Effect of corrugating roll type parameters on the production cost of carton factory
In the current global economic crisis, many packaging companies have encountered unprecedented difficulties. How to tap the internal potential of an enterprise and control production costs directly affects the survival of the enterprise. The CEOs of the carton plant are also brainwashed in this regard, but they often overlook the effect of corrugating roller squalling parameters on production costs. Corrugated rollers' paper consumption and the size of the amount of paste directly affect the production cost of the company. For packaging companies, the cost of paper and glue accounts for 80% of the total cost, and the paper consumption rate and the amount of food and paste are It is determined by the corrugating roll parameters. As early as a few years ago, many companies have recognized the importance of this issue, but there are still many manufacturers that have not paid enough attention to this issue, and they often passively accept the manufacturer's corrugating roller type or traditional tradition.楞型。 Although the same corrugated board can be produced, it brings completely different results to the product quality and the use cost of the carton plant, which is directly related to whether the plant is profitable or lossy. In recent months, the author visited many packaging companies in North China and found that many manufacturers still use corrugated rollers with high paper consumption. For example, the A-Watt has a height of 4.8, a number of turns of 35 teeth/300mm, a paper consumption of more than 1.58, a B-watt of 2.8mm and a paper consumption of 1.43. No one used it. In general, the paper consumption of A and B is about 1.50, while that of B is about 1.38. Some manufacturers use AC, which is between 4.0 and 4.4, to replace traditional ones, which are also known as small A (paper consumption is 1.45). A, even with a lower consumption of C 楞 to replace (usually paper consumption is about 1.42), the purpose is to reduce paper costs. When I asked the bosses of these northern manufacturers, why use such a high level? They replied: The thickness of some of our customers' five-layer cardboard is around 7.8. The author believes that for such problems, we must make a choice. If such customers account for less than 10% of total customers. The first is to guide them. If they can't give up, they can't give up 90% of the cost of paper because of the 10% of the amount, which leads to the loss of the company. The thickness of the five-layer cardboard is greater than 7.5, which is the previous standard. In the South, the consensus has been reached that the thickness of five-layer paperboard combined with A and B is not less than seven, and the thickness of five-layer paperboard combined with B and C is not less than 6.5. Nowadays, the customer's requirements for cardboard are good, the cardboard feels stiff, and the thickness requirements are not so sensitive. Reducing consumables is also advocated and encouraged by the state. The adjustment of new carton standards also embodies this principle. For example, the number of A turns from 34±2 to 34±3, and B楞 from the original 50±2 to 50±4. This is to implement this spirit and allow packaging companies to have more room to operate. The following is a detailed discussion of the ripple parameters of the corrugating roller, such as the number of turns, the height of the jaw, the arc at the end of the tooth tip, etc., which affect the amount of paper used. Number of turns The number of turns refers to the number of turns per 300 mm on the national standard. The denser the number of papers, the higher the paper consumption, and vice versa. Of course, the denser the number of turns, the flatter the cardboard, the stronger the resistance to pressure. The following table reflects the effect of the change in the number of turns on the amount of paper consumed in a given situation. From Table 1, it can be seen that for each additional tooth number, the shrinkage rate is increased by 3% (that is, 3 meters of corrugated paper is used for every 100 meters of paperboard produced). If the difference is 2 teeth, it is 6%. That is to say, if other conditions do not change, if A楞 and B楞 reduce two teeth per 300mm, the paper consumption of five-layer carton corrugated paper will decrease by 12%. What kind of concept is this? If corrugated paper is weighed at 110 grams and the price is 2,000 yuan per ton, the company's daily production of 100,000 square meters will save 1,320 kilograms of corrugated paper per day, or 2,460 yuan per day. What about that month? How about a year? Counting it is amazing. The adjustment of the number of turns should have a reasonable choice. The carton factory first needs to study what the customer has to do with the physical specifications of the cardboard. For example, what are the requirements for pressure resistance? For example, Mengniu has a higher demand for its carton suppliers in the pressure-resistance sector, and the number of carton boxes should be slightly closer. Otherwise, it can only be returned to the carton factory. However, if the customer only requires 150 kilograms of compressive strength, and the processed cardboard can reach 250 kilograms of compressive strength, this means that the additional 100 kilograms of compressive pressure is given to