WHITE PAPER -Corrugation & board printing improvement plans

101, VALLEY FIELD COURT, KOROSHO ROAD, off-Gitanga Road Kobil

petrol station, NAIROBI – 00604, P.O. BOX: 23365

PIN: P 051523207T Contact cellular: 0736322749 / 0786403634 Land line: 020-

5291385

1 | P a g e C r e a t i n g t h e t u r n a r o u n d a l g o r i t h m

The White Paper on the corrugation industry

This white paper is a commentary on the initiatives that can transform the corrugation industry for good

irrespective of the technology level at the disposal and the skill sets of the work force involved in the

routine operations so long as the spiritual connect to bringing in the fundamental changes is reinforced

and strengthened on a designed note.

This document is set apart in as much as the inputs come from the perspectives of mechanical and

electrical engineering besides the process aspects of paper technology and the structural changes within

the paper in the various stages of the conversion cycle.

The commentary has been differentiated into the corrugation and the printing features with segmented

approaches to the main corrugation machine and the similar engineering aspects of the printing

machinery.

A. Corrugation

1- Key determinants

1.1. Heat transfer and consistency

1.1. A – Properties of paper

a) The paper is hygroscopic and cellulosic in nature with high moisture regain properties implying that the

heat is gained and lost very effectively in shorter cycle times.

b) The granular structure of the paper varies with the source, pulp processing parameters and more

importantly the operating conditions in the paper mill. A close-knit granular structure causes closing in

the gaps and shunting out entry points for the moisture on the surface while the vice versa is true for a

loose-knit structure. Similarly for virgin paper, the properties are consistent across cross-sections and

hence the pattern of moisture regain as well as the linear expansion are predictable and do vary on a much




5291385


narrower bandwidth while the recycled composites are varying on the above mentioned properties on a

wider bandwidth.

c) The paper tends to expand on both the lateral as well as along the direction of the paper flow (MD-

machine direction); the extent of expansion being determined by the differential heat and the granular

structure of the paper composite; a close knit structure expanding less and vice versa.

d) The penetration of the moisture as well as the effective escape are determined by the mechanical

tensioning of the paper during the run since this tensioning is all important in creating the interstitial

spaces to allow free exchange of moisture radicals and help the board achieve the moisture equilibrium

and hence dimensional and tensile stability.

e) The pre-tensioning of the paper is achieved by the combination of the mechanical and thermal stresses

built up in the paper – both liners and right through the corrugation prior to the bonding. This is of

singular importance for enabling the migration of the glue into the paper at different stages in the line at

elevated speeds.

1.1. B – Steam quality

a) Fuel has to mix with air to get the right combustible mix that determines the rate of combustion in the

furnace of the boiler and the consequent transfer of the heat through the fire tubes to bring the water into

ignition point and eventual change in the state. The variations in the right fuel-air mixture are the bane of

inconsistent combustion and the resultant drops in effective steam pressure and heat transfer on the line.

b) Furnace oil or all fossil fuels tend to degrade with movement and generate contaminants in the flow

stream that increase the friction owing to the resultant concentration of the static charges in the fluids.

Frictional enhancements actually elevate the enthalpy in the system and increase the sensible heat;

otherwise known as the temperature of the fluid – an important condition that in turn accelerates the

chemical degradation process thereby creating a vicious cycle. All of these lower the combustibility of the

fuel and hence adversely affect the quality of steam and the heat transfer onto the paper of different




5291385


denominations. Variations in heat transfer influence the degrees of expansion of the paper causing

fundamental instability in dimensions and moisture equilibrium.

c) The bio mass fuels vary significantly in the structure of the briquettes and the combustibility owing to

the composition variants and the compactness that influences the air-fuel ratio in the furnace. The control

of the bio mass fuels in creating the right ignition dynamics in the fire tubes is the key determinant for

ensuring the consistency in the steam pressure in the boiler and the consequent transfer of heat.

d) The hot plates need insulation with material that is resistant to temperatures of around 200 degrees

Celsius to enable heat transfer consistency. Heat losses in the pre-heater and the corrugation zones are

critical in determining both the line speeds and the quality of the paper as it transform during the board

making process.

e) The corrosion of the steam pipes and line leakages cause pressure drops that are vital control points to

enable the process to be consistent so far as the quality of heat transfer is concerned.

1.1. C – Pre-tensioning of paper at all pre-heater zones

a) The paper wrap tensioning around the pre-heater is defined by the quantum of tensioning achieved

around the curvature; not always adequately determined by the tensioning device provided with the pre-

heater but more by the lack of suctioning on the paper prior to the wrap; an essential yet not part of the

OEM design. This lack of adequate pre-tensioning as part of the design of the machines is an important

deterrent in getting the right consistency of temperature across the segments of the width of the paper

thereby leading to a fundamental differentiation in the paper expansion properties.

b) The lateral balancing of the pre-heater roller also varies the tension on the paper around the wrap

curvature and needs control for effective tensioning of the liner as it approaches the bonding area.

c) The dynamics for the corrugation paper also remain the same to define the right pick up of the profile

around the wrap and also to facilitate the penetration of the glue in the composite formation at the right

elevated line speed. The pre-tensioning of the paper has a profound impact on the usage of the white

paper that has fundamentally different characteristics with that of the traditional brown paper. Composites

between different types of paper traditionally lead to lowering of line speeds on conventional terms.




5291385


1.2. Drive quality

1.2. A – Effective electromotive force for the mechanical transmission

a) The PF (power factor) is the discounting factor determined by the real power and the apparent power as

defined by the cosine of the phase angle. The PF =0 implies that the apparent power is a vector that

compensates the real load completely and hence the real load is almost non-existent while the PF =1

implies that the real load predominates with very low or non-existent apparent power. Low PF has

ramifications on a declining electromotive force that results in vital transmission losses in the mechanical

realm. The major impact in the corrugation line is that on the corrugation roller itself and the drives on the

hot plate as also on the down stacker. Low PF, in a nutshell, results in rpm (revolutions per minute) losses

in the driven corrugation roller that in turn affects adversely the friction-driven roller as well.

b) The major impact of the transmission losses is on the nature of the collisions – that can fundamentally

be resolved into HILF (high impact and low frequency collisions) and LIHF (low impact and high

frequency collisions). These collisions increase in varying intensity along the trajectory of all frictional

contact coordinates causing differential levels of wear and tear and more importantly loss of contact

curvature between the paper and the corrugation roller. This is the singular factor that defines the profile

of the flute on the paper and the consistency of the curvature at elevated line speeds. The major deterrent

of line speed is the loss in curvature around the corrugation roller as explained above.

c) The collisions are known to adversely impact the drive assembly around the bearing points and the

roller neck on a mechanical realm while also increasing the heat generated on the hydraulic systems that

eventually degrade the quality of the oil and lead to variations in the pressure roller itself across the lateral

direction thereby further limiting the line speed elevation.

d) Weaker paper configurations are often observed to be crushing around the corrugation roller curvature

and are fundamentally caused by the jarring effect of the paper collisions onto the roller around the

curvature coordinates.




