Corrugating Starch

Adhesives Manual
 Corn Products International, Inc.
Quality Policy on Products, Services and Customer Relations
It is the policy of Corn Products International, Inc., to provide products that not only meet
applicable government quality and safety standards, but also seek to meet evolving customer
expectations for quality, value and service; and to assure the accuracy and propriety of all labeling,
advertising, and other representations we make concerning our products and services.
INTRODUCTION
This manual is intended as a resource on starch, its
relationship to, and use in corrugating. It is designed
to make it easier to respond quickly and effectively
to adhesive and machine problems. The information
presented is based upon actual field and laboratory
work. It should not be viewed as providing advice or
solutions to particular applications, each of which
is unique and not susceptible to general advice.
We encourage you to call your representative at
Corn Products U.S., CASCO, Inc., or CPIngredientes
to discuss your specific situation. We will be happy
to lend our support.
TABLE OF CONTENTS
Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
The History of Starch . . . . . . . . . . . . . . . . . . . . . . .3
The Corn Wet Milling Process . . . . . . . . . . . . . . . . .4
The Role of Corn . . . . . . . . . . . . . . . . . . . . . . . . . .6
Starch Basics for Corrugated Board . . . . . . . . . . . . .7
Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Low Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
High Viscosity (Thick, Heavy Adhesive) . . . . . . . . . .9
Effects of Shear on Viscosity . . . . . . . . . . . . . . . . . .9
The Temperature Viscosity Control System . . . . . . . .10
Viscosity/Time Relationship . . . . . . . . . . . . . . . . .11
Viscosity/Resin Relationship . . . . . . . . . . . . . . . . .11
Microbiological Degradation . . . . . . . . . . . . . . . . .11
Care with Biocides . . . . . . . . . . . . . . . . . . . . . . . .11
Gelatinization Temperature . . . . . . . . . . . . . . . . . . . .12
Gel Temperature Too High . . . . . . . . . . . . . . . . . . .12
Gel Temperature Too Low . . . . . . . . . . . . . . . . . . .12
Gel Temperature/Time Relationship . . . . . . . . . . . .12
Determination of Caustic Concentration
In Liquid Caustic . . . . . . . . . . . . . . . . . . . . . .12

Corrugating Additives . . . . . . . . . . . . . . . . . . . . . . . .13

Penetrating Aids . . . . . . . . . . . . . . . . . . . . . . . . .13
Antifoam Agents . . . . . . . . . . . . . . . . . . . . . . . . .13
Liquid Additives . . . . . . . . . . . . . . . . . . . . . . . . .13
Corporate Headquarters Resins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Corn Products U.S.
5 Westbrook Corporate Center Corrugating Processes/Systems/Equipment . . . . . . . . . .15
Westchester, IL 60154 Stein Hall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
United States Jet Cook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
(800) 443-2746 High Shear . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
www.cornproductsus.com No-Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Starch Properties and Testing . . . . . . . . . . . . . . . . . .17

Alkali (Caustic) Sensitivity . . . . . . . . . . . . . . . . . .17
Measuring Viscosity of
Finished Starch Adhesive . . . . . . . . . . . . . . . . 17
Toronto Calibrating the Stein Hall Cup . . . . . . . . . . . . . . . .17
Casco, Inc. Gelatinization Temperature . . . . . . . . . . . . . . . . . .17
401 The West Mall, 2nd Floor Microbiological Testing . . . . . . . . . . . . . . . . . . . . .17
Etobicoke, Ontario M9C 5P7 Starch Solids Concentration . . . . . . . . . . . . . . . . .17
Canada
Board Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
(416) 620-2300 (Toronto)
(514) 694-4700 (Montreal/Eastern Canada)
Quality Monitoring and Control at
www.casco.ca
the Adhesive Station . . . . . . . . . . . . . . . . . . . . . .21
Statistical Process Control . . . . . . . . . . . . . . . . . .21

Troubleshooting Common
Corrugating Problems . . . . . . . . . . . . . . . . . . . . . .23
Diagnosing Viscosity Problems . . . . . . . . . . . . . . . .23
CPIngredientes, S.A. de C.V. Diagnosing Typical Gel Temperature Problems . . . . .26
Av. Mariano Otero #1249, Floor 9 Diagnosing Corrugating Equipment and
Board Quality Problems . . . . . . . . . . . . . . . . . .27
Torre Atlantico
Diagnosing Warp Problems . . . . . . . . . . . . . . . . . .31
Rinconada del Basque
44530 Guadalajara, Jalisco
Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Mexico
(33) 3884-9000 ext. 3520 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
www.cpimex.com
 CORRUGATED MAKES IT HAPPEN FOR FARMING

