In July 2020, Hinojosa Packaging integrated a Corrucleaner HE 90 web cleaner into their BHS corrugator, because of the need to eliminate dust and contaminants. This would enable them to produce corrugated board with optimal properties for their high-quality digital printing process. Efficient web cleaning avoids problems such as poor print quality and expensive production stops for cleaning and re-adjusting.
Hinojosa’s quality assurance committee examined all the available dust elimination options, starting at Fefco Technical Seminar 2019, where suppliers present their quality improvement innovations in the corrugated board industry.
After careful consideration, they decided on Weducon’s Corrucleaner HE 90, a web cleaning solution specially designed for the production of corrugated board.
Seamless integration of Hinojosa’s web cleaner not interfering with existing equipment
Seamless integration of the web cleaner, not interfering with Hinojosa’s existing equipment, was a major consideration. Initially, Hinojosa decided to let local engineers prepare the BHS corrugator for the installation of the new web cleaner.
After the final inspection of the delivery scope, shipment to Spain followed. Our proven installation protocol ensures that a weekend-installation is ready on Sunday afternoon.
Prior to the installation, we contacted the customer to verify that all preparations were in place — the alteration of the existing BHS corrugator components to make space for the Corrucleaner and the supply of electrical signals for the operation of the web cleaner.
At this point, the customer asked Weducon to supply a complete turnkey installation without the need for any involvement of the Hinojosa Engineers.
This meant that we need to generate the necessary electrical signals ourselves to make the installation work: start/stop of the filter/fan, opening and closing of the cleaner in case of order changes/stops, and measuring the running flute sizes.
For this purpose, we developed the AIG, incorporating a laser thickness sensor, which operates independently from the corrugator’s control system and enables a fully automatic stand-alone solution with easy installation and commissioning.
BHS 2.800 Corrugator before retrofit of the Corrucleaner HE 90.
Weducon’s AIG generates all needed signals for automatic operation of the Corrucleaner without any requirement to interface to the line’s PLC system.
Weducon’s AFS-420 filter/fan unit placed at the drive side of the corrugator. Ducting over the floor.Installing the Corrucleaner HE 90 web cleaner without any loss of production time
For a smooth installation, we use a replacement grating instead of adapting parts of the BHS corrugator. By properly designing the replacement part for the BHS corrugator, installation of the Corrucleaner is possible in 18-22 hours. The advantage is that when the corrugator is shut down on Friday afternoon, there is no need to lose any production hours.
Corrucleaner HE 90 after successful installation. On the left side after the cleaner, the stainless-steel adapter frame is visible.Weducon completed all parts, including engineering, production, and finishing in less than five weeks from receipt of order.
Hinojosa’s corrugated board production line was stopped on Saturday at 14.00 hrs. Nevertheless, the machine was ready for production again on Sunday evening at 22.00 hrs. During commissioning on Monday, two 15-minute stops were sufficient to enable optimal settings to the system. Since then, the full range of benefits of Corrucleaner is at Hinojosa’s disposal.
Details web cleaning installation:
Hinojosa Packaging, Xativa, Spain
Web type: Corrugated board
Application: Corrugated board production for direct to board digital printing
Speed: m/min: 350
Web width mm: 2.800
Web Cleaning System: Corrucleaner HE 90
Filter/fan unit: AFS420
