Advanced Bonding: An In-depth Look at the Bonding Process

Peachtree Corners (metro Atlanta), Georgia, USA
Wednesday, July 31, 2019

This course will help students increase their understanding of the corrugated bonding process including factors and variables that impact bond performance, determining proper bonding settings, glue line analysis, combined board caliber and process centerlining as well as identifying the causes of warp and how to correct warp with coated liners.

Corrugator Education for All Levels of Expertise

Today's corrugated industry advancements are causing conditions in box plants to change. This course explores methods to improve efficiency while maintaining standards and enhancing box quality.

Course Overview
A comprehensive look at the bonding process, this course will examine ingredients & mechanics of the starch-based adhesive, factors & variables of successful bonding, glue line analysis, process centerlining, bond strength testing as well as identifying causes & corrections for warp. 

Glue applicationIncrease your knowledge of:

• Factors and variables that impact bond quality
• Relationship between IR thermometers, heat imaging & moisture management
• How to determine proper settings
• Doublebacker problem-solving
• What the soak tank has been waiting to tell you

After completing this course, you will be able to:

• Identify factors and variables that impact a successful bond
• Understand the significance of temperature & moisture management
• Be better equipped to optimize centerlining & machine settings
• Increase process troubleshooting skills
• Better utilize the soak tank & other tests as diagnostic and performance tools

First things first…Every sheet that comes off your corrugator must meet or exceed various requirements to provide value and performance to the end user. But before any other quality metric can mean anything, "the Bond is Everything." Nothing else matters until you can be sure your bonding process is successful & strong.

Earn CEU Credits

Seventeen (17) Professional Development Hours or 1.7 CEUs are awarded for completion of this course.

IACET LogoThe Education Project Center of TAPPI has been reviewed and approved as an Authorized Provider by the International Association for Continuing Education and Training (IACET), 12100 Sunset Hills Road, Suite 130, Reston, VA 20190. TAPPI will award CEU credits to participants who attend at least 80 percent of the educational sessions and complete a final program evaluation.

Need a Refresher?

Our Introduction to Corrugated Course on will be held on August 7th, the day before the Advanced Bonding Course. This comprehensive, one-day course covers all of the basics for the newer members of your corrugated team, as well as updates and refreshers for the more seasoned pros.

Learn with Your Peers

This course is ideal for: Corrugator operators, Box plant supervisors, Production managers, Maintenance personnel, and Product quality control personnel.

Tim Church 200TIM CHURCH (Course Chair) is a Senior Technical Services Representative for HarperLove. Tim began his career in 1980 at the Georgia-Pacific box plant in Owosso, Michigan.  He has experience on flexos, diecutters, curtain coaters, tapers, stitchers and other miscellaneous finishing equipment.   Tim worked his way up through every position on the corrugator and learned to schedule by hand.  His natural leadership and interpersonal skills led to his joining the management team, and he has held supervisory roles in corrugating, converting, scheduling, and shipping.  Tim served as Corrugator/Cascader Superintendent, led the Food Safety program, and championed the Mobile Equipment & Pedestrian Safety program as well as many other safety initiatives.  He has been with HarperLove since 2014 and embodies HarperLove's ethic of “To Serve is To Solve.”  Tim has authored a segment in the Troubleshooting Board Defects series in Corrugated Today magazine, is active with TAPPI, and is currently the course chair for the Introduction to Corrugated, Corrugator Best Practices, and Advanced Bonding courses.

Joe headshotJOE SICILIANO is the Global Product Manager, of Albany International Corporation., has more than 29 years of progressively responsible experience in both the paper and corrugated box industry.  In his current role he is responsible for global product and services development. Among his significant previous positions, Joe served as Regional Business Director and Director of Marketing Communications Americas, for Albany International Corporation. Albany International is a global advanced textiles and materials processing company with plants strategically located to serve its global customers. The company's core business is the world's leading producer of custom-designed fabrics and belts essential to the production of paper and paperboard. Albany's family of growth businesses extends its advanced textiles and materials capabilities into a variety of other industries, most notably aerospace composites, nonwovens, building products, high-performance doors, and high-performance insulation and yarn. Joe Siciliano holds a Bachelor of Science degree from Siena College in Loudonville, NY and a Master of Business Administration (MBA) degree from Regis University in Denver.

 Robin Sommers Best PracticesROBIN A. SOMMERS is a senior project and process manager for Kadant Johnson Systems Division focused on process steam systems for the corrugator industry. He joined Kadant Johnson in the summer of 2014 after working at Donahue & Associates, supplier of Donahue Steam Systems, for 15 years. He previously was in R&D and product design engineering. Robin earned a BS degree in mechanical engineering from Purdue University.

