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From 10% waste to almost null with Induction Roll Heating system installed on Paper Mill calender for Caliper Control system

The Challenge:

Our client (a Major Paper Company) was experiencing quality and productivity issues in the manufacturing of carton paper made for coffee cups for major Café Outlets. As customer requirements demanded better control of Cross Dimensional (CD) paper profile, it was critical to solve that issue in pursuit to satisfy actual and new customers as well as increasing the profitability of the paper mill.

  • Mill producing 10% of waste;
  • Caliper control system (Hot Air Shower) isn’t able to control the required 2 sigma targeted specifications;
  • Reduced paper mill profitability significantly;
  • Not meeting new customers CD paper profile specifications.

Objective: Find a solution to reduce waste produced and increase mill profitability.

The Solution:

Induction Roll Heating Systems (IRHS) have been invented by the founder of Comaintel to address Caliper Control on Paper Machine calender stack. Widely used and a proven solution in the Paper industry, the Induction Roll Heating system is designed to efficiently and rapidly control zone controlled Work Roll diameter using a non-contact, and highly efficient energy source (up to 95%).

By heating independent zones (60 mm, 75 mm, or 120 mm), Comaintel’s IRHS controls the work roll diameter, by zone, to the optimal profile without using bending actuators excessively which would affect the sheet gauge and profile all across. The high power efficiency of Comaintel’s IRHS allows to rapidly reach the targeted CD profile therefor accelerating production start-ups and getting an optimal CD caliber control.

Comaintel’s Solution implemented:

  • Installed an hybrid Comaintel’s Induction system: xCore air-cooled 60 mm workcoils and xCore air-cooled 120 mm workcoils on an automated retractable beam;
  • Comaintel OptiDriver 0-6 kW Power Modules, providing the potential power equivalent to kW per linear meter;
  • Two Off-Machine cabinets to house up to 30 power modules per cabinet;
  • Comaintel’s Serial link communication to connect to the monitoring and control systems.

In summary, the heat applied to the roll using induction corrected work roll deformation caused by irregular nip friction across the entire length (mostly creating heat at the center of the roll and reduced temperature at sheet edges). By using induction, the work rolls edges (edges of metal sheet) are heated appropriately to increase Work Roll Edges diameter eliminating gauge and profile issues, and edge cracks leading to strip breaks and rejected products through Quality Control.

The Results:

Comaintel’s IRHS brought tangible results to this client which generated significant payback:

  • Reduced waste paper to a minimum;
  • Increased potential new customer list because they can produce carton according to clients’ profile specifications;
  • Reduced almost all strip breaks, reducing downtime due to strip breaks to a minimum;
  • Improved start-up time significantly by optimizing CD profile control;
  • Increased Mills profitability.

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