Web Cleaning for the Corrugated board Industry
Web cleaning for corrugated board industry is crucial in both manufacturing and processing.
The production process for corrugated board is inherently dusty, which poses considerable challenges for quality in all manufacturing and processing steps and for machine maintenance.
Effective web cleaning provides significant economic advantages by reducing downtime, lowering maintenance costs and improving product quality. During manufacturing, it significantly reduces dust, enhancing product quality. Similarly, cleaning before processing, such as printing, offers substantial benefits. These benefits help manufacturers and processors of corrugated board by enhancing efficiency and maximizing production hours.
Contact usWhy is web cleaning important in the corrugated board industry?
The corrugated board industry generates considerable dust and particles during cutting and scoring processes, which can negatively impact production quality and efficiency. Contaminated materials lead to defects in subsequent processing stages such as printing, increased maintenance, and downtime. Effective web cleaning removes these contaminants, enhancing product quality, reducing maintenance needs, and increasing operational efficiency. This not only creates a cleaner working environment but also extends machine lifespan and ensures consistent production quality.
Benefits of using web cleaning in corrugated board manufacturing and processing
Dust and particles generated during corrugated board production can adversely affect subsequent processes, especially printing. Removing these contaminants through web cleaning improves product quality and extends the lifespan of printing machines while reducing maintenance costs. Installing a KELVA web cleaning system after the scoring and cutting process significantly reduces dust and particles, leading to better print quality and less downtime.
Improved Productivity
Reducing machine downtime and cleaning cycles maximizes production hours.
Higher Quality Standards
Consistent high product quality regardless of raw material quality.
Reduced Maintenance Cost
Less dust and particles result in reduced wear and lower maintenance costs.
Improved Working Environnement
Reducing dust and particles enhances workplace safety and health.
Rapid ROI
Investments in a web cleaning system typically pay off within a year due to savings on cleaning and maintenance.
Additionally, web cleaning reduces waste and material consumption, leading to long-term cost savings and sustainable production. A clean production environment also improves employee satisfaction and reduces health risks. By installing a KELVA system, dust reduction can be increased by up to 80-90%, improving efficiency, extending machine lifespan, and reducing customer complaints.
How web cleaning works in currugated board manufacturing and processing
Web cleaning in corrugated board manufacturing involves removing dust and particles generated during cutting and scoring processes. A typical KELVA web cleaning system includes a non-contact cleaning head and a high-capacity fan/filter unit to extract and collect contaminants.
The corrugated board is neutralized by an antistatic unit, and compressed air dislodges particles from the material surface. These particles are then vacuumed away and collected in the filter
Overview of the web cleaning process in currugated board manufacturing and processing
The web cleaning process typically begins after the scoring and cutting stages, where most dust and particles are generated. The cleaning process includes the following steps:
Neutralization
The corrugated board passes through an antistatic unit to remove electrostatic charges, as static electricity can attract and hold contaminants on the web’s surface.
Particle Dislodging
Compressed air streams break the boundary layers on both sides of the board, dislodging dust and particles.
Vacuuming
Dislodged particles are vacuumed away and collected in a filter. Different filter configurations are available depending on the dust load.
Cleaning
The collected particles are caught in the filter. The removed contamination can be conveniently emptied and disposed of. The filtered air is fed back into the cleaning process.
Best products for web cleaning for corrugated applications
The KELVA ST85CC is a high-performance, non-contact cleaner designed for double-sided cleaning of corrugated board webs. It features a robust construction, integrated inlet guide and grids for secure web passage, and active antistatic devices to prevent dust re-deposition. Automated gap adjustment accommodates different flute profiles, and the system significantly reduces dust and debris in the production process. The ST85CC is also energy-efficient, reusing filtered air for maximum efficiency and cost savings.
Advantages of using Web Cleaning in the corrugated board industry
Web cleaning in corrugated board processing offers numerous benefits. Reduced downtime means more production time as fewer cleaning breaks are needed. Cleaner webs result in fewer print defects, ensuring higher quality end products. Cost savings are achieved through less waste, lower maintenance costs, and reduced cleaning expenses. Additionally, a cleaner working environment is created with less dust and particles, promoting healthier workplace conditions and reducing health risks for employees.
The advantages of using web cleaning
General
- Removal of Slitting Dust and Surface Debris: Significant reduction of dust after slitting.
- Productivity Increase: Up to 40% higher productivity and efficiency.
- Continuous Production: Increased production time and efficiency.
- Better Post-processing: Improved subsequent processing steps.
- Environmentally Friendly: Less dust load and healthier working conditions.
- Reduced Rejection Rates: Up to 50% less rejects and waste.
- Fewer Customer Complaints: Improved product quality leads to higher customer satisfaction.
- Healthier Working Conditions: Reduced dust load in the production environment.
Financial
- Quick ROI: Return on investment within a year.
- Easy Integration: Simple implementation into new or existing production environments.
- Lower Maintenance Costs: Reduced need for spare parts and less downtime.
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Looking for a web cleaning solution to improve your production and save costs?
Feel free to give us more details about your Application, Material, Dust type(s), Web width (mm) and Web speed (m/min), so that we then can already take your information into account when contacting you.
Contact usSuggested non-contact web cleaning model
KELVA ST85CC
For heavy duty corrugated applications with web widths from 2 000 up to 2 800 mm
Installation example
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