Corrugated Roller Cutting Edge Technology

The corrugating roller is the heart of the corrugating machine. Its durability, roughness, processing accuracy, and reasonableness of the retort type will directly affect the quality of the corrugated board and the speed of the production line. Therefore, we have deliberately selected some foreign and domestic frontier technologies for corrugating rolls to introduce to everyone, hoping that you can grasp the steering wheel of advanced technology development.

1. Advanced surface coating process Friese corrugating roller manufacturing company

ROCKWELLE tungsten carbide coating can be repeatedly refurbished, while the corrugating roller diameter does not change. Life is 2-3 times longer than chrome-plated corrugated rollers. The ROCKWELLE Cobalt-containing tungsten steel coating utilized by Flying Wire Corrugating Roller has a special hardness and smoothness. It is impossible to be worn except for diamonds, so the flying wire corrugating roller can run faster and longer, earning money for the carton factory. Get more money.

Terdeca's corrugating roller from Italy can provide a variety of coatings according to the customer's needs:
Tungsten carbide coating

As a high-density carbide, this tungsten carbide coating can be attached to the tip of the corrugating roll to ensure that the base paper passes through the corrugating roll, and that the corrugating roll has better wear resistance and longer work during corrugation molding. life. Tegra Corporation was the first corrugating roller manufacturer to use this type of coating. With experience gained from the installation of hundreds of tungsten carbide-coated corrugated rolls, Tegra offers an accurate assessment of the use of tungsten carbide coatings.

Mitsubishi Chrome Plating Coating

Mitsubishi's chrome coating was developed by engineers at Japan's Mitsubishi Corp. and is considered the best chrome coating technology on the market. Tegra Corporation can now use this technology. This technique has the following characteristics:
Thickness 0.15 mm = tight and uniform texture, this feature means that the corrugating roller has a longer working life.
The smooth surface (0.2 ? 0.4 mRa) means that the corrugation is more perfect.

NUchrome Chrome Plating

The corrugated rollers of the Tiru馻 corrugating roller company in Tiru馻 in Spain, whether it is new rollers or retreaded rollers, can provide extreme rigidity according to customer's requirements. NuChrome's chrome-plated or tungsten carbide coating gives the roller a harder surface and a longer working life. A dedicated department within the Tiru馻 Group produces chromium coatings and soon the company will start producing tungsten carbide coatings.

Shenzhen Yuanlu Machinery Co., Ltd. Corrugated roller surface hard chrome plating, deep hole plating, chromium layer processing thickness of 0.16mm or more, with the use of imported raw materials and the use of advanced foreign plating process to improve the binding of the coating and the substrate, better Refine the crystal structure, reduce the generation of micro-cracks, make the surface of the coating smooth, hard texture, solid and wear-resistant. At the same time in combination with electroplating treatment process, can restore the toughness and tensile strength of the substrate and maintain the original coating hardness.

Henan Yuanhang Packing Machinery Co., Ltd. adopts tungsten carbide plating on the surface. The Rockwell hardness can reach about 70°, and the life of the corrugating roller can be increased by 2-3 times compared with normal heat treatment.

2. Superior Heat Treatment Process Friese's corrugating roller manufacturing company uses a high-precision process to produce corrugated rolls that are 4-5 times longer than the nitrogen-hardened corrugating rolls.

The super-hardening technology used by Terdeca's Extra Fine Corrugating Roller is a unique hardening technique that includes a series of heat treatment processes to ensure the special properties necessary for corrugating roll production. Tejia is the only company that can provide this type of technology, far better than ordinary heat treatment technology.

The Tiru馻 corrugated roller company in Spain, inside the Tiru馻 Group, has a factory building that is responsible for the induction hardening of corrugating rollers.

Shenzhen Yuanlu Machinery Co., Ltd.

First quenched and tempered, after welding the shaft head with red beam steel pipe, the stress is relieved by the vertical oven, the vertical medium frequency electromagnetic hardening treatment process (Japan imported medium frequency quenching furnace) is adopted after rough machining, the surface hardness is increased, and the hardened layer is generally treated. It can be up to 5~8mm deep (unilateral). Its hardness can reach above HS83, and even, so it can greatly improve the wear resistance and toughness of corrugating roller.

Henan Yuanhang Packaging Machinery Co., Ltd.

At present, the surface hardness of domestic corrugating rollers is generally around HRC52° to 55°. Due to the low hardness of the teeth, it is easy to cause friction and extrusion of the relative displacement of the dome during ironing bending process at high speed. Crack wear or tooth surface produces pits and depressions, which seriously affect the overall machine speed and product quality. In view of this situation, the company has passed several tests and, with the help of domestic authoritative heat treatment experts, has developed a set of advanced technologies to perform several times of superhard heat treatment tests on the surface of corrugating rolls, adopting advanced heat treatment technologies. The ideal quenching medium is chosen to promote the uniform internal structure of the corrugating roll, and the grain refinement has small internal stress and is not easy to be deformed. The corrugating roll tooth surface quenching hardness is as high as about HRC62°-63°, the quenched layer depth is within 7m, the metallurgical structure The needle-like tempered martensite gives a significant improvement in the service life of the corrugating roller, reaching more than 12 million meters long.

3. New processing and grooving technology Friese corrugating roller manufacturing company

The German FRIESE corrugating roller factory uses the most advanced computer and the most precise and stable laser cutting machine, so the corrugating roller manufactured is very accurate, precise and smooth. It has a moderate height. And its surface smoothness is more important for the production of tiny pods (such as E, F and G 。).

Terdeca Corporation

Tejia now owns a total of 8 corrugating roller grinders, 5 in Milan, 2 in Lucca, and 1 in Zaoju, which can provide new corrugating rolls and refurbishment corrugating rolls for cartons in the world.