2

The History of Starch
The first uses of starch stretch back to the ancient
Egyptians and Chinese. They were quite adept at using
starches, a fact duly recorded in Catos Treatise written
in 184 B.C.
It was much later in Europe, however, that the
industry flourished. The source of grain supply then was
wheat and rice. As demand for starch increased, other
raw materials, including potatoes, were tried. It was the
English who brought the knowledge of producing starch
to the New World, where, after the Revolutionary War,
numerous small potato and wheat starch plants were
operating in the eastern United States. However, the
price of wheat and potatoes was rising to the point
where profit margins were seriously endangered.
The search for substitute raw materials resulted in
Americas most abundant crop as the answer, and the first
corn starch factory was built in 1844 in Jersey City, New
Jersey. From that point on, the industry grew by leaps
and bounds. In 1906, New York Glucose and the Glucose
Trust merged into Corn Products Refining Company under
the management of E.T. Bedford.
Background
Corn Products International, Inc.,
Leads the Way
Through the decades, Corn Products International
continues growing. Today, we operate nine corn refining
facilities in North America. Corn starches and sweeteners
produced in these plants are used in a wide variety of
food and industrial products.
Our long history with starch and experience with
the corrugating industry affords corrugators many
advantages. We have consistently sought new and
innovative methods of meeting the changing needs of
corrugators. Such efforts have led to the development
of quality modified and unmodified starches that
corrugators have come to expect. Our commitment to
the corrugating industry is further evidenced by our
pledge to excellence in technical services, sales
representation and engineering assistance.
3
 The Corn Wet Milling Process
The objective of processing corn is to separate the kernel
into its component parts with maximum purity. The five
basic products that result are starch, steepwater, germ,
feed and gluten.
The 40-hour steeping process softens the corn,
removes some solubles (steepwater), and breaks the bond
connecting starch, gluten, germ and fiber.
Germ, gluten and fiber are dewatered and dried by use
of filters, presses and dryers. The germ is further processed
to recover oil, while the remaining fiber is returned for feed.
Starch slurry is converted to food and industrial
grade starches for industries including corrugating.
It is dewatered in centrifuges to produce a starch cake.
This is then dispersed into a stream of heated air and
flash dried to a finished moisture of about 912.5
percent. The dried starch is pneumatically conveyed to
a storage silo where it can be loaded into bulk railcars,
bulk trucks or packed into 50- or 100-pound bags, or
super sacks.
During the drying process, it is common for corn
wet milling plants to maintain the moisture of about
912.5 percent. Great care must be taken to prevent the
starch from overheating in the presence of moisture.
If the process is not monitored closely, a starch product
with abnormally high sensitivity to caustic soda may result.
If the starch is to be further refined into a sugar, it
is processed in a refinery. Customers use dextrose, fructose
and corn syrup sugars in many food and beverage and
industrial applications.
4
Many factors affect the consistent production of
starch. As with any natural raw material, properties of
corn can be affected by temperature, hours of sunlight,
humidity, rainfall, year of planting, soil moisture, plant
population and fertilization rate.
Different corn varieties can also result in varying
starch properties. Corn varieties that contain all branched
starch molecules are called waxy maize. The types of corn
that contain unusually large quantities of linear starch
molecules are called high amylose hybrids. Starches
derived from these two hybrids have vastly different
properties that offer benefits in end-use applications.
Waxy maize starch tends to resist retrogradation, making
it ideal for certain food applications such as puddings
or in textiles because it produces a clear film. Conversely,
high amylose hybrids invert rapidly, which works well for
processes including fiberglass sizing or cotton-polyester
blend sizing.
Normally, corn starch is composed of two molecular
species. Amylose, a linear non-branched type of molecule,
makes up about 25 percent of the starch in conventional
corn starch. Amylopectin, the branched molecule in starch,
accounts for the remainder, or approximately 75 percent.
The Corn Wet Milling Process

