Fosber Complete Corrugated Board Production Line

WET-END AREA

PRO/FACER – Single Facer N.1 & N.2 (Qty: 1 each)

Each Single Facer is equipped with:

• Liner preheater (drum Ø 900 mm, motorised adjustable wrap arm)
• Medium preconditioning and steam shower (integrated fluting pre-conditioner roll Ø 500 mm, on-board steam shower system)
• On-board steam system with proportional pressure control, TLV steam traps, Johnson steam joint, manual quick disconnect for cartridge change
• Inclined belt take-up conveyor with high grip clipped belts (no nip point), reverse angle for easy paper threading, positive paper traction on liner side, independent servo motor and drive control
• Bridge belt and motor (horizontal, independent motor and gear, synchronised inverter drive, 6 x rubber belts)
• Chiller – closed loop water cooler maintaining cold water at 18°C; feeds the refrigerating bar within the single facer unit
• Automatic glue dams with edge guide (fully automatic motorised glue dam positioning with edge detection system)
• Motorised cart to move cassettes in/out of single facer (heavy duty, joystick controls, hydraulic pack, rechargeable industrial battery)
• Cassette with corrugator rolls and peripheral heating:
• One cassette module with corrugating rolls
• Upper corrugating roll: Ø 480 mm (without crown)
• Lower corrugating roll: Ø 305 mm (with crown)
• Reduced labyrinth design for differing roll sizes
• Infeed guide rails and self-adjusting centralising plate
• Quick-connect/disconnect system for fast flute changes
• Stainless steel glue station with minimum glue level alarm
• Motorised glue dams with automatic positioning
• Glue unit gap setting: 0.1 mm to 0.6 mm (hydraulic cylinders, mechanical gap setting with gauge)
• Automatic self-calibrating gap control
• Engraved chrome applicator roll
• Automatic disengagement during corrugator stop
• Chrome doctor roll with machine-tooled doctor blade
• Curve preheating plate for medium
• Vacuum system for constant and uniform pressure
• Single piece heavy duty frames with low centre gravity
• Extended nip system (upper corrugator roll section)
• Fully automatic "Kiss" pressure control (independently adjustable each side)
• Heated "Kiss" press roll (lifted away from corrugating rolls at machine stop)

LINK 400 A – Splicer (Qty: 5)

• High-speed low-tension splicer; splice speeds up to 350 mpm
• Paper tension range: 150 N to 900 N
• Paper grammage: 80 gsm to 440 gsm (recycled, semi-chem, kraft)
• Zero tail splice using 50 mm double-sided tape; splice length 55 mm
• Patented profile splice in a single continuous movement
• Rotating nip design for secure splice with zero impact
• 2 x fixed splice preparation positions at each end of the machine
• Innovative design: no need to dry/rewind the paper before splice preparation
• Automatic indexing of prepared splice into exact position
• 2 x fixed upper head splice heads (blade, brake assembly and upper nip roll housing on auto-positioning motorised carriage)
• Double festoon system with horizontally moving double dancer with AC servo motor control for instantaneous area/web tension control
• AC-driven accelerator roll
• On-board electrical cabinets and pneumatics
• Tail-link: auto-initialises the splice at paper break
• Auto roll detection (laser photo-eye) to automatically adjust roll diameter and paper width
• Exit idle roll (Qty: 5)

STAND M2 – Roll Stand (Qty: 5)

• Duplex shaftless roll stand
• Max roll diameter: 1,525 mm / max weight: 4,000 kg (direct loading from floor)
• Lifting by double hydraulic cylinders on each shaft (one at each end)
• Hydraulic unit driven by inverter
• Operator command console with regulators and pushbuttons
• Safety pedal to enable machine functions
• Expandable torque-activated radial expansion chucks: 100 mm or 4" diameter (different pressure types and chuck diameters available on request)
• Manually operated controls for roll loading and unloading cycle sequence
• Pneumatic brakes type RE-NOVA multi-disk
• On-board control panel
• Semi-automatic roll loading/unloading automation (additional sensors, controls and software for the auto loading/unloading cycle; operator must manually move the new roll onto the corrugator line before the Manual Assist sequence)
• Chucks – Torsion activated chucks (eccentric design, self-locking under all work conditions, automatically centred)
• Automatic core ejectors – Qty: 5 (pneumatically driven, physically push off the empty core)
• Mechanical bridge interface (Qty: 5) – special steel threaded bars and levelling shims

