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welcome to gp corrugated where we



manufacture and sell corrugated sheets



standard corrugated containers



and a variety of specialty packaging



products



today we'd like to show you how we make



our products



the beginning of all corrugated



packaging is corrugated board



a series of sophisticated machines



acting in unison to create the



corrugated board is called a corrugator



the raw material of corrugated board are



the container board grades of paper



liner which becomes the flat facings of



the board is primarily made from the



long fibers of softwood trees



medium which becomes the fluted middle



layer of corrugated board is made



primarily from shorter fibers from



hardwood trees



the first step in making corrugated



board occurs in a machine called a



single phaser



a single phaser combines a liner and a



medium to form a single face web



to do this the medium passes through a



set of corrugating rolls under high heat



and pressure to form the flutes that



give corrugated board its strength and



cushioning capability



each set of corrugating rolls are made



in specific flute profiles to create the



performance attributes needed for the



finished packaging item



a pressure roll loads the correct



pressure and also brings the liner into



contact with fluted medium after a



cornstarch-based adhesive is applied to



the flute tips by the glue roll



the glue roll turns against a metering



roll to control the proper amount of



adhesive that is delivered to the flute



tips



it is critical that the correct pressure



is applied to the corrugating rolls and



that the adhesive reaches the proper



temperature and consistency to form a



strong bond between the liner and fluted



medium this combination is called the



single face web



the single face web then leaves the



single phaser and is elevated to a



bridge that carries the web to the



double glue unit and the double backer



the liner and corrugated medium are fed



into the single phaser from opposite



sides via a pair of roll stands for each



they are connected by a device known as



a splicer



the splicer allows for changing from one



roll to another without stopping the



machine when the roll is consumed or



when a change in paper grade or width is



required



as roll stock is unwound and heads to



the single phaser the paper passes



around heated rolls or pre-heaters that



bring the paper to the proper



temperature for the corrugating process



wrap arms control the amount of time



that the paper is exposed to the heat



enabling a degree of control in



increasing or reducing heat to the paper



the single face web is carried up and



away from the single phaser by incline



belts



the web folds up in festoons for the



length of the bridge until it enters the



enl section of the bridge that leads to



the triple stack



this allows the single face web to cure



with a firm bond so the integrity of the



flute structure is not disturbed



if double wall board is being made both



of the corrugator's single phasers are



running and delivering two single face



webs to the bridge to be combined at the



double glue unit



the single face web is threaded through



heated rolls and into a machine called



the double glue unit that applies the



cornstarch based adhesive to the flute



tips the liner that will become the



outside facing of the corrugated board



is threaded through the heated rolls on



the bottom of the triple stack



the outside or double faced liner is



joined to the single face web as the



board is pulled into the double backer



the double backer generally has a top



and bottom belt that pulls the board



through the machine



the double backer has a series of heated



plates that continue to transfer heat



into the board to cure the adhesive bond



it is the belts in the double backer



that pull the board through the wet end



of the corrugator and push it to the dry



end where the combined board is scored



slit and cut to finished specifications



after the board goes through the double



backer it passes through a shear that



severs the board to permit order changes



and then into a slitter score



the slitter score slits the board into



the proper width



and if needed places the scores into the



board to the specific dimensions



the state-of-the-art slitter score shown



here has two separate slitter score



sections one section is setting up for



the next order while the other is



running



when it is time to change orders



the shear severs the board to create a



small gap to allow the slitter score



sections to either drop in or rise from



the board path



so the board can align between the top



and bottom shafts that the scoring and



slitting heads are mounted on



this feature allows order changes to



occur at line speed



after the board is slipped and scored it



continues to the cut-off knife



the cutoff knife cuts to the precise



dimensions requested of the finished



corrugated sheet



most corrugators have an upper and lower



knife so that two different orders can



be combined to run on the same width and



grade of paper



there are exit rolls that eject the cut



sheets onto belts that shingle the



sheets to the stacker bays



the stacker beds of the corrugator



accumulate the sheets into stacks which



are then discharged on moving belts for



the stacker operators to perform quality



checks and prepare for strapping and



shipment



converting machines turn corrugated



sheets into boxes



these machines print designs and



branding onto the boxes and cut the



boxes into the proper dimensions for



