Corrugator brakes increase productivity at Georgia Pacific container plant
3rd Quarter 2010
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Georgia Pacific’s container plant in Chicago was experiencing very high maintenance and downtime costs on the 8-inch (203 mm) corrugator brakes on its Martin roll stands. Georgia Pacific runs 1524 mm diameter rolls, 2489 mm wide at 260 m per minute. Maintenance manager Rodney Cotillie, explained that the airtube actuators and pressure plates were failing within eight weeks of operation due to the high heat generated during the unwind operation.
Cotillier approached clutch and brake manufacturer WPT Power Transmission to engineer a solution. It was found that the heat dissipation capacity would need to be doubled without changing the mounting or expanding the envelope dimensions of the existing brakes.
WPT came up with the WPT model 111 corrugator brake which featured a single 279 mm ventilated centre plate. This was designed to force cooling air through the brake and double the horsepower rating. Special low coefficient friction linings were used to maintain consistent brake torque without any fade which might be caused by temperature or speed change. The brakes were fitted with integral mounting plates which allowed for bolt up installation without machine modification.
Cotillier reported that the first set of corrugator brakes performed continually and reliably for 14 months without replacement of wear parts. The new brakes operated at only 17 to 20 psi, with 28 psi at full emergency stop, with no roll runoff.
Additional benefits of the new brakes were faster splices and reduced compressed air requirements on the entire system. Higher production capability, reduced maintenance and downtime cost, and greater efficiency were also credited to new brakes.
For more information contact Mike Vernes, PECS, +27 (0)31 303 3701, [email protected], www.pecspower.co.za
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