Single Facer Troubleshooting: Common Problems and Solutions

The single facer is the heart of a corrugating line. When problems occur here, they affect everything downstream. This guide covers common issues and their solutions.

Problem: Poor Flute Formation

Symptoms: Uneven or partially formed flutes, inconsistent flute height

Causes and Solutions:

• Worn corrugating rolls—inspect and regrind or replace

• Incorrect roll gap—adjust per paper specifications

• Paper too dry or too wet—check moisture content

• Low steam pressure (traditional lines)—verify boiler output

Problem: Web Breaks

Symptoms: Paper tearing during production

Causes and Solutions:

• Excessive tension—reduce web tension settings

• Paper defects—inspect rolls for damage

• Edge cracks—check slitter condition

• Roll alignment issues—verify tracking

Problem: Poor Adhesive Application

Symptoms: Dry spots, excessive glue, uneven coverage

Causes and Solutions:

• Worn doctor roll—inspect and replace if necessary

• Incorrect gap setting—calibrate adhesive applicator

• Adhesive viscosity wrong—check and adjust

• Glue pan level low—maintain proper level

Problem: Scoring or Marking on Liner

Symptoms: Lines, scratches, or marks on single-face web

Causes and Solutions:

• Debris on rolls—clean all roll surfaces

• Damaged pressure roll—inspect and repair

• Paper guide issues—check alignment

Problem: Delamination at Single Facer

Symptoms: Liner separating from medium immediately after bonding

Causes and Solutions:

• Insufficient adhesive—increase application

• Gel temperature incorrect—verify adhesive formula

• Low pressure roll pressure—adjust settings

• Paper surface treatment—may need adhesive adjustment

Preventive Measures:

• Daily cleaning of all contact surfaces

• Regular inspection of roll condition

• Consistent adhesive preparation procedures

• Proper paper storage and handling