Technical Improvements on a system based solution.pptx

Technical

1. Technical Improvements

2. Recent Top Defect of Postpress/Finishing: - Die Cut Bursting/Cracks - CorrLam Delamination

3. Investigation: Bursting/Cracks No crack appears when item folded only 90° or less. Bursting occurred mostly on local purchased papers. We don’t have equipment to measure paper strength in receiving of raw materials. Deliveries from local suppliers are inconsistent in terms of quality. Bursting/Cracks appears when item folded more than 90°.

4. Investigation: Bursting/Cracks No cracks appear when item folded 90°. Cracks appear when item folded more than 90°.

5. Adjustment: Bursting/Cracks Before After

6. Result: Bursting/Cracks Before After

7. Note: Applicable only on type of materials that has no cracks when folded 90° Bursting/Cracks

8. Investigation: Delamination Most Delamination issues occur in 4 Ply corrugated board. Most Delamination defect found in front edge of the board. For Single Face Corrugated paper, delamination found on warp board. Possible lack of compression in front edge. Unbalance moisture content of paper that leads to warping. Control of glue viscosity based on type of corrugated board. Delamination re-occurs after long vacation (holiday).

9. Investigation: Delamination Warp Single Face Corrugated Paper. Machine Direction Front edge of paper Lack of compression in front edge of 4 ply board.

10. Adjustment: Delamination For Single Face Corrugated Paper, do not remove stretch film wrap. To prevent moisture absorption of the paper until ready to use or scheduled to run in CorrLam . Use the spoilage from offset as Top Weight of every finished items.

11. Adjustment: Delamination For 4 Ply corrugated board, adjust the gap of each laminated sheets 7 cm. apart or 4 fingers to allow more compression in conveyor of the machine. Before After

12. Adjustment: Delamination *For Single Face E or B Flute do not add water on premixed glue. Glue Formula: 25 kg. Glue powder + 70L H2o + 2 kg Caustic Soda + 7L H2o. *For Corrugated Board 3 Ply, 4 Ply and 5 Ply adjust the glue viscosity to 30-35 secs. By adding 2-10 scoops of water depends on premixed glue viscosity. Glue Viscosity. *Measure the weight of every glue powder sack prior to mixing and adjust if necessary.

13. Adjustment: Delamination *Consume the premixed glue within 3 days. *Put label indicating date on when the glue was mixed. Long Vacation (Holiday). *Mix glue enough to consume within 3 days. *Consider the volume of glue to be mix when holiday is coming.

14. Mixing (Panel/Item) Investigation: Mixed items are not visible when paper was piled.

15. Mixing Panel/Item Investigation: Browsing could not guarantee 100% detection of mixing.

16. Mixing Panel/Item Investigation: Some client has traceability mark but visible only after die cut.

17. Mixing Panel/Item Proposal: Extend the traceability mark up to edge of paper. Before After

18. Mixing Panel/Item Proposal: Assign different color and location per panel/item.

19. Mixing Panel/Item Trial:

20. Mixing Panel/Item Comparison: Before After

21. Thank You!