The most popular way to reduce the cost of paper m

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Ways to reduce the cost of paper molded products

at present, the biggest difficulty encountered by pulp molded tableware in the process of replacing foamed plastic tableware is the high cost. Although the cost has decreased after several years of efforts by people in the paper mold industry, the sales cost of paper mold tableware is still unmatched by that of foamed plastic tableware. Under the condition of market economy, despite the guidance of national policies, the market of paper mold tableware is still struggling to grow with the reduction of electrolytic aluminum production to about 4.91 million tons per year in 2015, which is also an inevitable process for the development of this industry from scratch

the reasons why the cost of pulp molded tableware is higher than that of foamed plastic tableware are mainly reflected in the following four aspects: the cost of raw materials is high; High cost of chemical additives; High energy consumption; Compared with the modern foaming plastic molding equipment, the production efficiency of the existing paper mold molding equipment is still relatively backward. Therefore, in order to develop the paper tableware industry as soon as possible, in addition to the national policy guidance, paper mold enterprises must start from the four aspects mentioned above to study and improve, namely: first, in terms of raw materials, develop new material sources, such as studying and improving the filling technology, in order to reduce the material cost; Second, in the aspect of chemistry, seek new additives that can not only prevent oil and water, but also reduce the cost; Third, adopt the latest energy-saving technologies to reduce energy consumption; Fourth, and the most important aspect, we must focus on strengthening the research of paper mold forming process, developing full-automatic forming equipment in the true sense, and eliminating backward production equipment

full automation of equipment is the key link to improve labor productivity per unit time and reduce production costs. Therefore, the paper mold equipment manufacturing industry must learn from the foaming plastic tableware equipment manufacturing industry. On the basis of being familiar with and mastering the pulp molding process and the development of several generations of equipment, we should pay close attention to the development of a truly automatic production line from pulping to disinfection and packaging. This is a sign of the maturity of the industry technology and process, and is also the need for the development of this industry

it must be pointed out that the development of the paper mold industry in recent years, whether it is equipment research and development or product market development, has made remarkable achievements, but at present, it is basically in a situation of independent development of enterprises and disordered product sales competition. In order to change this situation, it is very difficult to rely on a certain enterprise alone without unified planning and leadership by the relevant national departments. Therefore, it is very important to establish an industry organization that can guide enterprises to develop together, actively explore domestic and foreign markets, and provide technical services for enterprises. Moreover, there must be some leading enterprises in the industry to drive the development of the whole industry

the development of pulp molding industry is the need to eliminate foamed plastic tableware and foamed plastic industrial packaging products, and the need of environmental protection. Therefore, the pulp molding industry must seize the opportunity and make great efforts to develop this emerging industry. The problems of high cost and unstable product quality of pulp molded tableware must be paid attention to. From the perspective of technological development prospect and application of paper mold industry, there is still a large space to reduce the cost, which is completely feasible. First of all, it is 51:49 in SAIC period to talk about the problem of pulp molding equipment

from the perspective of product upgrading and environmental protection, the pulp molding industry is an emerging industry with a small method of maintenance. However, in terms of the progressiveness of pulp molding equipment, compared with the production equipment of foamed plastic tableware, it is an objective fact that cannot be denied. Take the most advanced automatic pulp molding machine for example. The following connection can be used to replace the tooling (the length of the torsion bar is 700mm, and its production efficiency and stability can not compare with that of the foaming plastic product production equipment. The production efficiency and stability of the equipment are the primary factors determining the product cost. Therefore, through the development of electromechanical integration technology and computer control technology, the design and manufacturing level of paper mold equipment can be improved, and the current situation of low efficiency, poor quality and low benefit of paper mold equipment can be changed In addition, it is the primary task to reduce product costs. The following focuses on the fully automated pulp molding production line and several important indicators that its process flow and process design should achieve

I. concept of full-automatic production line from the production process, the full-automatic production line of pulp molded tableware should be completed by the automatic production line from the beginning of beating to the completion of packaging without manual intervention. In terms of production efficiency, yield and product cost, compared with semi-automatic forming equipment, it should be a modern production line with high efficiency, safety, stable operation, high yield, low product cost and high-tech content. At present, the development of full-automatic production lines is very necessary both from the social needs of eliminating "white pollution" and from the market demand of developing paper mold products. Therefore, China is stepping up the development of such production lines

according to the technical status of the domestic pulp molding production line, the process flow of the full-automatic production line should be: pulping - Dredging - pulping (adding chemical additives) - grouting (adsorption) molding - cold pressing and half drying - hot pressing and shaping - Disinfection - automatic stacking - automatic packaging. The whole process is automated (not limited to the automation of the forming process)

II. Several indexes that should be achieved in process design

1. improve the utilization rate of slurry. The utilization rate of slurry is an important economic index in the wet end production process of paper tableware. In addition to the chemical factors of the dehumidification part, the design of the forming machine, whether in the form of grouting or adsorption, must ensure the safety of slurry supply, minimize the amount of slurry return and avoid slurry running