 Herb Kohler - Adv.BondHERB KOHLER is President of Kohler Coating Inc.  He is the inventor on more than 50 U.S. and foreign patents for glue application, moisture application, coating and web handling machinery that has been installed in over 65 countries. A TAPPI member since 1983, he has chaired or co-chaired 5 TAPPI short courses and made presentations at over 25 TAPPI, AICC, FEFCO and VDW meetings.  He is a 3 time TAPPI Finest Faculty Award Winner. He has published papers on: “An Analysis of Heat Transfer and Moisture Management in the Doublebacker: How Cooler Corrugating Can heat Up Savings”; “Modern Rod Coaters”;“Air Knives and Other Contour Coaters.”

Mike Kohler - Advanced Bonding MIKE KOHLER is a Technical Sales Associate for Kohler Coating, Inc. and has worked for them since 2009.  Mike has extensive experience on corrugators and the world's only 13 inch corrugating line used for trials and testing in Canton, Ohio.  He specializes in rod-metering systems associated with Kohler's WaterDecks and Glue Units.  Mike was recently named Co-Director of Events for Tappi's Young Professionals Division.  He graduated with honors from Walsh University and owns Workhorse Training, an athletic training facility. 

Victor Pinto 100x150VICTOR PINTO is the Principal of Quantum Corrugating, LLC.  Victor has over twenty- five years of experience in the corrugated industry, starting his career as a Field Engineer and holding such positions as Regional Sales Manager, Vice President of Sales, Operations Consultant, Vice President of Business Development and Chief Operating Officer, all leading up to his current role with Quantum Corrugating.   



Learn with Your Peers

This course is ideal for: Corrugator operators, Box plant supervisors, Production managers, Maintenance personnel, Product quality control personnel

Advanced Bonding Course Schedule
Course Chair - Tim Church
Course Schedule - Download Here

Wednesday - August 8, 2018

8:00 - 8:30 - Tim Church

Opening Comments - Welcome

Meeting norms & safety

Introductions

Learning expectations

Learning Outcome - Your learning expectations from attending this class.


8:30 - 9:30 - Tim Church

Bond mechanics

Variables impacting the bond

One sheet, Two different bonds

Learning Outcome - Understand bond mechanics and identify the "enemy" variables of a good bond.

 

9:30 - 9:40 - BREAK

 

9:40 - 10:50- Tim Church

 

Singlefacer bonding

Glue machine bonding

Applicator rolls, lag speeds

Learning Outcome - Learn strengths, weaknesses and differences of the SF and DB bond

 

10:50 - 11:00 - BREAK

11:00 - 12:00 - Tim Church

Understanding starch-based adhesive

Gel Point, Viscosity Hands-On

Solids, Calculating consumption

Learning Outcome - Understand the starch-based adhesive and why its well suited for high speed bonding

12:00 - 1:00 - LUNCH

1:00 - 1:45 - Mike Kohler

Role of moisture in bonding

Deeper look into fiber moisture

Moisture management

Learning Outcome - Learn what moisture management means and why its important to the bond

1:45 - 2:30 - Paul Light

Managing heat & temperature

Heat imaging 

IR Thermometers

Learning Outcome - Learn to run by temperature science and the value of knowing heat balance


2:30 - 2:40 - BREAK


2:40 - 4:00 - Tim Church

Applicating system health check

Gaps-parallel, Circular runout

Photomicrograph Hands-On
Be equipped to perform critical adhesive system checks and how to c 

 

4:00 - 4:10 - BREAK

 

4:10 - 5:00 - Tim Church

The "Right" machine settings

Learning Outcome - Have an understanding on how to find and verify the best settings for your machine

 

 

Thursday, August 9, 2018

 

8:00 - 8:15 - Tim Church

Review previous day's learning


8:15 - 10:00 - Robin Somers

Steam system overview
Heat transfer & loading
Doublebacker zone control
Steam system troubleshooting
Learning Outcome - Increase your knowledge of the steam system's operation and basic troubleshooting


10:00 - 10:10 - BREAK

 

10:10 - 11:15 - Ryan Jansen

Role of the doublebacker belt

Belt troubleshooting & maintenance

Learning Outcome - Understand the belt's significance

 

11:15 - 11:25 - BREAK

 

11:25 - 12:00 - Ryan Jansen

Re-flocking the doublebacker belt - Hands On

Learning Outcome - Learn to re-flock your belt

 

12:00 - 1:00 - LUNCH

 

1:00 - 2:00 - Instructor TBD

Corrugator Controls

Wet end speed/sync/wraps/ballast

Learning Outcome - Understand how controls improve runability and bonding

 

2:00 - 2:30 - Tim Church

Understanding Warp

Learning Outcome - Deepen your ability to understand and troubleshoot warp

 

2:30 - 2:45 - BREAK

 

2:45 - 4:15 - Tim Church

Operator checks

Lessons from the Soak Tank
"Looking under the hood"  Hands-On
Learning Outcome - Learn how to perform a soak test properly and the value of what it can tell you

 

4:15 - 4:45 

Wrap Up - Learning review

 

4:45 - 5:00

Course Critiques - Adjourn

 

 

Learn with Your Peers

This course is ideal for: Corrugator operators, Box plant supervisors, Production managers, Maintenance personnel, Product quality control personnel

Register by July 6th for Early Bird Rates

TAPPI members receive discounts on registration. If you're not already a member, join today.

