Double Facer: The secret to high efficiency

Innovative high technology for your Double Facer

The performance of your Double Facer is a critical factor for the productivity of your entire corrugator: this applies in particular to achieving the best possible maximum and average production speeds. For physical reasons, production speeds are often severely limited in this area of the corrugator. Whether you are running double or triple wallgrades: investment in proven technical developments on the Double Facer will always sustainably increase the performance of the entire corrugator.

With “DualBoost", BHS Corrugated has developed a specific module for the critical infeed of the Double Facer, to achieve a quick return by significantly increasing the production speed. The many years of market leadership and the pronounced innovation potential that BHS Corrugated can bring to bear with the aim of maximum economic efficiency for the operators of corrugated box plants is impressively reflected in this exclusive additional module.

The name DualBoost already gives a clear indication of how the module works. "Dual" refers to the clever combination of heating the lower top web liner in a functional unit with steam moistening of the upper, single-wall web. The high efficiency of the unit results in a "boost" of the gluing process as far as double-wall or heavier grammages are concerned. The optimum positioning of the DualBoost in the specially optimized infeed stand maximizes the effectiveness of the process, as the webs finally run together. The so-called "double kiss effect" is also significantly reduced by the special web guide, which leads to just before the gluing point. This leads to a constantly even gluing across the working width without edge gluing problems, again, the optimal design of the infeed stand is decisive for this.

The two independent functions - liner heating / corrugated web moistening - can be individually controlled depending on speed and board grade. The outflowing steam, which is directed in the running direction of the corrugated board, conditions the paper and starch at the flute tips prior to bonding with the liner. At the same time, the inner volume of the corrugated board is filled with saturated steam as an energy carrier, thus increasing the energy inside the corrugated board. This leads to faster heating and conditioning, which further reduces the risk of the corrugated board drying out. The spraying unit sprays saturated steam where it is really needed. This helps to save energy permanently and reduces energy losses.

The intelligent control system ensures that the amount of steam flowing out is not only in relation to the line speed, but also in accordance with the current paper width being run. The openings of the spray unit are arranged in such a way that they are maintenance-free. This ensures minimal maintenance and cleaning of the entire system. The increased energy level of the steam/air volume introduced into the web shortly before the gluing point results in a much more effective heat transfer. In this way, the use of DualBoost technology enables the adhesive strength of the webs to be increased by up to ten percent.

DualBoost units installed have resulted in production increases averaging up to 30 m/min with double wall qualities and up to 20 m/min with triple wall.