Several measures for achieving energy saving and consumption reduction in carton factories
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Throughout the current operation of China's carton industry, the production of raw and auxiliary materials is sometimes rising, and the vicious business competition between carton factories has made the thin profit of production more and more prominent, resulting in the falling profits of the carton industry and the survival of the factory. And development is facing a more severe test. In such an environment, carton companies only have to rely on energy saving to reduce their vitality and outlets. Therefore, it is the only and difficult for carton enterprises to improve the utilization of resources, earnestly maintain and rationally use precious production resources, and focus on reducing production energy consumption and raw material consumption, and obtaining the greatest economic return with as little resources as possible. Way. The author is particularly concerned about the energy saving and consumption reduction of carton enterprises.
1. Carton factories must achieve energy saving through management means
The energy conservation and consumption reduction of the factory should be mainly achieved through production management and process control, and the management measures and means are the most important. There is a saying that is good: "Things are artificial." Nothing in the production of the factory is done by people. The scientific and rational operation of the machine, the utilization of raw materials, and the arrangement of production processes are inseparable. In reality, the same machines, the same raw materials, different operating unions produce different production effects, and there are many examples. For example, when a single-sided machine produces corrugated paperboard, when the moisture content of the base paper is high, if the operator pursues the output in a one-sided manner and blindly drives the car, the corrugated cardboard produced is not only poor in hardness and stiffness, but also prone to degumming, curling, etc. Bad phenomena, production consumption is also large. Another example is the replacement of a key position manager, which may make a big difference in the management situation. Management is first of all the management of people, and humanized management is the source of energy conservation and consumption reduction. In view of this, the author believes that, first of all, the factory must be equipped with employees with certain management qualities to manage the workshop, to do a good job of propaganda and education for employees, to strive to create energy-saving and glory, waste shameful management atmosphere, improve staff Energy saving and consumption reduction awareness. Secondly, the factory must calculate and consume the data for each machine and each position, and conduct statistical statistics and assessments, and regularly publish the assessments so that they can be compared with each other. In this way, "the opposite is the case", invisible can greatly stimulate the entrepreneurial spirit of each employee, so that employees with high energy consumption and raw material consumption and poor product quality will turn pressure into motivation, produce work momentum that will catch up and make the production process There will be a significant improvement in the control of operational technology. Third, the factory should also actively organize and carry out various forms of energy conservation and consumption reduction competition; production management and production process rationalization proposals; equipment improvement and technological innovation and other activities to stimulate employees' production processes, technological innovation, energy saving The enthusiasm of consumption. Fourth, the production energy consumption, raw material consumption, technological innovation, energy conservation and consumption reduction of the factory should be included in the track linked to the employee's economy. Employees who have made certain achievements in energy conservation and consumption reduction should give certain spiritual encouragement and appropriate economic rewards. . If the production resources are wasted and the production quality is poor, the corresponding economic penalties should be given. In this way, Enwei and Shi, the factory's energy saving, production and management can form a virtuous circle, the factory has vitality and vitality.
2. Control production technology to achieve energy saving
In daily production, there is no shortage of energy and raw material waste due to improper control of production processes. Therefore, it is very important to scientifically and reasonably control the production process.
2.1 Single-sided machine production line should be properly distributed. If the single-sided machine is not produced with effective technical control, blind paper distribution, and the boxboard paper and corrugated paper with obvious difference in water content are matched and formed. The corrugated paperboard processed is easy to appear warping and has poor hardness. On the other hand, since the warped corrugated cardboard is attached to the facial tissue, quality problems such as foaming and degumming are likely to occur, resulting in an increase in the loss rate and a poor quality of the product. Therefore, when the single-sided machine production line is used for paper, the moisture content of the corrugated paper and the cardboard paper should be tested, and the corrugated paper and the cardboard paper with the similar water content should be matched to form the corrugated paperboard with high hardness and flatness. Well, in this way, when processing in the next process, the loss of semi-finished materials is small, and the quality of semi-finished products is also good.
2.2 Reasonable arrangement of the production process of the laminating machine. After the pre-printed carton paper is printed, the corrugated cardboard can be finished by the laminating machine. Due to the various structures of the laminating machine, the production performance of different laminating machines is different, and the production effect is also significantly different. If the flat paper with poor flatness, hard material, and calendered is arranged in a hand-operated laminating machine for laminating, it is prone to quality accidents such as foaming and degumming, resulting in an increase in scrap rate. Therefore, when arranging the production process, such facial tissue should be arranged on the automatic laminating machine for smearing, which can effectively reduce the production consumption and better ensure the product quality.
