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INDUSTRIAL TECHNOLOGIES PROGRAM The Lateral Corrugator New Method to Corrugate Will Significantly Increase Strength Benefits for Our Industry and Our Corrugated boxes are currently manufactured This project will develop a lateral corrugator Nation by orienting the load-bearing direction (flute that increases box compression strength by • Decreased raw material costs direction) perpendicular to the machine aligning corrugations with the linerboard direction (MD). The compressive strength of MD. This configuration will increase box • Reduces drying energy the MD exceeds that of the cross-machine compression strength up to 30% and allow • Reduces fiber consumption by 1.6 million direction because paper is non-isotropic, that manufacturers to use 15% less fiber than tons per year is, the fibers are oriented in the MD. Therefore, conventionally manufactured boxes of the a typical corrugated cannot take same strength. Strong boxes using thinner • Strengthens corrugated boxes advantage of the MD’s stronger compressive paper will cut raw material costs and reduce • Allows full trim-out of paper machine strength. drying energy requirements. Using less fiber will also reduce sludge and greenhouse • Reduces box plant trim emissions. • Supports paper roll transportation and inventory optimization

Applications in Our Nation’s Industry

Approximately 38% of all boxes require stacking strength. This process can increase the compressive strength of any box requiring high stacking strength. A lateral corrugator’s capital and operating costs are expected to be similar to a conventional corrugator. The lateral corrugator can be installed as a retrofit at an existing corrugating facility.

For additional information, please contact Drew Ronneberg, Ph.D. Industrial Technologies Program Phone: (202) 586-0205 Fax: (202) 586-9234 E-mail: [email protected]

Michael Schaepe Institute of Paper Science and Technology at Georgia Tech The lateral corrugator drive system (left) and the lateral corrugator roll stack (right). Atlanta, GA 30332 Phone: (404) 894-6640 E-mail: [email protected]

Boosting the productivity and competitiveness of U.S. industry through improvements and environmental performance INDUSTRIAL TECHNOLOGIES PROGRAM

Project Description Progress and Milestones Project Partners

Goal: Build and demonstrate a 12-inch • Evaluated heat transfer properties of board Institute of Paper Science and Technology at wide prototype and make “lateral” board for in lateral corrugator design (Completed Georgia Tech evaluation. June 2004) Temple-Inland During the first phase of the project, researchers • Conducted splicer and seam analysis will build a prototype lateral corrugator, and the (Completed June 2004) Smurfit-Stone Institute of Paper Science and Technology at • Built and installed lateral corrugator roll Georgia Tech will demonstrate the feasibility MarquipWardUnited stack (Completed December 2005) of the process using the laboratory-scale model. Corrugated Gear After the first phase is complete, researchers will • Built and installed lateral corrugator conduct trials and evaluate board performance hydraulic and drive systems (Completed Albany International for a wide range of paper grades. Collaborators January 2006) from industry will design, and build components • Finish testing and demonstrate overall Container Graphics Corp. for the prototype lateral corrugator. The sheet concept feeding and splicing operation will be the most Harper-Love technically challenging aspect of the project. Commercialization Kadant Johnson Corp. Achieving a combining speed of 300-500 ft/min Tri-Star Packaging is planning to install a at the pilot-scale will be rated as successful. Corn Products International lateral corrugator in a bulk box manufacturing facility in Kentucky. Bulk box production is Wika an ideal first application of this technology because corrugating speeds are slower than Hardy Instrumentation for other applications. In addition, heavier weight material used in bulk boxes generates a Louisiana Steam disproportionately greater strength improvement over lighter weight materials. CUE

Pamarco

Chicago Electric

Bill Nikkel A Strong Energy Portfolio for a Strong America Energy efficiency and clean, renewable energy will mean a stronger economy, a cleaner environment, and greater energy independence for America. Working with a wide array of state, community, industry, and university partners, the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy invests in a diverse portfolio of energy technologies.

Ending FY 2006 October 2006 Full Award#: FC36-01GO10616

For more information, visit www.eere.energy.gov/industry or call 1-877-337-3463