Four key points of tile line transformation are exposed! Can greatly reduce the consumption of base paper!
The cardboard profit is thin, and the savings are all earned! In the carton factory, the loss of the tile line part accounts for about 80% of the loss of the whole plant. Therefore, some people say that those who get the tile line have the world. Who can minimize the loss of the tile line, who will be able to gain a foothold in this industry! Taking a carton factory with a monthly output value of 10 million as an example, for every 1% reduction in loss, 4.2 million can be saved a year!
From the perspective of the transformation of corrugated board production line, this article introduces the method of reducing the loss of raw materials for the reference of carton enterprise managers.
Renovation point one: the application of the splicer
——Reduce paper breakage and reduce scrap rate by 60% ～ 80%
Nowadays, the automatic paper machine has become an important equipment in high-speed corrugated board line, it is the guarantee to drive the production of corrugated board at high speed. High-speed automatic paper splicing machine, its function is to ensure that the entire paper splicing process is automatically completed under the condition of high-speed movement of the paper belt, when the required paper roll is used to the specified diameter (usually called the old paper roll when used ), Automatically and accurately paste the old and new paper rolls together, and cut the old paper rolls in time, and the new paper rolls are provided for printing in time. Because the paper tape does not stop moving during the high-speed automatic paper receiving process, it can continuously feed paper to the printing part, so there is no need to install a paper storage mechanism.
The advantages of the splicer:
â—† Especially in the process of changing paper, improve the success rate of receiving paper and ensure smooth production without downtime;
â—† Zero tailing to reduce unnecessary waste of base paper;
â—† Realize automatic detection of paper break, no waste when the core is used up;
â—† The tension is automatically adjusted to reduce paper breaks caused by human error;
â—† After configuring the paper receiving machine, the scrap rate can be reduced by 60% to 80%.
Reconstruction point two: pay attention to the application of zero-cut technology
——Using zero-cut waste technology can reduce the waste paper waste rate by 2% ～ 3%
In the selection of slitting machine and cross-cutting machine, we should pay attention to the application of zero-cutting technology. Zero-cut waste technology means that the paperboard passes through the press line and then cross-cuts. There is no waste paper in the conversion process of the order, or the waste paper is controlled within a certain range. There are currently two ways to use this technique.
One is foreign technology, the input cost is relatively large;
One is the domestic technology, which adds two vertical cuts and one horizontal cut. The technology is realized by data transfer between each other. For example, 250 ～ 300 orders / shift, after the vertical and horizontal cutting machine system transformation, the use of zero-cut waste technology can reduce the waste paper waste rate by 2% to 3%.
The traditional slitting and pressing machine is replaced with a computer thin-knife slitting and pressing machine, which can realize the order change of the computer and automatically arrange the knife. The high-quality thin blade can automatically sharpen the knife, so that the paper edge is cut smoothly and the corrugation does not deform. Computerized cross-cutting machine is composed of computer digital control system and mechanical cutting mechanism. The computer-controlled straight knife cross-cutting machine is the most mature technology at present, and the use and maintenance cost is the lowest. The straight knife used has a large thickness, long service life, and low price. Computer-controlled spiral knife cross-cutting machine is a relatively new technology at present. Its design adopts a low-rotation inertia knife shaft design. The knife shaft is small, the control is relatively easy, and the power is small, which can achieve the requirements of high-speed production.
For the corrugated cardboard with patterns, not only the horizontal cutting of the mark, but also the control of the left and right positions, otherwise the position of the pattern to the front edge of the cardboard may change when slitting the edges, and it is easy to cause waste products. Photoelectric correction device. Adding LPC to the upper left of the face paper holder can eliminate the left and right axial errors caused by the printed face paper during winding and unwinding, and correct the deviation with the line through the LPC to ensure that the face paper is smoothly fed according to the line.
Reconstruction point three: the selection of corrugated automatic switch
——After configuring the corrugated automatic switch, only 3 to 6 meters of loss
The corrugated automatic switch is widely used. It is recommended to configure the corrugated automatic switcher if the average change of the third floor to the fifth floor is more than 20 times per shift. The corrugated automatic switcher is to change the third layer to the fifth layer. In order to avoid parking and cleaning hot plates as much as possible, the production of corrugated cardboard generally arranges orders from wide to narrow according to the size of the cardboard door. Multiple switch of corrugated shape in the same width (that is, switching between three-layer cardboard and five-layer cardboard). And now some factories still use manual switching, that is, cut or wear paper after reducing the speed. Through system control, instead of manual operation, improve efficiency and reduce losses.
The advantages of corrugated automatic switch:
â—† Accurate paper feeding, manual paper feeding will cause waste of 8-15 meters of base paper, only 3-6 meters of loss after configuring the corrugated automatic switch;
â—† Quickly align to reduce unnecessary waste caused by misalignment;
â—† Compared with manual operation, the operation is safe and the hidden dangers are eliminated.
Renovation point four: the use of on-site production management
——Informatization and systematize carton factory management
On-site live management is equivalent to our satellite navigation. The entire assembly line is coordinated and operated by several individuals at the same time. On-site live management controls the coordination between each machine. Among them, on-site production management and ERP are connected to analyze your production results, including loss, production capacity, output, parking speed, etc., to avoid fraud, and can truly reflect the production situation. The remote control of ordering flyers is relatively quick, and the integration of incoming orders, demand orders, production and distribution is easy to manage.
The use of on-site production management makes the carton factory management information and systematization. It is convenient for enterprise leaders to grasp the production situation of the enterprise in time and accurately, and can open the computer at any time to find the data data report, without going to each department to request the data.
The advantages of on-site live management:
â—† Accurately detect the accumulation amount of the flyover and improve the accuracy of paper exchange;
â—† Automatic connection with paper receiving machine to reduce loss;
â—† Coordinate the operation of each machine in the production line;
â—† Connected with ERP, remote control of sorting flyers.
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