Gold winners:
Kang Qilai has worked in carton and printing companies since 1979, printing, postpress processing, quality control, and production management. In more than 20 years of production line work practice, we have devoted ourselves to researching production technology, and have invented relief printing technology of one-off printing, resin printing, and “large-printing†printing process, and used the old blankets to make relief printing (including flexo printing). Field printing technology, embossing with offset press, indentation process and many other practical technological innovations have been promoted in the printing industry and have received good economic and quality benefits. Currently he is the Production Manager of Fujian Putian Hongli Printing and Packaging Co., Ltd., the color printing professional class teacher of Fujian Putian Vocational Technology School, the expert committee of the China Packaging Federation Paper Product Packaging Committee, and the quality judge.
In the past 30 years of reform and opening up, China's paper packaging industry has been developing rapidly, especially in the context of the cyclical economy and the general trend of green environmental protection. Cartons are only developed in the direction of low quantitative and high strength, so that the packaging industry can become fierce. Under the market environment, we have achieved real competitive advantages and thus won better development space. Looking at the development trend of China's carton, low-quantity and high-strength carton production technology is an eternal theme worthy of attention and research in the current and future packaging industry. Therefore, the author believes that with the further integration between China and the international economy, the production technology of paper packaging in China will gradually catch up with the manufacturing level of advanced countries in the world. Under the guidance of the scientific concept of development, it is beyond doubt that China is moving from a packaging power to a packaging power.
Correct Understanding of the Concept of Low Quantitative and High Strength in Carton Products
The so-called low-quantity and high-strength means that through the innovation and improvement of production technology, the use of paper for packaging products is significantly reduced, while the overall strength of the product remains unchanged or increased, and the production cost of the product is reduced to some extent. The economic benefits of the company have been improved. Innovations and improvements in paper packaging production include production design, production technology, production processes, production equipment and raw materials. For example, if the production of base paper is improved through formulas, techniques, etc., it can achieve a strength and quality index of about 140g for corrugated paper of about 90g, and a strength and quality index of about 180g with corrugated paper of 125g. Through the improvement of adhesives or the control of corrugated molding production technology, the lightweight carton strength is required to maintain the quality standard or increase. At present, the country's low-quantity and high-strength paper packaging has not yet established a standard concept. The author believes that the base paper is reduced quantitatively and the production cost is also reduced, but the quality of the finished product still meets the basic requirements for meeting the standard. This is the definition of low quantitative and high-strength paper packaging products, but also the inevitable development trend of circular economy.
Improve the quality of single-sided corrugated board through the technical transformation of single-sided machines
Corrugated board strength is an important factor in determining the quality of the carton. The corrugation height of corrugated cardboard, the number of turns in the unit of 30cm length, and the waveform characteristics of corrugated medium are important conditions that affect the strength of corrugated cardboard. Because the structural characteristics of corrugated paperboard determine the papermaking rate of corrugated fiber in the length unit, the competition in the carton industry requires the production of a carton whose quality meets the standards on the basis of the most economical use of materials. So how can we do it? The author once decided to use a corrugating roll with a large amount of paper to carry out the equipment transformation, and a single-sided machine (hereinafter referred to as 1# machine) in which the corrugating roll wears badly was replaced by a new specification corrugating roll and the corrugated roll was customized directly. The number of corrugated teeth in a 30cm unit length is 48 teeth; the corrugation roll tooth height is set at 2.9mm, which is 4 more teeth than the original caries tooth, while the caries height is reduced by 0.22mm, but the corrugated board thickness index remains Controlled within the standard range. Another unit (hereinafter referred to as #2 machine) is that the number of corrugated teeth in a unit length of 30cm is 44 teeth, and the height of a corrugated roll is 3.12mm. Two sets of single-faced corrugated units of the same type have undergone multiple production trials in the same production process, environment, and paper quality. Through comparison and analysis of on-line inspection data, the following production process conclusions were obtained: Although 1# machine has 4 more teeth than 2# machine, its caries height is 0.22mm lower than 2# machine, and the machine is 2m long. Corrugated paper can be molded into 1.405m corrugated cardboard. The 2m long 2m corrugated paper can only be formed into 1.385m corrugated paperboard, and the machine's corrugated board's edge pressure strength and plane compressive strength values ​​are slightly lower than 1# machine. It can be seen that No. 1 machine not only saves paper than No. 2 machine, but also produces corrugated board with high strength. Without affecting the overall quality of the carton, the thickness of corrugated board is reduced by 0.22mm, which may seem insignificant at first glance. However, through careful calculation of bills, the cost of corrugated paper saved by a single-sided machine after transformation is quite considerable. If corrugated sheets with a single-sided machine have an average paper width of 1.6m and an average paper basis weight of 125g is used to produce corrugated paperboards, the length of one year production of corrugated board is measured at 3,1104,000m (1,423,004m), and 1# machine needs corrugated paper, 44260,992m; 2# machines. (The rate of 1.444) needs to use corrugated paper 44914176m, and 2# machines use 653184m of corrugated paper more than 1# machine. Then, 653184m×1.6m≈1045094; 1045094×125g=130636750g, equivalent to 130.63675t, if the average price per ton of corrugated paper is tested at 2,000 yuan, worth more than 260,000 yuan. It can be seen that, without affecting the quality of finished products, through the design of the production process and the transformation of the equipment to reduce unnecessary waste of materials, it is actually a considerable profit.