5291385


e) The migration properties of a given glue chemistry are adversely affected when the substrate is in a

state of disequilibrium caused by the magnitude of these vibrations or collisions.

1.2. B – High CF and consequent damage to the cables and armature wiring

a) The lowering of PF always causes a higher current to be drawn while yet generating a significantly low

load and hence the load generation efficiency drops causing high CF (crest factor) to be developed

implying that the peak current is higher for a given magnitude of the base current. High CF is always the

major cause for generating unabated thermal stresses in the cables and the armature wiring of the motors

causing the eventual micro-rupture points that lead to current leakage way before the actual burning sets

in. Thus, in effect, a virtual cycle of low PF, high collisions intensity and high CF rolls in causing all-

round electro-mechanical damage to the drive systems that have large impact on both the in-process

quality and the line speeds in the corrugation.

b) The impact of low PF and consequent high CF on the hydraulic systems of the pressure roller and the

hot plate loading cannot be understated. All of these vicious cycles cause the hydraulic oil temperatures to

rise substantially thereby accelerating the chemical degradation process and eventual loss of transmitted

hydraulic load and subsequent damage to seals and the lowering of the flux strength of the solenoids.

c) The board making process requires uniform heat across the lateral segments of the paper and the

minimized curvature vibrations of the paper all along to ensure bond strength and expansion differential

on a narrower bandwidth and all of these can be assured through initiatives to maintain the engineering

derivatives of the machine as explained above.

1.2. C - High THD% in the non-linear profile of the drive systems

a) Harmonic distortion causes the fundamental sinusoidal curve of the AC current to be distorted thereby

increasing the energy curve area and more importantly leading to major collisions in the mechanical

drives that receive the electromotive forces to begin with through these drives.

b) Load profiles are fundamentally nonlinear in nature around the corrugation, the pressure roller, the hot

plate and more importantly at the down stacker causing the generation of high THD% all along. This

leads to all of the above mentioned symptoms of low PF, high CF and thermal stresses in the drives.




5291385


c) The PFC bank gets stresses on the capacitive load utilization since the incoming PF requires heavy

compensation all along. This factor is often ignored blissfully without being aware of the consequences

and the serious implications on the machinery health and performance with direct impact on the quality of

the board and the line speeds.

1.2. D – Line leakage on hydraulics and pneumatics

a) The non-linearity of the load dynamics always causes stresses to alternate between peaks and

extremely low points causing the pathways to be stressed for both the hydraulic and the pneumatic lines.

b) Non-linearity of load also gives rise to differential rates of oil degradation in the hydraulic system and

pressure drops in the pneumatic lines; both causing micro-rupture coordinates to be developed along the

transmission lines. Contaminants in the oil caused by the chemical degradation and the residual micro-

dust released by the pressure drops in the pneumatic lines are the primary reasons that influence the

strength of the pathways and eventual decay in the walls causing the loop to be adversely affected.

c) The affected quality and productivity points are the pressure roller, the creasing blocks and the rubber

rollers that guide the boards after the NC cutter zone. The pneumatic and hydraulic solenoids in the

corrugation line get adversely affected owing to these issues

1.2. E – NC cutter drives

a) The mechanical quality of the knives and the fitment bolts are the key determinants in the performance

of the drives. The bolts get worn out owing to the abrasive effects on the threads and cause collisions

within the bolt- anchor systems. The quality of cutting gets affected and the system has a bumpy effect at

higher speeds causing the drives to peak and fail intermittently.

b) The quality of gear oil in the NC cutter systems also define the performance of the drives in as much as

the mechanical fluidity defines the performance characteristics of the drive.

c) The drive performance directly affects the quality of edges of the boards and the line speed capabilities

in the system but is linked primarily to the mechanical quality of the elements constituting the system.




5291385


1.2. F – Synchronized drive systems

a) The belt synchronization is an important component of the productivity mechanism and is influenced

by the quality of suction in the blower, the friction in the pathways of the drive systems and the ratio of

drives as a function of the board density (linear) and cut outs.

b) The hydraulic systems of the down stacker define the performance of the motor on the quality of power

as well as the cabling properties that determine the transmission of the non-linearity of the load.

2. Pathway for solutions

a) The templates clarify the actions with a purpose.

b) The actions are designed to provide guaranteed solutions that are reproducible irrespective of the

technology by and large.

c) The actions are time bound and are founded on the engineering principles.

101, VALLEY FIELD COURT, KOROSHO ROAD, off-Gitanga Road Kobil petrol station, NAIROBI – 00604,

P.O. BOX: 23365

PIN: P 051523207T Contact cellular: 0736322749 / 0786403634 Land line: 020-5291385


CORRUGATION APPLICATIONS FOR PRODUCTIVITY AND WASTE % BOOST

Key

parameter Influence Ideal state Impact Recommended activity

Heat in

line

Quality of paper

bonding, strength,

heat distribution and

line speed

195 - 200 degrees celsius

to mainatin

Line speeds - 120-150 mpm for 3-ply and

100-120 in 5-ply

Weekly maintenance of the

boilers

B-flute

motor &

suction

motor

Flute profile, paper

speed, bond strength

>15kW load + >0.65 PF

for B-flute motor and> 4

kW load + >0.65 PF for

suction motor


100-120 in 5-ply

Suction hood cleaning -

weekly, regular readings on the

kW of B-flute and suction

motors, rpm check for the

corrugation roller,

Doctor

roller -

glue

applicator

roller

Bond strength and

calliper

Calibration accuracy and

standardized glue gap

applcatiosn for paper-

specific uses


100-120 in 5-ply

Weekly calibration required

with feeler gauges and religious

monitoring of the profile of the

cylinder with three gauges -

0.3/0.5/0.6 (mm)


P.O. BOX: 23365



Key


Hydraulics

for

pressure

roller

pressure roller load

transmission onto the

paper

Oil temperature < 60

degrees clesius

Low incidence of leakage, preservation of

oil seals and cylinders

Tracking temperatures and

cooling with oil radiators,

periodic replacement of seals

and servicing of the cylinders

and solenoids- once in three

months

Double

backer

paper reel

Paper tensioning to

ensure good path

stability

Dedicated suction fan

needs to be in place for the

reel to pass through so that

a pre-tensioning ensures

good trajectory

Currently, with white papers, the brown

paper is never wrapped around the pre-

heater to allow equilibrium of heat between

the white and brown at the bonding zone;

