Energy-Saving and Cost-Reducing Functions of Corrugated Cardboard Production Lines
Apart from carton manufacturing companies and equipment suppliers, conscientious industry exhibition organizers have taken on the heavy responsibility of promoting green energy saving. Reed Exhibitions is key among these. SinoCorrugated South 2014, organized by Reed, will be held at the GD Modern International Exhibition Center in Dongguan from April 10 to April 12.
- (1888PressRelease) January 18, 2014 - Today, environmental protection, energy-saving and consumption reduction are global issues and major considerations for customers when they choose products. In order to take advantage of this new situation, many enterprises have "greened" their brand marketing strategies in a number of ways, to the extent that environmental protection is no longer just a buzzword for marketers.
The win-win of brand promotion and profit growth cannot be achieved unless coupled with green concepts and integrated into the daily production and operations of the enterprise. In recent years, green practices and energy savings have also been introduced into the carton industry. As a result, many carton production and equipment manufacturers have become more environment friendly, trying to reduce production cost and contribute to sustainable development.
Diverse specifications, small orders and customer demand for fast delivery have forced carton manufacturers to enhance the automation levels of corrugated cardboard production lines, as well as production management levels, to improve quality and efficiency, save energy and labor, reduce consumables and cut waste. Cost management of corrugated cardboard production lines is very important, as this is where the key cost cuts can be achieved. Energy-saving and cost-reducing methods of corrugated cardboard production line are explored below:
Establish Advanced Energy-saving Ideas for Corrugated Cardboard Production Line
Energy saving and environment protection is, and has always been, key to maintaining the human living environment. It is the focus of the national sustainable development strategy and a priority in the current Five-Year Plan. In the face of growing resource and environmental constraints, it is up to every part of society to be aware of the impending crisis. Carton companies are no exception. They must establish green and low-carbon development ideas; emphasize energy conservation and emission reductions; improve the mechanisms of motivation and self-discipline and carry out basic national policies that encourage resource saving and environmental conservation.
While the concept of energy saving and environment protection has long been prevalent in developed countries, it is relatively new to China's carton industry. The focus needs to shift to popularizing this eco-concept in China. Wu Xiaohui, Chief Operating Officer of BHS (Shanghai), a famous supplier of corrugated manufacturing machinery and services, said, "We'll first promote the idea to customers. Once they accept the idea, they will bring it to suppliers, who in turn will pass it back to manufacturers. So the idea goes along each link of the supply chain, right through to the end user. The belief is that those advanced ideas will gradually be adopted by the Chinese market and applied into the actual production and sales". To this end, BHS has let the way in the industry, producing equipment that can save 1.7% to 23.4% of electricity.
Reduce Downtime and Waste Generation
The haphazard downtime of corrugated cardboard production lines generates a large amount of waste, and drives down efficiency, thereby increasing production costs. The main reasons for the downtime of corrugated cardboard production lines are due to five elements: man, machine, materials, method and environment. These are resolved individually.
To reduce costs, the production of corrugated board must be smartly scheduled. Cartons of the same quality grade, for different customers, should be produced together, as far as possible. This will cut production costs more effectively. Additional factors such as size of carton should also be considered, to minimize the wastage generated along the cardboard production line. In addition, special calculations of the cardboard area, optimizing the processing area of the cardboard, reduce unnecessary waste of materials. The scheduling of corrugating machines should follow the principles of placing the body paper with the same quality and size together. Paper should be fed in from wide to narrow to reduce switching time.
To reduce downtime, maintenance of the corrugated cardboard production line should be efficient. Giving full play to the performance of equipment and enhancing production efficiency are effective ways to indirectly cut production costs. Maintenance should be performed by the operator and supervised by equipment and management personnel, especially the lubricating of mechanical equipment. Secondary maintenance should be done by equipment maintenance personnel and assisted by the operator. They should mainly focus on steam deflation, steaming and leakage of the equipment and adjustment of equipment status. For renovations, the Equipment Department should establish a detailed, major overhaul plan and implement it according to the problems that occur during equipment use. Daily equipment maintenance is also very important. Despite low investment costs, its effect is good.
On one hand, it can prolong the life of the machinery and maintain smooth operation. On the other hand, it also can reduce the frequency of mechanical failure and the occurrence of defective goods and save labor/material resources. This is the key to cutting costs along the corrugated cardboard production line. Regular inventory of equipment spare parts to reduce the amount of illiquid funds and ensure the timely maintenance and production should be observed.
Perform Technical Upgrades and Apply New Technologies
In production, average speed is the major determinant for the productivity of corrugated cardboard production lines. At present, many carton equipment manufacturers have adopted new control technologies to optimize electric power distribution for use during the manufacturing process. Compared with corrugated cardboard production lines of the same type, high speed corrugated cardboard production lines can easily achieve the same productivity requirements without frequent speed changes. They consume about 20% less power, greatly reduce wastage and minimize the consumption of energy and materials in production.
The stable operation of corrugated cardboard production lines ensures the consistent quality of the cardboard produced. Moreover, the use and maintenance costs are extremely low, increasing the return on investment in the equipment. The use of intelligent designs of integrated control panels and human-computer interfaces makes the operation of the corrugated cardboard production line more intuitive and simpler. It also significantly reduces maintenance and labor costs.
Using the production line's production management system to control costs can accurately calculate efficiency, achieve speed synchronization of the whole production line and effectively reduce waste. Using automatic splicers significantly reduces the waste of body paper, improves machine speed and enhances production efficiency. If considering cost, at least one automatic splicer should be installed before the plywood process. It is important to pay attention to the choice of production control system, because many kinds of products can be used to realize production and management. The key point of selecting these cannot be limited to price comparison, but should focus on how to achieve the goal of accurately saving raw materials, especially by raising the accuracy of changing paper.
The computer can also automatically control the paste volume according to different paper qualities, as well as varying machine speed so the paste gap can be automatically reduced when operating at high speed, and paste volume can increase when operating at low speed. This saves at least 15% of paste volume. Furthermore, for temperature control, a computer can automatically adjust the drying area of the preheating cylinder according to paper quality. The speed of the machine can also be modified to ensure the hardness of the cardboard.
Apart from carton manufacturing companies and equipment suppliers, conscientious industry exhibition organizers have taken on the heavy responsibility of promoting green energy saving. Reed Exhibitions is key among these. SinoCorrugated South 2014, organized by Reed, will be held at the GD Modern International Exhibition Center in Dongguan from April 10 to April 12.
As the leading Asia-Pacific corrugated carton industry showcase, the event will feature the newest in printing technologies for this industry, namely, green practices, loss reduction and technological advances. The top local and international carton equipment manufacturers will take part in the exhibition and technological innovation products will be prominently profiled onsite.
Major corrugated carton production equipment like corrugated cardboard production lines as well as machines for printing, die-cutting, pasting boxes and laminating will be displayed, so will body paper, printing oil ink, printing plate materials and ERP production software. Each of these devices and solutions represent new technological highlights. These innovations have the effect of significantly improving efficiency in production equipment and broadening the options for users. Visitors will learn new trends from across the whole corrugated carton industry and benefit from technological innovation and efficiency promotion.
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