Accurate Measurement Method for Paper Rake Rate of Corrugated Layer
The amount of forming paper per unit length of the corrugated layer, commonly referred to as the corrugation rate, generally refers to the length of corrugated paper consumed by the length of the corrugated cardboard after molding. Nowadays, many manufacturers calculate the enthalpy rates of various types of helium based on geometrical theory based on the 楞 type characteristics of corrugated rollers. However, this subjective measurement method has a certain degree of one-sidedness, and there is a certain amount of error. Because of the difference in the gap between the single-faced corrugating roll and the difference in base paper thickness and moisture content, the molding coefficient and shrinkage rate will also be different. Corrugated paper consumption rate will not be constant data. Therefore, the author believes that to accurately measure the defect rate of corrugated fiber, the actual test data of on-line production of a single face machine should be used as the basis for corrugation rate assessment. The specific detection method is: first, measure the moisture content of the web, and at the same time, make a mark at the position of 1m or 2m in the web, and then measure the mark of the formed corrugated cardboard, and measure the corrugated cardboard. The length is the actual length of a 1m or 2m corrugated paper type corrugated cardboard. In this way, the corrugation rate can be accurately measured. The formula is: corrugation rate = length of corrugated paper, length of corrugated board after molding. For example, the distance between the two marks of the corrugated paper is 2m, and the distance between two marks after the corrugated paperboard is 1.385m, then 2÷1.385=1.444. This number is the corrugation rate of the 2m corrugated paper. There may be differences in the moisture content at each stage of a reel corrugated paper. In order to obtain relatively accurate data, it is better to detect 5 or more times in different sections of the web, and then to test each time. The water content and the corrugation rate were averaged separately. Under the premise that the moisture content of the base paper meets the standard, the detected corrugation rate can be used as the valid standard data for the single-sided machine of the table to ensure the accuracy of production cost accounting.
Using Nano Corrugated Paper to Improve Corrugated Board Strength
Using nano-calcium carbonate materials and additives with superior performance, after special equipment processing, nano-technical new papermaking additives can be made, and the additives can be directly added to the slurry with a concentration of about 1%, and then uniformly mixed. The papermaking machine manifold tube type headbox is uniformly sprayed onto the corrugated paper forming net so that the corrugated paper contains nano-calcium carbonate components. As nano-CaCO3 contains positive and negative fibers, the nano-CaCO3 is retained in the corrugated paper with the help of auxiliary agents. After high-vacuum dehydration, squeezing, and high-temperature drying, the nano-CaCO3 is retained. , About 8% of water is formed into nano-corrugated paper. The corrugated paper made of nano-calcium carbonate material has greatly increased strength and can be made into a relatively thin high-strength corrugated paper. For example, a low-quantity nano-corrugated paperboard with a weight of about 90 g/m2 is used to make cartons. The strength of the cartons can be comparable to the quality of cartons made with ordinary 150 g/m2 or so corrugated paper. Nano corrugated paper is one of the important production methods to improve the quality of corrugated boxes.