Corn

Steeping Milling & Screening Germ Corn Oil

Feed &
Steepwater Germ Meal
Dietary Fiber

Starch Separation Corn Syrup

High
Starch Fructose
Gluten Feed Syrup Refining
Slurry Corn Syrup

Industrial Food Dextrose

Starch Drying Starches
Starches Family
 The Role of Corn
There are factors that affect the makeup of corn. For
years, seed-corn suppliers have worked to improve the
characteristics of the corn plant. Corn hybrids have
increased resistance to disease and pests and improved
yields. These improvements benefit all industries that
use corn by-products.
For corrugators, the most important properties are
viscosity and gelatinization point. These properties can
vary from corn crop to corn crop.
Data shows the natural gelatinization temperature
varies depending on the climate or growing region of
the world.1 (See Figure 1.) Process modifications may be
necessary to compensate for raw material variations.
Even granule size (diameter) is affected by environmental
factors. Granule size is important since it is known that
smaller granules have reduced amounts of amylose, the
linear molecule fraction in starch.2 Larger starch granules
gelatinize more easily than small particles.3 It also is
known that starches with lower gel temperature than
entire high quantities of amylose yield much higher
gelatinization temperatures than conventional corn starch.
(See Figure 2.)
When heated in water, native starch granules, regardless
of molecular type, hydrate (absorb water), increase in size
and thicken to form a viscous liquid, gel or paste. This
single property is probably the most important characteristic
of the starch and is relied upon to provide thickening.
In the corrugating industry, this gelatinizing property of
starch is encouraged by the addition of caustic soda and
used effectively to suspend or carry pearl starch that has
not been gelatinized.

FIGURE 1 FIGURE 2
Geographic Relationship to Reported Gelatinization Temperatures of Conventional
Gelatinization Temperature Corn Starch and High Amylose Starches

Geographic Location Gelatinization of Identification of Gelatinization Range

and Growing Conditions Corn Starch Starch Type of Starch Type
(Unmodified) (Initiation, Midpoint, Completion)

Location A 143-158F [61.7-70.0C] Conventional Corn 143F 158F 167F

[61.7C] [70.0C] [75.0C]

Location B 147-165F [63.9-73.9C] High Amylose Corn 153F 176F (Note)

[67.2C] [80.0C]

Note: Complete gelatinization of high-amylose starch is not affected

in boiling water, 212F [100C]. It has been stated that high amylose requires
pressure for complete gelatinization.

FIGURE 3

The Corrugating Process

Bridge
S. F. to bridge

Open
steam Medium
shower preconditioning
180-190F roll 250F [121.1C]
236-266F [82.2-87.8C]
[113.3-130.0C] Greenline
Liner steam
preheater shower
378F [192.2C] Pressure roll 370F
180-210F [187.8C]
[82.2-98.9C]
Doctor roll
D. F. Line
Starch Dance roll Open
370F steam
[187.8C] shower
Starch
Adjustable applicator
wrap roll roll
Roll stan
Footnotes:
6 1. F.R. Earle, Protein and Oil in Corn: Variation by Crop Years from 1907 to 1972, Cereal Chem., Vol 54(1), pp. 71-79.
2. R.L. Whistler, J.N. BeMiller and E.F. Paschall, Starch: Chemistry and Technology, 2nd Edition, (Academic Press, 1984)
Chapter III, pp. 34 & 36, Jack C. Shannon and Douglas L. Garwood, Contributing Authors.
3. R.W. Kerr, Chemistry and Industry of Starch, 2nd Edition, (Academic Press, Inc.,1950) Chapter I, p. 3
 Starch Basics for Corrugated Board The primary value of borax is to buffer the caustic soda
present in the formula. It also provides viscosity control
For 2005, the value of the corrugated board market in the
and adds tack to the finished adhesive. For equivalent
U.S. is estimated to be over $24 billion. Corrugated board
amounts of borax for starch formulations, see Appendix A.
is made up of liners and the fluted medium. Many weights,
thicknesses and combinations of liners and medium are Generally, 1520 percent of the starch is fully cooked
used for different applications. The principles of manufacture in part of the water with caustic to provide a carrier for
are simple. (See Figure 3.) the pearl starch. Starch solids levels usually are 2335
percent to achieve finished adhesive viscosity of 3050
Starting at the single facer, flat corrugating medium
Stein Hall seconds. After the adhesive is applied to the
is softened with heat and moisture and passed between a set
flute tips and heated, the pearl starch gelatinizes in
of corrugating rolls to form it into flutes. Adhesive is applied
place. When the starch swells and gelatinization begins,
to the flute tips on one side of the medium. Then, a single
a green bond is formed. Nearly all of the corrugated board
facer linerboard is brought into contact with the fluted
produced today is bonded with a starch-based adhesive.
medium under heat and pressure to produce a single facer
Since the quality and bonding properties of the starch
web. This web is conveyed to the double backer station
directly affect final board quality, decisions regarding
where adhesive is applied to the exposed flute tips and the
starch should be made carefully and treated with
double backer liner is applied. The combination is finally
importance in the process.
conveyed over a series of hot plates to set the adhesive.
Pearl starch, or unmodified starch, typically has
Modern corrugating machines can run at speeds
been the key product used for starch adhesive. However,
in excess of 1,200 feet per minute, depending on the type
with the introduction of high performance papers and
of board being produced. These high speeds are possible
the increased use of recycled paper, the porosity of the
because of corn starchs ability to gelatinize and produce
corrugated medium and liners has changed. Therefore,
high viscosities at the glue line.
the adhesive must change, too. Modified, or carrier,
A mixture of pearl starch, borax, caustic soda and water starches, when used in conjunction with pearl starch,
is suspended in a paste of cooked starch. The addition of allow an increase in solids for better bonding and the
caustic soda helps gelatinize the starch. An increase in the ability to achieve higher machine speeds.
amount of caustic soda, based on the total starch, will lower
the gel temperature of the entire adhesive.