with suction on white paper, the wrap

around the pre-heater shall be significantly

better causing the equilibrium to be

achieved - that shall ensure that both the

white and brown papers are bonded well

with high heat - an essential quality and

productivity determinant in the line

Suction fan to be installed

above the pre-heater

All papers need to compulsorily

pass through the suction prior

to wrapping around the pre-

heater


P.O. BOX: 23365



Key


Hot plate Bond strength and

line speed

Ballast rollers need to be

balanced out on both the

drive and operator sides

along the racks

The line speeds can be increased with high

end quality by around 20%

Weekly check with the level

during PM and correcting for

anomalies

The oil temperature

should be < 50 degrees

celsius through oil

radiators and dosing of

the oil bath with hot car

engine oil at 70-80

degrees celsius @ 1.5%

The cooled oil shall maintain the seals and

the solenoids- mechanically

Daily checking out on the

temperature and maintaining

the same within the prescribed

limits

Solenoids should be

checked periodically for

flux strength and key

electrical indicators

The maintenance of solenoids for

functioning is the key to achieving line

speeds at high bond strength and flute

calliper in the hot plate zone

Weekly check of the electrical

indicators during the PM


P.O. BOX: 23365



Key


Slitter

zone

knife sharpness ,

alignment with the

paper through

activation of the pre-

roller IN-PROCESS

COMPLAINTS OF

ROUGH EDGES

Grinding of stones after

each shift / checking for

alignment after each shift

The bolts should be changed with fresh taps

once each month to maintain the

concnetricity of the knife positioning and

the alignment with the paper

Reviews and corrections during

the weekly PM

The pneumatic pressure quality needs to be

checked once in a week for leakages and

corrected during the PM

The quality of compressed air needs regular

weekly checks and corrections during the

PM interventions

Key

parameter Influence Ideal state Impact

Creaser

zone

profile sharpness,

alignment with the

paper through the


Working on the profile of

the creaser rollers once in

three months



concentricity of the knife positioning and



P.O. BOX: 23365



roller, QUALITY

COMPLAINTS OF

MISSING

CREASING

The pneumatic pressure quality needs to be

checked once in a week for leakages and

corrected during the PM

The quality of compressed air needs regular

weekly checks and corrections during the

PM interventions

NC cutter

profile sharpness,

alignment with the

paper through the


roller, IN-PROCESS

COMPLAINTS OF

POOR CUTS

Blade alignment- once

weekly during PM and

grinding daily once in 24

hours



concnetricity of the knife positioning and


Monthly

The gear oil should be checked for

temperature daily and controlled within

limits

Daily.

The rubber rollers should be maintained for

transmitting pressure and pneumatic

leakages for effective drive transmission

and reduction of load on the AC drives

Weekly during the PM

Additional

pre-rollers

These need to be mounted along the DF and on the passage to the creasing and slitting zones to ensure better paper control - this

shall improve significantly on line speeds and shall help the cut2mark jobs achieve higher speeds


P.O. BOX: 23365



Key


Down

stacker

Hydraulics

Oil temperature < 60

degrees Celsius, good

solenoid strength and

other electrical indicators,

pump characteristics

through flow rate

monitoring as indicated by

gauge, nitrogen usage

monitoring through

pressure gauge

Movement of the railing should be tracked

both ways for timing in coordination with

line speeds to monitor the impact

Daily tracking of indicators

with weekly servicing of

solenoids and corrections

Motor > 20 kW and PF > 0.70

consistently




5291385


2.1. B – Incentive scheme with fundamental integration of the work force


P.O. BOX: 23365



SIMULATED PLANT PERFORMANCE OVERLAPPING ORGANOGRAM - FLOOR

MANAGEMENT

KPIs TARGE

T

ACTUA

L

VARIANCE(

+/-)

PARAMETR

IC

WEIGHTED

VARIANCE

SCALA

R

SCORE

Paramet

ric

weight

Operations

Functio

ns

Producti

on

Maintenance

(Mechanical &

Electrical)

Quality

Control

Node

Matrix of Shift Manager - QA

Manager- Plant Superintendent

Players

Shift

Supervis

or -

Team

Captain

Team-Captain

VC - I/C

VC-

MAINTENAN

CE

VC-

QUALI

TY

Tonnage 110 115 0.0455 0.0452 1.0463 0.995 1 0.5 0.5

Waste% 5 4.7 0.0600 0.0597 1.0615 0.995 2 0.5 0.5

Downtime

% 0.2 0.1 0.5000 0.4950 1.6405 0.99 3 0.5 0.5


P.O. BOX: 23365



MTBF 1000 1100 0.1000 0.0990 1.1041 0.99 4 0.5 0.5

MTTR 0.25 0.15 0.4000 0.3960 1.4859 0.99 5 0.5 0.5

Warped % 0.02 0.02 0.0000 0.0000 1.0000 0.998 6 0.5 0.5

Flute

depth 0.1 0.1 0.0000 0.0000 1.0000 0.998 7 0.5 0.5

ECT 0.1 0.25 -1.5000 -1.4970 0.2238 0.998 8 0.5 0.5

Moisture

% 0.1 0.22 -1.2000 -1.1100 0.3296 0.925 9 0.5 0.5

Glue

strength 0.1 0.15 -0.5000 -0.4990 0.6071 0.998 10 0.5 0.5

PLANT

SCORE 95%

Derivativ

es 0 Rule XY

X Rule X/0

Y X

Z Z




5291385


2.1. C – Printing solutions

a) These are real time solutions with performance guarantees.

b) The principles of mechanical and electrical engineering are brought into focus to get the real time

results.

c) The reproducibility of the results is across technologies and is fundamentally universal in application.


P.O. BOX: 23365



PRINTING ROADMAP FOR PRODUCIVITY AND WASTE % BOOST

Key parameter Influence Ideal state Impact Recommended activity

Slotting block Quality of printed

cartons

Perfect slot profile is

dependent on the slotting edge

sharpness and applied pressure

Printing line speed IN PB/MIN

can be increased by 20% through

productivity enhancements and

minimized stoppages

Slotting units should have the

anchor bolts replaced at

periodic intervals of one

month with fresh taps

The leveling shall ensure that

lower pressure is applied in

the slotting unit - a vital

requirement to ensure that the

crushing of boards do not

happen

On each PM, the alignment

with the engineering level

(sensitivity 0.3mm.meter)

needs to be done

The positiong of the slotting

unit and the retention of load

curvature during the

revolution are important

derivatives

The bolts need to have spring

washers all over for damping

the vibrations

Creasing block Quality of printed

cartons

Perfect alignment shall

prevent differential wear of

the rubber on the creasing

Vibrations of the frame need to

be monitored at each of the units

- the slotting, creasing, the anilox

Same as for the slotting unit


P.O. BOX: 23365



block and the arms of the locking

system and closely controlled

within 5% deviations - that is the

only way of ensuring life of

critical spares and trouble-free

runs in the process Anilox rollers Quality of printed

cartons

Registration of good

impressions

Cleaning of the anilox rollers

with hot car engine oil and

scrubbing the engraving

manually and gently to

eliminate the micro-particles

that are usually embedded in

multiple layers

Sharpness of the color profile

Color projection and

reproducibility of color

composition

Ink Pump cleaning with

flexowash fluids - cold state

Ink chamber

Quality of

impressions and ink

transfer

Color consistency

Ink anchor bolts should be

changed periodically with

fresh taps - preferably

monthly

Spring washers need to be in

place


P.O. BOX: 23365



Chamber washing should be

done twice a week to prevent

corrosion

Counter ejector Accuracy of material

transfer

Drive motor load - > 7 kW

with PF > 0.65

Cylinders and pneumatic

solenoids need to be serviced

once in 3 months

Pneumatic leakages along the

network in the counter -ejector

need to be plugged at a

minimum

Electrical indicators for the

pneumatic solenoids need to

be tracked on a weekly basis

Locking system

Quality of

impressions and

creasing / slotting

The load should be optimum

with minimized or non-

existent leakages

Pneumatic cylinders need to

be serviced on a monthly

basis

The quality of compressed air

needs regulation, monitoring

and controls

Leakage detection through

the ultra-sonic detection

needs to be on a weekly basis




5291385


2.1. D – Printing and finishing incentive scheme – the simulation

a) The cross-functional teams are forged to create better work systems and work flows for improved

accountability.

b) The accountability indices are crystal clear and easily understandable so that the stake holders can put

in their best efforts to make things work.

c) The operational indices are linked up to the financial performance data to ensure that the loop is

complete and the plant is integrated in the approaches to success.