Control the quality of corrugated paper
The process practice shows that the quality of the corrugated paper material directly affects the molding quality of the corrugated paperboard. Among them, the moisture, sizing degree, water absorption, tightness, and lateral crush strength of corrugated base paper have the most obvious effect on the strength and quality of finished cartons. Therefore, it is very important to test and control the corrugated paper. Controlling the moisture of the corrugated paper is actually controlling the paper rate of the corrugated paper. If the moisture of corrugated paper is too high, corrugation shrinks due to the loss of moisture due to the temperature during the forming process of the corrugated paperboard, the consumption of the base paper will increase accordingly, and even the amount of kerf paper in the corrugated paperboard of the horizontal paperboard will not be enough. Roughness affects the appearance of the carton. Corrugated paper with poor sizing, its relatively high water absorption, relatively sensitive to the external environment of the humidity, easy to absorb the moisture in the air and make the cartons soft, the quality of the quality decreased significantly. Corrugated sheet tightness index and index of ring pressure index mainly depend on the degree of looseness of the base paper fiber and the hardness of the fiber. The corrugated box with poor tightness appears thick and rough. If the original paper fiber is not uniform, on the one hand, it is easy to produce a wear effect on the surface of the corrugating roller, and on the other hand, it also affects the ring-press strength of the base paper. The national standard corrugated paper only has the items of quantitative, tightness, moisture, crack length and lateral pressure index testing items, and no sizing or water absorption test items. In fact, the degree of sizing and the water absorption have a great influence on the processing quality of corrugated board and the stability of the quality of finished carton. These two indicators are also complementary. The author proposes that the carton factory should formulate the corresponding corporate standards according to the actual production conditions, and conduct sizing or water absorption inspection on the corrugated papers purchased, which is an important control link to increase the strength of the carton.
Improve single-sided machine with plastic facilities to improve the adhesive strength of corrugated board
How does the quality of the single-sided corrugator adhesive quality directly affect the adhesive strength of the corrugated paperboard, especially if the adhesive pipe has a longer parallel transport form? If the machine stops during the production process or half-way, the adhesive in the pipeline can be easily precipitated and the viscosity of the adhesive becomes unstable. Therefore, in order to break the layout of the traditional adhesive pipeline transportation, it is advisable to set the glue dispensing device higher than that of the single-sided machine. If the glue dispensing device is located on the second floor, the pipeline of the adhesive is changed from parallel feeding to top-down conveying. This helps the adhesive to maintain a uniform state throughout the delivery process, and can better avoid the disadvantages of the adhesive being easily transported in parallel and increase the adhesive strength of the corrugated cardboard.
Production of corrugated cardboard using tungsten carbide corrugating rollers
Since the ordinary corrugated roller dies do not wear, and the area of ​​the rake tooth after wear becomes larger, the sizing amount when corrugated is adhered increases, which makes the cardboard easy to become soft and curled. After obvious wear and tear on the top of the crucible, it will directly affect the quality of the corrugated board, so that the machine has to replace the corrugating roll. The use of wear-resistant tungsten carbide corrugating roller, you can better improve the service life of corrugating roller, effectively reduce the wear and deformation of the top of the caries and the caries side, improve the processing quality of corrugated cardboard. In addition, the use of tungsten carbide corrugating roller due to the wear resistance of the surface coating of the caries, the use of tungsten carbide corrugating roller can also be better avoided because the machine after a while, the corrugating roller appears "concave" wear phenomenon. The height and thickness of the tungsten carbide corrugating roller roll teeth are kept stable, which can effectively avoid the degumming and dripping caused by the corrugating roll's “concave†phenomenon and the two ends of the roll being easily crushed and the middle part being unevenly glued. The occurrence of quality defects such as lumps, blisters, and blisters significantly reduces the number of defective and defective products in corrugated board. When the machine is used to produce wide corrugated boards, the quality of the entire web of corrugated board is basically the same. Tungsten carbide rolls are generally about four times the life of ordinary rolls, and their price can be compensated by the increase in service life and the strength of corrugated board. Therefore, I believe that the use of tungsten carbide corrugating roller or value for money.
With the continuous deepening of the circular economy, increasingly fierce market competition, will inevitably promote the pace of innovation in the production process of low-quantity, high-strength corrugated cartons. So, how to produce a qualified, suitable low-quantity, high-strength corrugated box? There is a saying "Eight Immortals crosses the sea and each shows a supernatural power." Due to the different factory conditions, the production process of low-quantity and high-strength corrugated cartons also has a variety of ways. However, the quality standard of finished carton products is the same, and there is only one, that is, the only prerequisite for the quality of the finished product of the carton is that it meets the standards. This requires the implementation of technological innovation, technological innovation, equipment innovation or material innovation. Real test production, after confirming the reliability and rationality of production, can produce low-quantity, high-strength corrugated box products that are recognized by the market.
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