There are many factors that affect the profit of the paperboard production line. Today, I will take you to analyze in detail, that is, paper receiving, which is very easy to be ignored or rarely received attention.

What is perfect paper pickup? The simple action of transferring from one paper roll to another without tearing the paper web is not a perfect paper pickup. When you transition from one roll of paper to another at the design speed of the paper receiving machine, you can achieve perfect paper receiving without affecting the downstream process (ideally, there is no remnant). During the whole paper pickup process, the consistent tension and alignment must be maintained until the machine returns to its pre pickup speed.

1. Synchronous paper pickup

Some wet end controllers have the advantage of synchronous paper pickup. These systems have the ability to place the paper receiving positions of face paper and core paper within 3 feet (about 0.9144 meters) from each other. Since only one piece of paper is discarded during roll change, waste is reduced. However, if the staff must discard the excess paper every time they change the paper due to warpage or other quality problems, there is no benefit in synchronous paper pickup.

The operation procedure of the factory shall specify the correct method of using the wet end controller to start the synchronous paper receiving. Manually changing the paper should be the last choice, because operators try to "guess" when they will master the perfect paper pickup time and the correct alignment position, which will often cause more waste.

Using the wet end controller for synchronous paper pickup can reduce waste. Ensure that these systems are mechanically and electrically intact and can operate in automatic mode. Remember to "put the wrapping arm back in place" before changing paper. And the synchronous paper pickup should be verified regularly by measuring the distance between the first and the next paper pickup included in the stacker. If the distance is greater than 3 feet (about 0.9144 meters), it needs to be adjusted in the controller.

It is estimated that the success rate of the automatic paper feeder should reach 98% or higher to greatly reduce the cost waste associated with downtime. The time loss due to poor paper pickup can be calculated by multiplying the error rate of the paper pickup machine by the number of paper pickup in a year by the average lost minutes of each missed paper pickup. For example, 54000 paper pickup times a year, with an efficiency of 91%. Each missed pickup loses 2 minutes, equivalent to 54000x0.09x2=9729 minutes, or 20 shifts a year.

When the factory leaves the surplus paper on the paper roll, it will generate unnecessary waste costs. During the audit period, we often found that more than 60% of the paper picking machines operated in manual mode. When using synchronous paper pickup, paper pickup in manual mode usually increases waste to 0.4%, while in automatic mode it is 0.10%-0.12%.

2. Tracking paper pickup performance

The first step to reduce production losses due to inefficient paper pickup is to determine why paper pickup is missed. Accurate reporting is critical to achieving efficiency goals and troubleshooting when goals are not met. The updated and upgraded paper feeder can record the efficiency of the paper feeder, but if no one views these reports, the problem may get out of control. You can also use the log of the paper receiving machine similar to the next page to complete tracking through the manual tracking process. The report should be reviewed by the corrugated supervisor and maintenance personnel. Adequate maintenance is essential for the proper function of the paper feeder and will have a significant impact on the quality and production of paperboard.

In addition, the accumulation of sundries on the preparation roll is very common, which will lead to serious problems when picking up paper. If it is not cleaned regularly, the friction force will eventually boil this material onto the roller, and it is difficult to remove.

3. Buffer area

The buffer area is a controlled paper reserve generated between a fixed stationary roller and a dynamic roller. The dynamic roller is actually a group of rollers, which move back and forth along the paper receiving machine, thus generating excess paper for suction during the paper receiving process. During the paper receiving process, the dynamic roll moves to the main static roll, so that the tile line is pulled out of the reserve paper. In this way, the new paper receiving roller can have time to slowly start unwinding and increase the speed, so that the force applied on the paper receiving joint is smaller. After the paper receiving is completed, the dynamic roller will automatically move back to the original position to create a new buffer area for the next paper receiving.

The buffer zone in the paper receiving machine is the key factor affecting the paper receiving speed. You can increase the number of dynamic roller components to create a larger buffer area, so that the paper shuttles back and forth to increase the stock of paper. By checking the edges of the paper as it passes through the feeder, it is relatively easy to see if anything is not parallel. During operation, all edges must be aligned through the paper feeder. A skewed edge indicates the need to check whether the feeder or base paper holder is parallel.

4. Gap control

Since the thickness of paper receiving is the sum of two chucks, it is necessary to carry out some type of gap control on the single-sided machine to make it pass. Most single-sided machines are equipped with an accumulator in the feeding system of the roll, which acts like a shock absorber when the thickness of the web increases. Some single-sided machines open the rubber roller to the gap of the metering roller during the paper receiving process, so it is necessary to apply additional adhesive to ensure the firm connection during the paper receiving process.

Unusable fragments can lead to unnecessary factory waste. Rolls of paper with a diameter of 15 inches or less are generally considered fragments. Each fragment represents about E113 in the waste. If one butt roll is produced per shift every day, the plant waste produced by the butt roll alone will be about e90500 per year. Many factories have successfully implemented the "half roll" plan.

Conceptually, if the tile line leaves less than 5000 feet of material on one roll of paper, another roll of paper should be connected to keep the partiallyconsumedroll greater than 5000 feet.

5. Core issues

If the operator stands up a roll of paper and tightens the chuck so that the core passes over the edge of the chuck, the edge of the rolled paper will be wrinkled. This may lead to tearing of the paper, resulting in missing paper and increased paper waste. It should be expected that all the paper rolls are completely separated from the paper core. For example, improvement measures such as installing a wet end controller and an automatic paper feeder with tail grab function can help achieve this goal. Ensure that these systems are mechanically and electrically intact and operate correctly at all times. The operation steps shall specify the correct setting of the chuck diameter to enable the paper to enter the chuck and trigger the end of the reel to receive the paper.

Cleaning the eyes of the tail grab regularly can ensure that the tail grab function can work normally in case of tearing. The management should regularly check the paper core in the waste truck to ensure that there is no remaining paper. These can ensure a success rate of 98%-99% for the paper feeder. Regular feeder audits will enable you to monitor the performance of the feeder and identify necessary improvements to equipment and processes.