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Importance of Gypsum Board Line Alignment – Part 1

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.

Misalignment in the paper stand can cause missed or poor splices – leading to decreased uptime and/or decreased line speed

Product Issues

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

Wrinkles

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:

Image shows uneven product formation due to improper leveling of the forming table and forming section components

Image shows uneven product formation due to improper leveling of the forming table and forming section components

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

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 customerservice@oasisalignment.com.

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