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Press forming of paperboard – advancement of converting tools and process control

Tanninen, Panu (2015-12-14)

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Tanninen A4.pdf (2.305Mb)
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Tanninen, Panu
14.12.2015
Lappeenranta University of Technology

Acta Universitatis Lappeenrantaensis

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Julkaisun pysyvä osoite on
https://urn.fi/URN:ISBN:978-952-265-897-5

Tiivistelmä

Press forming is nowadays one of the most common industrial methods in use for
producing deeper trays from paperboard. Demands for material properties like
recyclability and sustainability have increased also in the packaging industry, but there
are still limitations related to the formability of paperboard. A majority of recent studies
have focused on material development, but the potential of the package manufacturing
process can also be improved by the development of tooling and process control.
In this study, advanced converting tools (die cutting tools and the press forming mould)
are created for production scale paperboard tray manufacturing. Also monitoring methods
that enable the production of paperboard trays with enhanced quality, and can be utilized
in process control are developed.
The principles for tray blank preparation, including creasing pattern and die cutting tool
design are introduced. The mould heating arrangement and determination of mould
clearance are investigated to improve the quality of the press formed trays. The effect of
the spring back of the tray walls on the tray dimensions can be managed by adjusting the
heat-related process parameters and estimating it at the mould design stage. This enables
production speed optimization as the process parameters can be adjusted more freely.
Real-time monitoring of pressing force by using multiple force sensors embedded in the
mould structure can be utilized in the evaluation of material characteristics on a modified
production machinery.
Comprehensive process control can be achieved with a combination of measurement of
the outer dimensions of the trays and pressing force monitoring. The control method
enables detection of defects and tracking changes in the material properties. The
optimized converting tools provide a basis for effective operation of the control system.
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PL 20
53851 Lappeenranta
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