Machine Maintenance Guide for Corrugated Equipment

Well-maintained machines produce better quality, break down less, and last longer. A solid maintenance program is essential for profitable operations.

Why Maintenance Matters

Cost of breakdowns:

• Lost production time (₹10-50K per hour)
• Emergency repair costs (2-3x planned repair)
• Missed delivery deadlines
• Quality issues from malfunctioning equipment

Benefits of preventive maintenance:

• 25-30% fewer breakdowns
• 15-20% longer equipment life
• Consistent product quality
• Lower total repair costs

Types of Maintenance

1. Daily Maintenance (Operator Performed)

Before shift:

• Check oil levels
• Inspect belts and chains (visual)
• Clean sensors and guides
• Check safety guards
• Test emergency stops

After shift:

• Clean machine and work area
• Remove paper dust and debris
• Lubricate per schedule
• Report any unusual sounds or behavior

Time: 15-30 minutes per shift

2. Weekly Maintenance

Performed by: Maintenance technician or trained operator

Tasks:

• Check and adjust belt tension
• Inspect and clean rollers
• Check glue system (nozzles, temperature)
• Lubricate moving parts per schedule
• Inspect electrical connections
• Check compressed air system

Time: 1-2 hours

3. Monthly Maintenance

Performed by: Maintenance technician

Tasks:

• Deep clean all components
• Check and adjust alignments
• Inspect and replace worn parts
• Calibrate sensors and gauges
• Check and clean cooling systems
• Inspect hydraulic systems

Time: 4-8 hours (often on maintenance day)

4. Annual Maintenance (Major Service)

Performed by: Manufacturer service or specialist

Tasks:

• Complete machine inspection
• Replace wear parts (bearings, seals, belts)
• Overhaul critical systems
• Update software/controls
• Recalibrate entire machine
• Electrical system check

Time: 1-3 days

Equipment-Specific Maintenance

Corrugator

Daily:

• Clean glue applicator rolls
• Check web tension
• Inspect preheater temperature
• Clean steam traps

Weekly:

• Inspect corrugating rolls
• Check doctor blade condition
• Clean vacuum systems
• Verify temperature controls

Common issues:

• Delamination → glue system problem
• Washboarding → pressure or temperature issue
• Warping → moisture imbalance

Printer/Slotter

Daily:

• Clean printing plates
• Check ink system
• Inspect feeding mechanisms
• Verify registration

Weekly:

• Clean anilox rolls
• Inspect slotting knives
• Check vacuum and air systems
• Lubricate per schedule

Common issues:

• Poor print → dirty plates, ink viscosity
• Incorrect slots → worn knives, misalignment

Die Cutter

Daily:

• Inspect cutting dies
• Check ejection systems
• Clean platen

Weekly:

• Inspect stripping tools
• Check cylinder alignment
• Verify counter pressure

Folder Gluer

Daily:

• Clean glue applicators
• Check belt condition
• Verify folding accuracy

Weekly:

• Inspect folding hooks
• Check glue temperature
• Clean compression belts

Creating a Maintenance Schedule

Step 1: List all equipment

Create inventory with:

• Machine name and model
• Installation date
• Manufacturer recommendations
• Current condition

Step 2: Define tasks

For each machine:

• Daily tasks (operator checklist)
• Weekly tasks
• Monthly tasks
• Annual tasks

Step 3: Assign responsibilities

• Daily: Operators
• Weekly: Maintenance technician
• Monthly: Maintenance team
• Annual: External specialist

Step 4: Schedule

• Daily: Start/end of shift
• Weekly: Specific day (e.g., Saturday morning)
• Monthly: First Sunday of month
• Annual: During slow season or planned shutdown

Step 5: Document

Create forms/checklists:

• Task completed (checkbox)
• Date and time
• Person responsible
• Issues found
• Actions taken

Spare Parts Management

Critical spares to stock:

• Belts and chains
• Bearings (common sizes)
• Seals and gaskets
• Sensors
• Fuses and relays
• Glue nozzles
• Slotting knives

Inventory management:

• Minimum stock levels
• Reorder points
• Supplier lead times
• Storage conditions

Budget: 2-3% of equipment value annually

Maintenance KPIs

Overall Equipment Effectiveness (OEE): Availability × Performance × Quality

Target: 75-85% OEE

Mean Time Between Failures (MTBF): Operating time ÷ Number of failures

Target: Increasing over time

Maintenance Cost per Unit: Total maintenance cost ÷ Units produced

Target: Decreasing or stable

Key Takeaways

1. Daily maintenance prevents most breakdowns
2. Follow manufacturer recommendations
3. Document all maintenance activities
4. Stock critical spare parts
5. Train operators on basic maintenance
6. Schedule major maintenance during slow periods
7. Track OEE and MTBF to measure improvement