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.
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)
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)
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)
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)
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)
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
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)
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)
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
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.
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.
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