P.O. BOX: 23365



SIMULATED PLANT PERFORMANCE - Printing OVERLAPPING ORGANOGRAM - FLOOR

MANAGEMENT

KPIs TARGE

T

ACTUA

L

VARIANCE(

+/-)

PARAMETR

IC

WEIGHTED

VARIANCE

SCALA

R

SCORE

Paramet

ric

weight

Operations

Functio

ns

Producti

on

Maintenance

(Mechanical &

Electrical)

Quality

Control

Node

Matrix of Shift Manager - QA

Manager- Plant Superintendent

Players

Shift

Supervis

or -

Team

Captain

Team-Captain

VC - I/C

VC-

MAINTENAN

CE

VC-

QUALI

TY

OC

conversio

n rate

0.95 0.88 -0.0737 -0.0733 0.9293 0.995 1 0.5 0.5


P.O. BOX: 23365



Waste% 0.05 0.064 -0.2800 -0.2786 0.7568 0.995 2 0.5 0.5

Downtime

% 0.2 0.1 0.5000 0.4950 1.6405 0.99 3 0.5 0.5

MTBF 1000 1100 0.1000 0.0990 1.1041 0.99 4 0.5 0.5

MTTR 0.25 0.35 -0.4000 -0.3960 0.6730 0.99 5 0.5 0.5

Rejection

% 0.002 0.004 -1.0000 -0.9980 0.3686 0.998 6 0.5 0.5

BCT 0.1 0.1 0.0000 0.0000 1.0000 0.998 7 0.5 0.5

Flute

Gradient 0.1 0.25 -1.5000 -1.4970 0.2238 0.998 8 0.5 0.5

Slot

quality 0.9 0.88 0.0222

Moisture

% 0.1 0.22 -1.2000 -1.1100 0.3296 0.925 9 0.5 0.5

Glue

strength 0.1 0.15 -0.5000 -0.4990 0.6071 0.998 10 0.5 0.5

PLANT SCORE 76%

Derivativ

es

0 Rule XYZ

X Rule X/0/Z

Y X

Z Rule X/Y/0




5291385


2.1. E – Electrical maintenance

a) The fundamentals of maintenance are related to condition based maintenance and not breakdown

trouble shooting. The core issues boil down to generating the check sheets to work on with decisions

founded on sound data interpretation of scientific approaches of statistical analyses.

b) The presence of cross-functional work groups is vital to enabling the teams to achieve more in real

terms.

c) Cross-functional data linked with the quality derivatives always help us migrate to higher levels of

performance with the given technology.


P.O. BOX: 23365



CRITICAL ELECTRICAL MAINTENANCE COMPONENTS

Key parameter Influence Ideal state Impact Recommended activity

Power surge protection

systems Stability and low breakdowns

Logging of trends

for proactive

corrective

measures

Breakdown %

reduction shall be

more than 50% from

current levels with

immediate effect -

both mechanical and

electrical breakdowns

are linked and

integrated

Logging in energy

analyzer data and

comparing with

mechanical data of

vibration and thermometry

Electrical / electronic signal

activity tracking

Monitoring and improving on the

mechanical performance of the

machinery

Initiating corrective

measures wherein

deviations are more than

5%

Motor performance

Critical influence on mechanical

performance

Thermometry of circuitry

tracking for current and

cable leakage along the

entire equipment as well as

in the mains distribution

Drive performance

Circuitry maintenance -

MCBs, contactors and

relays




5291385


2.1. E – Condition Based Maintenance Systems (CBM template for the corrugation industry)

SECTION-A: MAIN DRIVE – MECHANICAL CHARACTERISTICS

Product features B-flute main drive motor performance (mechanical)

B-flute main drive motor RPM transmitted

Paper specs Line speed Motor shaft

vibrations

Motor

bearing

Bottom

corrugation rpm Top corrugation rpm

12 75 43 45

8 73 51 47

12 69 44 43

14 71 47 44

11 77 45 48

-0.64 -0.95 -1.26 -2.22




5291385


SECTION-B : MAIN DRIVE – ELECTRICAL CHARACTERISTICS

B-flute drive motor - Energy Analysis (electrical)

PHASE

Plastics - 349 MODEL M/C - fundamental

energy data

Plastics - 349 MODEL M/C -

Power Quality Data

AMPER

ES

VOLTA

GE

THD

% KW

KVA

R

KV

A PF

tan

Phas

e

Ang

le

Pea

k i

RM

S

CF

(Cres

t

Facto

r)

R 15 418.4 7.10

%

34.3

1

38.3

3

33.2

5

0.8

1

0.6

3 64

79.

5

14.9

5 5.32

Y 10 418.4 4.88

%

79.

5 9.6 8.28

B 19.21 418 6.52

%

79.

5

19.2

1 4.14

PHASE

IMBALAN

CES

100% 0% 45%

100

%




5291385


SECTION-C: HYDRAULIC PERFORMANCE INDICATORS

Hydraulics Performance

Hydraulic

motor

Hydra

ulic

Oil

tempe

rature

Hydraulic

Hose Drive side cylinder

Operator side

cylinder

Pressure

roller

gauge

M

oto

r

sha

ft

Mo

tor

bea

ring

Low

(2.5/

10)

sensi

tivity

Medi

um

(5/10

)

sensi

tivity

High

(7.5/

10)

sensi

tivity

Low

(2.5/

10)

sensi

tivity

Medi

um

(5/10

)

sensi

tivity

High

(7.5/

10)

sensi

tivity

Low

(2.5/

10)

sensi

tivity

Medi

um

(5/10

)

sensi

tivity

High

(7.5/

10)

