Influence of Corrugated Roller Shape Parameters on Carton Factory Production Cost
Under the current global economic crisis, many packaging companies have encountered unprecedented difficulties. How to tap the internal potential of the enterprise and control the production cost directly affects the survival of the enterprise. The carton factory executives have also used their brains in this regard, but they often neglect the influence of the corrugated roll's corrugated parameters on production costs. The amount of paper consumption and paste consumption of corrugated rollers directly affects the production cost of enterprises. For packaging companies, the cost of paper and glue accounts for 80% of the total cost, and the paper consumption rate and paste consumption are It is determined by the corrugation parameters of corrugated rollers. As early as a few years ago, many companies have recognized the importance of this problem, but there are still many manufacturers who do not pay enough attention to this problem. They often passively accept the corrugated roll type provided by the manufacturer or follow the tradition Flute type. Although it can also produce the corrugated paperboard it needs, it brings completely different results to the carton plant's product quality and cost of use, which directly affects whether the plant is profitable or lossy. In recent months, the author visited many packaging companies in North China, and found that many manufacturers are still using corrugated rollers with extremely high paper consumption. For example, the corrugation height of A tile is 4.8, the corrugation number is 35 teeth / 300 mm, and the paper consumption is more than 1.58. The corrugation height of B tile is also 2.8, and the paper consumption is 1.43. No one uses it anymore. Generally, the paper consumption of their A flute is about 1.50, and that of B flute is about 1.38. Some manufacturers use AC flutes with flute heights between 4.0 and 4.4, also known as small A flutes (with paper consumption of about 1.45) instead of traditional ones. A flute, even replaced with C flute with lower paper consumption (generally the paper consumption is about 1.42), the purpose is to reduce the cost of paper. When I asked the bosses of these northern manufacturers, why should I use such a high height? They replied: The thickness of five-layer cardboard of some of our customers is about 7.8. The author believes that there must be some trade-offs for such problems. If such customers account for less than 10% of the total number of customers. The first is to guide them. If they ca n’t do it, they should abandon them. They cannot increase the cost of paper consumption by 90% because of the 10% amount, which in turn leads to losses for the enterprise. The thickness of the five-layer cardboard is greater than 7.5, which is the previous standard. In the South, such a consensus has been reached: the thickness of the five-layer paperboard in combination of A and B is not less than 7, and the thickness of the five-layer paperboard in combination of B and C is not less than 6.5. Now the customer's requirements for the cardboard are good in feel, the cardboard feels firm, and it is not so sensitive to the thickness requirements. The reduction of consumables is also advocated and encouraged by the state, and the adjustment of the new carton standard also reflects this principle. For example, the A flute number is adjusted from 34 ± 2 to 34 ± 3, and the B flute number is adjusted from 50 ± 2 to 50 ± 4. It is also to implement this spirit and make the packaging company have more operating space. Let's talk about the corrugated roller's corrugated parameters, such as the number of corrugations, the height of the corrugation, the arc of the top of the tooth and the bottom of the tooth, etc. on the amount of paper used. Flute The number of flutes refers to several flutes per 300 mm on the national standard. The denser the flute number, the higher the paper consumption, and vice versa. Of course, the denser the flute number, the smoother the cardboard and the stronger the pressure resistance. The following table reflects the effect of flute number change on paper consumption under certain circumstances. According to Table 1, it can be seen that the shrinkage rate is increased by 3% for each additional tooth of the flute number (that is, 3 meters of corrugated paper is used for every 100 meters of cardboard produced). If the difference is 2 teeth, it is 6%. That is to say, under other circumstances unchanged, if A flute and B flute reduce 2 teeth every 300 mm, then the paper consumption of corrugated paper of five-layer carton drops by 12%. What kind of concept is this? If the price of corrugated paper is 110 grams and the price is 2,000 yuan / ton, the daily production capacity of the company is 100,000 square meters, which can save 1,320 kilograms / day of corrugated paper, which is 2,460 yuan / day. What month? What about a year? Counting is very amazing. The adjustment of the flute number should have a reasonable choice. The carton factory must first study what the customer has to do with the physical indicators of the cardboard. For example, what are the requirements of anti-stress? For example, Mengniu has relatively high requirements on the pressure resistance of its carton suppliers, so the number of corrugations of the carton should be slightly denser, otherwise the waiting for the carton factory can only be returned. However, if the customer only requires 150 kg of compression, and the processed cardboard can reach 250 kg of compression, this means that the additional 