

The heating section of the DoubleFacer can be supplied in different versions according to the plants performance and production requirements.

BEARING WEAR

CHECKING TEMPERATURE

HOT PLATES TEMPERATURES/STEAM


Desired hot plate temperature Over 325 degrees F ( 161 degrees C)

Cooler Temperatures are being used dependent on papergrade, flute, Plants mode of operation (cooler vs. hotter)
Steam pressure - 150 psi and above for 325 degrees F Pressure must be adjustable to run the cooler corrugating concept

CHECKING THE TEMPERATURE

CHECKING WITH A PYROMETER

HOT PLATE LUBRICATION


Liners that are subject to drag also create high power demand Symptoms Variation in cut length Increased Amp draw on DB drive Remedies - applied when the current demand exceeds a set point

By wax bar
By wax emulsion spray systems

WAX BAR AT THE D/Ber

HEAT TRANSFER

LEVELING HOT PLATES

LEVEL CHECKS
=10 mm

CHECKING PLATE LEVEL

WEIGHT ROLLS

WEIGHT ROLLS

PRESSURE BY AIR

PRESSURE FOOT SYSTEMS

BELT PROBLEMS
Belt
Worn Tension

Belt dirty
Belt weaving Belt marking the board

Dirt
Lacing

BELT TRACKER

WORN BELT

BELTS CAN CAUSE QUALITY PROBLEMS


SYMPTOM CAUSE REMEDY

Edge bond
Edge crush Edge trim waste Damp board Sheet length variation Marks on board Indentation on board Board weave

worn or plugged belt


weight rolls check belt weave plugged belt dirty belt starch build-up starch build-up check belt guide

measure or clean
adjust adjust clean clean clean clean re-lace belt/tension

BELT MAINTENANCE
Belt cleaning Belt wear Belt life Belt starch pick -up

Belt tracking
Belt splicing Belt tensioning

Belt lagging
Belt speed -top and bottom

BELT CLEANING

RE-INFORCEMENT TAPE

BELTS AND BELTLESS


Purpose of a belt - apply pressure -assist bonding - apply pulling for traction Types of belts - a. Heavy interwoven cotton 5/16 thick absorbs moisture b. Synthetic needled felt type 1/2 weight Steam passes through c. Woven polyester belt

Beltless

Most suppliers since 1995 offer


a. Fully beltless with vacuum traction section b. First section beltless, traction section uses belt

BELTLESS -1

BELTLESS 2

VACUUM TRACTION SECTION

Flat Crush vs Moisture