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PART 2

CONTINUED FROM PART 1

1. What are the important process variables ?

It is called so because it varies according to each and every job.

a. paper
b. steam
c. glue

2. Why is the web tensioned on the reel stands before start of the
production ?

Case 1 - the reel of paper is good condition i.e. circular in shape

if the web of paper is let lose wwhen it enters the single facer then it may
result in forming of bad quality of fluting medium and as well as the pasting of
fluting medium with the liner board will not be proper

Case 2 - the reel of paper is not in good shape i.e.

1. Or 2.

Shown in the above figure the paper is under different tension at different
position and hence subjected to tear. Here is were the role of automatic tension
unit above the web reel comes into action.when the paper is being let out of the
reel is under high tension the tensoning unit roller above moves in the running
direction hence giving paper to the single facer avoiding tear of paper and when
the paper supplied is lose it under low tension then the automatic web teensioner
collects paper on its rollers so as to avoid giving more paper to the single facer
and maintaining uniform tension and flow of paper intop the single facer.
3. What is the basic requirement to make an 3 ply board ?

2 roller stands before the single facer for liner

1 single facer
2 roller stands after the single facer for fluting medium
splicer unit at each pair of roller stands
1 overbridge
roller stands for outer liner
1 Glue Station for gluing of outer liner and single facer board
Thermoplan
Shearing unit
Slitter and scoring section
Polygon knife cutter
Transfer section
Stacking/ delivery section

4. Why is glue applied only on the flutes ?

This is to apply only adequate quantity of glue other wise the glue if applied
on to the liner it will be shear wastage of the glue and also result in warpage
of the board due excess moisture on the board, hence deriving a bad quality
of board.

5. Why is web tensioned increased with increase in the GSM of the board
and vice versa ?

Lower the GSM of the board lower is the tensile strength of the board hence if
tensioning is excess on the roller stands it results in tearing of the web.
When the GSM of the board is higher the paper will remain lose when being
fed to the machine hence may result in improper feeding of the web to the
single facer and may result in Alignment defect.

6. When is warped angle increased ?

When the warp angle is increased the liner medium comes in more contact
with the heating cylinders hence we can heat the paper more if the moisture
content is more and incase the web moisture content is as per the required
standard then the angle is reduced hence resulting in lesser contact with the
heating cylinder.

7. Why is web tension maker required on the bridge ?

If there is no tension provider to single facer board then it results improper

feeding of Singlefacer board to the Gluestar section hence resulting in
formation of bad quality of board. Improper tensioning on either the single
facer board or the top liner may result in defective board/ Warppage
8. What are upper and lower corrolls ?

The cassettes contain pair of corrugating rolls which are termed as upper and
corrolls. Depending on their position they are called as upper and lower
corrolls

9. What is a press roll ?

It is the roll in the single facer section which presses the liner medium with the
fluting medium after the fluting passes through the glue station.

10. What is quick retraction when the machine stops ?

11. What is the function of sandwiched conveyor frame ?

This unit is present just after the fluting medium and the liner medium are
glued together. The conveyor frame conveys the single facer to the overhead
bridge above and as the single facer is carried between the belts, the whole
of the frame is called the sandwiched conveyor frame.

12. What is a thermoplan ?

This the start of the dry end section of the corrugator. It consists of bed of
plates which are heated approx. for 180 C temperature. The board formed is
passed through it so that the glue dries and a perfect onding between all the
mediums take place.
After the board passes through the bed of hot plates it is conveyed to the
Maxi shear Unit with the help of belt conveyor system known as the Pulling
Station.

13. What is the function of cut-off machine ?

This unit is provided with cut off knife so that itcuts the board to required sizes
as said and instructed in the control room for that particular job.

14. What is the function of maxi shear equipment

In this section of the board which is not formed to the requirement i.e. the liner
may not have been glued properly, job change over waste etc. is cut out. At
the gluestar Station if the operator sees a board is an defective one then he
activates the maxi shear station. The sensor senses the start of the board at
which the command was given and cuts away the length of board and stacks
it in the waste section below till the stop command is given. When the stop
 command is given the sensors sense the point at which the command was
given and till that point on the board it shears of as waste

15. Why does the thermoplan move up when the machine stops ?

When the Machine at any point stops the feeding of board to the dry end then
the dry end section stops. Due to this the belt driver in the thermoplan lifts the
belts up and also with it takes the board up, hence avoiding unneccessary
drying of the board.
If this does not happen then in that case the board would not withstand the
excess heat and may also result in damage of the belts conveying it.

16. What is the need of the air brake in the roller stands ?

It is through the air brake system that movement of the web reel is controlled.
If the brake is released then the rollers will move freely and give away excess
of paper web due to the pulling action of the single facer.

17. Why Pulling station is an necessity ?

This station is on the thermoplan just after the hot plates. It keeps on pulling
the board and feeds it to the slitting and Scoring Section of the Machine.