2. strictly controlling the gram weight of paper mold tableware is the most basic quality index of paper mold tableware. There are clear requirements for the national standard of universal paper mold tableware, which must be strictly controlled. Neither cutting corners nor overweight are allowed. For an enterprise with an annual output of 50million paper-based tableware, if the weight of each tableware is increased by 1g (at present, the cost per gram is about 1:2), 50million tableware means 50million grams of multi-purpose slurry, i.e. 50 tons. If the cost is calculated at 4000 yuan per ton, it means an increase of 200000 yuan. If the consumption of corresponding chemical additives and energy consumption of 50 tons of slurry are added, the cost will increase by about 120000 yuan, which adds up to about 320000 yuan. If 40000 paper mold tableware are produced per ton of 50 tons of slurry, each tableware is calculated at 0.3 yuan, that is, the loss income is 600000 yuan. Therefore, the grouting (suction) mechanism must strictly control the weight of the product

3. improve the yield and qualified rate of products

the yield and qualified rate of the product is an important economic index of the molding machine, and it is also a necessary condition to ensure the normal operation of the equipment. Finished products include genuine products, substandard products and substandard products, excluding waste products. As long as the equipment does not produce waste products, it can ensure its normal operation, and the normal operation of the equipment can ensure its design ability and improve the economic benefits of the enterprise

4. to improve the utilization rate of equipment, the reliability of equipment is a primary condition to improve the utilization rate of equipment. In order to improve the utilization rate of equipment, paper mold tableware enterprises generally adopt the workshop production mode of four shifts and three shifts, that is to say, the equipment must be able to operate normally 340 days a year (21 hours of normal operation are guaranteed every day, and 1 hour of downtime for cleaning, replacement and troubleshooting is reserved every day), and the other 25 days are used for medium and overhaul of equipment, as well as necessary holiday rest for workers

5. improve labor productivity, use high automation of equipment, reduce the number of operating workers and reduce labor intensity

6. ensure the safety of equipment. The safety of equipment is an important condition to ensure the safe and civilized production of enterprises, the personal safety of workers and avoid accidents. 7. the automatic equipment must consider the equipment servo mechanism. The automatic equipment has the characteristics of high production efficiency and fast operation speed. In case of any fault, the servo mechanism must be able to give an alarm and display the fault position in time, so that the maintenance workers can quickly eliminate it and reduce the downtime

8. reducing energy consumption is an important economic index for evaluating a device. In addition to the forming machine, the cost of pulp molded products mainly consists of three parts: pulp, chemical additives and energy consumption, so reducing energy consumption is an important factor to reduce product cost. The ways to reduce product energy consumption are as follows: first, optimize the design of energy intensive parts, such as energy-saving measures for hot pressing parts; The second is to consider the comprehensive utilization of energy consumption, such as the use of double row stations to improve the energy utilization rate of the equipment. In addition, by optimizing the design of the wet end mold, double station hot pressing shaping and other measures, we can reduce the shaping time and speed up the production cycle, so as to improve the output per unit time and achieve the purpose of saving energy. In the early stage of the hot pressing station, the fibers can move freely between the cold pressed green slabs. When the free water is removed, the surface tension of the water begins to pull the fibers together. It is generally believed that when the moisture content of the green billet is 45 ~ 55%, the fibers quickly approach each other and form hydrogen bonds. With the decrease of the moisture content of the green body, the strength of the tableware increases continuously until the moisture content drops to 20%. Drying is the last stage of sizing. It is required to gradually increase the drying temperature for sizing. It is generally believed that the most ideal sizing effect can be obtained when the water content is 50 ~ 60% and the temperature is 130 ° - 180 ℃

9. the integration of hot pressing, disinfection and packaging simplifies the separate disinfection process and packaging process, which not only saves equipment and manpower, reduces production costs, but also realizes automation in a real sense

all the above design indexes must be considered comprehensively, and one side should not be taken into account while the other side is ignored. The development and improvement of equipment must rely on the efforts of the whole industry. Enterprises must not be complacent. They must absorb not only the advanced technology within the industry, but also the advanced technology outside the industry. For example, Shandong Sanjin Glass Machinery Group has successfully developed czs-550 automatic forming machine on the basis of absorbing some advanced experience in the paper mold industry and adding its own advanced technology and strict quality management in manufacturing glass machinery. The test run was successful. Its production efficiency, energy consumption and equipment stability have reached a new level, and the comprehensive cost of products has decreased significantly. This fully shows that supporting and encouraging the development of advanced production equipment with high technology content is one of the effective ways to reduce product costs

the development and use of raw materials, technology and energy saving are also important ways to reduce the cost of paper molded products. The method of adding retention aids and fillers to the slurry of paper molded products discussed by the author has attracted the attention of some enterprises. At present, the author is working with relevant research units to develop new high-efficiency retention aids, with a view to contributing to friends in the paper mold industry. This article will not elaborate

in a word, through the efforts of all members of the paper mold industry, continuously improve and develop new equipment, develop new materials, and adopt high-efficiency and energy-saving measures, the cost of paper mold products can certainly be reduced, and the market will recognize it

as for the quality of products, paper mold enterprises must be self disciplined and must

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