21619 Produce Fibreboard on a Double Backer During Paper Changes

Explanatory notes

1All workplace practices must meet any applicable and recognised codes of practice, and documented workplace health, safety, and environmental procedures for personal, product, workplace health, safety, and environmental matters, and the obligations required under current law including the Health and Safety in Employment Act 1992, Hazardous Substances and New Organisms Act 1996, Resource Management Act 1991, Privacy Act 1993 and their subsequent amendments.

2Workplace practices refer to the documented procedures for the equipment and/or workplace.

3Revisions (reflecting New Zealand practice and experience) have been made by the PAITC to Corrugating Defect/Remedy Manual, editor James T. Carbone, TAPPI Press, AtlantaUSA, Sixth Edition 1999. These revisions, available from the PAITC, PO Box 31 131, Lower Hutt, shall be used when determining the achievement of evidence requirements within this unit standard.

4Faults included in this unit standard, and defined by the PAITC revisions to the TAPPI publication, are: blisters, wrinkles, cockles, splices, slot lines, edge fluff outs, other delamination and poor adhesion whether localised or extensive, cut and fractured and crushed corrugations, low flutes, leaning flutes, highs and lows, other damage and deformation to corrugations, indentations, scuff marks, dry streaks, washboarding, splits at crease lines, other damage to liner papers, unslit board, untrimmed board, badly trimmed board, misalignment exceeding 1mm on trimmed board, wet board, green bond.

5It is recommended that correcting twin cushion faults be included within this unit standard in those workplaces producing this type of board.

6Excess misalignment is measured at operator side, and is present where: in double faced board the edge of the single face web is aligned more than 5mm from the edge of the bottom liner; and in twin cushion board where all three edges (of the two single face webs and the bottom liner) fail to align within a 5mm or lesser overall spread.

7Excess misalignment is defined in double faced board as: the edge of the single face web being aligned more than 5mm from the edge of the bottom liner at the operator side; and, in twin cushion, where all three edges (of both the single face webs and the bottom liner) fail to align within a 5mm or lesser overall spread at operator side.

8‘Plant listed maximum speed’ is that speed determined by each workplace as appropriate for the board type, board dimension, and run length in production.

9Unless explicitly specified to the contrary, all actions available may be taken in any combination or sequence as determined by workplace practice and equipment configurations.

10Warp is excluded from this unit standard.

Outcomes and evidence requirements

Outcome 1

Demonstrate knowledge of the reasons for faults occurring in manufactured board, and the corrective actions available in the workplace for rectifying these faults.

Rangemis-alignments, washboarding, wet board, any form of delamination (extensive or localised), folded edges, leaning or deformed or damaged flutes, wrinkles, indentations or crushed or damaged board.

Evidence requirements

1.1A minimum of two causes are provided for each fault listed in the range.

1.2A minimum of one corrective action to rectify each fault cause given at 1.1 is provided.

Outcome 2

Start up the equipment, and establish brake controls over the liner and single face web(s).

Rangeequipment configurations, workplace practices.

Evidence requirements

2.1Board is moved through the platen section at the speed determined by workplace practices and equipment operating procedures.

Rangemay include – twin cushion, double faced board.

2.2Any slack in the bottom liner between the reel and the double backer glue station is removed by use of brake control.

2.3Slack in the single face web(s) between bridge and glue station is removed.

2.4Bottom liner or single face web(s) are free from ‘wandering’ and any breaks.

2.5Procedures for establishing brake control prior to board manufacture are explained in terms of workplace practices.

Outcome 3

Produce fault free board during grade and width changes, whilst achieving plant listed maximum speeds.

Evidence requirements

3.1Awareness of forthcoming paper changes is demonstrated.

Rangecheck production documentation, communicate with other corrugator crew members, identify possible equipment adjustments.

3.2Proactive corrective actions at the double backer and platen sections are described and/or taken in anticipation of paper changes.

Rangechanges in type, grade, width and any combination;

adjustments to – adhesive application to flute tips, platen temperatures, rider roll pressures, main belt pressures, liner tensions; single face web tension (through joint action with the single facer operator).

3.3The effects of the corrective actions available are explained in terms of workplace practices.

Rangeadjustments to – adhesive application to flute tips, platen temperatures, rider roll pressures, main belt pressures, liner tensions; single face web tension (through joint action with the single facer operator).

3.4Procedures to be followed in the event of faults developing are explained in terms of workplace practices.

3.5Board is produced at plant listed maximum speed in accordance with workplace practices, except for when changing reels.

Outcome 4

Rectify faults without causing production delays.

Evidence requirements

4.1Procedures for rectifying faults are explained in terms of workplace practices.

Rangeindentations, folded edges, wrinkles, excessive misalignment.

4.2Any faults that occur at start up are rectified within two minutes by resetting the equipment.

4.3Other faults within the operator's control are rectified within two minutes of receipt of notification.

4.4Procedures to be followed in the event of inability to rectify a fault within the required period are explained in terms of workplace practices.

4.5All faults within the operator's control (other than for rectifying indentations) are rectified in accordance with workplace practices at plant listed maximum speed.

Outcome 5

Follow safety requirements for the equipment being used.

Rangeoperating manual, workplace practices.

Evidence requirements

5.1Equipment start up, shutdown and emergency procedures in the workplace are explained.

5.2Hazard control measures, as circulated by the company, are described and followed.

5.3Hazards or potential hazards in the workplace are identified and reported in accordance with workplace practices.

This unit standard is expiring. Assessment against the standard must take place by the last date for assessment set out below.

Status information and last date for assessment for superseded versions

This CMR can be accessed at

Please note

Providers must be granted consent to assess against standards (accredited) by NZQA, before they can report credits from assessment against unit standards or deliver courses of study leading to that assessment.

Industry Training Organisations must be granted consent to assess against standards by NZQA before they can register credits from assessment against unit standards.

Providers and Industry Training Organisations, which have been granted consent and which are assessing against unit standards must engage with the moderation system that applies to those standards.

Requirements for consent to assess and an outline of the moderation system that applies to this standard are outlined in the Consent and Moderation Requirements (CMR). The CMR also includes useful information about special requirements for organisations wishing to develop education and training programmes, such as minimum qualifications for tutors and assessors, and special resource requirements.