Organised Paper Handling & Logistics (OPHAL)

Industry partnership project

OPHAL partners•

European Rotogravure Association (ERA)

•

Nordic Offset Printing Association (NOPA)•

Idealliance

(International Digital Enterprise

Alliance), USA•

IcmPrint

(International Centre for

Manufacturing by Print•

WAN-IFRA

•

Supporting sponsors (eg. ABP, ToI, TH, etc.)

Paper (and board): vital resource•

400 mn

mt

consumed annually worldwide

•

Cost critical element•

Focus of this project is transport, handling and storage; some elements of paper on press also included

Report/book structure1.0 Paper and cores –

wrapping and pallets

2.0 Inspection, diagnosis, and reporting3.0 Warehouse/paper store4.0 Handling equipment5.0 Best practice roll and pallet handling6.0 Transport securing and lashing6.1 Road transport6.2 Rail transport6.3 Containers6.4 Maritime transport7.0 Paper onto press and recycling

Paper should remain wrapped in its damp-proof packaging throughout the logistics and storage chain. It should not be unwrapped until any difference in its temperature and RH has been balanced out with the ambient pressroom conditions. Paper stability for optimized printing is achieved at 20 to 25 deg C and 50-55% RH.

1.

Dynamic strength2.

Critical speed for wide web presses

3.

Straightness and roundness4.

Torque transmission

5.

Dimension6.

Moisture

7.

Handling/flat crush

Cores

Correct wrapping criteria

Inner head covers adjusted to diaCorrect plug properly in positionCore must not protrudeProperly sealed rollAdequate moisture barrierWrapper well stretchedWrapper end well secured to roll bellyHead covers adjusted to roll diaSharp and sufficiently wide foldingOuter head cover same as roll diaOuter head cover well centred

Rolls are carried with the friction force generated between the wrapper and clamp pads. The wrapping carries approx. 30% of the weight when correct clamping force is used.

Roll damage

Recommendations to optimize paper storage

•Store under good ventilation conditions. Air should circulate freely around stored paper which should not touch outside walls.

•Avoid storing paper in areas that are subject to extreme temperature changes such as heated objects, vents or cold walls. Paper should never be stored in direct contact with concrete where it may be exposed to damp conditions.

•Storage conditions should be the same as pressroom if possible.

•Adequate acclimatization is essential for very cold paper (see chart).

•Paper should be kept in its protective wrapper. Re-wrap any paper not used.

•Prior to printing, paper rolls should be conditioned with their edge covers removed but with the body wrap left in place until preparation of the splice.

Overlapping stacks create high risk for edge damage. The edge is the weakest part of the roll.

Rolls stored in 60 deg angled rows using FIFO movement with separate roll-in roll-out aisles.

Stacking heights

Ratio of roll diameter to stack height –

1:6 or 1:8

Paper handling equipment•

Paper handling chain is long: 16 stages

•

Paper is variable, so too the handling tools•

The lift truck –

with clamps

and forks

•

Different paper grades require different clamping force (see roll label)

•

Softer grades deform locally under clamp pads•

Higher recycled fibre

roll more prone to out of

roundness damage•

Wrapper handling properties are important

•

Detailed specifications for lift trucks must be developed

Mast tilt

A 5 degree forward tilt to ensure that the short arm pad is under the paper roll and the long arm

pad is over the top.

High stacking and mast tilt:

A forward tilted mounting has a severe negative effect when there is a need to stack the paper rolls. To overcome the built-in forward mounting tilt, the lift mast itself must be tilted backwards when rolls are being stacked. Then, when the mast is tilted backwards during the stacking operation, the lift truck cannot anymore reach the correct position on the side of the roll stack. In some situations this can prevent the stacking

operation

completely. For this reason all paper roll clamps used for high stacking should be delivered with near-zero or zero degree mounting.

Paper typeContact pads All round Soft paper Medium-Hard Tissue Durability MaintenanceCast pads l l m High LowRubber faced pads l l l Moderate LowSteel-sprayed pads l (1) l l Moderate Low-ModeratePolyurethane faced pads l (2) l m Moderate Low-ModerateRubber faced pads with grooved rubber l (3) l l l Moderate Low-ModerateFlexible pads with rubber band l (4)Oversized rubber faced pad for tssue l (5)

Clamp contact pads

1: Steel sprayed pads have very high friction, good for icy environments. Not recommended for plastic wrappers.2: Polyurethane faced pads non-marking friction surface have relatively good friction properties.3: Rubber faced pads with grooved rubber ”sticks”

less to the wrapper.

4: Flexible pads with rubber band adjusts to different roll diameters. Primarily for newsprint to minimise surface pressure.5: Tissue paper uses oversized rubber faced pad.

Not always smooth sailing!

•Container sizes are highly variable and rarely coincide with the sizes and weights of paper rolls.

•Containers may be subject to harsh treatment both when handled at the shipping terminal and also by all types of transport from braking, sharp turns and uneven ground.

•Bad conditions at sea have an effect similar to a truck braking sharply. In addition, containers may be subject to brief peak loads and repetitive stresses from a ship’s rolling motion.

•As their average service life has increased along with difficult cargoes such as metals and plastics that deteriorate containers, the condition of containers is declining. Repairs are often inadequate.

The greatest moisture stresses occur in winter when transporting from a cold to a warmer climate.

Containers exposed to the sun can have temperature variations of 20-30 deg Celsius. Any moisture trapped inside will evaporate and when the temperature falls at night condenses and falls onto the paper cargo.

Containers

Protect cargo along the container sides by using runners strong enough to resist transit forces.

Loading must be uniform with the container’s centre of gravity.

The cargo must be secured so that it does not move in transit.

CONTENTS

FUNDAMENTAL PAPER CONDITIONS FOR PRINTERSOptimise

temperature and humidityPaper rollsStatic charge

INTERNAL LOGISTICS FOR PRINTERSPaper delivery inspectionStoragePaper handling

ROLL PROCESSING EFFICIENCYWeb breaksSplice faults and web breaksRoll changing and splicing devicesRoll coresSplicing tapes and tabsWeb tension –

a key to efficiencyPreparing the roll for splicingRoll to web processing stepsFlying splicer

straight patternsSplice tailsZero speed splicingCore troubleshootingTroubleshooting and maintenancePaper roll repairs