Training
Services
This is what we're About
At Corrugator Training and Services, we have extensive corrugator machine experience and a vast understanding of the corrugated process. Our training includes classroom and hands-on corrugator machine training with classroom evaluations to ensure understanding. We also conduct corrugator performance evaluations and provide coaching during the operation process.
Featuring
This Is What We Do
Our trainers work with your on-site champion to reinforce training and ensure sustainability after our departure. We provide radio communication with our trainers so they can hear and coach your team effectively on the corrugator. We take time during stressful corrugator situations to evaluate the issues with your team and discuss corrections that reduce downtime or prevent it.
- 01
Basic Training
Classroom training – 1-2 Hours
• Theory of bonding paper together
• Starch understanding
• Machine Cleaning – Key areas for inspection
• Communication on corrugator
On Machine follow up – Two weeks of follow up and reinforcement
• Radios provided by plant for trainer
• Communication reinforced over radio
• Established plant lead for sustainability to work directly with trainer
• Daily pre-shift cadences reviewing previous scenarios with entire group
- 02
Theory Training
Fundamentals of Corrugation
3 elements of focus in reference to bonding paper:
• Heat
• Starch
• Pressure
Starch - Application Process
• Applicator Roll / Metering Roll
Lagging – purpose
• Absorption Process
• Moisture implications
Heating – Steam Transfer
• Vessels
• Verification
• Moistureretention
• Troubleshooting
Pressure
• SF Pressure – Belt / Roll
• DF Pressure – Ballasts / Shoes
Quality Control System evaluation/training (where applicable)
• BHS – WCS/WEC
• COPAR
• QualiTek
- 03
Starch Understanding
Formulation
• Ingredients
• Purpose of each ingredient
• Impacts from each ingredient
• How formulation is determined
Gel Point
• What it is
• How to pick the gel point
• How it can change / what affects it
Viscosity
• What is it – what affects it
• How to pick the Viscosity
• How it can change
- 04
Machine Cleaning / Key Areas
General machine components and functionality
• Corrugating Rolls
• Pressure belt / Roll
• Applicator roll / Metering Roll
• Heated Vessels
Key areas of focus for cleaning / inspection
• Moving parts / sensors
• Seals
• Known wear items
BHS MF-B Example:
- Glue roll cleanliness
- Metering roll cleanliness
- Wiper blade inspection
- Eddie current sensors
- Corrugating roll end cleanliness
- Upper and lower seals
- Felt
- Teflon Bar
- Vertical seals for corr rolls
- Rubber seals
- Brass seals on corrugating rolls
- Drain on glue unit
- Corrugating roll prism cleanliness
- Glue unit rail cleanliness
- Air flow ports above glue roll
- Rinse bar cleanliness and functionality
- Verification of chilled waterflow
- Glue dam functionality
- Cleaning, greasing and inspection
- 05
Communication
Communication and teamwork
• Pre-emptive downtime communication
• Splicing
- Splice coming up
- On the way
- How it looked
- Stacker positioning
- Communicating quality after splice
• Quality changes
- Calling out paper before getting to it
- How it looked going up
- Communicating in plates or if splice sync is not correct
• Size changes
- Calling out ahead of time
• With Trim amount
- How it looked going up
- Communicating in plates o When dams are in position
• Flute changes
- Communicating prior the needs and position of people
- Communicating when all is in the plates
• Speed changes
- Communicate prior to taking up to ensure wet end set
• Dams
• Lineup
• Lineal on rolls
Short / long cutoffs
- StackerpositioningNarrow / wide trim
- Setting dams
- Communicating quality
Butt rolls
- Line all efton roll
Startups
- Location of start up
- Bridge break
- Hot plates
Quality issues
Support needed
Issues with roll stock
Issues with Conveyor System
Breaks
Communicating estimated duration of downtime
• Tasks to be completed during these times based on duration
- CleaningMF
- Pulling trolley tracks
- Cleaning glue dams
- Keeping MF running
- WIP full pushed to 1st Shift
- 06
Focused Training
Focused Individual Training – 1 Trainer – 4 weeks
Designed for individual or small group training with no previous
Corrugator experience – operations / supervision options
Classroom training – 6+ Hours broken throughout week with testing
• Corrugated overview
• Quality – ‘what’s what and what’s good’
• Machine functions and terminology
• Preventative maintenance – key areas of cleanliness – operation inspections
On Machine – Reinforcement of classroom material on machine
• Radios provided by plant for trainer and trainee
• Application of classroom material
• Hands on observation with group where applicable
Theory of Corrugating
• Understanding of adjustments based on testing results
• Reviewing situational decision making
- Scenario work