100 kg of compression is given to others in vain. The amount of paper used to achieve 150 kg of compression and 250 kg of compression is very different. How to properly match the relationship between the corrugated number and the corrugated number, so that the quality of the cardboard can be accepted by customers, and the cost of paper is more economical? This is a difficult problem. The company where the author is working is developing such a software, that is, in combination with the paper consumption of the carton factory, such as the weight and level of facial paper and tile paper, how much pressure can withstand the number of flutes high and the number of flutes. If it can be developed successfully, it will definitely help packaging companies. [next] The effect of flute height on paper consumption The corrugated roll's flute height has a huge impact on paper consumption. Tables 2 and 3 reflect the effect of flute height change on the shrinkage of A flute and B flute when the flute number is constant. It can be seen from Tables 2 and 3 that for every increase in flute height by 0.1, the paper consumption of A flute increases by 2%, and that of B flute increases by 2.5%. For corrugated cardboard, 9% less is used. Similarly, based on the above daily production capacity of 100,000 square meters, it can save RMB 1980 / day. If this is done, some customers will wonder whether such an operation will affect the quality of the cardboard? The author does not think so. Because tungsten carbide corrugated rolls can be used to replace traditional chrome-plated corrugated rolls, since ordinary chrome-plated rolls will produce concave wear after a period of time, the carton factory should appropriately add about 0.2 of the amount of wear when ordering corrugated rolls Virtual height. When it is worn out, it can be accepted by customers with the required height, and the tungsten carbide corrugated roller, because its corrugated height will hardly change, so it does not need to consider the amount of wear, and it is processed directly when ordering the corrugated roller Out of the acceptable height of the customer. This can save an imaginary height of 0.2 and reduce paper costs. The birth of tungsten carbide corrugated rollers is a milestone in the manufacturing of corrugated rollers. Not only does it have a long service life, but it also reduces the consumption of consumables for packaging companies, and the quality of the paperboards produced is stable and the loss is reduced. At present, most packaging companies in the south are using corrugated rolls of tungsten steel, and many manufacturers in North China are also using them. The influence of tooth top and tooth bottom on the removal rate The larger the tooth tip arc, the higher the paper consumption. Although its influence is not as obvious as the number of flutes and the flute height, it cannot be ignored. Table 4 reflects the influence of the change of tooth tip circle on the paper consumption rate when the flute height and the flute number are unchanged. It can be seen from Table 4 that the addendum arc is increased by 0.1, and the paper consumption is also increased by nearly 1%, and it has a greater impact on the amount of paste. Here, the author gives an example. The author company has a customer in Jiangsu, which has always used sharper tungsten steel rollers. When the tungsten steel rollers need to be repaired, they are temporarily replaced with ordinary chrome-plated rollers. A week later, he was surprised, why? When he sorted out the report, he suddenly found that 7 to 8 bags of starch were used every day (his line opened about 120,000 square meters a day), a bag of 25 kg of starch, and the price was about 2,000 yuan per group, which increased daily 8 bags of starch, a total production cost of 400 yuan. The reason is that the arc of ordinary chrome-plated rollers does not have the tip of tungsten carbide, and the amount of paste is of course larger. Of course, if it is made as sharp as a tungsten carbide corrugated roll, it will wear out quickly, and this boss would prefer to be sharper. Although the life of the corrugated roll is shorter, it is more cost-effective. A customer of the company in Shanghai made two pairs of tungsten steel corrugated rolls with the same corrugation height and the same corrugation number. The only difference is that the tooth tip arc is slightly different. Due to the dry climate in winter and the tendency to produce craters, he put the pair of rollers with a slightly larger top circle in winter. He fully recognized the impact of the change in top circle on the amount of paper and glue used. A pair of corrugated rollers is more than 100,000, but he saved more than a few tens of thousands. Of course, the control of the glue line is very related to the manufacturing accuracy of the corrugated roller, otherwise it is easy to produce false sticking. Choosing tungsten carbide corrugated rollers can reduce costs and cannot be ignored in other aspects of the equipment. For example, the reformation of the steam recovery device can reduce the fuel cost by 1/3; double slitting can reduce the loss of the carton factory when changing orders. Generally, a factory has at least more than 200 orders a day. Can save about 0.5% of paper cost. These inputs don't actually require a lot of money, and the costs can be recovered quickly. If the carton factory can pay attention to these issues, I believe it must have done very well. Eye Pads,Pure Cotton Eye Pads,Disposable Eye Pads,Medical Eye Pads COTTONWHISPER (TAIZHOU) DAILY PRODUCTS CO.,LTD , https://www.cottonwhipershop.com