sensi

tivity

Dri

ve

side

pres

sure

roll

er

gau

ge

Ope

rator

side

pres

sure

rolle

r

gaug

e

12 65 72 0 22 30 2 13 15 7 22 30 22 18

10 72 75 0 21 25 2 12 10 10 21 25 18 17

8 68 73 2 20 22 1 10 12 12 20 27 18 19

11 62 69 2 20 25 1 10 15 8 20 25 25 20

12 65 67 3 22 30 2 12 12 7 18 27 22 20

-

0.3

6

0.9

5 -0.38 2.68 -1.00 -1.82 6.21 6.41 5.63 -1.75 -0.13 -0.88 0.33

-

0.92

0.30 1.50 -0.29

135% 446% 75%




5291385


3. Analysis of outcomes for the interventions done hitherto in Plant – A

3.1 Corrugation productivity

ILLUSTRATION-A: RAW DATA COMPARISON THROUGH 2015

PERIOD PRODUCTIVITY TREND IN THE

CORRUGATION IN 2015 IN PLANT-A G

AIN

/ L

OS

S %

REGULAR

PERIOD

Jan 71,785.396

70,339.521

Feb 70,552.333

Mar 72,275.490

Apr 65,347.451

May 71,710.346

Jun 67,222.196

Jul 73,827.957

Aug 69,171.520

Sep 71,163.000

INTERVENTION

PERIOD

Oct 73,727.333

74,291.338 6% Nov 74,288.255

Dec 74,858.426




5291385


ILLUSTRATION – B: GRAPHICAL TRENDS ANALYSIS OF REAL TIME DATA

y = -0.881x4 + 12.07x3 + 136.5x2 - 1737.x + 73563R² = 0.442

60,000.000

62,000.000

64,000.000

66,000.000

68,000.000

70,000.000

72,000.000

74,000.000

76,000.000

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

2015 trend analysis of plant-A

2015 - analysis of Plant-A MT/ day

2015 - analysis of Plant-A Average in Q4

Poly. (2015 - analysis of Plant-A MT/ day)




5291385


ILLUSTRATION – C: WASTE % IN CORRUGATION ANALYSIS

PLANT-A: CORRUGATION WASTE

% ANALYSIS

GA

IN /

LO

SS

% JAN 6.10%

6.16%

FEB 6.50%

MAR 6.20%

APR 6.30%

MAY 5.70%

JUN 6.60%

JUL 5.80%

AUG 6.10%

SEP 6.13%

OCT 6.04%

6.00% 3% NOV 6.22%

DEC 5.73%




5291385


3.2. Printed boards productivity

ILLUSTRATION-A: PRINTED BOARDS / MONTH ANALYSIS FOR 2015 IN PLANT-A

PLANT-A: PRINTED BOARDS PER

MONTH ANALYSIS

GA

IN /

LO

SS

% JAN 4941970

4626141

FEB 4497499

MAR 4507528

APR 4104307

MAY 4455502

JUN 4758018

JUL 4420937

AUG 4646024

SEP 5303488

OCT 4802891

5017589 8% NOV 5104041

DEC 5145835




5291385


3.3. Quality systems – formation and establishment

3.3. A – Corrugation line

a) Focus is on the tracking of the paper temperature all along as also on the hot plate temperatures at

different zones.

b) The automated responses are generated for the operator and the line supervisor to act on and maintain

consistency.

c) The line speeds are a function of the quality being derived and the challenges therein.

d) A detailed glue chemistry analysis in the line is of primary importance in determining the quality

derivatives.

e) These are real time illustrations and can be customized and improved on further with additional inputs

drawn in from the relevant resources.


P.O. BOX: 23365



CLIENT

XYZ LTD

PRODUC

T BRAND-B PWD DESTINY PINK 144X40G

PAPER

QUALITY 125K/127B/125T/127C/125K

-0.25 0.778800783

MACHIN

E SPEED 110m/min

CALIPE

R 6.4

DATE

08/12/201

5 (DAY)

Area

Paper Temperature Analysis

A0

(optr

side)

A1 (Left

Middle)

B1 (Right

Middle)

B0

(Driv

e

side)

Varianc

e

Statistica

l gap

Performanc

e %

Recommende

d Actions

Spool 27.8 27.9 28.6 29.3 5.40% -0.68 50.71%

Increase

corrugation

heat transfer

Pre-heater 116 118.4 118.6 114.8 3.31% 0.74 209.17% ProcessOK

Bonding

zone

117.

8 120.4 121.6 118.8 3.23% 0.35 142.60% ProcessOK


P.O. BOX: 23365



Hotplate -

heating

135.

6 137.8 139.6 129.3 7.97% -1.19 30.33%

Increase

corrugation

heat transfer

Hotplate-

curing 92.1 91.3 92.7 93.1 1.97% 2.91 1827.80% ProcessOK

Hotplate-

cooling 77.9 78.7 81.9 80.9 5.13% 0.67 196.02% ProcessOK

DF

Slitter

blade zone 72.9 75.4 76.1 72.8 4.53% 1.29 364.52% ProcessOK

Paper

board drag

zone

67.3 65.1 64.1 62.1 8.37% 0.03 102.56% ProcessOK

Quality LUC RUC

NUCLEU

S LLC RLC Variance

Statistical

gap

Performance

%

Recommende

d Actions

Moisture 9 8 10 8 8 25.00% -2.30 10.03% Increase Wrap

ECT 6.7 6.9 7.4 7.3 7 10.45% -0.99 37.17%

Increase Wrap,

add moisture at

bonding

Box Comp

Strength


P.O. BOX: 23365



Flute

depth 6.3 6.4 6.4 6.4 6.2 3.23% 2.15 862.65% Process OK

Inspection tests

Glue

bonding

strength

bonding strength ok

Frayed

edges No Frayed edges observed

Damaged

flute no damaged fluting




5291385


3.3 B – Glue chemistry

GLUE QUALITY TEST RESULTS – PLANT A

(08/12/2015) Day shift

FORMULATION TANK

STORAGE TANK

1. The properties in the storage tank are vital and often ignored in the industry. A regular check

out with varying levels of depletion shall reveal the real properties that can influence performance

at elevated speeds.

2. The dynamic states at the pick-up trough for the glue would give the right insights of the paper-

temperature interface and the corresponding changes in the properties of the glue that are required

to be registered for bringing in productivity compatibility.

Solid Content Gelling Point ( 0c) Viscosity (Sec) Temperature (

0c)

25 60 38 37 (formulation tank)


P.O. BOX: 23365



TIME SERVICE

TANK

VISCOSIT

Y

TEMPE

RATUR

E

MACHIN

E

SPEED

QC REMARKS

12:15 pm

B-flute

37

N/A

101m/min

3ply 150K/127C/150K (TCA)

Glue bonding OK

No wrapping,No gumless .

Double

backer

72 (tank)

62(machine

glue trough)

N/A

2:35pm

B-flute

30

N/A

120m/min

3ply 150K/127C/150K (TCA)

Glue bonding OK Double 68 (tank)


P.O. BOX: 23365



backer 47(machine

glue trough)

N/A No wrapping,No gumless .

3:45pm

B-flute

30

N/A

110m/min

5ply

125K/127B/125T/127C/125K

No warping ,no delaminating or

gumless board

NB;this was achieved with a

machine glue gap of 3.0 and not

the usual gap of (2.0-2.5) for

double boards.

Double

backer

60(tank)

48(machine

glue trough)

N/A




5291385


3.3 – C: Printing quality systems




5291385





5291385


INFERENCES:

1. A detailed outlook is essential and should be way beyond the mundane levels currently existing in the

industry.

2. Vital emphasis is required to carry forward the functional expertise in detailed quality evaluation to the

operator-mechanic matrix.




5291385


4. Real time case studies (realm of energy management) at Plant-A:

1. The motor PF of the down stacker was improved from 0.2 to 0.66 through enhanced cable

design and solved the electro mechanical drives that were causing the receipt of the boards

on to the down stacker not to be synchronized with the drives.

