In the world of corrugated cardboard production the corrugated single facer machine has emerged as a game-changer. This versatile piece of equipment plays an important role in creating the fluted layer that provides cardboard its rigidity and strength.
1. What is single-facer corrugated machine?
The single-facer machine is one of the vital pieces of equipment of the corrugated board production line. The forming standard of the corrugated board has a remarkable relationship with the right use and maintenance of the single facer machine. A single-facer machine is a cardboard machine that generates corrugated core paper. In the corrugated packaging industry, it is famous as the heart of the “corrugated cardboard production line”.
2. How do single facer corrugated machine work?
The basic single facer operation must perform the following.
- Permit for unwinding and controlling the single face medium and liner.
- Preheat/preconditioning the medium and liner to prepare them for the flute forming and bonding process.
- Form the flat medium web into its feature fluted shape
- Apply adhesive to the tip of the newly made flute
- Join the medium with the one face liner
- Transport the one face web into the bridge.
- There are 3 key points to be considered in single facer operation.
1) Unwinding and tension control
At the single facer corrugated machine, a roll of liner is placed on the single side of the station. A roll of the medium is placed on the opposite side. Each roll is supported by a roll stand that permits the paper to unwind freely as it is pulled into the one facer corrugated machine. Generally two roll stands exist for the liner and two roll stand for the medium. This makes it easy to operate one roll for use while other roll is unwinding.
Tension must be maintained on the paper as it unwinds to keep it tracking straight in to the machine and stop wrinkling. Continue tension is maintained by using force to brake mounted on the rotating core chunk that grip the roll in position. The brake force requirement change as the diameter of the roll is decrease.
2) Preheating & preconditioning
Preconditioning and preheating are the process of preparing the liner and medium, respectively for the fluting and the bonding by adding heat. Moisture and heat are included to the corrugating medium in the preconditioning process to soften the fiber and make the more pliable. This permit the flutes to form without losing or fracturing there shape. Heat included to the liner to start the gelatinization process of the adhesive.
3) Flute formation and bonding
Flute bonding and formation of the fluted medium to the single face liner happen in the single face corrugated machine. The general components of the single face process have remained essentially the same since the starting of the corrugated industry. The corrugating rolls are a set of grooved warmed rolls that mesh combine under force and impart a fluted shape to the medium as it passes via the nip. A hold-down mechanism keep the fluted medium in contact with the corrugating roll while an applicator roll uses a starch-based adhesive to the flute tip. A pressure roll secures the connection between singe face liner and corrugation medium to form single face web.
3. Advantages of single facer corrugated machine
Here are some of the key advantages of single facer corrugated machine:
1) Efficiency
One of the key advantages of the corrugated single facer machine is its efficiency. It can handle a big range of paper thickness and grades, permitting manufacture to produce different types of corrugated cardboard products. Whether it is easy shipping box or a complex display stand, the single facer machine can adapt to the specific needs of each product. Additional, this machine makes sure consistent and uniform corrugation, outcome in cardboard with superior durability and strength.
2) Precision
The precision of the corrugating rolls promises that each flute is formed to perfection, creating a powerful structure that can withstand the problems of transportation and handling. Additionally, the single face machine provides flexibility in terms of customization. Producers can adjust the glue application, flute size, and other parameters to meet their specific needs. This versatility permits them to cater to a big range of industries, from retail and e-commerce to electronics and automotive.
3) High strength
The single face corrugated machine plays an important role in the manufacturing process of cardboard, mainly contributing to the structural strength and integrity that are essential for shipping and packaging applications. One of the initial functions of the single facer machine is to make the corrugated or fluted layer, which is sandwiched between the 2 liner boards. This corrugated layer provides durability, ensuring that the cardboard can withstand many stresses during handling and transportation.
4) Reduce material waste
Another important advantage of using single-facer corrugated machines is the reduction of material waste. The accuracy and precision with which these machines run make sure that raw materials are utilized optimally, there reducing off-cuts and scrapes. This successful use of materials not just contributes to sustainability efforts but also better the full cost-effectiveness of the production process. By reducing waste, manufactures can lower their material costs and better their profit margins.
5) Advance technology
The integration of latest technologies in new single face machines permit for greater customization and control of the corrugated process. This adaptability make sure that the cardboard produced meets specific needs for various packaging needs, whether for heavy industrial items or lightweight consumer goods. As a result, single facer machine are best tools in the cardboard manufacturing industry ensuring that the end product is both economically viable and reliable.
4. Maintenance tips of single facer corrugated machine
Here are the key tips to follow to maintain your single facer corrugated machine:
1) Install the limit device
In the single facer machine on the corrugated board production line, when the corrugated board has been coated with adhesives and the corrugated board is connected to the face paper, a certain force between the pressure roller and the corrugating roller is required to make sure the bonding effect.