Bridge
S. F. liner
Adjustable
itioning wrap roll
F [121.1C] Hold
Preheater 36" down Rider roll
roll
150-160F
[65.6-71.1C]

Doctor roll
Adjustable
wrap roll Preheater 36" Starch
D. F. Liner
en Starch applicator roll
am Preheater 18"
ower 180-210F
[82.2-98.9C]
Roll stand

7
 CORRUGATED MAKES IT HAPPEN FOR SHIPPING

8

In the corrugating industry, the term viscosity is used
to describe adhesives flowability. (Tests for measuring
viscosity can be found on page 17.)
Low Viscosity
When adhesive paste is too thin, or has low viscosity,
the water tends to wick into the medium. This wicking
action may remove the needed water from the glue line,
which means the pearl starch may not have enough water
to gelatinize completely.
Many times the board will be dry and brittle coming
off the corrugator, or may become brittle as it stack
cures. If a pin adhesion test is performed on a sample
of this board, low numbers will result. There may be
very little fiber pull and the glue line will have an amber
appearance. Since the bond is marginal, one solution is
to open the glue settings on the machine to deliver more
adhesive to the glue line. The downside to applying more
adhesive is the potential for warp, washboarding, higher
starch consumption and slower machine speeds.
High Viscosity (Thick, Heavy Adhesive)
When the adhesive is too thick (high viscosity), it tends
to sit on top of the flute tip, penetrating the medium
and glue line very slowly. This will lead to a soft, wet
board coming from the corrugator. It is difficult to print
on wet board and it is hard to convert in the finishing
department. Starch consumption will also increase
because of the wide glue lines associated with thick
adhesive. Adhesive flowability is reduced in the glue
pans, which pushes adhesive to the back of the pans
and allows heat to build up. This usually leads to
gelling problems at the single facer.
Overflowing adhesive and poor transfer of the
adhesive from the glue roll is associated with high
viscosity adhesive. On some of the new, high speed
single facers, the machine will shut down if the
viscosity is too high.
Effects of Shear on Viscosity
Shear is the mechanical action of breaking down the
adhesive resulting in reduced viscosity. Shear can occur
at the mixers, pumps, pipes, elbows or valves, and at
the actual corrugator.
Viscosity
In mixing systems, mixing blades shear the adhesive
to a workable viscosity. When an adhesive formula is
developed, the mix times are calculated to perform this
task correctly. When the mix times are changed, quality
of the finished adhesive will vary.
The secondary mixer blades must be properly placed
and in good repair to prevent areas of over-agitation.
Missing or broken blades will add mixing time and may
reduce the flexibility of the formula.
The storage tanks should have agitators operating on
timers. Agitators should be set to mix for five minutes out
of every 30 minutes. These agitators also should operate if
the Temperature Viscosity Control (TVC) system calls for heat.
Temperature is very important when taking a
viscosity reading. The viscosity of the adhesive
will vary proportionally with the temperature of the
adhesive. As the temperature goes up, the viscosity will
drop (become thinner). Conversely, as the temperature
decreases, the viscosity will increase (become thicker).
This inverse relationship of viscosity to temperature
is approximately 10 percent for every 2F [1.1C]
change. (See Figure 4.)
The piping system used in the plant should not have
dead ends. Fewer elbows and turns help reduce friction
and pressure buildup within the lines. The lines should
be pitched to ensure adequate drainage for cleanups.
The pumps (often positive displacement pumps)
used to transfer adhesive from the mixer to storage
tanks and from storage tanks to corrugator can
cause unwanted shear. It is important to have
the proper size pump operating at the correct
rpm. A plants starch supplier should be
able to help calculate system needs.
9
 FIGURE 4

FIGURE 4
Temperature - Viscosity Correction Table (for Stein Hall Viscosity)
Temperature - Viscosity Correction Table (for Stein Hall Viscosity)
90F
90F 92F
92F 94F
94F 96F
96F 98F
98F 100F
100F 110F
110F 104F
104F 106F
106F 108F
108F 110F
110F
[32.2C]
[32.2C] [33.3C]
[33.3C] [34.4C]
[34.4C] [35.6C]
[35.6C] [36.7C]
[36.7C] [37.8C]
[37.8C] [43.3C]
[43.3C] [40.0C]
[40.0C] [41.1C]
[41.1C] [42.2C]
[42.2C] [43.3C]
[43.3C]