Tiru馻 corrugating roller company in Spain

The company has been investing in high-quality corrugating roller raw materials, and has added new types of grinding equipment to production facilities in Spain and the United States. In early 2003, the company moved into the newest plant in Spain. The new plant covers an area of ​​17,000 square meters, enabling the company to provide the best corrugating roller prices and solutions. In addition, in 2003, the company also established a joint venture with Fosber to produce new rollers.

Shenzhen Yuanlu Machinery Co., Ltd.

In the finishing process, the arc height control of the corrugator wheel, the surface finish, the precision of the rake tooth formation, the control of the corrugation tooth angle, and the roundness precision control of the corrugating wheel are all set by trained technical workers. The special grinding machine is completed by the computer according to the input instructions and its error is calculated by differential.

Henan Yuanhang Packaging Machinery Co., Ltd.

In order to prevent the final quenching deformation of the corrugating roller, the annular suction slots of the outer suction corrugating roller and the unconnected crescent suction slots of the inner suction corrugating roller are subjected to high-speed grinding and grooving after rough opening and quenching. The suction holes on the suction-type corrugated roller wall are generally difficult to machine due to their length and precision requirements. The company has successfully developed a deep-hole machining technology based on military-industrial drilling-gun-pipe technology. The deep hole machining accuracy deviation within 2.5 meters is only ±1mm.

4. Scientific optimization design

Germany Friese corrugated roller manufacturing company

The FRIESE corrugating roller made in Germany is one of the best corrugating rollers in the world. It adopts a unique “ROCKWELLE” 楞 type design to replace the traditional “U” and “V” 楞 type. It provides The world's finest and most accurate mortises make it possible to produce corrugated board with the best strength. The 楞-type accuracy can be measured with 2 to 3 digits after the decimal point. The "ROCKWELLE PROFILE" rake design saves a lot of paper consumption. The perfect 楞-shaped design, with its extremely smooth surface, greatly reduces the tension of the core paper, making it easy to operate on all kinds of low-weight materials. FRIESE corrugating rollers can reduce the use of core paper by 2-5% or more due to the unique ROCKWELE PROFILE® model, thus saving a lot of money for the carton factory every year.

Depending on the yield, the cost of the core paper, which is usually saved within 3 to 12 months, is sufficient to recover the cost of the corrugating roll. If the cost per million meters of paper is calculated, the FRIESE corrugating roller is actually one of the cheapest corrugating rolls in the world. FRIESE Corrugating Roller is the latest ROCKWELLE PROFILE TYPE to replace the old U and V shapes with the latest technology and the most advanced processing. The ROCKWEL PROFILE 不 model not only has a small amount of paper for core paper (2-5% on average), but also produces a stronger cardboard with better printability. Assumption: Core paper is US$300 per ton. The use of core paper accounts for 40% of the total paper used. The average corrugation rate is reduced by 3-5%, so the total consumption of raw paper can save 1.2%.
Total monthly paper consumption 1,000 tons/month 2,000 tons/month 3,000 tons/month tons saved per month 12 tons 24 tons 36 tons saved in US dollars per month US$3,600 US$7,200 US$10,800
Annual savings of US$43,200 US$86,400 US$129,600
If the monthly output is 8,000 tons, it will save US$345,600 per year, equivalent to RMB 2,860,704.

The majority of FRIESE corrugating roller users consider ROCKWELLE PROFILE to be the best 楞-shaped design, and it is most suitable to operate on high-speed single-faced machines. It is surprisingly low vibration and low noise.

Terdeca Corporation

Tejia can manufacture corrugated rollers according to the customer's specifications for saggers, and designs the best stencil according to the customer's requirements: squeezing rate, compressive strength and compression degree.

In any case, regardless of the type (spacing and height) selected by the customer, Tegra Corporation can verify/optimize the shape of the cymbal according to the height of the core paper of different materials and the proportion of the core paper used in different materials ( Top and bottom radius).

Tegal pays great attention to the radii of the top and bottom of these crucibles as this will reduce the pressure lines applied to the corrugated tissue as much as possible without increasing the consumption of starch paste.

For corrugated rollers coated with a coating (chrome or tungsten carbide), when designing the stencils, Tegras considers the thickness of the coating adhered to it along the stencil so that, even after the coating, the stencils are guaranteed. Accurate shape.

For grinding rolls, thanks to the use of computer numerically controlled grinding machines and unique software, Tegra can optimize the corrugating roll shape, ensure optimal operation (clearing the waistline) and minimize the increase in defect rate.

With the launch of a new generation of single-sided machines, such as the MRF and ZRF series requiring very large diameter corrugating rollers and pressure rollers, Tegal reviewed the traditional 楞 shape and relaunched the so-called “V-type corrugating roller 楞 type”. . Compared with the ordinary enamel type, this newly introduced enamel type can save 1-3% of the corrugated core paper consumption without reducing the compressive strength value of the carton.

In addition, a new model called Equirade designed by Tegra Corporation is suitable for any low-weight and high-strength base paper that can be produced at the fastest speed on a single-sided machine.
Tejia's attitude towards the corrugated type is that no one type is suitable for all customers. On the contrary, Tejia's goal is based on the customer's actual needs, and a group of R & D most suitable corrugated type.

Tiru馻 corrugating roller company in Spain

Tiru馻 corrugating rollers are specially designed according to the customer's requirements and can provide more than 280 different types of stencils to meet the needs of customers.

The company has been working on the characteristics of different types of enamels, and designed corrugated rollers to increase the strength of the carton while reducing the consumption of the original paper, thereby ensuring that customers ultimately enjoy lower costs.

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