DS Smith Tri-Wall hots up plant capacity with infra-red drying 03 January 2012

DS Smith Tri-Wall is reporting massive improvements in coated board capacity at its Monmouth plant since installing an infrared drying system from Heraeus Noblelight.

Operational improvement manager Paul Welford says the new equipment has also contributed to a reduction in downstream waste and energy usage.

Welford explains that some of the company's new and existing markets require packing cases to be covered with an acrylic coating, to aid water resistance and to improve cosmetic appearance.

This, he says, involves applying the acrylic coating to the outer liner sheet board before the layers of board pass into the blanketing section of the line, where they are heated under hot plates to gel the bonding glue between the layers.

Previously, the coating had been dried by passing the layered boards over a steam-heated roller. However, this had not proved very efficient, as an increase in running speed had resulted in inadequate drying of the coating, which, in turn, led to coating being deposited on the hot plates in the blanketing section – with consequent quality problems and increased maintenance.

Faced with the need to increase output of coated corrugated board, DS Smith allowed Heraeus Noblelight to carry out preliminary on-site tests, using portable rapid response carbon medium wave infra-red heaters.

These proved so successful that a full-scale 56kW carbon infra-red heating system was installed, providing a total heated length of 2,500mm.

"Since installing the system, we have been able to double the line speed at the coating drying section," says Welford.

"This means that we can now double our production speed of coated corrugated board and boxes to meet anticipated growth projections. Not surprisingly, this means a pay-back for the project of less than 12 months."

Brian Tinham

Related Companies
Heraeus Noblelight Analytics Ltd

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