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Time to review your Machine’s Specifics

As we begin the New Year, I believe that it is a good time to pause and
review the basic functions of all converting machines in our plants.
We all know, it is quite common for each of us to have a variety of
converting machines from a group of different manufacturers running
side by side every day. Many of our converting machines have unique
designs, individual controls and features that are machine specific.

For the last number of years, machine have done for generations. Maybe the
manufacturers have been rapidly moving manufacturing methods have somewhat
towards supplying box plants around the changed, and the speeds have increased Dick Target
world, Flexos and Rotary Die Cutters, but we’re still supplying properly designed “On Target Consultants”
with modern looking exteriors along corrugated shipping containers for our
with sophisticated computer control customers.
systems. Folding sections have been so are the paper grades. [ Note: Many of
greatly improved along with new counter I want to take some time now to discuss the rolls that are delivered to the wet end
ejectors that offer box manufacturers the and review some important details: of the corrugator come from a variety of
opportunity to produce quality boxes 1. Board Caliper and Caliper Loss paper mills from around the country.]
consistently at higher speeds. These during Manufacturing. The order may start with a 35# liner and
designs offer box makers the ability to end up with a 39# liner or vice versa as
manage closer tolerances as a tool to satisfy 2. INK Management. the 39# liner was the roll stock that was
customers with very specific requirements. next in line or one that was available. It is
3. Skew a common practice for corrugator crews
Let’s not forget that we still have machines to upgrade the paper with in one order
in our plants that are 10 + years old with 4. Printing Plates as a tool to maintain ECT numbers. This
manual controls and operating functions. 5. Cutting Dies is used as an insurance policy during
They may or may not have worn components paper changes as a way to guarantee box
however, they are still required to produce Managing and understanding board performance. This can and will change the
a quality box and compete with the modern caliper is certainly a very important subject nip setting requirements in our presses.
machines that I mentioned above. Many and we should never forget its influence
times, the same order is produced on the in our world of converting. We all know Remember, we can lose no more than
new piece of equipment one day and then that a 0.170” (4.3 mm) “C” flute sheet is not 0.003” (0.08 mm) in board caliper during
on an old piece of equipment three days always a 0.170” (4.3 mm). Be sure to check the converting process in the non-printed
later. The dimensions of the boxes have to incoming stock on every order, whether it area of the sheet. Maybe 0.006” (0.16
be the same as well as the color and print is from your own corrugator or from a sheet mm) in the printed area of the sheet. This
tolerances. ECT numbers must also be the supplier for you sheet plant. Paper changes should be constantly checked for every
consistent. The customer should really see are a way of life on the corrugator and order on a regular basis. As a quality check,
no difference. as the rolls are constantly being changed sheets should be checked as they enter the
feed section and as the sheets are delivered
As we move forward in this very from the counter ejector or the stacker
competitive industry, we cannot forget section in the case of a Rotary Die Cutter. I
the fact that we must still understand how do believe that a lot of money is “lost” due
to manage the very basics of corrugated to poor process checks regarding caliper
box manufacturing. We are still printing, loss. Many times, we ship the customer
slotting, scoring, folding and gluing more than he needs.
corrugated sheets and converting them
into proper shipping containers as we I will discuss this and other calibration
methods in future articles.
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The Corrugator | January - June 2020 13