42 38 34 31 28 25 15 20 18 17 15
44
44 40
40 36
36 32
32 29
29 26
26 16
16 21
21 19
19 17
17 16
16
46 41 37 34 30 27 16 22 20 18 16
46 41 37 34 30 27 16 22 20 18 16
48 43 39 35 32 29 17 23 21 19 17
48 43 39 35 32 29 17 23 21 19 17
50 45 41 37 33 30 18 24 22 20 18
50
52 45
47 41
42 37
38 33
34 30
31 18
18 24
25 22
23 20
20 18
18
52
54 47
49 42
44 38
40 34
36 31
32 18
19 25
26 23
24 20
21 18
19
56
54 50
49 46
44 41
40 37
36 33
32 20
19 27
26 24 22
21 20
19
58 52 47 43 38 35 21 28 25 23 21
(Stein Hall)

56 50 46 41 37 33 20 27 24 22 20
60 54 49 44 40 36 21 29 26 24 21
58 52 47 43 38 35 21 28 25 23 21
62 56 50 45 41 37 22 30 27 24 22
60 54 49 44 40 36 21 29 26 24 21
64 58 52 47 42 38 23 31 28 25 23
(Stein Hall)

62
66 56
60 50
54 45
48 41
44 37
39 22
23 30
32 27
29 24
26 22
23
Viscosity Viscosity

64
68 58
61 52
55 47
50 42
45 38
41 23
24 31
33 28
30 25
27 23
24
70
66 63
60 57
54 51
48 46
44 42
39 25
23 34
32 31
29 28
26 25
23
72
68 65
61 59
55 53
50 48
45 43
41 26
24 35
33 31
30 28
27 26
24
74 67 60 54 49 44 26 36 32 29 26
70 63 57 51 46 42 25 34 31 28 25
76 69 62 56 50 45 27 37 33 30 27
72 65 59 53 48 43 26 35 31 28 26
78 70 63 57 52 46 28 38 34 31 28
74
80 67
72 60
65 54
59 49
53 44
48 26
28 36
39 32
35 29
32 26
28
82
76 74
69 67
62 60
56 54
50 49
45 29
27 40
37 36
33 32
30 29
27
84
78 76
70 68
63 62
57 56
52 50
46 30
28 41
38 37
34 33
31 30
28
86 78 70 63 57 51 31 42 38 34 31
80 72 65 59 53 48 28 39 35 32 28
88 79 72 65 58 52 31 43 38 35 31
82 74 67 60 54 49 29 40 36 32 29
90 81 73 66 59 54 32 44 39 35 32
84
92 76
83 68
75 62
67 56
61 50
55 30
33 41
45 37
40 33
36 30
33
86
94 78
85 70
76 63
69 57
62 51
56 31
33 42
46 38
41 34
37 31
33
96
88 87
79 78
72 70
65 63
58 57
52 34
31 47
43 42
38 38
35 34
31
90 81 73 66 59 54 32 44 39 35 32
92 83 75 67 61 55 33 45 40 36 33
94 85 76 69 62 56 33 46 41 37 33
96 87 78 70 63 57 34 47 42 38 34