A. Process Description Statement:

a) The down stacker is the area wherein corrugated boards stack up before being offloaded into

the transfer bay.

b) The stacker reciprocates on a vertical trajectory and is driven by the hydraulic motor. The

transmitting forces are hydraulic in nature with the motor providing the desired electromotive

force.

c) The stacker is synchronized with the incoming speed of the corrugated boards to enable a

perfect pick-up, stacking and offload.




5291385


PHASE

Down Stacker - fundamental energy data - BASELINE

AMPERES VOLTAGE THD% KW KVAR KVA

R 7.71 415.8 16.30%

3.35 3.26 14.2 Y 8.15 414.9 17.54%

B 8.78 414.8 16.46%

PHASE

IMBALANCES 14% 0% 8%

Inferences:

1. The harmonics are high as are expected of non-linear loads.

2. The kW drawn in was significantly lower commensurate with the current being drawn in

thereby leading the team to the conclusion that the desired electromotive force was missing to

generate the right hydraulic load for synchronizing the timing.

Down Stacker - Power Quality Data - BASELINE

PF tan Phase

Angle Peak i RMS

CF

(Crest

Factor)

0.24 3.14 114

34.2 7.71 4.43

34.2 8.15 4.20

34.2 8.78 3.90




5291385


14%

Inferences:

1. The PF was abysmally low.

2. The phase angle is very high clearly indicating the onset of the impedance factors in the motor.

B. Problem Statement:

a) The synchronization was missing causing the corrugated boards to fall off.

C. Analysis:

a) The down stacker’s synchronization was affected owing to the low electromotive force

generated by the motor PF of 0.24.

b) The main reasons for the low PF were analyzed as below:

i) Impedance factors determine the concentration of the magnetic field that is essentially

redundant in nature and minimizes the incoming vector.

ii) The CF – crest factor implied by a higher ratio of the peak-baseline current multiple is the key

determinant for higher thermal stresses in the wiring as also the cable network.

iii) The copper impurities eventually give in to micro ruptures when the wiring is subjected to

sustained levels of high thermal stresses. This leads to systemic current leakage and disruption in

the electromotive ecosystem.

D. Solutions:




5291385


a) The impedance factors yield permanent magnetic fields that are redundant in nature and hence

need to be overcome to solve the problem on a sustainable mode through changes in cable

network and wiring.

b) The cables in the distribution board that connected to the down stacker hydraulic mode were

changed – original 8 mm 4 core flexible cable – 30 meters in length were changed to 16 mm.

c) The hydraulic oil dosing was done with car engine oils SAE 40 at the rate of 1.5%

concentration. The reduction in static charge concentration is the key solution determinant for

fluids. The dosing caused a significant improvement in the flow characteristics of the hydraulic

oils and the purging of contaminants. The contaminants concentrate owing to the degradation of

the fluid and the consequent carrying of static charges that effectively reduce the flow of the oil.

The hydraulic pressure improved as a result and caused the problem to be sorted out.

PHASE

Down Stacker - fundamental energy data - AFTER

CHANGE OF CABLE


R 8.35 415.8 16.30%

9.22 3.26 11.5 Y 7.79 414.9 17.54%

B 9.12 414.8 16.46%

PHASE


Down Stacker - Power Quality Data - AFTER CHANGE OF

CABLE




5291385


PF tan Phase

Angle Peak i RMS

CF

(Crest

Factor)

0.80 3.14 114

27.7 8.35 3.31

27.7 7.79 3.56

27.7 9.12 3.04

17%

Inferences:

1. Significant improvements in both the fundamental energy and the quality of power.

2. The phase angle remains the same and is in line with the permanent decay caused by

impedance.

3. The CF has improved. However, the values are still high calling in for the fundamental change

of the wiring to overcome the redundant magnetic field.

Down stacker hydraulic bath analysis

Logged-in data

Oil bath temperature

analysis

Hydraulic oil (

Tellus -68)

Tank

quantity Low High

NO DOSING -

REGULAR STATE

Week-1

40

83 88

Week-2 86 95

Week-3 88 97




5291385


Dosing the hydraulic oil

tank with 1.5% engine oil

- once a week

Week-1 73 77

Week-2 71 75

Week-3 66 72

Inferences:

1. The hydraulic oil and the rate of degradation are indicated by the oil bath temperature.

2. The quality of flow improves with lowering of friction caused by the neutralization of the static

charges – something that the hot engine oil is supposed to be doing on dosing (dosing is usually

done by heating up the engine oil to temperatures of above 100 degrees Celsius)

3. The hydraulic dynamic flow quality is a key drive determinant apart from the kW load of the

motor.

E. Final accrued gains:

a) 25% higher line speed translating to 12% gain in energy density.

b) Hydraulic oil change schedule extended by 30% and still counting (till the time of filing the

report)

2. The PF of the AC drive 94kW motor was increased substantially to improve on the

quality of mechanical drives and solve the problem of the crushing issues on the paper

board.

A. Process Description Statement

a) The 94kW motor is on AC drives and is designed to provide the transmission through

hydraulics to the belt on the hot plate.




5291385


b) The canvas belt is designed to transfer the corrugated paper and the liner through the bonding

zone, the curing and cool off zones; the bonding and curing zones being maintained at 170-175

degrees Celsius on the hot plate with the paper temperatures of around 130-140 degrees Celsius.

The tensioning and the wrap of the papers around the pre-heater rollers are maintained to ensure

that the temperature gradient is maintained to a desired level of 5-7 degrees Celsius for better and

consistent quality.


a) The fluting on the paper was getting crushed on the drive side on and off and that is evident

from the calliper difference to the tune of 0.8-1.1 mm between the operator and the drive sides.

This difference weakens the board strength and can cause a dimensional difference in the carton

on the printing line.

b) The line speeds were forced to be reduced to minimize the flute crushing effect and maintain

the acceptable quality levels on the carton in the down processing zone.

PHASE

94 kW hot plate drive motor - fundamental energy data -

BASELINE


R 37.30 412.3 23.30%

12.4 13.45 47.33 Y 35.50 409.8 22.80%

B 34.80 411.7 25.50%

PHASE





5291385


94 kW hot plate drive motor - Power Quality Data -

BASELINE

PF tan Phase

Angle Peak i RMS

CF

(Crest

Factor)

0.26 3.14 114

114.8 37.3 3.08

115.5 35.5 3.25

115.0 34.8 3.30

7%

Inferences:

1. The usual impedance factors are evident.

2. Low PF is the main cause of the mechanical problem of the drive transmission quality

C. Analysis:

a) The drive transmission was lower in power owing to the reduction in motor PF.

b) The kW load was very low for a disproportionately high current being drawn into the system.

c) The correction of the electromotive load factors would solve the problem of inadequate power

in transmitting the mechanical drives and restore quality of calliper as explained in the problem

statement.

D. Solutions:




5291385


a) Impedance factors were high and were the determinant in lowering the PF to low levels.

b) The cables were changed from 16 mm 4-core armoured to 50 mm 4-core armoured to reduce

the CF- crest factor and the consequent thermal stresses commensurate with the copper quality of

the line.

c) The increased PF was achieved to transmit the dives and establish a permanent solution for the

flute – crushing problem as explained above.