BRIDGE – Double Flute (Qty: 1)

• Robust modular steel structure
• Driven conveyor belt section with inverter control for festooning single face board
• Walkway along full length on the operator side with access staircases at each single facer
• Adjustable support positions to fix guide rollers, bridge drive rollers, etc.
• Waste divert flap (pneumatically activated, directs waste sheets into a trolley)
• Pendular rolls – compensating and self-aligning rollers to remove unequal paper tension across the web; more uniform flute formation and glue application

PRO/BACKER – 300 (Qty: 1)

Composed of 3 main units: Multiple Preheater, Glue Unit, Double Backer

Multiple Preheater – 3 Preheaters:

• Pre-heater drums: Ø 900 mm, driven at line speed for 300 m/min operation
• Motorised adjustable wrap arm with automatic control
• Upper level fitted with piping and siphon, steam joint and flexible hoses
• Upper level (no mandatory stacking, not vertically stacked) to reduce paper path distance to glue machine and reduce heat loss
• On-board modular steel frame support with stairs and walkway
• On-board electrical cabinets (unified single PLC and 1 touch screen control for the entire PRO/BACKER group)

Glue Machine – 2 Levels:

• Servo drive system; each level fully independent settings
• Doctor roll: Ø 200 mm, chromed with adjustable scraper blade
• Engraved Anilox applicator roll: Ø 200 mm, chrome engraved with individual speed control (positive or negative coil design)
• Auto glue gap/film thickness control via on-board database glue curve controls
• Precision glue gap setting between doctor roll and applicator roll: 0.05 mm to 0.65 mm with micro incremental adjustment control
• Glue film generated submerged so always created under constant hydrostatic pressure
• Counter flow stainless steel glue pans designed to prevent slinging
• Minimum glue level alarm system
• Quick drain facility for easier cleaning
• Automatic glue dams system (auto-positioned)
• Applicator roll stops at all corrugator stops to prevent gelling; filled with high thermal inertia liquid to stabilise temperature of applicator roll
• Auto gap/film thickness maintained through simple geometric design

Pressure System – Rider Rolls:

• Two pneumatic cylinders placed at extremities applying pressure on the flutes
• Each level has an independent pressure system
• Pressure on paper regulated by the effective thickness of the paper being worked

Double Backer – 16 Hot Plates:

• AC-controlled lift platform for smooth sheet-by-sheet descent
• Platform counterweight system for faster lift deck cycle time
• Touch screen controls; diagnostics and manual override stand-alone machine program, independent of dry-end controller
• Intelligent program to synchronise cycles and movements to minimum working speeds for gentler handling of sheets according to speed, flute and format
• Constant shingle density feature (adjustable via touch screen)
• Backstop drive controlled by Servo PLC and absolute encoder feedback (no homing required)
• All platform I/O connected to AC Drive
• Lenze AC Drive with embedded Servo PLC
• "Steady Stack" belt over roller inverter-driven platform deck fitted with powered rollers underneath
• On-board cabinets to reduce wiring, noise and installation time
• All standard catwalks, stairs, platforms and handrails

E+L Alignment System (Qty: 1)

• Model: BVW 9325 – aligner with outer liner sensor
• Web positions detected by non-contact wide band sensor
• Pivoting non-crash wheel assembly to steer the web
• Manual override allowing operators to offset the single faced web from the centre line
• System detects the position of the outer (bottom) liner via wide band sensor COMPACT line
• Aligns the single faced web to the exact position of the bottom liner
• Constant master/slave operation even after paper changes

E+L Brake – Closed Loop Tension Control (Qty: 1)

• Model: PFW 9321T
• Actual tension measuring and monitoring system
• Maintains constant paper tension after the web guide system
• Closed loop system with preset values according to net weight of single faced web and friction value of the bridge
• One rubber roll per station each with 2 x ventilated pneumatic brakes for uniform and constant braking of the web
• Frictionless braking with zero speed differential between braking rubber roll and single faced web
• Continuously measures actual single face tension
• Automatic tension adjustment according to preset values