2.3 Energy saving and consumption reduction through rational imposition and reduction of trimming margin. The pre-printed corrugated box is cut by the die-cutting process to cut the edges of the paper or the adjacent side of the paper to ensure the appearance quality of the finished product. For cartons with a large number and special specifications, it is generally necessary to use custom-made base paper for production. The size of custom base paper specifications is directly related to production and production costs. Therefore, if you can print multiple versions for printing, and there are equipment conditions, it is best to use large-format printing. For example, a single carton unfolding format is 1200×530mm, and the layout of 530mm can be printed in two layouts. Then, using the oversized laminating machine and the die-cutting machine to carry out the splicing and die-cutting respectively, each piece can at least save the trimming amount of 1200×3mm2 area. In addition, the trimming amount of the front paper edge of the semi-finished product is reduced to 3 mm on the basis of 6 mm, and the amount of trimming of the area of 1200×3 mm 2 can be saved. In addition, the lap joint of the carton can also be left without trimming the paper edge. Thus, for a large number of cartons, its direct or indirect energy saving effect is a very substantial profit for the company.
2.4 Reasonable purchase of production equipment to achieve energy saving. Equipment is an important factor in the production of three elements. Only by purchasing appropriate production equipment according to the actual conditions of the factory can energy conservation and consumption reduction be achieved. There are various types of carton production and related equipment, single-sided machine, double-sided machine, paper machine, roll-cutting machine, laminating machine, packing machine, paste box machine, dryer, lithographic printing machine, soft Plate printing machine, glazing machine, die cutting machine, etc., the specifications, functions, performance, etc. of various machines are also different, the production must achieve the purpose of energy saving, the most important thing is to choose the appropriate according to the characteristics of the factory products Production equipment. The function and specifications of the equipment, the degree of automation of the equipment is often an important hardware that determines production efficiency and quality, and is related to energy consumption and material consumption. Therefore, when purchasing equipment, it is necessary to go deep into the market to fully understand the equipment market and see what is suitable for its products. Sample production equipment; see what kind of equipment has high production efficiency, stable quality, and low energy consumption; for the use and situation of other carton plant equipment, it is necessary to carry out detailed investigation and research, and through data analysis and demonstration, aiming The procurement direction of the equipment effectively avoids the production energy consumption and material consumption caused by blindly purchasing equipment. It takes a lot of money to buy a long time and it is difficult to break the regret. For example, a corrugated box with a quality grade can be purchased as a flexible printing device that integrates printing, slitting, slotting and indentation. It is not necessary to purchase a roll-cutting machine. Printing, indentation, etc. are completed in one time, with high production efficiency, stable quality, and low energy consumption and material consumption.
3. Technical transformation of equipment to achieve energy saving
3.1 The guide type single-face machine was transformed into a cover type vacuum adsorption method. When the guide claw plate of the guide type single-sided machine is used to a certain extent, a large wear phenomenon occurs, so that the corrugated paper cannot be accurately positioned on the lower corrugating roller for coating and molding. In addition, the applicator roller tends to accumulate adhesive on both sides of the guide plate, all of which will affect the uniform molding quality of the gluing and corrugating, the quality problem of poor adhesion, and the consumption of raw materials. The vacuum-adhesive positioning device of the outer cover eliminates the disadvantage of positioning instability caused by mechanical wear of the claw-type structure, so that the machine can realize normal high-speed operation. The guide type single-face machine is transformed into a cover-type vacuum adsorption mode, which can effectively ensure the processing quality of the corrugated board and reduce the consumption of the corrugated forming process. A significant advantage of the housing-type vacuum adsorption unit is that continuous, normal and stable high-speed operation is achieved when the production paper web has only 50% of the corrugated roll nominal size.
3.2 Replace the corrugated roller to save energy and reduce consumption. The high height of corrugated board, the number of turns in the unit of 30cm length and the waveform characteristics of corrugated board are important conditions that affect the strength of corrugated board. The structural characteristics of corrugated board also determine the corrugated paper rate for length units. The competition in the carton industry requires the production of quality-compliant cartons on the most economical basis. For example, the corrugated roller transformation that determines the amount of paper is used as an example to carry out technical transformation of the single-sided machine to achieve energy saving and consumption reduction. Based on the damage of the pick-up of a unit corrugating roller, it is necessary to replace the new roller. Therefore, when making a new corrugating roller, the corrugating roller is directly customized as: 48 teeth/30cm; the height of the roller roller is 2.9mm, The original number of teeth increased by 4 teeth, and the height of the molars was reduced by 0.2 to 0.3 mm, but it still falls within the standard range. In this way, the single-faced corrugated unit is subjected to process test analysis under the same production process, environment and paper quality conditions. The results show that the corrugated board produced by the machine before the transformation has more paper, but the quality is Not as good as corrugated paper with a small amount of paper on the corrugated layer. That is, the original 2m long corrugated paper can only form 1.385m long corrugated cardboard, and the 2m corrugated paper machine can form 1.405m long corrugated cardboard. After many tests and comparisons, the edge pressure strength, bond strength and plane compressive strength of the corrugated board produced after the machine transformation are higher than before the transformation, not only achieving the production purpose of energy saving and consumption, but also the quality of the product. Slightly improved.
