High-Consistency Cleaning Systems for Quality Corrugated Medium Production
High-Consistency Cleaning Systems for Quality Corrugated Medium Production
Corrugated medium and testliner produced from recycled fiber face two primary challenges: maintaining strength properties from lower-quality furnish and managing the high contaminant load typical of mixed waste paper. High-consistency (HC) cleaning at 3-4.5% consistency before screening significantly reduces downstream equipment wear while improving overall fiber recovery rates.
Technical Specifications: Leizhan Recycled Fiber Processing Line
- High-Consistency Cleaner: Operating consistency 3-4.5%, pressure drop 1.0-1.8 bar, heavy contaminant removal >95%, accepts loss <3%
- Coarse Screen: 2.0-3.0mm holes, consistency 2.5-3.5%, rotor speed 1,200-1,500 rpm, rejects 10-18%
- Fractionator Screen: 0.30-0.50mm slots, separates long and short fiber fractions, accepts 55-70% long fiber
- Fine Screen: 0.15-0.25mm slots, consistency 1.2-1.8%, sticky removal 85-92%
- Double Disc Refiner: 660-910mm diameter, 250-700 kW, specific energy 40-80 kWh/t depending on freeness target
- Disc Thickener: 250-400 TPD, outlet 10-14%, filtrate suspended solids <300 ppm
Energy Efficiency Data
Processing OCC and Mixed Waste to corrugated medium typically consumes 180-220 kWh per ton of finished paper. The HC cleaning stage, operating at 3-4.5% consistency versus conventional 0.8-1.2%, reduces pumping energy by 22-25% in the cleaning circuit alone. Leizhan Double Disc Refiner with optimized plate pattern achieves a 15-18% reduction in refining energy compared to conventional single-disc refiners at the same freeness drop.
Maintenance Recommendations
- HC cleaner cones: Inspect lower cone section for wear every 3 months; replace when wall thickness reduced by 1.5mm or more
- Screen baskets: Coarse screen (2-3mm holes) service life 18-24 months; fine screen (0.15-0.25mm slots) 10-14 months
- Fractionator rotor: Foil clearance check every 6 months; adjust to 0.5-0.8mm gap
- Refiner plates: Track kWh/ton trend; replace when energy increases 20% above baseline for same freeness target
For technical consultation and equipment quotation, contact our engineering team.
Email: leizhanzhang@gmail.com