At present, many single facer corrugated machines do not have limit gadgets, some of which are unreliable, and some operators are not told prohibits the direct contact between the pressure roller and the corrugating roller, so the surface of the pressure roller is frequently destroyed. By installing the limit device and perfectly adjusting the pressure and gap between the pressure roller and the corrugating roller, the damage to the corrugating roller and the pressure roller caused by bad space control can be avoided.
2) Grinding
After the corrugating roller is worn, a stepped pattern will emerge on the roller surface. The center part of the corrugating roller wears the most. This results in uneven force on the pressure roller nips and makes it hard to use the glue evenly. To overcome this, a little amount (0.05mm) of material can be removed by grinding with diamond paste or from the ridge tip at the journal.
Anyway, this operation is extremely hard and needs a high level of expertise so as not to wear off the vital coating on the flute. A little jig made by some factories that can be mounted on a single facer corrugated machine to make grinding work more accurate.
3) Regular cleaning
Corrugating roll wear is reduced by removing paper dust, contaminations and carbonized adhesives. Practice has proven that attendance of metal particles with a diameter of more than 0.5mm will cause problem to the corrugated roller. The corrugating roller and single facer machine should be kept clean enough to avoid unnecessary big particles or impurities passing between the rollers. So, it is necessary to regularly clean the corrugating roller and machine.
4) Lubrication
Do not let the corrugating roller run lazily. If the production of the order ends and the paper needs to be out of order, the pressure should be quickly decomposed and stopped. If a single facer corrugated machine, it should keep rotating to lubricate the corrugating roller before stopping. Since pressure roller bearings and corrugating operate at high pressures and temperatures, right lubrication is a must. The lubricating system should be dismantled and checked every month to make sure the general flow of lubricating oil, so that the bearings can be rightly lubricated, otherwise the old bearings will cause vibration and cut down the life of the corrugating roller.
5. Troubleshooting issues and how to fix it
Here are some of the key issues and how to solve it:
1) Flute fracture
This happens during the forming of the flutes in the corrugating roller nip. It is generally observed as the single face web moves from the force roll nip up via the incliner conveyor. Likely causes are dry medium moisture content below 6.0 percent high tension somewhere in the medium path, or possibly an issue with the medium itself. Sources of high tension may be as follows:
- High brake at the roll stand
- Pre-conditioner running below paper speed
- Squeezing the roll with the roll chucks stand
- Issues with the splicer dancer mechanism
2) Low caliper
(1) Medium or liner caliper
The caliper of the medium and liner plus the flute height profile of the corrugating rolls determines what the top single face caliper can be. With change in pressing technologies and use of top performance papers, this caliper may no longer be what people are familiar with viewing.
(2) Tension
Similar to the flute fracture, high tension on the medium can cause bad flute formation and low caliper. Source of tension are roll stand brakes. Frozen or slow preconditioner, squeezing the roll with the roll stand chunk, and issues with the splicer.
(3) Heat
Sufficient head power must be accessible to drive moisture from the medium during the flute formation and set the memory of the flutes. Wet flute are more prone to crushing later in process.
(4) Pressure
Insufficient or uneven force exists along the corrugating roll nip, pressure roll nip or both.
(5) Excessive adhesive application
This may cause wet flute. Check roll parallelism M/A ratio, A/LCR ratio viscosity and starch temperature.
3) Blisters/ Delamination
These 2 issues are usually due to issue with heat transfer, insufficient heat accessible for bonding. Blister will happen somewhere within the web either continuously like a intermittently or streak. Delaminations generally cover a big area in the sheet or happen at the edge of the sheet.
6. Single Facer Corrugated Machine FAQs
1) Why single facer corrugated machine is so expensive?
The single facer is known as the heart of corrugated cardboard production line, making the medium into corrugated is the most vital piece in production. Just like the heart supplying blood for us, the machine supplies the most vital element single face corrugated board for production line, and 3/5/7 ply corrugated cardboard is consist of 1/2/3 layer with one layer linear paper.
2) What types of single facer machines are there?
There are two kinds of single facer machines, one is general traditional single facer machine, and the other is a latest type of cassette-type single facer machine. The traditional machine has a low investment cost and perfect for little and medium-sized cardboard producers. The cassette-type single-sided machine belongs to the heavy industries.
3) What is the base material of single facer corrugated machine?
The standard of the corrugated board produced by the single facer machine directly affects the carton production cost. The base paper is the key material for the production of cartons. About 75 percent of the carton production comes from raw materials. If the corrugated board produced by the single face is defective or unqualified, it means the waste of raw paper and other materials, a rise in production costs, and reduces in production profits.
7. End words
Single face corrugated machines are largely used in various industries such as home appliance & electronics, food & beverages, pharmaceutical industry, consumer goods, and others. These machines are used produce protective packaging for products, such as trays, boxes, and displays. The quickest growing application segment in terms of revenue is the food & beverages industry, as the demand for eco-friendly and a sustainable packaging solution is rising. These machines help in creating cost-effective and efficient packaging solutions for food products, ensuring their safety during storage and transportation.
