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Corrugated 4.0: optimal process control

The objectives are clear: to produce high-quality corrugated board while utilizing raw materials and energy as cost-effectively as possible. One of the primary success factors is optimized process control for the entire corrugated board production process. This is why process automation is becoming increasingly important in modern corrugator systems. BHS Corrugated offers you a comprehensive range of software solutions and process control systems for both the Wet End and the Dry End. We call it Corrugated 4.0. With these solutions, you can improve the quality, environmental compatibility and cost-effectiveness of your plant.

Corrugated 4.0: process control systems and machines from a single source

Corrugator Control Center (CCC)

Corrugator Control Center (CCC)

Centralized order management

The Corrugator Control Center is the "boss" of the corrugator system. It receives all the orders from the host system and administers them across all machines.

Wet End Controller (WEC)

Wet End Controller (WEC)

The brain of the Wet End

The Wet End Controller (WEC) is the “brain” of the corrugator system. It stores all the settings for the Wet End. The advantage: same qualities or grades can always be produced using the same settings. The result is reproducible quality. The WEC features a straightforward visual display and state-of-the-art industrial design as well as intuitive operation.

Automatic Quality Change (AQW)

Automatic Quality Change (AQW)

Fast type change

The “Automatic Quality Change (AQW)” module allows your system to automatically change all quality-related settings as soon as a new grade passes through the machine. The result? Quick grade changes and faster average production speed.

Splice Synchronization System (SSS)

Splice Synchronization System (SSS)

Easily reduce waste

The Splice Synchronization System (SSS) allows your system to bring individual splice points together in the event of a quality change, thus minimizing waste.

Roll Verification System (RVS)

Roll Verification System (RVS)

Keeping track when you’re on a roll

The Roll Verification System (RVS) allows you to verify paper rolls before production and also to trace them back to the respective order. This is an increasingly important requirement, especially for customers who supply corrugated board to the food industry.

Warp Control System® (WCS)

Warp Control System® (WCS)

Keep it cool at the Wet End

The Warp Control System® (WCS) is a cutting-edge process control system for optimizing process temperatures at the Wet End of the corrugator. This reduces flatness errors while also allowing for colder and more energy-efficient production.

Optimized and safe production by AutoPilot (API)

Optimized and safe production by AutoPilot (API)

Optimized and safe production by AutoPilot

The AutoPilot of BHS Corrugated supports your corrugator crew in real time and optimizes the production speed concerning all process participants and their individual maximum production speed. This enables the corrugator to speed up to maximum speed by itself in a safe and stable way and also react to format and quality changes. Both,  machinery of BHS Corrugated and also external process participants such as the boiler or the conveyor system are connected to the supervising  AutoPilot. This enables a coordinated production even on plant level.

An additional module is the Dynamic Temperature Loop. This system provides the tracking of paper temperatures as well as the status of the Preconditioners and Preheaters. Based on this information a closed loop algorithm increases the production speed dynamically. This innovative procedure enables another huge increase of productivity.

This improved automatization and networking of your production process enables not only a significant increase of average production speed and product quality, but also a precise analysis of the process. Based on this, an accurate overview of its limitations can be derived.

Zero Defect System (ZDS)

Zero Defect System (ZDS)

For flawless bonding and high quality

Zero Defect Systems (ZDS) monitor the quality of the corrugated board you produce. During operation, the board is checked for gluing defects at two locations: at the Dry End, right after the Double Facer, and just behind the Webtrol unit. A number of sensors check the board for the smallest bonding defects, folds or splices. Any defective portions can then be ejected at the Cutoff at speeds of up to 400 m/min. These systems are available in various configurations.

Board Dimension Control (BDC)

Board Dimension Control (BDC)

The benefit always in view

Board Dimension Control (BDC) is your insurance for continuously dimensionally accurate cutting and scoring in corrugated board production. A high-precision laser sensor paired with an intelligent algorithm for profile identification enable the recording of all cutting and scoring positions on the board. In addition, the system monitors the board caliper and reacts immediately if deviations from the target are noticed. This reduces manual checking of the sheets and guarantees error-free output at any time.

Corrugator Resource Monitoring

Corrugator Resource Monitoring

Sustainability with a proof

Better stay on the safe side with BHS Corrugated – now and into the future. Our solution is based on a retrofit-ready sensor set. As it uses real physical measurement (no data interpolation), you can rely on safe documentation which also facilitates certification. Your customers will ask for such aspects in the future if not already today. Moreover, certification is an essential basis for incentives according to the EEG (Renewable Energy Act) in Germany.

HydroBar

HydroBar

Constant moisture for consistent quality

Paper is a product with complex characteristics – including inhomogeneous moisture throughout the working width.

HydroBar helps you to tackle this challenge and achieve high board quality with an excellent warp profile. The water spraying system can be finetuned in both distribution and quantity. Use our HydroBar where you prefer, at the Single Facer or the Preheater. For good reasons, the operator can use his experience to individually activate and set the nozzles.

Another benefit is its flexible use: It can be moistened both on the inner and the outer paper side, just according to your preferences.

At BHS Corrugated, we offer HydroBar first-hand as your OEM (Original Equipment Manufacturer) and face to the customer.

Our solutions for your corrugator

Our Portfolio includes single machines, complete lines and connect process- and control systems under the topic Corrugated 4.0.

Trainings

DATES and Events
Show all
Corrugator Training Seminar Advanced
Process technology in corrugated board production is a very complex issue. Very important is good and constant board quality. Therefore, it is…
Corrugator Online Training Seminar Basic
Process technology in corrugated board production is a highly complex issue. Different papers are processed under heat influence with adhesive to flat…
Corrugator Online Training Seminar Advanced
Process technology in corrugated board production is a very complex issue. Very important is good and constant board quality. Therefore, it is…
Troubleshooting Methods
A core task of technical staff is to find sources of errors systematically and to eliminate them permanently. This is particularly demanding in…

Your direct way to the corrugator

Contact

BHS Corrugated
Maschinen- und Anlagenbau GmbH
Paul-Engel-Straße 1
92729 Weiherhammer

+49 96 05 - 919 - 0info@bhs-world.com

Hotlines

24-hour Emergency Hotline
+49 9605-919-191

Spare Parts Hotline
+49 9605-919-291 spareparts@bhs-world.com

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