PHASE

94 kW hot plate drive motor - fundamental energy data -

AFTER CHANGE OF CABLE


R 39.35 410.7 22.70%

23.1 14.34 35.3 Y 38.43 411.5 21.80%

B 39.22 412.3 24.20%

PHASE


94 kW hot plate drive motor - Power Quality Data - AFTER

CHANGE OF CABLE

PF tan Phase

Angle Peak i RMS

CF

(Crest

Factor)

0.65 3.14 114 86.0 39.35 2.18

85.8 38.43 2.23




5291385


85.6 39.22 2.18

2%

94 kW hot plate drive motor - hydraulic bath analysis

Logged-in data

Oil bath temperature

analysis

Hydraulic oil (

Tellus -68)

Tank

quantity Low High

NO DOSING -

REGULAR STATE

Week-1

40

95 107

Week-2 93 110

Week-3 95 109

Dosing the hydraulic oil

tank with 1.5% engine oil

- once a week

Week-1 77 83

Week-2 74 77

Week-3 69 73

E. Final accrued gains:

a) Line speed increase to the extent of 25% on equivalent products and consequent drop in energy

density to the extent of 12%.

b) Better quality allowed printing output to increase to 30% levels and again with lower energy

density




5291385


3. The aerodynamic balancing of the narrow width paper was done through mechanical

controls on the TCY corrugation to improve on the line speed. The design is patentable and

serves to improve on resource utilization management – a key component of the energy

conservation measures (ECM).

A. Problem Description Statement:

a) The narrow-width papers were poorly controlled in the machine owing to the lack of

aerodynamic controls on wider machine cross-section.

b) The suction caused by the vacuum forces was inadequate in controlling the paper

curvature around the corrugation roller thereby forcing the operator to reduce the line speeds

substantially. This was a product-specific issue resulting in a disproportionately high energy density.

B. Analysis:

a) The vacuum forces were weakening owing to the turbulence in the air that was

uncovered by the paper.

b) The turbulence caused an uneven curvature of the paper around the corrugation roller.

c) The uncovered sections needed to be controlled for better aerodynamic controls on the

paper selvedge and improve on the line speed.

C. Solutions:

a) The flaps were fabricated for improved aerodynamic controls and reduce the air

turbulence.

b) The controls ensured that the line speed increased by 50% for the given narrow-width product

and establish a reduction of 22% in the product-specific energy density.




5291385


4. The 45 kW B-flute drive motor triggered process improvements


a) The B-flute is the fluting imparted onto the paper in the corrugation process and is of vital

importance from the quality perspective as also from the run speed in the line.

b) The paper curves around the fluted roller that is driven by the motor and the pressure roller

applies the pressure onto the paper to enable the glue application. The pressure is hydraulic in nature.

c) The drive to the corrugation roller determines the speed of revolution and hence the contact

angle between the paper and the corrugation roller (fluted roller) – the all- important determinant

for flute profile and depth.


a) The drives were not consistent with respect to the rpm and hence caused slippage of the

paper around the corrugation roller.

b) The paper used to be crushed with increasing line speed.

c) The profile of the flutes was not strong on account of erratic pressure and inconsistent

curvature on the paper.

C. Analysis:

a) The transmitted revolutions per minute of the corrugation roller was of primary

importance in defining the quality of the flute profile on the paper and consequently the line

speed.

b) The only tangible way of improving the above was to enhance the load transmitted for

achieving the desired rpm.

D. Solutions:




5291385


a) The drive quality was improved through the improvement on PF.

b) Wiring of AWG rating 14 was used instead of AWG 18 for the 45 kW motor

c) The cable of 50 mm 4-core was used instead of 16 mm 4-core

d) The hydraulic oil bath for transmitting the pressure onto the paper was injected with 1.5%

care engine oil - SAE 40 regularly.

E. Accrued Gains

a) The energy density improvement to the tune of 12%.

b) The quality leadership in the market place.

c) Productivity improvement in the printing area resulting in the significant improvements

in the overall energy density – please check out the real time chart showcasing the gains.

5. Life span of the canvas corrugation belt

a) The critical component life is an important ingredient for asset management and herein

is the crux of the initiative.

b) The global lifecycle of the canvas on the corrugation is around six months but we

extended the life by 30% with the introduction of steam wash mechanism that eliminates

grime, dirt and wax.

c) The steam wash system on the corrugation belt is designed to improve on the resultant

tensioning of the belt and the consequent performance on the corrugation sheet – this again is a

patentable design that can be retrofitted on any machine.

6. Implementation of the best practices at the boiler have improved the performances

substantially – to levels of one of the best in the bio mass industry and is subject to external

validation and implementation county wide as a preferred practice.




5291385



a) The bio mass has typically lower calorific value.

b) The ignition point for the water to be raised to the change over phase state

consumes the bulk of the energy.

c) The air-fuel ratio is adverse for effective combustion causing significant delay in firing

up the boiler.

d) The ash residue is high and causes an adverse effect on the combustion process.

e) The variables in the bio mass fuel are high causing disruption in the combustion cycles

of the induced draft-forced draft sequences.

B. Problem statement:

a) Varying steam-biomass fuel consumption trends – the boiler combustion efficiency

dips sharply.

b) The quality of steam in the form of i) achieved pressure, ii) steam leaks and iii)

moisture carry over in the distribution networks are areas of major concern.

C. Analysis:

a) The ash residue causes a dip in the combustible power of the fuel.

b) The clinkers are caused by incomplete combustion and adversely affect the fuel-air ratios

causing soot and deterioration in the quality of steam.

c) The steam pressure is directly related to the combustion and hence influenced the quality

parameters of the generated steam.




5291385


D. Best practices:

a) The fire tubes and the economizer tubes are cleaned with soap water and then with car

engine oil to eliminate the static charges – the primary cause of accumulation and consequent

resistance to combustion.

b) The cleaning is a weekly routine. Empirical evidence suggests that a gap of more than 10

working days immediately causes a sharp dip in steam-fuel ratio - a key indicator of the boiler

efficiency.

c) The primary data of the boiler needs to be tracked on a statistical mode and with normalized

data – an illustration of Plant-A practices are enclosed for a reference. Also, the dip in efficiency

is highlighted owing to a delay in the boiler maintenance program as described above.

d) An extract of the daily process control on the boiler is illustrated hereunder.

e) Normalization of data is done for the standardization process to establish the impact

of each of the parameters.


P.O. BOX: 23365



Timeline Pressure in

bars

Briquettes

in Kgs.

Flue gas

temp. -in

Flue gas

temp. -

out

Economizer

temp.

Water

temp.

Ashes

in kgs.

