Examination of the Transferability of Technological key Features of Paperboard Deep Drawing Towards the Application in Fast‐Running Packaging Machines

Abstract

The deep-drawing process of paperboard has experienced essential improvement in the recent past; however, the technological advancements have not been transferred to packaging machines yet. Two of the most important issues with regard to the reliable production of high quality 3D shapes are the use of elevated moisture and defined blank holder force profiles. This paper examines a roll preparation method for applying additional water to the paperboard and analyses a spring-loaded blank holder solution with regard to its achieved accuracy and reliability of the force characteristics. A two-sided roll application of water on the paperboard using a sponge rubber cover on one of the rolls produces a water intake of up to 12%. The effect of moisture applied by roll preparation is higher compared to conditioning under controlled climate conditions, and the preparation time is reduced to a few seconds. The spring-loaded blank holder introduced in the paper completely works in position control and avoids the switch over to force control as well as the problem of small position steps, which were necessary during force control. A harmonic oscillation of the blank holder while the material is drawn out of it could not be observed up to an output of 150 cycles per minute. An application of a roll-based moisturization unit and a spring-loaded blank holder force in modern packaging machines appears feasible and favourable according to the results of this paper and maintains the capabilities of this 3D forming technology to a large part.

Process cycle optimization in press forming of paperboard

“…2,10,11 Investigations to predict and analyze the failure of material in forming of paperboard have also been done by Linvill and Östlund 8 and Wallmeier et al 12 The process optimization of manufacturing processes has been done for traditional manufacturing processes, such as sheet metal forming, 13,14 but the optimization of the process cycle in the press forming to improve the quality and production speed has not received wide attention in previous studies with paperboard. However, there is increasing interest in this field, as shown in recent work by Hauptmann et al, 15 which analyzed a novel spring-loaded blank holder mechanism in high speed production of deep drawn paperboard products.…”

“…The process optimization of manufacturing processes has been done for traditional manufacturing processes, such as sheet metal forming, but the optimization of the process cycle in the press forming to improve the quality and production speed has not received wide attention in previous studies with paperboard. However, there is increasing interest in this field, as shown in recent work by Hauptmann et al, which analyzed a novel spring‐loaded blank holder mechanism in high speed production of deep drawn paperboard products. According to Groche and Huttel, there are several deficits in the terms of constitutive material and friction modelling, characterization methods, and process technology when stretch or deep drawing is applied to paperboard.…”

Converting and its effects on barrier properties of coated packaging materials: A Review

“…While many parameters result in complex trade-offs and constraints, for example, between visible forming quality and durability of a product, or dimensional stability and production speed, some parameters act synergistically to achieve better converting quality. Examples of such synergistic parameters include many that are closely connected with the mechanical properties of the materials used, such as temperature, moisture, and blank holding force (BHF) (Hauptmann et al 2011;Hauptmann et al 2017). Paperboard forming practices came originally from metal forming, with changes to account for the differences between the materials, in particular, the anisotropy of paperboard and its sensitivity to moisture and temperature change (Groche and Huttel 2016).…”

Role of blank moisturisation in press forming of paperboard

“…Conditioning paperboard at specific climate conditions can be expensive or time consuming and difficult to organize at industrial production sites. Active manipulation of water content in paperboard (and not obtaining equal moisture content nor equilibrium), such as spraying (Niini et al 2022), rolling (Hauptmann et al 2017), or steaming (Franke et al 2018), formerly has gained interest in paperboard forming. Previous works have provided starting points for this study.…”