Description
| Flute Type | Flutes per feet | Height (mm) | Take-up Ratio |
| A | 34 ± 3 | 4.6 ± 0.2 | 1.4 – 1.52 |
| C | 39 ± 3 | 3.6 ± 0.3 | 1.36 – 1.45 |
| B | 49 ± 3 | 2.7 ± 0.25 | 1.32 – 1.4 |
| E | 74 ± 3 | 1.6 ± 0.25 | 1.27 – 1.38 |
| F | 120 ± 3 | 0.7 ± 0.2 | 1.15 – 1.25 |
Factors Affecting T.U.R.
| FLUTE #1 | FLUTE #2 | FLUTE #3 | |
| Flute Type | B | B | B |
| Flutes per feet | 48 | 48 | 49 |
| Flutes | 163 | 163 | 166 |
| Height | 2.8 mm | 2.7 mm | 2.8 mm |
| Outer diameter | 324.29 mm | 324.28 mm | 323.5 mm |
| T.U.R. | 1.386 | 1.359 | 1.405 |
Page Consumption of Flute Type B – If the speed of corrugated paper machine is 120m/min and it operates 12 hours per day
1. The same flutes per feet (48) but different heights
Flute #1 has height of 2.8 mm with T.U.R. 1.386 while Flute #2 has height of 2.7 mm with T.U.R. 1.359.
Flute #1 consumes paper 119750 m while Flute #2 consumes 117417 m. Flute #2 saves 2333 m per day.
2. The same height (2.8 mm) but different flutes per feet
Flute #1 has 48 flutes per feet with T.U.R. 1.386 while Flute #3 has 49 flutes per feet with T.U.R. 1. 405.
Flute #1 consumes paper 119750 m while Flute #3 consumes 121392 m. Flute #1 saves 1642 m per day.
Why Tungsten Carbide Coating?
There are 3 advantages of tungsten carbide corrugating roller compared to chrome plating process:
1. Higher life expectancy
Tungsten carbide coating has a hardness of MHV1300 while chrome plating can only reach MHV800. The hardness of its layer is only less than diamond in the world. From a variety of experimental data and production practice, its life is generally 2-5 times of chrome plating corrugating roller, up to 30-50 million meters long.
2. Better quality
Because of excellent abrasion resistance, tungsten carbide production generally selects flute types with sharper shape and lower height. Through the optimization design of flute shapes, we can increase the strength of the fiberboard, and keep the thickness stable. Meanwhile the consumption of glue is saved. As a result, the quality of the cardboard can maintain stable in a long term scale, so the print quality can be controlled.
3. Lower cost
As the tungsten carbide coating is extremely wear-resistant, the flutes can be maximum optimized in the production with the flute-shape optimization software. The paper consumption can be saved 2% – 8% for customers compared to chrome plating roller.
The coating is removed by a special method and the roll blank can be reused. Therefore the performance of repaired and new ones are not very different, so that we can reduce downtime rate, glue consumption, and wear of pressure roller and glue roller. Hence the service life can be extended.
Tungsten Carbide Coating V.S. Chrome Plating
| Type | Coating Process | Flutes per feet | Height (mm) | Take-up Ratio | Page Consumption Saving |
| C | Tungsten Carbide | 38 | 3.7 | 1.405 | 4.3% |
| Chrome Plating | 39 | 3.8 | 1.448 | ||
| B | Tungsten Carbide | 48 | 2.7 | 1.39 | 4.5% |
| Chrome Plating | 49 | 2.8 | 1.435 | ||
| E | Tungsten Carbide | 72.5 | 1.6 | 1.28 | 5.4% |
| Chrome Plating | 74 | 1.7 | 1.334 |
| Chrome Plating | Tungsten Carbide | |
| Flute Type & T.U.R. | Due to the poor wear resistance of ordinary corrugating rollers, the height of ordinary flute is designed to be higher to ensure life, so the corresponding TUR will be higher; In order to achieve a certain service life, the flute tip of ordinary corrugating roller is designed to be rounder, so TUR is also high. | Due to higher hardness and wear resistance, lower flute height can be designed, so it saves paper compared to ordinary corrugating rollers; The wear of the flute tip will not reduce the compressive strength of the finished product and will not affect the quality. It can be designed with a sharper flute shape, leading to better strength of the cardboard, lower glue consumption and paper saving. |
| Cardboard Thickness | Due to flute wear in daily production, the flute height of ordinary corrugating roller becomes lower, the cardboard thickness is reduced accordingly, and constantly changing. | Tungsten carbide corrugating rollers are theoretically never worn, the thickness of the cardboard is always uniform, guaranteeing the continuity of quality. |
| Lifetime | The service life of ordinary corrugating rollers is generally between 6 million meters and 8 million meters | Tungsten carbide corrugating rollers can reach at least 30 million meters, reducing the times of replacement, saving labor and material expenditure. |
| Roll Reusability | Due to serious wear of ordinary corrugating roll, the outer diameter and hardness are reduced every time when repairing, so the T.U.R. is increased accordingly. Besides, it can be repaired few times. | Tungsten carbide coated corrugating rollers do not have this problem, the coating is applied by a special method, so the roll blank can be reused. |
Our Strength
We have three unique strength that other tungsten carbide coated roll makers in China don’t:
- Roll base metal: 4145 steel
- Multiple stage heat treatment: soft nitriding plus supersonic frequency — others use intermediate frequency
- Coating powder: Praxair 1342VM imported from USA — others use Chinese made powder
Besides, we have other four strength:
- Ease of use: roll serve immediately after setting up
- Quality: assure agreed hardness of roll
- Stability: bare possibility of down-time — we’ve completely solved the issues of coating peeling-off and roll cracking
- Durability: guarantee more than 35 million long meters life — warrant free renovation if do not reach the life time
Production Flowchart
Ensure roller stably running at high speed with small noise
Embed shaft extensions made of forged alloys with modulation treatment to roller blank by interference fit
Customize flute to final size by grinding rather than drawing
Quench by 10mm effective depth and grind by Siemens high precision CNC grinder
Thermal spray tungsten carbide and polish to roughness below Ra2.0
Inspect flute shape and surface hardness
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