Ref. 676 TAPPIt 1997-98 V.

Technical Information Papers

Corrugated Containers 0300
Table of Contents
TIP Title

Prefeeder quick reference specifications (English units)........................................... P. 3

Corrugator steam systems .......................................................................................... p. 11
Corrugator rolypressure roll journal failures ............................................................. p. 14
Computerization of maintenance department ............................................................ p. 21
Engineering economics using discounted cash flow ................................................. p. 22
Procedure for setting up a raw material trial on the corrugator ................................. p. 29
Boxplant quality measurement: why test? ................................................................ p. 32
Corrugated caliper: why is it so important?.............................................................. p. 33
Quality assurance of a corrugating adhesive: starch gelatinization temperature...... p. 34
Starch adhesive preparation and distribution systems: housekeeping ...................... p. 36
Warp in corrugated board ......................................................................................... p. 38
Some questions and answers on gel temperatures and on the gel temperature test
for corrugating adhesives ........................................................................................... p. 42
The edge crush (ECT) test: Its relationship to box compression and its derivation
from containerboard edge stiffness............................................................................ P. 44
Troubleshooting a glue lap problem .......................................................................... p. 47
Utilizing statistical process control techniques to assist in meeting specification at
finishing crush process control points to the paper and paperboard industries ......... p. 49
Obtaining combined board caliper off the corrugator for use in statistical process
control procedures...................................................................................................... p. 54
Statistical process control . procedures for charting warp .................................... p. 57
Statistical process control of starch gelatinization temperature................................. p. 66
Statistical process control of starch viscosity ............................................................ p. 70
Evaluating glue lap adhesives .................................................................................... p. 74
Addendum to Corrugating Defect Terminology Manual. defects related to the use
of fingerless singlefacers............................................................................................ p. 76
Viscosity reading procedure for flexographic corrugated inks .................................. p. 82
Curtain coating weight test ........................................................................................ p. 83
Calibration of flexible beam crush tester ................................................................... p. 86
Caliper measurement of corrugated board ................................................................. p. 90
Starch adhesive trial .................................................................................................. p. 93
Statistical process control pin adhesion..................................................................... p. 95
Calibration and maintenance of the burst tester ........................................................ p. 99
Understanding formaldehyde management ............................................................... p. 102
Common curtain coating problems: causes. detection. and correction .................... p. 105
Green peel bond test at the corrugator ....................................................................... p. 108
Rapid determination of moisture content in starch products ..................................... p. 111
Petroleum waxes used in the corrugated industry...................................................... p. 113
Calibration and maintenance of the manually operated micrometer ........................ p. 117
Splicer defects and cures .......................................................................................... p. 119
Causes and corrections of zipper bonding ................................................................. p. 124
Proper methods of measuring starch adhesive viscosity .......................................... p. 128

iii Corrugated Containers and Packaging

TIP Title

0304-34 Statistical process control: friction. slide angle ....................................................... p. 130

0304-35 Procedure for utilizing statistical control techniques to monitor the tare weight of a
run of boxes ............................................................................................................... p. 137
0304-36 Liquid caustic soda for starch adhesive preparation .................................................. p. 146
0304-37 How to prevent score cracking in a box plant ............................................................ p. 152
0304-38 Material safety data sheets, what to look for . how to understand them ................... p. 154
0304-39 In-line coating at the corrugator ................................................................................. p. 157
0304-40 Techniques for bonding of densified liners ............................................................... p. 161
0304-41 Understanding hazardous materials warning labels ................................................... p. 163
0304-42 Golno go gauge devices for the boxplant .................................................................. p. 166
0304-43 "High density liners...what are they?" ....................................................................... p. 168
0304-44 Using washup water as the vehicle in starch-based corrugating adhesive ................ p. 171
0304-45 A guide to proper wipe roll selection for the corrugated box industry ...................... p. 173
0304-46 Techniques for running " WRA (Water Resistant Starch Adhesive)........................ p. 175
0304-47 Bearing clearance checks and their impact ................................................................ p. 177
0304-48 Guidelines for training laboratory technicians ........................................................... p. 179
0304-49 Suggestions for developing a boxplant quality manual ............................................. p. 182
0304-50 Techniques to minimize twist warp ........................................................................... p. 185
0304-51 A source of information on the German "green laws" .............................................. p. 187
0304-52 Characteristics of starch (flow properties) ................................................................. p. 188
0304-53 Copper sulfate test for corrugator roll wear ............................................................... p. 190
0304-54 Measurement of rub resistance of a printing ink ...................................................... p. 192
0304-55 Corrugated boxplant - list of potential hazards .......................................................... p. 195
0304-56 Total indicated runout and its impact on combined board quality ........................... p. 199
0304-58 An explanation of the CONEG heavy metal guidelines ............................................ p. 201
0304-59 Important quality parameters of a printing ink .......................................................... p. 202
0304-60 A method to proof a printing ink ............................................................................. p. 204
0304-61 The role of copper in a printing ink ........................................................................... p. 206
0304-62 Checking the parallel of corrugating rolls with "NCR" paper................................... p. 207
0304-63 Determination of moisture in containerboard using a hand-held moisture meter ..... p. 209
0304-64 How to minimize rolling scores on lightweight and high-performance liners in
diecutting operations .................................................................................................. p. 212
0304-65 Conducting a corrugator temperature audit ............................................................... p. 214
0304-66 The impact of doublebacker hot plate level on board quality and how to measure it p. 216
0304-67 Reference system for technical information paper use ........................................ p. 218
0305-01 A two-minute lesson in computers ............................................................................ p. 220
0305-02 Computer-assisted machinery .................................................................................... p. 221
0305-03 Computer-assisted machinery glossary ..................................................................... p. 223
0305-04 Index and introduction to flexo folder gluerlrotary die cutter TIPS........................... p. 228
0305-05 Computer-assisted setup for flexo folder gluers ........................................................ p. 231
0305-06 Machinery considerations and selection .................................................................... p. 234
0305-07 Purchase order ............................................................................................................ p. 241
0305-08 Automatic strapping units .......................................................................................... p. 242
0305-09 Automatic feeders ...................................................................................................... p. 245
0305-10 Palletizers ................................................................................................................... p. 251
0305-11 Wastewater treatment equipment ............................................................................... p. 254
0305-12 Installation................................................................................................................ p. 258

