2015 TAPPI Improving Containerboard Mill Operations
Monday, August 17

Supplemental Overview of  Corrugating; Board Properties & Tests; Liner & Medium Manufacturing

(Introductory, for those without experience. Additional Registration Required)

1:00 – 5:00                                                                                               
Overview of Corrugating                                                                                                 J. Porter, Fosber America
Overview of Tests & Properties                                                                                     M. Kocurek, N.C. State University
Overview of Pulp Mill Operations & Recycling                          
Overview of Stock Preparation
Overview of Paper Machine Operations
 Day 1: Tuesday, August 18

8:00 – 8:50      Welcome, Introductions, Networking
  Learning Objective: What do you need to know, and how to improve Containerboard and Corrugating Operations

9:00 – 12:00    The Corrugating Process                                                                  J. Porter, Fosber America
Overview of corrugating equipment and operations; how to improve bonding between the liner and medium; liner & medium problems affecting corrugating runnability and product quality

Identifying Factors That Impact Corrugator Runnability
Data Collection
Liner and Medium
Managing Butt Rolls
Basis Weights
Ring Crush
Water Drop

What is a Corrugator
• Identifying Obstacles to High Speed
   What Type of Plant
      Sheet Feeder
      Box Plant
• Corrugator Design Considerations
       Corrugator Make-up
       Support Equipment
Buiding Layout

Troubleshooting Runnability Problems and Product Quality
Paper issues including wet and dry streaks, loose roll edges, caliper variations, moisture variations, sizing, others
Mechanical issues including on heat bonding, starch application, others.
Operational issues including common process setting errors, scheduling, butt roll and, rollstock inventory management, others

• Optimizing Bonding Conditions in the Corrugator 
Properties of Starch and Starch Application 
Wetting and Penetration Step 
Gelatinization & Green Bond Steps 
Evaporative Bond - Wetting/Penetration (DF) Step
Gelling & Green Bond for Pressure Bond (DF) Step
Drying/Fully Curing Step

 12:15 – 1:00      LUNCH
1:00 – 1:50   Changing Market Trends & Demands on Linerboard               C. Klass, Klass Associates       
  • Global Market Trends
  • Developments in Printing
    Linerboard Surface Requirements
    Flexo Process Improvements
       Photopolymer Plates and Packing Materials
       High Definition Halftones
       Staccato Screening
       More Colors
    Digital Printing of Containerboard
       High Speed Pigmented Ink Jet
       Surface Quality Requirements

2:00 – 2:50  Improving Containerboard Machine Performance                             C. Klass

  • Machine Performance Benchmarks
  • Addressing How to Improve Performance
3:00-5:30   Improving Product Quality: Linerboard & Medium Properties & Tests   M. Kocurek
Sheet Structure & Why It’s Important                                                            
MD/CD Fiber Orientation, Formation

             Properties & Tests                                                                                                                       
                  What they are telling us, and what contributes to their values

                        Stiffness, Ring Crush, Mullen, Concora
                        Edgewise Compression Test, Short Span Compression (STFI)
                        Tensile, Modulus, Stretch
                        Printability, Smoothness, Porosity
                        Liquid Absorption, Sizing tests, Cobb, Water drop, etc                      
                        Moisture & Humidity Effects on Performance Properties
                        Causes of  Curl, Warp, & Wash Boarding
                        Viscoelastic Creep Failure of Boxes                         

Note – Board testing videos can be shown after class adjourns.

 5:30   Adjournment

Day 2: Wednesday, August 19

8:00 – 8:50 Improving Performance: Fiber Raw Materials, Pulp Properties                               

  • Fiber Properties & Effects on Sheet Structure 
  • Effects of Pulp Mill Operations on Container Board Operations                            M. Kocurek

9:00 – 11:00  Improving Performance: Recycling Pulp & Challenges                    C. Klass   
                                                                                                                                                                       D. Swales, Kemira    

  • Recycling Processes for Liner & Medium 
  • Common Recycled Pulp Quality Problems
  • Stickies Control I-Equipment (Screening, Cleaning, Flotation)
  • Stickies Control II-Chemical (Stabilization, Dispersion, Fixation, Encapsulation, Passivation, Modification, Solvation)     

11:15 – Noon   Improving Performance: Refining                                                           M. Kocurek             

  • Refining Mechanism, Measurements and Variables
  • Effects on Sheet and Properties
  • Improving Refining for Linerboard & Medium

12:00 – 1:00  LUNCH

1:00 – 3:30   Improving Performance: Chemical Additives                                         D. Swales       

  • Important Measurements & What to Control to Improve Efficiency
  • Effects of Water Variables on Efficiency (pH, Conductivity, ORP, Hardness)
  • Charge Control Variables and Targets (Cationic Demand vs Zeta Potential; Additive Charges; Case Studies)
  • Retention Aids-How and Why Which Ones Work Best
  • Dry Strength Options
  • Foam and Deposit Control Options

3:45 – 5:15   Improving Performance: Wet End Operations I                                J. Shands, Paperchine

What are Important Variables That Affect Improving Operations:                                                                                                              

  • Approach System
       Reducing Approach System Variations
       Vacuum Deaeration Concepts
       Fan Pump Recommendations
  • Headbox Operations 
       Uniform Stock Flow in the Headbox
       Formation Improvement & Microturbulence Stratetegies
       Slice Profile Variations
       Dilution Profiling – Keys to Efficiencies

5:15  Adjournment

Day 3: Thursday, August 20                                                                       


8:00 – 8:50   Improving Performance II: Wet End Operations  
                     Headbox Optimization: TSI/TSO Analysis and Case Studies                            Marty Wakefield, L&W       

9:00-12:00   Sheet Forming Operations (Fourdriner & Twin Wire Gap)                                   J. Shands, PaperChine

  • Fourdrinier Table Variables
  • Slice Geometry & Jet Angles
  • Forming Board Calculations
  • Stock Activity, Harmonics, & Formation
  • Twin Wire Gap Forming Mechanisms of Dewatering
  • Assessments & Limitations
  • Blade Technology
  • Improving LoVac & HiVac Zones
  • Couch Operations                      

12:00 – 1:00   LUNCH    

1:00 – 1:50   Improving Performance: Pressing

                                                                                                                                  D. Lange, Andritz

  • The effect of couch solids on dryness out of the press
  • Nip venting: grooving and drilling of roll covers and shoe press belts
  • Sheet break reduction schemes in the press section
  • Steambox pro’s and con’s
  • What the State-of-the-Art press section looks like & why


2:00 – 3:00   Improving Performance: Drying

  • Important drying variables that improve performance                                      C. Klass/ M. Kocurek
  • Dryer Performance Benchmarks 
  • Process for Improvement: Data & Audits
  • Efficiency Models 
  • Variables Affecting Strength Development and Loss
  • Moisture Variation Effects and Control 
  • Effects on Liner & Medium Sheet Properties and Tests



3:10 – 4:00   Improving Performance: Surface Treatments                       

  • Calendering                                                                                                                      C. Klass
    What Are the Important Variables the Affect Improving Calendaring Operations
  • Winding Comments      

4:00  Adjournment  
         Wrap Up,  Turn In Evaluations,  and Pick Up Certificates