If air pumps are to be used to circulate the adhesive
to and from the machine, proper air pressure is essential.
Most air pumps operate at 40 to 60 psi, depending upon
the distance to pump. Too much air pressure will force the
adhesive through the lines and cause shear.
Valves in the lines must be inspected regularly.
A worn valve may appear open when it is only partially
open, causing shear of the adhesive.
10
The Temperature Viscosity Control System
To control the adhesive temperature in storage properly,
a Temperature Viscosity Control (TVC) system is required.
Typically, the system uses a small tank of heated water
positioned slightly above and between the adhesive storage
tanks. Water from this tank is circulated through coils
inside the storage tanks at the same time agitators are
moving adhesive. The water should be heated to a
temperature 10F [5.6C] lower than the lowest gel
temperature of the adhesive in storage. When the
temperature of the adhesive falls below 100F [37.8C],
the TVC system should activate automatically. Probes inside
the TVC water tank and storage tanks monitor temperature.
If the water temperature becomes too high (higher
than the gel temperature of the adhesive), the adhesive
will begin to gelatinize on the coils. When this happens,
the heat transfer from the water in the coils to the starch
is reduced, which increases the agitation time of the
adhesive. This can result in low viscosity. The longer it
takes for the temperature to rise, the longer the storage
tank agitators must run, and the higher the risk of shear.
Plants that have complete steam shutdown on weekends
rely on electric units to heat TVC water. This is an important
consideration in new installations to insure proper
adhesive viscosity control.
Viscosity/Time Relationship
The length of time the adhesive is held in storage can
be critical. Over time, the raw portion of the adhesive
will begin to separate from the cooked portion. This
causes viscosity to drop. Fast turnover of the adhesive
is the best solution. Reducing the amount of material
for storage during down periods is also wise.
Viscosity/Resin Relationship
To make adhesive water resistant, you must add resin.
This creates a chemical reaction when the mixture is heated
on the corrugator. The result produces a water-resistant
bond. The degree of water resistance is related to the ratio
of resin solids to starch. However, it is difficult to generalize
about the amount of resin needed because resin solids
vary dramatically.
Never mix resin-treated adhesive with adhesive in
storage. When resin is added to a batch of adhesive, it is
advisable to use all of the adhesive as soon as possible.
The adhesives resin potency will last approximately eight
hours after a batch is made. After that, the resin loses the
ability to react with the starch and viscosity breakdown
begins, affecting the entire batch. Also, resins have a
finite shelf life.
Resin should be added slowly to the adhesive, usually
during the final mix. Adding the resin too fast can cause
viscosity changes. It is not advisable to add resin to the
storage tanks because viscosity changes can occur in
storage, to the point that the adhesive will be unable to
pump. In addition, the storage tank agitators are not
designed to blend resin, and permanent damage can occur.
Some resins will react with borax in the formula causing
a change in viscosity. Using the correct amount of resin
in the formula is critical. The resin supplier should be
contacted for proper addition rates and/or limitations.
Microbiological Degradation
Starch, a carbohydrate, is often considered food for bacteria.
It has been found that some bacteria will survive, and
may even thrive, in a strong alkaline medium such as
starch-based corrugating adhesives. If the bacteria
population increases to, or exceeds, 10,000 colony forming
units (cfu) per gram, starch adhesive could show viscosity
loss. This results from the gelled starch being attacked by
bacteria and converted to a soluble carbohydrate, which
will lower viscosity.
At levels greater than 1,000,000 cfu per gram, an
odor may also develop. However, odor alone should not be
considered an indicator of microbiological growth. When
microbial problems are suspected, microbiological testing
can be a valuable tool. Test laboratories generally require
an aseptically obtained sample of the corrugating adhesive
to achieve meaningful results. Contact your biocide
supplier and request a test of the plants adhesive.
Care With Biocides
To prevent microbiological growth, biocides should be
used with care. Most manufacturers recommend changing
the biocide regularly to prevent the growth of a colony
that may resist the action of a particular biocide.
(See Appendix B.)
It is recommended that the entire adhesive system
be cleaned twice per year using a commercially available
industrial strength cleaner and commercial household
bleach, or a treatment from your biocide supplier. The
lines to and from the machine also should be flushed
and cleaned. If the adhesive system uses bulk starch,
the discharge chute should be cleaned or changed since
it is a breeding ground for bacteria. Details on system
cleaning should be provided by the biocide supplier.
11
 Gelatinization
Temperature
Gelatinization temperature, or gel temperature, is the Gel Temperature/Time Relationship
temperature at which the adhesive begins to thicken
The gel temperature will rise the longer the adhesive
and develop its bonding properties. Although it is often
is held in storage. This happens because over time the
expressed as a single temperature unit (F or C), in reality
starch will absorb some of the free caustic present in
it is a temperature range dependent upon the molecular
the adhesive. Periodic checks of the gel temperature
size and composition of the starch.
will prevent unwanted high temperatures at the double
The natural gelatinization temperature of corn starch backer glue station.
is generally too high for normal corrugating operation.
Running an adhesive with high gel temperature could
affect bonding, especially at the double backer. Machine Determination of Caustic Concentration in
speed could also be affected. Addition of caustic soda Liquid Caustic (Hydrometer Method)
suppresses the gelatinization temperature, thus providing The caustic concentration of liquid caustic can be
corrugators the flexibility to set the gel temperature at a determined by utilizing a caustic specific gravity chart
desirable level for the individual machine conditions and and specific gravity spindle. Equipment needed is a
paper combinations. specific gravity spindle, a clear 500-mL plastic cylinder and
Gel temperature is measured by simply heating the a specific gravity concentration chart. (See Appendix D.)
adhesive as it is stirred with a glass thermometer. When Fill the plastic cylinder so that it is about 2/3 full
the paste begins to thicken (gel), the temperature that with liquid caustic. Make sure the sample is at or above
appears on the thermometer is recorded. (See Appendix C.) room temperature. Gently insert the spindle into the liquid
so that it floats freely without touching the sides or the
bottom. The spindle stem has graduated marks (specific
Gel Temperature Too High
gravity units), and the reading is taken at the point where
If the gel temperature is too high, there may not be the liquid level intersects the spindle stem. The specific
enough heat present to gelatinize all the starch granules. gravity reading is applied to the chart to determine the
This will result in a white glue line and a poor bond. percent caustic (% NaOH) directly.
The speed of the corrugator must be reduced to achieve
For example, if the sample is 50% liquid caustic,
an acceptable bond, particularly on double wall board.
the spindle reading will be 1.530. If the reading is higher,
The dry end operators also may notice wet or soft board
the caustic solution is higher than 50%. Similarly, if the
coming off the machine.
reading is lower, the caustic solution is diluted with water
and its concentration is less than 50%. (See Appendix D.)
Gel Temperature Too Low
If the gel temperature is too low, several conditions may
result. The adhesive will gel before it has a chance to
penetrate into the paper. This may result in brittle board,
dry bond, raspy-feeling glue lines and cracking board.
There also may be severe gelling on the fingers of the
single facer or gelling in the pans.

