January 23, 2025
Steam Systems Upgrades Improve the Operational Runnability of Corrugators
Kadant Johnson is a full-service provider of steam and condensate system solutions for the wet end of corrugated packaging plants. Our expertise is in heat transfer, steam and condensate behavior, and steam system controls. Our technologies enable corrugators to run faster without board defects, use more recovered fiber in board, and use less energy. We partner with corrugators to improve their operational runnability and are proud to have contributed to an industry that has reduced greenhouse gas emissions by 50% per box from 2006 to 2020*.
Audits
Understanding the performance of a corrugated steam system and how to improve productivity starts with a steam system audit. This includes an evaluation of the boiler room and corrugator steam and condensate system equipment. This holistic evaluation includes transient condition analysis and paper temperature measurements after all heating components. Our experts partner with corrugators to prioritize improvement opportunities in production speed, board quality, and energy efficiency.
Hardware
We have a full portfolio of steam and condensate handling hardware that helps provide consistent heat transfer to form, adhere, and heat corrugated board.
As corrugators use more recycled fiber, the average length and freeness of the fiber is declining and it is becoming more difficult to form flutes, particularly at high speeds. Our ThermoMax® steam moisturizer system helps precondition the medium and improve flute formation on single facers. The medium is also able to accept starch more deeply and uniformly for better bonding at faster speeds.
As the liner and single-face pass over steam heated rolls, they need even and efficient heating. Our steam joints, including the LJX™ and CorrPro® rotary joint, securely support our rigid syphons to maintain precise syphon clearance and reliably evacuate condensate for even heat transfer. Traditional bent pipe syphons are flimsy, move erratically, and provide inconsistent condensate removal.
Once steam releases its heat energy into the process, it condenses into condensate. The ThermoZone™ condensate handling station moves the condensate to the boiler room for recycling and does not require differential pressure. This allows hot plates to run certain grades at the low pressures and temperatures needed for flatter board.
Systems and Controls
Hardware upgrades increase the capability of a machine section, but they are most effective when they’re part of an integrated steam system. Our ThermoMax® control technology combines PLC-based automation to manage rapid roll and hot plate temperature responses for real-time grade changes. Its supervisory control of blow-through steam increases energy efficiency. Our newest enhancement, the ThermoMax® alert system, provides remote performance monitoring by customers or Kadant experts. Steam system issues can be identified before they impact machine performance. Combining our hardware with our expertise in controls creates a steam and condensate system optimized for each corrugator’s process.
Services
The final piece to delivering turnkey solutions is installation and maintenance. Our team can install or supervise installations to make sure systems are installed correctly, the first time. Once installed, we can provide routine maintenance and safety inspections such as nondestructive testing and boiler room safety audits. This single point of accountability lets maintenance supervisors focus their limited resources elsewhere.
For more information, contact us at info@kadant.com.
* Source: fibrebox.org/life-cycle-assessments
