MAY 2006

The well-trained operator

Some things he really ought to know, and how to make sure he does
By Wayne Porell Paper:

T o realize the business imperatives of efficiency and

profitability, corrugators face daily the challenge
of maximizing productivity, maintaining quality, and
• Why we add wrap to a preheater, and how much
is enough
• Proper paper temperatures and how to control them
minimizing waste.
• Why liners cannot be overheated and how to know
There is no magic, set-it-and-forget-it formula for success. when they are
We deal with a host of variables that change continuously. • Why liners are run on wire or felt side
Today’s fact is tomorrow’s fiction. Today’s answer is
• How to run preprinted liners
tomorrow’s question.
• The proper loading pressure for different widths
About the only constant is the need for people who of paper
know what they are doing. Ideally, all your crews and
crew members should be able to operate well and deal Corrugator:
professionally with issues that arise with or without
• How to hang rolls of paper safely and efficiently
supervision.
• Proper operating procedure for splicers to reduce
Your best shot at making this happen is continuous tail waste
training. Here is a short list of some things a well-trained • The best way to control each type of warp
operator knows: • How to operate his machine station safely
Adhesive: • How to perform a visual check of board
and test board quality
• Is the starch formulated to specifications, and why
• How to identify bonding problems
• Why we run specified starch viscosity and gel and how to solve them
temperature, and what happens when we don’t
• How to read and interpret soak samples
• How to check adhesive viscosity, temperature and make adjustments accordingly
and gel point
Corrugating companies deal with training with more or
• How to identify the cause of an out-of-spec batch
less formality, depending on their needs and resources.
of adhesive
TAPPI, of course, has available to its members a deep
• How to correct or compensate for a batch of adhesive reservoir of technical information. Another valuable
that is out of spec resource available to all is the technical knowledge and
• Fully understand the mixing equipment and TVC system assistance of industry suppliers. Nobody knows their
and be able to identify and respond to an equipment products better than the people who make them. Paper
problem suppliers, adhesive suppliers, and equipment manufacturers
• When waste water is used to formulate the adhesive, are all eager to help you succeed with their products.
be able to troubleshoot issues caused by the water From our beginning, Harper/Love Adhesives has striven to
• How to run water-resistant adhesive and produce provide a technical resource for the corrugating industry.
the best water resist board with the current adhesive With combined experience totaling more than 600 years,
formula our field staff has solved just about any problem you’re
• Why we run a particular starch setting likely to encounter, and is eager to help.
• Why starch cannot be used to control warp
 What’s happening?
M.E.T. — a formal program What do we want to happen?
for corrugating success How do we make it happen?
by John Kohl

H arper/Love Adhesives Corporation was founded almost

30 years ago with the idea that the corrugated industry
needed a leader, not only in adhesives, but in all aspects
a team effort and agreed upon by both the crew and plant
management.
With the MET program in place the Harper/Love team sets
of support to a corrugated box plant. With this as our goal up monitoring for a wide range of corrugator and adhesive
we have become the industry leader as an information data points. Some of these points are;
resource with our extensive library, and also as a provider
of technical service and training support. We currently have • Board quality
the largest field support staff in the industry with forty • Warp and warp control
people in sales and technical service dedicated to helping • Board testing
box plants with problem solving, continuous process • Board wet strength testing
improvement, and training. • Paper testing
• Paper temperatures
Our in-house library contains a vast amount of • Adhesive testing and charting
information and specifications on all types of starch mixing • Raw materials testing
equipment, storage tanks, pumps, and silos in use today. It • Adhesive consumption
also contains information on most corrugating equipment, • Waste identification and ways to control, reduce,
steam systems, waste water use, paper and board testing and eliminate it
information, and various crew training videos. • Training programs needed for the operators
Ten years ago Harper/Love organized all this knowledge • Service program and frequency needed
and information into a formalized package we call the MET
program. MET stands for “Management Extension Team.”
It is a program where we work with the plant management The net result of the initial audit and
and crews to establish a continuous improvement process base-line monitoring is total cost reduction for
for all aspects of the corrugator. This includes both training
the corrugating process by correcting
and documentation for the starch adhesive and all the
corrugator operations. or improving the processes and improving
board quality. The more effort put into
To establish
a base line of improving quality and efficiency, the higher
current machine the return to the plant.
conditions,
product quality,
and to set goals As the program progresses we reevaluate periodically
for improvement, with the plant management what is being done and repeat
the Harper/Love the improvement process.
Team audits the As each goal for improvement is reached in an area, the
entire corrugator team sets a new goal that is realistically obtainable. With
process. the crews, management, and the supplier involved, there is
This comprehensive audit includes: a constant exchange of ideas and information that help a
• Complete equipment survey plant improve quality and efficiency while reducing overall
• Current adhesive formulation evaluation costs.
• Current adhesive mixing equipment evaluation The effort that the Harper/Love technical representatives
• Adhesive storage and transfer equipment put into each box plant that wants the value-added benefit
• Adhesive application equipment of the MET program is tremendous. It is why Harper/Love
(glue rolls, metering rolls, rider rolls, contact bars) has become the corrugated industry leader in not only
• Corrugator heat assessment on all vessels water-resistant products and performance products, but in
• Corrugating roll wear training and service, as well.
• Bearing wear With this much emphasis—by all members of the team—
• Splicer evaluation on the many variables that affect the total cost and quality
• Level of corrugator crews skill and knowledge of the finished box, there is a higher degree of success
Based on the information collected during the audit, for the plant involved. It truly becomes a clear win-win
areas for improvement, potential savings, and crew proposition for any box plant.
training needs are assessed and goals set. These goals are
 Training is a priority for Northeast sales-tech tag team