iv Corrugated Containers and Packaging

TIP Title

Project leader .............................................................................................................. p. 265

Printing plates ....................................................................................................... p. 266
Ordering printing plates ............................................................................................. p. 268
Flexographic ink ........................................................................................................ p. 270
Importance of anilox rolls ......................................................................................... p. 272
Proper use of pull bands ........................................................................................... p. 276
Plate mounting systems ........................................................................................... p. 279
Preplanning checklist for rotary die cutting ............................................................... p. 281
Ordering cutting dies .................................................................................................. p. 283
Slot design for good stripping ................................................................................... p. 284
Rotary cutting die maintenance ............................................................................... p. 286
Storage racks for rotary cutting dies .......................................................................... p. 289
Buying, storing. and handling adhesives .................................................................. p. 292
Introduction to the flow chart .................................................................................. p. 295
In-process checklist .................................................................................................p. 298
Setup and run checklist ......................................................................................... p. 299
The need for planned maintenance ......................................................................... p. 300
Daily and month-to-date status report .................................................................. p. 301
Housekeeping at order and shift change and weekly ................................................. p. 302
Cleanup procedures for flexo folder gluerlrotary die cutters .....................................p. 305
Daily. weekly. and monthly maintenance checklists ................................................. p. 308
Rotary die cutter urethane anvil maintenance.......................................................... p. 314
Common operating problems and probable solutions: introduction.........................p. 316
Feed section................................................................................................................ p. 317
Printing section ........................................................................................................ p. 319
Diecutting section ...................................................................................................... p. 327
Reduction of ink smear on rotary diecutting.............................................................. p. 329
Slotting section ...................................................................................................... p. 330
Folding section .......................................................................................................... p. 335
Extruded glue mechanism supplement .................................................................... p. 338
Counter ejector section .............................................................................................. p. 341
Squaring flap cut (center special) boxes .................................................................... p. 343
Stacking off the rotary diecutter ............................................................................... p. 345
Multiple-out rotary diecut stacking ........................................................................... p. 347
Divider rails for multiple-out rotary diecut stacking ................................................. p. 351
Checklist: Preparing die cuts for shipment ............................................................... p. 352
The state of the art of feeders ..................................................................................... p. 355
Folder gluers ............................................................................................................. p. 361
Counter ejectors ....................................................................................................... p. 363
Machinery considerations and selection: yoked scoring slotting section ................. p. 365
Material handling considerations for flexo folder gluers ........................................... p. 367
The use and care of ink transfer rolls ....................................................................... p. 370
Pin register mounting ............................................................................................... p. 374
Photopolymer plate update ..................................................................................... p. 380
Glossary of flexographic terms ................................................................................ p. 384
Dryers and drying techniques for in-line diecutters ................................................... p. 421
SPC as it applies to corrugated flexo presses............................................................. p. 424

v Corrugated Containers and Packaging

0306-08 Automatic viscosity controllers for flexo inks ........................................................... p. 426
0306-09 Ink metering systems for corrugated flexo presses.................................................... p. 431
0306-10 Instruments for handling color ................................................................................... p. 434
0306-11 Quality techniques using existing equipment ............................................................ p. 437
0306-12 Anilox rolls: How do we keep them clean without harming them? ......................... P. 440
0306-13 Mounting procedures and equipment......................................................................... p. 442
0306- 14 Laser anilox cell configurations and angles .............................................................. p. 446
0308-01 Determining construction of corrugated board .......................................................... p. 450
0308-02 Edge crush comparison. waxed vs. neckdown.......................................................... p. 457
0309-02 Troubleshooting guide - corrugating......................................................................... p. 460
0800-01 Units of measurement and conversion factors ........................................................... p. 465

vi Corrugated Containers and Packaging