The ABEL Pump solution at a Corrugated Cardboard facility
Today, corrugated cardboard packaging is seen everywhere. However, even though this product has been around for over 100 years, few know how complex the production process can be and how varied the product is depending on configuration and structure.
Klingele Papierwerke has been producing raw paper for corrugated cardboard in two different locations in France and Germany, for more than 50 years. These raw papers are the basis for producing packaging and corrugated cardboard products.
The factory produces corrugated boxes, die-cut packaging and folding boxes in various shapes and sizes.
Corrugated cardboard is light and at the same time stable. The secret – as the name indicates – are the corrugations that lend the cardboard very high stability. At the same time, the air-filled chambers created by the corrugations ensure its unique cushioning function.
The product is produced by combining different layers of paper by means of starch glue.
Fluted sheets and flat liner boards are glued to each other in several layers, so that the final result is a single, dual, or triple wall corrugated cardboard.
The core manufacturing piece is the flute lamination machine. This very long machine consists of several individual units which are separately and independently controlled. Inside the machine, individual layers of paper are heated, moistened, laminated and then dried. Afterwards the desired format is cut to size.
An important component in manufacturing corrugated cardboard is the glue that is used. Klingele uses glue that is based on natural starch. Electric-diaphragm pumps made by ABEL (model EM) are used to transport the glue at a temperature of 35-40°C to and from the flute lamination machine as well as for continuous circulation.
These pumps are electrically driven, double-diaphragm pumps with mechanical membrane deflection. Unlike the previously used compressed air operated diaphragm pumps, the EM generates considerably less noise; the irritating ventilating noisewhen the control valve is triggered does not occur.
In addition, the energy savings is impressive due to the pumps high efficiency…consuming a fraction of the energy required by air operated pumps.
Cost savings are especially significant during continuous operation. Energyconservation was one of the main reasons Klingele selected these pumps.
All installed pumps are controlled with a variable frequency drive (VFD).
Being true positive displacement pumps, EM pumps are very tolerant of changing degrees of viscosity which is common with starch glue and therefore can deliver reliable and consistent flow independent of counter-pressure.
The first ABEL EM pump was delivered and commissioned in the summer of 2011. Since then, another 7 identical EM pumps have been added.