Two corrugating pros keep customers happy in eleven-state area

B etween them, Sales Rep Phil Smith and Tech Rep Wayne
Porell have over a half century of corrugating experience.
Their customers have learned to rely on that experience and
expertise not only to keep their starch kitchen and related
systems in order, but also for training and troubleshooting
throughout the corrugating operation.
“Harper/Love is very
helpful,” says Joe Pagani,
production manager for
Wayne Porell in classroom and checking a sheet with Danny Miller, cor-
Accurate Box in Paterson, rugating supervisor for Tim Bar, Oxford Division.
New Jersey. “They spend
time with our people and
high marks for technical support and training. “They do
help us know what to watch
formal training for us at least once a year, and in their regular
for—whether it’s what makes
visits, they keep an eye on our systems and make sure
a good sheet, why problems
they’re operating as they ought to. Just because a system is
occur, what the technical Lisa Hirsh, president of Accurate Box automated doesn’t mean it’s working right; Harper/Love helps
parameters are to get a good Company, reviews reports with Phil
Smith. Accurate Box specializes in
us keep an eye on things.”
result.”
litho-laminated packaging. Mr. Snyder says he also knows he can rely on Phil and Wayne
“What we’re all after,” says
to respond quickly to technical problems that might arise, and
Phil, “is to produce consistently a firm, flat, dry sheet. There are
to stay up to date on industry developments. “We know they
a lot of variables that go into that and we try to watch them all.”
will pass along technical know-how they pick up in their work
Training is both formal and informal. Wayne has developed a experience and steer us in the right direction,” he said.
series of seminars on starch, roll stock, the double backer, the
Harper/Love help goes beyond just technical issues, Phil
single facer, the slitter, the downstacker, and supervision. These
says. “For example, because of Wayne’s experience, he is a
are presented classroom style. Says Wayne, “Whatever the
good coach for new foremen who have never been in a position
subject, I try to present to the whole crew, so everybody has the
of management. It’s a new environment for them and it can be
same information.” Wayne and Phil also spend time as needed
difficult. Wayne’s been there and can give these guys good,
one-on-one at the machine, helping with troubleshooting or
practical advice.”
specific technical questions.
Phil and Wayne serve Harper/Love customers in Connecticut,
Wayne says he and Phil each try to visit each customer at
Delaware, Maine, Maryland, Massachusetts, New Hampshire,
least once a month. “How much training is needed depends on
New Jersey, New York, Pennsylvania, Rhode Island, and
the plant, the issues they face, and how much turnover they
Vermont.
experience.”
Even in a plant that enjoys a relatively stable work force,
training is ongoing. “We’re big on cross training,” says Accurate
Box’s Joe Pagani. “We rotate our guys so they can work
anywhere on the
line. That way we
can cover a long
vacation or other
absence without
worry.”
Gene Snyder,
vice president and
plant manager Phil Smith lives in Delran, Wayne Porell lives
for Tim Bar, New Jersey. He joined in Chambersburg,
Oxford Division Harpºer/Love 15 years Pennsylvania. He has
in New Oxford, ago. been with Harper/Love
Wayne Porell with Gene Snyder, vice president Pennsylvania, gives 8 years.
and plant manager for Tim Bar, Oxford Division, Harper/Love
in New Oxford, Pennsylvania.
 Sales-tech tag team •

for success
M.E.T.—a formal program •

The well-trained operator •

In this issue:

ADVANCED ADHESIVES REPORT

e-mail: [email protected]
800-438-3066 • www.harperlove.com

Charlotte, NC 28241-0408
P.O. Box 410408
11101 Westlake Drive
Harper/Love Adhesives Corporation
good adhesives better™
of making
Leaders in the science

Common problems on the corrugator: the book

This handy 16-page pocket guide by Chris Polster and
Bill Nikkel addresses directional fiber pull, and seven
delamination issues, including flutters, cold spots,
light-test blisters, no-starch blisters, and more. Ask
your Harper/Love rep for your copy.

Decades of experience in your pocket!

Between them, Chris and

Bill have over 75 years of
experience in all aspects of
corrugating operations. Add
the wisdom in this booklet to
your personal know-how.
Chris Polster Bill Nikkel