Common faults in the corrugating process and their remedies:
Broken flutes
Causes: insufficient preheat tension on the single facer, corrugating paper brake problems, bending and shear force as the paper enters the upper and lower corrugating rolls.
Fixes: replace corrugating medium, repair or replace corrugating rolls, adjust corrugating roll gap, check and repair mechanical damage, adjust air brake pressure, reduce brake tightness, reduce preheat wrap angle.
Wrinkled flutes
Causes: poor corrugating medium quality, weak braking force, poor parallelism of corrugating rolls, uneven moisture.
Fixes: increase preheater wrap angle, increase braking force, correct corrugating roll parallelism, adjust preheating or steam spraying to keep moisture balanced.
Deformed flutes
Causes: low-strength corrugating medium, uneven moisture in corrugating medium, worn corrugating rolls, improper gap between the glue roller and loading roller on the double facer, improper pressure from heavy rollers in the heating and cooling sections, high moisture in corrugated board or insufficient hot plate temperature.
Fixes: use high-strength corrugating paper, increase preheat wrap angle or spray to balance moisture, adjust pressure properly, replace corrugating rolls and pressure rollers, adjust gap to normal, increase pressure roller gap height, increase steam pressure or check the cause of low temperature, adjust heavy roller clearance distance.
When corrugating rolls, pressure rollers, or glue rollers need replacement, we machine these precision parts from customer drawings in single pieces or small batches.
Tilted flutes
Causes: too much tension at the paper bridge, too much pressure from gravity rollers on the double facer, improper gap between pressure roller and feed roller, felt belt slipping.
Fixes: reduce controller tension, adjust gravity roller gap properly and check balance, adjust gap to a suitable value, adjust felt belt tightness to normal.
Uneven flutes
Causes: uneven surface temperature of corrugating rolls, abnormal operation, inconsistent bonding gap, dirty surface, improper gap of glue roller and floating roller, poor adhesive quality, uneven moisture in corrugating medium, uneven paper bridge.
Fixes: check condensate discharge, check bearings and transmission parts, adjust bonding gap, clean corrugating rolls, adjust gap, check and remake adhesive, increase preheating and tension control properly, adjust tension control properly.
Poor bonding
Causes: too much face paper tension, too much moisture in face paper and medium, low adhesive application, imbalance between glue roller and floating roller, abnormal canvas belt lifting device, poor adhesive quality, insufficient or excessive heat, adhesive lumps.
Fixes: adjust brake device to reduce friction, increase preheating surface or change paper and reduce machine speed, increase adhesive application, adjust gap, check hydraulic device and mechanical adjustment system, correct adhesive quality, check and remove causes of insufficient heat, reduce preheating properly or reduce pressure, solve adhesive quality problems.
Skip corrugation
Causes: too much or too little moisture in corrugating medium, improper braking force of the corrugating brake, insufficient or uneven pressure on corrugating rolls, dirty or damaged corrugating rolls or worn bearings.
Fixes: increase preheating area when moisture is too high, use steam humidification when moisture is too low, adjust brake friction to a suitable state, adjust corrugating roll pressure to a suitable value, replace or clean dirty parts or components.
Our precision custom machining covers more than corrugating rolls and pressure rollers. Hansheng Automation also produces non-standard components for printing equipment, food machinery, medical device production equipment, yacht hardware, RC car parts, tobacco packaging machinery, and filling machinery. We work from customer drawings for single pieces or small batches. The focus stays on precision parts machining and delivery, which keeps maintenance and replacement flexible across different industries.