others in vain. The amount of paper used to achieve 150 kg of compression and 250 kg of compression differs greatly. How to properly coordinate the relationship between the number of high-quality products, so that the quality of cardboard can be accepted by customers, and the cost of paper is more economical? This is a problem. The company where the author is working is developing such a software, that is, combined with the situation of the paper used in the carton factory, such as the weight, the level of the paper, the level of the paper, how high the number of defects, and how many turns, can withstand much pressure. If it can be successfully developed, it will certainly help packaging companies. The effect of height on paper consumption The height of the corrugating roller has a great impact on the amount of paper consumed. Tables 2 and 3 reflect the effect of the high enthalpy change on the shrinkage rates of A and B in the case where the number of turns is constant. From Table 2 and Table 3, it can be seen that for each increase of 0.1 inch, the paper consumption of A waste increases by 2%, and the amount of paper consumed by B increases by 2.5%, which means that if A 楞 and B 楞楞 decrease by 0.2, five The use of 9% cardboard paper corrugated paper, the same daily production of 100,000 square meters, you can save RMB 1,980 yuan / day. If this is done, some customers will question whether this operation will affect the quality of the board. I don't think so. Because you can use tungsten carbide corrugating roller to replace the traditional chrome-plated corrugated roller, because the ordinary chrome roller will produce concave wear after a period of time, so the carton factory to order the corrugated roller should be appropriate to add 0.2 or so amount of wear, call it Virtual height. When it is worn out to be unusable, it has the required height to be acceptable to the customer, and the tungsten carbide corrugating roller will hardly change due to its twisting height. Therefore, it is processed directly when ordering the corrugating roller. The height that the customer can accept. This can save the virtual height of 0.2 and reduce the cost of paper. The birth of tungsten carbide corrugating roller is a milestone in the corrugating roller manufacturing industry. It not only has a long service life, but also enables packaging companies to reduce consumables, produce stable cardboard quality and reduce losses. At present, most packaging companies in the south use tungsten steel corrugating rollers, and many manufacturers in North China use it. The effect of tooth top and bottom on the dismantling rate The greater the circular arc at the top of the teeth, the higher the amount of paper consumed. Although its effect is not as pronounced as the number of turns and height, it cannot be ignored. Table 4 shows the effect of changes in the tip circle on the paper consumption rate with the same height and number of turns. Table 4 shows that the tooth tip radius 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 company has a customer in Jiangsu and has always used a relatively sharp tungsten steel roll. When the tungsten steel roll needs to be repaired, it is temporarily replaced with an ordinary chrome roll. One week later he was surprised. Why? Because he suddenly found in the finishing of the report every day starch to use more 7 packs to 8 packs (he's one line open 120,000 square meters a day), a pack of 25 kilograms of starch, the price is about 2,000 yuan / group, making daily increase 8 packets of starch, total 400 yuan in production costs. The reason is that the arc of ordinary chrome-plated rollers does not have the tip of tungsten carbide, and the amount of food to be eaten must be large. Of course, if it is made as sharp as a tungsten carbide corrugating roller, it wears out quickly, and the owner prefers to choose sharper, although the corrugating roller life is shorter, but it is more cost-effective. A customer of the company's company in Shanghai has made two pairs of tungsten steel corrugated rollers with the same height and the same number of turns. The only difference is that the tooth tip arc is slightly different. Due to the dry weather in winter and the easy occurrence of a crater, he used the pair of rollers with a slightly larger circle for winter use. He fully realized that the change of the top circle had an effect on the use of paper and the amount of glue used. A couple of thousands of corrugated rollers, but he saved more than a few hundred thousand. Of course, the control of the gluing line is closely related to the manufacturing accuracy of the corrugating roller, otherwise false sticking may easily occur. The use of tungsten carbide corrugating rollers can reduce costs and cannot be ignored in other aspects of the equipment. For example, the transformation of the steam recovery device can reduce the fuel cost by 1/3; double longitudinal cut can reduce the loss of the carton factory when changing the order. Generally, at least 200 orders per day in a factory, the loss cannot be ignored; The use can save about 0.5% of paper cost. These investments do not require a lot of money, and they will be able to recover their costs quickly. If the carton factory can pay attention to these issues, I believe it must be done very well.
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