3.3 Select a heat transfer oil furnace to achieve energy saving. Energy is a prominent factor affecting the production cost of carton. The heat transfer oil furnace can obtain a higher working temperature at a lower operating pressure. The heating temperature is generally 250-320 ° C, which can meet the requirements of carton production. Its main advantages are: thermal efficiency can be maintained at an optimum level over a wide load range; stable heating and precise temperature can be achieved; thermal oil furnace outlet temperature error is small; complete operational control and safety monitoring Device; can save energy and reduce consumption. Therefore, the heat transfer oil furnace has become the choice of some factories to replace the traditional steam boiler to achieve energy saving.
3.4 Add steam and condensate recovery system to save energy and reduce consumption. The steam and condensate recovery system is installed on the production line, and the condensed water and waste steam generated by the production line are pressurized by the principle of piston cylinder compression, and the water vapor mixture is directly pressed into the boiler to recover the boiler steam and steam. The machine forms a closed circulation system to achieve maximum energy savings. This steam recovery compressor adopts a new material with high temperature resistance and wear resistance, and has oil-free wear resistance. The steam recovery machine is directly recovered by high temperature method, the thermal efficiency is up to 60%, and the steam trap of the steam equipment can be eliminated. The steam recovery compressor is driven by a mechanical transmission system to pressurize the high-temperature steam-water mixture to reach and exceed the pressure during operation of the boiler, and press it into the drum to achieve recovery and save soft water and save electricity and coal energy. .
4. Energy saving and consumption reduction through procurement control
There are many raw and auxiliary materials produced in the carton, and the quality grades have standard ranges, but not all the products of the factory have reached the standard of the quality level of the calibration, and the products of the same grade, due to the management and production methods between the factories. There are some differences in the price of the factors, such as conditions. Therefore, the purchase of raw materials with reasonable price and quality is directly related to the quality and production cost of the carton products. The author believes that scientific and reasonable procurement methods should be: carry out necessary market research and inspection, master accurate market and information; improve the transparency of factory material procurement, bulk procurement should be determined through bidding; for the procurement of raw materials for production, Establish a warehouse inspection system; track the quality of the raw materials used; use the raw materials provided by different manufacturers, and conduct comparative analysis and evaluation when using them. In this way, the economical and affordable raw materials can be accurately selected to make the factory better. Achieve energy saving and consumption reduction.
5. Energy saving and consumption reduction through rational layout of plant layout and facilities
Carton production has the production characteristics of assembly line operation. The factory for carton production must consider the rationality of the layout, so that the materials and equipment between the original paper warehouse and the workshop, between the production lines, between the upper and lower processes, and between the workshops More reasonable. Standard factory buildings should consider the convenience of transportation of raw materials and semi-finished products, and also consider the transportation effect of pipeline energy; minimize production costs and meet the requirements of environmentally friendly production. The setting of the production layout cannot be perfect, but it is necessary to make a comprehensive trade-off between the advantages and disadvantages and to reasonably determine the rationality of the layout of the plant. For example, when there is a contradiction between production costs and environmental protection requirements, it is still necessary to make the setting of the factory meet environmental protection requirements in a one-off manner in favor of environmental protection and long-term interests. In addition, the newly built factory, especially the printing workshop, must consider the good lighting effect, and it can be produced normally without turning on the light during the day. The wiring of each machine's lighting device should be individually controlled. It is necessary to avoid the production of one machine at night, and the whole workshop has unreasonable wiring with bright lights.
In summary, the production consumption of carton enterprises involves factors such as production management, process control, raw material procurement, equipment characteristics and operation technology. Therefore, the author believes that the factory is only people-oriented, and it must be managed by humanity. Inculcate new ideas and concepts of modern enterprise management; and strengthen and strengthen enterprise management, establish and improve various management systems and measures; both must have a certain degree of punishment, but also implement appropriate spiritual encouragement and material rewards; From the point of view of the production source, we must pay attention to the control of all aspects of production, so as to better achieve energy saving and consumption, and improve the competitiveness of the factory.