DRY-END AREA

PRO/CUTTER – Single Level 300 (Qty: 1)

Composed of 3 main units: Rotary Shear, Slitter Scorer, Cut-Off Knife

Rotary Shear:

• Blade-to-polyurethane rotary shear for a single cut; gap-less AOC (or multiple chop) to eject waste sheet boards
• Blades installed in the upper roll can be divided into independently activatable sections for partial cuts and order change commands
• All blade sections activated for full-width cut-to-waste or conventional gap order change
• Max single chop speed: 200 mpm
• Max waste discharge (multiple chop-to-waste): 150 mpm
• Operable from Rotary Shear and Dry-End Control Desk
• Automatic waste removal system with corrugator stops
• Automatic waste sheet extraction via pneumatically activated diverter to direct sheets into a trolley
• Waste removal trolley

Slitter & Scorer:

• Order change time: 0.3 sec (plunge system)
• Order change speed: up to 200 mpm (conventional type)
• 2 independent slit-score stations (slit + slit + score)
• Minimum distance between scoring heads: 40 mm on each shaft (no limits in tandem mode)
• Single piece slitting and scoring tools for long life
• All tools for 7 boxes out: Tungsten thin blades
• Fast set-use via precision rack and pinion robotic system
• Intelligent robot system – selects Fast Set or Steady Set mode according to actual order run length
• Auto scanning system to ensure tools are set in correct position
• 2 x upper robot and 2 x lower robot to set the score stations
• 1 x upper robot to set the slitter heads
• Slitting head position from above the board line
• Thin-blade slit system for virtually perfect edges with tungsten-coated hardened blades
• Fast replacement of individual blades (2 minutes)
• Each slitting blade independently disengaged from the board line
• Facility to exclude individual blades from normal operation
• Program to allow uniform wearing-down of all mounted blades
• Fixed metal contact bar with Teflon strip anvil for simple maintenance
• Magazine system to hold Teflon blocks for automatic loading and displacement along anvil contact bar; Teflon blocks reusable up to 4 times
• Automatic tool sharpening system with computerised monitoring and control
• Zero blade lubrication: totally eliminated

Automatic Auxiliary Score Station:

• Fully automatic, for scores against shaft
• Max speed: 300 mpm
• Allows individual scoring distances less than 40 mm
• Uses the same robot from the main unit for complete automatic set-up
• Mechanically identical to main scoring stations

Cut-Off Knife – Single Level (Qty: 1)

• Complete inlet frame manually retractable for maintenance and cleaning (fully opened)
• Double pull roll in-feed per knife level with common drive controls
• Cut with light inertia knife bars driven by specially designed servomotors
• Patented technology in knife bar for extremely long tuning frequency and blade life
• Knife bar and servomotors connected with high quality oil-lubricated gears
• Helical single piece knife with fully adjustable blade position
• Knife bar equipped with 2 serrated blades that run without lubrication
• OIL-FREE technology
• 2 x 52.8 kW motors per level
• Measuring wheel

ZDK Stacker – Single Level (Qty: 1)

• Max sheet lengths per bay: 2,600 mm to 6,000 mm
• Max total weight per stack: 3 tons
• Auto order change and stack separating via moving clamp system
• Precise sheet count per stack
• Automatic brush control system with 4 x brushes
• Vacuum section under first brushes
• 6 x individual anti-skew V-belts with own AC speed control
• "Auto-Step" control to track amount of product on belts to platform
• AC controlled lift platform for smooth sheet-by-sheet descent
• Platform counterweight system for faster lift deck cycle time
• Touch screen controls with diagnostics and manual override
• Intelligent program to synchronise cycles to minimum working speeds for gentler sheet handling

GENERAL CORRUGATOR COMPONENTS

PRO/SYNCRO – Corrugator Control System

• Version: Complete Corrugated Control
• Model: Comfort
• PRO/Syncro licence for client PC (Qty: 2)
• Overhead display: Fosber LED TV (Qty: 1)
• PRO/Active – closed loop by operator (Qty: 1)
• Interface with Roll Management (Qty: 1)
• Client Consoles (Qty: 3)
• PRO/REMOTE Service Pack (Qty: 1) – remote service software
• Signal Centralizer (Qty: 1)