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