12

Penetrating Aids
When dense liners and/or mediums are used, penetrating
aids may help bonding by reducing the water surface
tension, so the adhesive can penetrate the sheet. If a
plant suspects that a penetrating aid would be beneficial,
the plant should contact the starch supplier for assistance.
Antifoam Agents
The use of antifoam agents is common with todays
corrugators. As machine speeds increase, foam is often
created in the glue pans as starch cascades off the
metering roll and wiper blade. If the foaming becomes
severe, it can overflow the pan, causing higher than
normal starch consumption; or it can transfer from the
glue roll to the flute tips, causing poor bonding. Should
foaming occur at the double backer, it could overflow onto
the paper, resulting in a poor bond on the double facer
side. For antifoam options, contact your starch supplier.
Corrugating
Additives
Liquid Additives
Liquid additives are often used to enhance the wet tack,
or green bond, of starch-based adhesives. Green bond is
the measure of an adhesives wet tack and the major factor
affecting the potential machine speed of the corrugator.
These products can potentially increase corrugator operating
speeds. Although suited for any adhesive mixing system,
liquid additives are an ideal choice for high shear mixing
systems that may be equipped with liquid dosers.
For liquid additive options, contact your starch supplier.
Resins
Resins are used in starch adhesive formulations to impart
varying degrees of water resistance to corrugated board.
The resins react with hydroxyl groups on starch and render
the starch insoluble to water. Degrees of water resistance,
ranging from moisture resistance to waterproof, depend on
the functional use of the container. Various types of water
soluble thermosetting resins are available to the corrugating
industry. Ketone aldehyde-type resins are particularly well
suited for corrugating applications. They require caustic
and heat in order to react. For resin options, contact
your starch supplier.
13
 CORRUGATED MAKES IT HAPPEN FOR CONSUMERS

14
 Corrugating
Processes/Systems/Equipment
FIGURE 5

Caustic
Starch plays an important role in the corrugating process, FIGURE 5 Secondary
mix tank
so the integrity of the starch production process is critical. mixer
Recirculation Caustic
Four processes are common in starch adhesive Secondary Primary
mix tank
production: Stein Hall, Jet Cook, High Shear and mixer mixer
No-Carrier methods. Basic adhesive preparation consists of Recirculation
Primary
a cylindrical primary mixer with a low-speed, high-torque mixer
mixer situated above a secondary tank with a high-speed, Pump
To storage
lower-torque agitator. A drop valve generally controls the
flow of adhesive from the primary mixer into the secondary Steps: (1) WaterPump
primary and secondary; (2) Starch primary;
tank. However, No-Carrier adhesives differ significantly (3)ToAdd
storage
caustic to primary; (4) Cook primary; (5) Add borax to
in preparation since only one mixer tank is used and no secondary; (6) Add starch to secondary; (7) Add cooling water
to primary;
Steps: (8) Drop
(1) Water primary
primary and into secondary;
secondary; (9) Final
(2) Starch mix;
primary;
gelatinization of starch occurs. (10) Pump
(3) Add to storage
caustic to primary; (4) Cook primary; (5) Add borax to
secondary; (6) Add starch to secondary; (7) Add cooling water
to primary; (8) Drop primary into secondary; (9) Final mix;
Stein Hall (10) Pump to storage

This system uses a two-phase process. The first phase

FIGURE 6
is referred to as the cook phase. Here, starch, water
and caustic are combined to create a gelatinized starch
adhesive. This product is also referred to as the carrier. Starch 6
FIGURE Water Chemical tank

20 Gal.
The second phase is the blend phase where starch, Raw
Slurry
Starch Water Chemical tank
water and borax are added together and mixed with the tank Steam Cooling
column
cooked portion to form a finished adhesive. (See Figure 5.) 20 Gal.
Raw
Slurry
tank Steam Cooling Mixer
column
Jet Cook Scales
Pump