18. What is the function of belt tensioning unit useful for in the
Thermoplan?

When the dry end is not working the thermoplan lifts up its belt sytem and the
tension on the belt becomes very low . But when the thermoplan lowers the
belt the tension on the belt increases hence resulting in easy and even
transfer of the board to the pulling section

19. Need of Air pressure hood ?

This is on the top at the starting of the thermoplan, hence when the board
comes to the dry end it comes in full contact with the hot plates because of
the continuos blowing action of the Air Hood on to the board.

20. What is the use of deflector plates in the machine ?

After the board has been Slit and Scored , and if the job combination on the
manufactured board is of different sizes, then deflector plates are used to sort
them out and take them to different delivery stations at the downstacker.
Hence helping in sorting out two different board sizes
21. What do you mean by slitting?

Cutting of the web off board to different sizes through out the same thickness
of the board is known as Slitting

22. What do you mean by Scoring ?

Impression made on the Board through out the length of board at the same
thickness is known as Scoring

23. Why do you have to leave a trim of 20 mm on the either side of the
corrugated board ?

At the edges of the formed board there is a slight mis alignment of the liners
and the fluting medium, hence on the either side of the formed web we trim
20 mm to get at perfect edged board at the downstacker/ delivery.

24. Why the gel tempreature at the Glue Star kept lower ?

After the Glue Star station the board enters the thermoplan where the board
is heated for good bonding action. Hence it does not make sense in raising
the temperature of the gel formed.

25. What is gel temperature ?

The Gel temperature if kept higher the adhesive action is immediately trigged
and if the gel temperature is low then the bonding action is delayed as still the
adhesion property is not triggered fully

26. How is the glue prepared for corrugator?

Glue preparation is done by Stein Hall method

There are two steps involved in the making of the glue.
a. Primary process and
b. Secondary process
In the primary process water starch, caustic soda are mixed together at a
temperature of 40oC. the heating is done with the help of this whole process
consumes a time of around 10 minutes approximately.
In the secondary process the mix formed in the primary process is further
mixed with starch(for the second time), borax , Resin.
The whole mixture is mixed for approx. another 10 minutes and now the glue
is ready to be pumped to glue tanks at the corrugator.
27. What is the intermediate stacking time prescribed for the corrugated
board ?

The intermediate stacking time is approximately around 24 hours.

This is done for the following reasons
a. board does not get warpped due to stacking problem
b. board does not absorb moisture from atmosphere, if it does so then it may
not give good quality out at the converting section.

28. How is the job routed to converting sections ?

The routing of the job depends upon the further processes to be done on the
basis of type type box.

CORRUGATED BOARD

Flexo Folder Gluers Flexo printing machine

( if it is an RSC box (If more than two colour printing
and requires 2 colour printing) is needed)

if RSC box

Punching Machine
( It comes here if the box is other
than an RSC box)

Folder Gluer

Dispatch
80.What are the different types of equipments required for converting ?

The different types of equipments used for converting are

a. Flexo Folder Gluers
b. Printing ( Flexo) machine
c. Punching Machine
d. Folder Gluers
e. Sticthing / stapling machine

81.How is the Raw material sequence maintained on the corrugator to

achieve the specification of box determined at the design studio?

Every time the job order is placed it does not necessarily mean that the
manufacturer goes and buys one deckle of paper for few 1000 boxes. Here
the manufacturer combines the available raw material with him and then
makes a board specified strength and then passes it on to the converting
section.

Here the planning is on the shop floor and he always procures the deckle's of
paper based on his experience and his present dedicated client list.
If planning is not done for procurring of paper the amount of wastage is
enormous.

82.What are the different types of printing ?

Offset printing
Gravure Printing
Flexo Printing
Letter Press Printing
Screen Printing

83.Why you require a flexo folder gluer ?

Most of the jobs or we can say around 80 percent of the jobs are RSC boxes,
where as flexo folder gluers are meant for 2 colour printing and die cuting of
RSC boxes. Hence it becomes economical to have a machine which can
print, and die cut RSC boxes and paste them in line rather than having a
punching machine, folder gluer and a printing machine for pre conversion
activites.
This minimises the handling of different units

84.How does gluing action happen in the corrugator ?

It is caused by the pressure and the heat which develop the adhesive power
power of starch contained in the glue.
85.Where is the pre heater located ?

It is located between the roller stand and the single facer and the liner is
prepared for the gluing.

86.Where is the pre Conditioner Located ?

The preconditioner is loacted between the corrg. Medium roller stand and the
single facer.

87.Where are the single wall web heated while forming the 5 ply board and
why

The liner medium always touches the heating cylinders so that it gets heated,
the glue is applied on the flute medium of the other single facer board.

88. What is Doctor Roller and Applicator roller?

Applicator roller is the one which which applies glue to fluting medium by
taking the glue from the doctor roller.
Doctor roller is the one which which takes the glue from the glue pan.

89.Why is gap between the doctor roller and applicator roller reduced at
high speed?

The gap between the doctor roller and the applicator roller determines the
thickness of the glue film.when the speed increases the gap should be
reduced to maintian unifrom thickness of the glue.

90. What is rotary shear and where is it ?

It is the first unit between the double facer and the slitter scorer and is there
to remove the waste during order change.

91.What is the use of suction nozzles ?

Suction nozzles carry away the trim waste to the waste station. It is situated
just after the slitter and scoring section.