  Before July 6th  After July 6th
Individual Registration   
 Member$955  $1055 
 Join/Renew and Save $1305  $1409 
 Young Professional under 30 Join/Renew and Save$1245  $1345 
 Nonmember$1745  $1855 
    
Group Registration, per person (3+ people from same location)    
 Member$870 $980
 Join/Renew and Save $1225  $1335 
 Young Professional under 30 Join/Renew and Save$1160  $1270 
 Nonmember $1480  $1590 

 

Cancellation Policy:

If you find that you have to cancel, your full registration fee will be refunded if TAPPI's Registration Department receives written notification (fax acceptable at  +1.770.209.7206) by July 6, 2018.  

Please note:  There will be a 50 percent refund for all written cancellations made after July 6, 2018, but no later than five (5) business days prior to the start of the course Wednesday, August 1, 2018.  Understandably, after Wednesday, August 1, 2018 no refunds can be issued.  Substitutions, however, will be accepted any time without a penalty.
          
Refund:
100% - Cancellation received by July 6, 2018.
50% -  Cancellations received after July 6, 2018 and no later than August 1, 2018.  
NO REFUND- Cancellations received after August 1, 2018.

Learn with Your Peers

This course is ideal for: Corrugator operators, Box plant supervisors, Production managers, Maintenance personnel, and Product quality control personnel

Order these publications when you register to save on price and shipping

Corrugator Bonding:  A TAPPI Press Anthology of Published Papers, Second Edition
Item #: 0101R265
Special Course Price: $65
(That's a $32 discount off the list price.)
Back in Print for the first time in more than 10 years.

"The Corrugator Bonding Anthology is an unsurpassed resource for anyone who wants an introduction as well as insight into the corrugated world. It will never be outdated.”
- Jon Porter, Senior Instructor/Process Specialist, JPorter Consulting

Corrugated Adhesive Preparation, 5th Edition
Item #: 0101R301
Special Course Price:   $75
(That's a $75 discount off the list price.)

NEW-Adhesion Science Principles and Practice
Item #: 18ASPP
Special Course Price:  Member - $133   Non-member - $174

Critical Thinking in Converting
Item #: 0101R302
Special Course Price: $70
(That's a $51 discount off the list price.)

The Corrugated Containers Manufacturing Process
Item #: 0101R281
Special Course Price: $70
(That's a $45 discount off the list price.)

Corrugated Defect Remedy Manual
Item #: 0101R153
Special Course Price: $85
(That's a $64 discount off the list price.)

Synthetic Coating Adhesives
Item #: 0101R276
Special Course Price: $30
(That's a $18 discount off the list price.)

Starch and Starch Products in Surface Sizing and Paper Coating, 3rd Edition
Item #: 0101R336
Special Course Price: $129
(That's a $70 discount off the list price.)

World of Market Pulp (Soft Cover)
Item #: 08WOMPB
Special Course Price:  $160.00

Learn with Your Peers

This course is ideal for: Corrugator operators, Box plant supervisors, Production managers, Maintenance personnel, Product quality control personnel

We have arranged a special corporate rate for your convenience

Hyatt Place Atlanta/Norcross/Peachtree


5600 Peachtree Parkway
Norcross, Georgia, USA, 30092
Tel: +1 770.416.7655

Hotel Website 

Download Hotel Information

$124 (+ taxes & fees) includes: breakfast buffet, wireless internet, self-parking in a covered parking garage, shuttle service within a five mile radius of the hotel.

Directions to the Hotel: Hotel Website 

 MARTA  - FROM AIRPORT

Take the Gold Line from the Atlanta Airport all the way to the Doraville stop, last stop on the gold line.

Call the Hilton front desk to arrange a hotel shuttle pick-up from the Doraville Station +1-770-447-4747

Marta- Catch the Gold Line from Atlanta Hartsfield International Airport(ATL) to the Doraville Station, the train ride takes approximately 45 minutes from the airport to the Doraville station. A cab will cost approximately $15 and will take about 15-20 minutes to get from the Doraville Station to the Hyatt Place. Marta cost is $3.00 each way.  Shuttle service available during non-peak hours (the shuttle does not run from 7-9:30am & 4:30-7:30pm)

Cabs from the Atlanta airport cost roughly $65 to $75 one way the trip is 45 minutes to an hour.

Rental cars are available at the Atlanta airport.

Parking at the Hilton is complimentary.

 avis 2

Avis offers special discounts off regular rates for participants. To reserve your car, call 1-800-831-8000 and refer to the code AWD: #U226600.

Learn with Your Peers

This course is ideal for: Corrugator operators, Box plant supervisors, Production managers, Maintenance personnel, Product quality control personnel

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