In this first post of a series on the importance of gypsum board line alignment, we provide an overview of the issues that can occur when there is misalignment within the line. In upcoming posts, we will provide tolerance guidelines and alignment inspection methods for gypsum board lines.
As the construction industry (both residential and non-residential) continues to see an upturn, so too is the demand for gypsum board increasing.
This rise in demand typically pressures board manufacturers to operate their lines at optimum production speed – with a minimum amount of downtime and product scrap.
In order for gypsum board lines to continuously run with minimal disruption and product defects, all components within the line – upper and lower paper runs, creasers, forming tables, forming belts, live roller sections, knives, transfer conveyors, dryers, up-enders, and stackers – need to be properly aligned.
Misalignment can cause, or contribute to, many of the issues that cause board manufacturers severe headaches – both in product defects and equipment reliability problems.
Here we highlight some of the areas within in the board line that when misaligned, can cause the following issues:
Paper stands and automatic splicers
⇒ Missed or poor splices – leading to decreased uptime and/or decreased line speed
S-wrap pull stacks and paper carrying rolls
⇒ Upper or lower web tracking and tension problems
⇒ Baggy edges
⇒ Uneven mating of upper and lower webs
Forming table and plate
⇒ Uneven slurry distribution/formation
Forming belt components (head and tail pulleys, s-wrap and stretch rolls, conveyor top carrying rolls, “wobble rolls”)
⇒ Forming belt guiding/tracking and wear issues
Board formation/separation problems caused by:
⇒ Poor transition of product between forming table and forming belts
⇒ Poor transition of product from one forming belt to another
Live rollers/lead-in rolls
⇒ Poor product transition from the forming belts to the knife
⇒ Uneven cuts if the knife is not properly aligned to the product path
Equipment Reliability Issues
Equipment problems that can arise when areas within your board line are misaligned include:
⇒ Premature bearing and coupling issues
⇒ Increased or uneven wear of rolls and roll covers
⇒ Unusual increase in vibration
⇒ Increased energy consumption (steam, electricity, gas, air or hydraulics)
In the next post in this series, we will provide suggested alignment tolerances for your gypsum board line. In the meantime, if you have any questions or would like a quote for an alignment inspection, please contact firstname.lastname@example.org.