Mayr-Melnhof Baiersbronn produces virgin-fiber board of the highest quality. For many years their two sheeters were equipped with a first-generation web cleaning solution that recently needed replacement.
Because of their focus on quality and performance, Mayr-Melnhof was curious to see whether new developments in web cleaning technology led to improved cleaning results. Other priorities included decreasing energy consumption and lowering noise levels.
As the supplier of the old web cleaning equipment was still around, they were the first to show the contemporary possibilities.
First of all, it is remarkable that the original 30-year-old equipment is still available. But since the design hadn’t changed, this would for sure not lead to better results. So this opened the doors for recent developments.
Delivering on promises
The route to a web cleaning solution offering all that Mayr-Melnhof needs was a tough one. Because how can you be sure that the chosen solution keeps all its promises? And how to evaluate if the cleaning results are as good as expected?
The new web cleaning solution kept all its promises: energy consumption is down by a positive 50%. Noise levels are well below the legal limits and don’t exceed 83 dB. And the best is yet to come: the cleaning performance exceeds all expectations.
Considerations to take into account before choosing a web cleaning system
First of all, we carefully considered the complete labor environment.
- How much space is available?
- Can we gain space around the production lines to make operator tasks safer?
- Is the web cleaning solution operator-friendly?
- Can the system be automated?
- What is the use of consumables and spare parts?
- Can we simplify regular maintenance compared with the previously installed equipment?
One thing was clear: in addition to excellent cleaning capability, Mayr-Melnhof’s system had to be maintenance-friendly and take up as little space as possible.
How we built Mayr-Melnhof’s bespoke web cleaning solution
To start with, we equipped Mayr-Melnof’s two sheeters with 2.500 mm wide Weducon HE-90 series web cleaning devices. By using the available space efficiently, we avoided complicating operators’ live.
Treading the web is without obstructions. When the cleaners open for feeding in a new web, pneumatic slide valves cut-off the air flows immediately. As a result, no vacuum catches the web, so this further simplifies handling.
To retain space, we placed the filter/fan unit in an adjacent warehouse. Rigid laser-welded ducting connects the two sheeters to the filter/fan unit. Using the same track as the trim extraction saved additional space.
Saving space and power, optimizing cleaning performance
To maximize productivity and ease operator tasks, we considered all maintenance around the lines. All electrical cabinets open without obstruction. And all brackets are accessible and positioned with operator-safety in mind.
The interfaces that connect the web cleaning systems to both production lines were included in the scope. An individual switching guarantees energy reduction when a single production line runs. Furthermore, two setpoints command the standard frequency converter to use as little power as possible while guaranteeing the stunning cleaning performance.
Reducing maintenance and downtime
We automated all operator functionality, from the self-cleaning filter/fan unit to the protected 24V DC active ionization. Except for regular emptying of the dust collection tray, the only maintenance task is an annual service (carried out by the supplier).
The results prove that effective web cleaning improves quality and production, without the need to complicate operators’ tasks.
Take a look at Weducon’s efficient web cleaning methods for paper and board production. For more information, references, and details on the made-to-measure solutions that Weducon offers, please contact us.
Details web cleaning installation:
Mayr-Melnhof Frischfaser Baiersbronn, Germany
Web type: Board (paperboard/solidboard)
Application: Board production
Speed: m/min 300
Web width mm: 2.400
Web Cleaning System: HE 90
Filter/fan unit: AFI-840