Corrugated Paper Making Line: High-Performance Production for Packaging Grades
Corrugated Medium and Testliner Production
Corrugated paper, including corrugating medium and testliner grades, forms the structural core of corrugated board packaging. Production volumes for these grades are among the highest in the paper industry, with single machines producing 300-800 TPD. The stock preparation line must handle high volumes of recycled fiber, primarily OCC (Old Corrugated Containers), while maintaining consistent quality for high-speed corrugator operation. Basis weights typically range from 90-180 gsm for medium and 115-200 gsm for testliner.
High-Capacity Pulping for OCC Processing
The pulping stage uses large-capacity Hydraulic Pulpers rated at 400-800 TPD for single-line operations. Operating consistency of 3.5-5% with rotor power of 250-500 kW ensures rapid defibering of OCC bales. The pulper includes efficient junk removal through raggers, junkers, and a debris extraction well. Pulping energy consumption for OCC is relatively low at 18-25 kWh per ton due to the already-processed nature of the fiber, though starch and adhesive residues from previous converting operations require additional cleaning stages.
Robust Screening and Cleaning Systems
Pressure Screens with 0.20-0.35mm slot baskets form the primary screening stage, handling the high contamination load typical of post-consumer OCC. A two-stage screening cascade with secondary and tertiary stages recovers usable fiber from the primary screen rejects. The reject thickening and dewatering system concentrates the final reject stream to 30-35% dryness for efficient disposal. High-density cleaners operating at 3.0-3.5 bar and forward cleaners at 2.0-2.5 bar provide complementary contaminant removal with combined efficiency above 90%.
Refining for Strength at High Production Rates
Corrugated grades require refining energy of 60-100 kWh per ton to develop the burst strength, ring crush, and Concora values specified by packaging converters. The 1100mm Double Disc Refiner with 700-900 kW motor handles the high throughput volumes, processing 200-400 TPD per unit. Refining control is based on freeness targets of 350-450 mL CSF for medium and 320-380 mL CSF for testliner, with specific edge load of 1.0-1.5 Ws/m to balance strength development with drainage rate on the paper machine wire.
Energy Consumption and Cost Optimization
Total stock preparation energy for corrugated paper lines runs 100-150 kWh per ton. The largest energy consumers are refining (60-100 kWh/ton) and pumping (15-25 kWh/ton). Energy optimization focuses on matching pump speeds to actual production rates through VFD control, reducing recirculation flows in screening and cleaning circuits, and implementing medium-consistency technology where applicable. Annual electricity savings of ,000-15,000 per production line are achievable through systematic energy audits and equipment optimization.
Maintenance for High-Volume Operations
High-volume corrugated paper production places significant demands on equipment wear components. Pulper extraction plates in OCC service should be inspected bi-weekly and rotated monthly. Screen baskets in primary position require cleaning every 1-2 weeks due to high stickies loading from OCC. Refiner plates for corrugated grades wear faster than those for virgin fiber grades, with typical service life of 4-8 months for cast plates. Planned maintenance shutdowns every 6 months, with a 2-3 day window, allow comprehensive inspections and scheduled part replacements.
Complete Line Engineering and Support
Leizhan Technology engineers complete corrugated paper production lines with capacities from 100-800 TPD. The project scope includes process design, equipment manufacturing, installation supervision, commissioning, and operator training. Equipment is designed for the specific furnish characteristics and end-product quality requirements of each mill.
Contact for production line planning and equipment specifications:
Email: leizhanzhang@gmail.com
Website: www.pulprefining.com