92.Why is the control desk situated at the cut off section ?

So that the flatness of the blanks can be checked immediately and any
corrective action if necessary can be taken on the respective units.
93. What is warping?

The bending of the board due to imbalanced moisture presence on any one
or more ply on the corrugated board.

94. What are different types of warping ?

1. length wise warp

2. Side to Side warp
3. S - warp

95. What is the general layout of an corrugated plant ?

Generator & water

Waste Collector softening plant
System
OFFICE &
QA Dept. C PAPER
O
Dispatch
R
W R REEL
& .
FLEXO FOLDER U
GLUER G
Storage I A STORE
Die Flexo printing T
Cutter machine . O
R
P
Folder Die Cutter
Gluer

96. What is graphics designing ?

As box has to help in selling the product to potential customers. The

asthetics of the box plays an important role. Hence good asthetics of the box
can be derived by good graphics and good box geometry/ shape.

97. What do you mean by dimensional tolerance of the product ?

Dimensional tolerance of the product is a function of :

a. Application and handling
b. Material used
c. Technology
 d. Environment Influence
e. Dimensional variation due to "inners"
f. Original length

98. What is crow feet

The cut which is rough and does not cut the board sharply leaving shredds of
liner and fluting or results in improper cutting is called as crow feet.

99. What do you mean by deckle ?

The paper web which is formed is known as deckle ( the web roll)

100.What is honey comb / or bubble effect?

This defect arises due to presence of moisture on the fluting medium,

because of which bubbles are formed on the board.

101. What is washboard effect on the board?

When the glue applied is excessive the final board which is formed results
in the sagging of the liner into the trough and crest of the flute. Hence
resulting in bad quality of board.

102. What is creep effect ?

When the deformation on the board is because of the continuos load of the
product. The deformation after this effect is very small.

103. What do you mean by delamination ?

The sepration of liner and the fluting medium due lack of adhesive action of
the glue is known as delamination.

104. What do you mean by cut flutes ?

This b'coz of corrugating rolls getting worn out, dirt or because improper
corrugating medium humidity.

105. What are the different types of printing ?

1. Offset printing
2.Gravure printing
3. Flexo Printing
4. Screen Printing
106. What are the questions asked when designing the box?

- what is the product and what is the packaging need.

107. What does the functional design encompass ?

The box should protect its contents in its journey from the factory to the
consumere. It should be strong enough to take the load of the boxes
stacked above each other and design should be user friendly to minimise
the chances fo mis handling. The main highlights are
internal dimensions of the box - example: the box
should neither be to long or to deep. Say if it is deep then it may result in
dropping of product inside the box as his hand is not reaching the bottom of
the box.
Box style - it determines how easily the product can
be packed inside the box and how th end user will use the box. The aim is
to provide the box which is user friendly throughout the distribution chain.

108. How can the structural design affect the Graphics of the Box?

This is aimed at arriving of optimium specifications for the boxes after a

careful study of product, packaging needs, warehousing, transportation and
handling systems

109. What is Extended glue lap joint and when is it required?

When there is an need to provide additional strength to the corrugated box

the glue flap is extended till the top flaps of the box. This extension is called
as the extended glue lap joint.

110. What is Flexo Printing ?

Flexo graphy is a printing process derieved from letter press printing. The
printing die is made up of flexible plates. It is a rotary printing method,
requiring the use of raised printing plates and fluid ink which dry quickly by
evaporation and absorption. This enables colour to be super imposed and
the sheets to be processed as soon as they have been printed

111. what is an Anilox roll ?

Anilox roll has always been considered as the heart of Flexographic printing.
They are engraved with a large number of small cells, the prupose of which
is to transfer a predetermined quantity of ink to the plates.
There are 3 types of Anilox rolls :
1. chemically etched rolls, not very much popular
 2. Rolls or cylinders which are mechanically engraved and then chrome
plated, in -order to increase their resistance to wear.
3. Laser - engraved "ceramic " cylinders. The advantage of these cylinders is
that the cells can transfer almost all the inks contained.

112. why are water based ink used more for corrugated boards?

Two types of inks are used for flexo printing:

1. water based , and
2. solvent based.

Solvent based inks are not used much for the printing of corrugated board,
because of fire hazard and some of them react with the flexible plates while
printing. These inks dry so fast that the printing station would have to be
enclosed so that the evaporation of the solvent is low.

113. Main elements for the making of the flexo inks are :

Pigments: each pigment has a specific characteristics which cannot be

modified and must therefore must be taken into account.
Additives :the properties to the inks are there because of number fo
additives like
a. Waxes - this improves the machanical strength
b. Anti foaming agents - It prevents the build of foam in the pump and
tanks.
c. Hydrophilising agents - they are use dto adjust the pH of the ink.
d. Special UV stabilisers are added if the box made of the board is to
be exposed to sun for quite some time.

114. Importance of the pH of Ink ?

When the machine is running the pH reduces , hence because of which the
viscosity of the ink increases. pH of the ink if low then the ink will dry to
quickly and then it also becomes cleaning activity difficult on the rolls.

And if the pH is high then the pigment will become destabilised and dry
time for the ink will be to high