Increased visibility into the system, from boiler to condensate return, maximum heat transfer, and improved runnability are what top-performing corrugators are saying can make a critical difference in their plants - allowing them to run consistently at cut-off knife speeds.

Kadant Johnson recently introduced a revolutionary change in corrugating steam systems designed for high-speed single-facers as well as premium corrugators that demand a high degree of control throughout the process. The first modern corrugating steam system was just installed at a U.S. corrugating plant and started up as part of a single-facer rebuild project.

The single-facer started up in January and has produced three of six grades at 1500 fpm or higher and the other three were all over 1300 fpm.

The pre-heater and pre-conditioner rolls are now able to operate at the main-header pressures with system venting and high operating speeds have been achieved without a dramatic loss in roll temperature that occurs with conventional steam systems.

The operating steam pressure is under the control of the steam system, operators are now able to maintain production without the need to intervene and set individual section pressures.

All testing, data, and indications are that the first installation of the modern steam system has been successful in meeting the plant’s goals of improved corrugator availability, improved heat transfer, improved system control, and machine reliability.