Water

meter

reading

07:45-09:30 12.5 503 244 73 142 74 466

09:30-10:35 13 433 245 69 143 70 62 469

10:35-11:55 13 444 245 75 145 75 471

11:35-13:30 13 447 245 73 145 76 473

13:30-14:45 12.5 492 245 71 140 72 475

14:45-15:20 12.5 517 245 73 142 72 44 478

15:20-17:20 13 542 245 60 142 69 481

17:20-18:20 13 563 240 70 142 72 484

18:20-19:55 12 546 242 72 143 73 485

19:55-21:00 13 497 244 75 143 76 488

21:00-22:40 13 499 246 74 147 75 489

22:40-00:54 12.5 477 245 69 147 72 493

00:54:01:56 12 488 245 76 145 76 497

01:56-03:00 12.5 590 244 73 145 71 98 499

03:00-04:40 13 456 245 74 143 73 501

04:40-06:07 12.5 448 250 75 144 74 504


P.O. BOX: 23365



06:07-07:15 12.5 349 245 75 147 75 506

Standards 13 340 245 75 145 85 50

Actual for the

day 12.69 479.51 244.72 72.33 143.89 73.89

Steam /

briquettes ratio

Total Briquettes consumed 8128

Total water

consumed in m3 40 4.90

Standardization -0.87 -2.44 -0.14 -0.70 -0.55 -5.20

Overall

average -1.65

Score 66%




5291385


7. Best practices for non-linear loads:

a) The THD% is extremely high in all the non-linear loads like the AC drives.

b) The element of wear is evident from the following table THAT SHOWCASES THE 45

kW B-flute drive motor:

Inferences from the case study:

a) Harmonic distortion is a drain on the energy waste and the proportion can be explosive at a time when

the mechanical loads are high.

b) Thermal wear and onset of impedance are the main factors that define the deterioration in the quality of

the load transmitted.

c) Unchecked proliferation can be disastrous from an energy conservation perspective as also in the

context of drive quality and process controls.


P.O. BOX: 23365



PHASE

45 kW B-flute drive motor - fundamental energy data - AFTER

CHANGE OF CABLE + WIRE

45 kW B-flute drive motor - Power Quality Data - AFTER

CHANGE OF CABLE + WIRE

AMPERES VOLTAGE THD% KW KVAR KVA PF tan Phase

Angle Peak i RMS

CF

(Crest

Factor)

R 16.88 412.8 24.35%

17.4 11.85 27.8 0.63 3.14 114

67.3 16.88 3.99

Y 17.35 411.7 25.15% 67.5 17.35 3.89

B 16.94 409.9 26.21% 67.8 16.94 4.00

PHASE

IMBALANCES 3% 1% 8%

3%

PHASE

45 kW B-flute drive motor - fundamental energy data - AFTER

THD% DRIVEN THERMAL WEAR

45 kW B-flute drive motor - Power Quality Data - AFTER

THD% DRIVEN THERMAL WEAR

AMPERES VOLTAGE THD% KW KVAR KVA PF tan Phase

Angle Peak i RMS

CF

(Crest

Factor)

R 40.60 408.5 24.35% 6.17 30.19 30.74 0.20 4.49 115 75.3 40.6 1.85


P.O. BOX: 23365



Y 40.85 410.6 25.15% 74.9 40.85 1.83

B 41.25 411.2 26.21% 74.8 41.25 1.81

PHASE

IMBALANCES 2% 1% 8%

2%


P.O. BOX: 23365



y = -1E-05x4 - 0.002x3 + 0.040x2 - 0.155x + 4.64R² = 0.180

0.00

1.00

2.00

3.00

4.00

5.00

6.00

1 2 3 4 5 6 7 8 9 10 11 12

ENERGY DENSITY -1: Units consumed per MT of production

Series1

Poly. (Series1)


P.O. BOX: 23365



y = -12.21x4 + 42.89x3 + 2188.x2 - 15874x + 33911

R² = 0.132

0.00

50000.00

100000.00

150000.00

200000.00

250000.00

300000.00

350000.00

400000.00

0 5 10 15

CO

NSU

MP

TIO

N (

UN

ITS)

MONTH

MONTH VERSUS CONSUMPTION (UNITS/KWH)

FIGURE 1. MONTH VESUS CONSUMPTION (UNITS/KWH)

Poly. (FIGURE 1. MONTH VESUS CONSUMPTION (UNITS/KWH))




5291385


Inferences:

1. Energy density has improved substantially in the factory in the year- 2015.

2. Productivity improvements is the single most important factor contributing to the trends.

y = 0.003x4 - 0.078x3 + 0.727x2 - 2.640x + 17.22R² = 0.549

0.00

2.00

4.00

6.00

8.00

10.00

12.00

14.00

16.00

18.00

20.00

1 2 3 4 5 6 7 8 9 10 11 12

ENERGY DENSITY-2: Printed volumes per unit power consumed

Series1

Poly. (Series1)




5291385


3. Systemic efforts in improving the equipment performances go a long way in improving energy

conservation as is evident from the series of steps enlisted above.

ASSET MANAGEMENT EFFICIENCY – an important energy determinant

y = 334.0x4 - 10507x3 + 10332x2 - 32896x + 67413R² = 0.432-

100,000.00

200,000.00

300,000.00

400,000.00

500,000.00

600,000.00

700,000.00

800,000.00

900,000.00

1,000,000.00

0 2 4 6 8 10 12 14

AM

OU

NT

(KSH

S)

MONTH

TCY corrugation maintenance costs

Linear ()

Poly. ()




5291385


y = 87.00x4 - 2717.x3 + 27059x2 - 10841x + 33676

R² = 0.805

-

100,000.00

200,000.00

300,000.00

0 2 4 6 8 10 12 14

AM

OU

AM

OU

NT

(KSH

S)

MONTHS

6PA maintenance costs. MONTH VESUS AMOUNT (KSHS)

FIGURE 1. MONTH VESUS AMOUNT (KSHS)

Poly. (FIGURE 1. MONTH VESUS AMOUNT (KSHS))




5291385


y = -337.7x4 + 9529.x3 - 90269x2 + 31099x -68560

R² = 0.537

-

50,000.00

100,000.00

150,000.00

200,000.00

250,000.00

300,000.00

350,000.00

0 2 4 6 8 10 12 14

AM

OU

NT

(KSH

S)

MONTH

5 PA maintenance costs. MONTH VESUS AMOUNT (KSHS)






5291385


y = 192.2x4 - 5644.x3 + 48191x2 - 10111x + 13189

R² = 0.420

-

50,000.00

100,000.00

150,000.00

200,000.00

250,000.00

300,000.00

350,000.00

400,000.00

450,000.00

0 5 10 15

AM

OU

NT

(KSH

S)

MONTH

9 PB maintenance costs. MONTH VESUS AMOUNT (KSHS)


Linear (FIGURE 1. MONTH VESUS AMOUNT (KSHS))





5291385


Conclusions:

1. Any corrugation plant can improve substantially through a host of measures designed

scientifically.

2. Engineering principles and mathematics are the key functional areas of intervention to achieve

lasting success.

3. The connect to spirituality is the nucleus of all initiatives in the material plane.

Warm regards

Debashish Banerjee

CEO –Blackstone Synergy Consulting group Limited,

Nairobi- 00604, Kenya

Contact cell: 0786 403 634 / 0736 322 749

Dated ; 16th

of May, 2016.

WHITE PAPER -Corrugation & board printing improvement plans

Documents

Transcript of WHITE PAPER -Corrugation & board printing improvement plans