their need



there are two main types of machines



rotary die cutters and flexo folder



gluers



the flexo machine glues and folds the



box upon completion



while the rotary die cutter leaves the



box unglued and flat



rotary die cut boxes are typically



formed by hand such as pizza boxes or



wrapped around a product and joined on a



customer's equipment



a rotary die cutter also has the ability



to produce multiple boxes from each



sheet whereas a flexo machine yields one



box for every sheet



through a series of lasers and optical



sensors called photo eyes and



communication between an inventory



management system and real-time



production scheduling material is



transferred to each machine center onto



an in-feed conveyor



automatic transfer carts keep each



machine fed with corrugated sheet stock



each stack is broken down into smaller



sections called blocks and shingled



individually to a feed table



the sheets are fed via a set of feed



wheels that work in conjunction with



feed rolls that insert the sheet in the



machine



feed rolls are made of a soft durometer



material that prevents the board from



being crushed



maintaining board caliper or thickness



is essential to providing overall board



strength to the final box



a vacuum transfer system carries the



sheet through the machine across



multiple print sections



on a rotary die cutter machine the



designs and branding are printed on the



bottom of the corrugated sheet stock



after the stock moves through the print



section it reaches the rotary die



cutters



there are different cutters for every



box type that the factory produces



the cutters are built from two half



cylinders with metal blades embedded as



well as foam rubber sections to eject



the cut board scrap pieces



scrap is recaptured and recycled back to



a paper mill to be used in future roll



stock production



the next section is called the scrubber



which removes any remaining loose



cutouts and any rough edges on the cut



sheets



the sheets are then shingled again to



slow down the speed in which they reach



the stacker



if the cut sheets hit the stacker too



hard it will damage their edges



the stacker beds accumulate the sheets



into stacks which are then discharged on



moving belts for the stacker operators



to perform quality checks and prepare



for strapping and shipment



the beginning of the flexo process is



very similar to that of the rotary die



cutter



stock is fed into the conveyor by the



automatic transfer carts



each stack is broken down into blocks



in this flexo machine the printing is



done on the top of the sheet so the



stock must be inverted



the stock is transferred to a pre-feeder



where the stacks are inverted



this automation eliminates the need for



manual inversion



the sheets are then shingled and loaded



into a feed bed where feed rolls insert



the sheet in the



machine print plates are mounted on a



cylinder and an ink system allows ink to



be applied to the print plate where it



transfers the ink to the board as it



passes through the machine



this machine uses rotary die cuts as



well but it only produces one box per



sheet unlike the rotary only cutter



which can produce multiple boxes per



sheet



the scrap is again recaptured and



recycled for future roll stock



on a flexo machine glue is applied in



preparation for folding



after the glue is applied



boxes are carried through a folding



section with vacuum assisted belts and a



series of folding rods



forcing the panels to fold in the proper



sequence



the folded box is now glued and joined



as it exits the machine and is stacked



into bundles to the customer



specifications



compression time is given to allow the



glue to fully cure



depending on customer specifications



each bundle is strapped together to



provide for stability in transit and



ease in handling at the end user



to aid in the quality process especially



at high speed



a high-speed detection system called



clear vision is used to monitor glue



placement and gap measurements on every



box



a high-speed camera is placed at the



point of glue application and can detect



the amount and thickness of the glue



lines as well as the measurement of the



slots in the front and back of each box



these measurements are compared to a



developed standard that can predict



whether a bad box will be produced as it



travels through the machine



any out of spec box that is detected



will be sprayed with the uv coating and



the bottom of the bundle will also be



sprayed



as the bundle travels down the conveyor



system a black light detects the uv



coating and will eject the bundle so



that an operator can locate the off



quality box and remove it prior to



reaching the customer



to account for the speed of production a



doubler is used to assist crew members



in combining each bundle in preparation



for load forming



the doubler stacks bundles on top of



each other



these combined bundles are then



assembled into a specific stacking



pattern to meet customer needs



load tags are inserted into each unit to



uniquely identify each load as it is



sent to shipping to be made ready for



delivery to the customer



at the end of another workday you can



rest easy knowing that you have the very



best corrugated supplier in the industry



whether you need corrugated sheets



standard corrugated containers or



specialty packaging products we hope



you'll look to georgia pacific as your



supplier of choice



safety sustainability



innovation quality



customer focus and value creation



it's in our dna in everything we do