The Jet Cook system is a modification of the Stein Hall Carrier 190F To storage
Mixer
[87.8C]
process using a single vessel horizontal mixer. Pump 150F [65.6C]
Scales
With the Jet Cook system, all the water, caustic and Steps: (1) Raw starch water; (2)190F
Carrier Raw starch; To storage
[87.8C]
(3) Transfer to mixer; (4) Add chemicals;
borax are mixed together with approximately half of the 150F [65.6C]
(5) Add carrier water; (6) Add starch carrier;
total starch in a horizontal mixer. The amounts of caustic (7) Jet cook carrier; (8) Final mix;
Steps: (1) Raw starch water; (2) Raw starch;
and borax are determined by the gel temperature that is (9)
(3) Pump toto
Transfer storage
mixer; (4) Add chemicals;
(5) Add carrier water; (6) Add starch carrier;
needed for a given adhesive. This starch/water/chemical (7) Jet cook carrier; (8) Final mix;
slurry is then circulated through pipes and returned to the (9) Pump to storage
mixer. Live steam is injected into the pipe, causing the
slurry to swell (gelatinize) as it is being pumped back into
the mixing tank. Monitored by an automatic viscometer, the
process continues until a given viscosity (set point) is
reached. Upon reaching its set point, the steam is shut
off and the remainder of the pearl starch is added to the
adhesive. A timed mix then finishes the process.
(See Figure 6.)

15
 High Shear FIGURE 7
The High Shear system is an improvement on the
Caustic Borax
conventional Stein Hall process.
Starch Motor Water
40 hp
When trying to achieve a high solids adhesive formula
with the conventional Stein Hall system, the limiting
factor is that high viscosities develop as the amount of
primary starch is increased. One way to overcome the high
viscosity is to mechanically shear the cooked portion of
the formula. Using a vertical mixing tank with a mixing
blade designed to shear the gelled starch, batches with
higher solids can be made faster with better results.
To storage
Different manufacturers use different mixer and blade Scale
20,000 r.p.m.
combinations to achieve the same results. Adhesive is
usually made in a single vessel resting on weight sensors.
High Shear Adhesive System
Water is added (by weight) and heated to a set point.
Some automatic systems compensate for condensation
by adjusting the programmed ingredient weights to meet
any changes caused by the added water. Other systems
heat the water using a heat exchanger so no condensation
is added to the programmed formula. Starch and caustic FIGURE 8
(usually 50% liquid) are added and mixed under high
shear. Borax, secondary water and starch are then added Bulk starch
From liquid
and mixed for a cycle timed anywhere from 12 to 35 caustic
130F
minutes. Some systems allow for up to 20 different [54.4F]
storage
Scale hopper
formulas to be programmed into the system so customized Caustic
tank
adhesive can be made for different board combinations Water
Caustic
or special papers. Boric
Norcross supply
acid
viscometer line
Most automatic systems incorporate level controls in Boric acid
addition
the storage tanks and automatically make a batch when system
needed. This allows for lower storage volumes, which
results in fresher adhesive being used at the corrugator.
One major advantage of the new High Shear mixing To storage
system is that it dramatically reduces adhesive preparation Pump Pump
time, freeing up manpower to be used in other plant
Steps: (1) Water; (2) Starch; (3) 130F [54.4C]; (4) Mix to X
operations. Even though some of the systems are fully Norcross Units; (5) Add boric acid to terminate; (6) Final mix;
automatic, they still must be checked daily and put on (7) To storage
a preventative maintenance schedule. (See Figure 7.) No-Carrier Adhesive System

No-Carrier
This process is very different from the others. No
gelatinization of any of the starch takes place. In the
No-Carrier process, starch, water, 50% liquid caustic and
boric acid are used to swell the starch granule. This is
accomplished by monitoring the viscosity of the adhesive.
All mixing of ingredients takes place in a lower mixer.
(See Figure 8.)

16
 Starch
Properties and Testing
Alkali (Caustic) Sensitivity A reading other than 15 seconds may indicate a
plugged or enlarged opening, or the pins may have
One critical property of the starch is the ability to
become bent. Carefully clean the orifice and check the
perform in alkali (caustic) conditions.
volume between the pins. Recheck the flow of water.
During the manufacturing process, starch granules can If it is not correct, replace the disk.
become damaged. When a sample of starch containing an
excessive amount of damaged granules is mixed in a solution
of caustic (alkali), the starch swells at too rapid a rate. Gelatinization Temperature
This results in a viscosity that is higher than normal. Gelatinization (gel) temperature will affect the corrugating
There are several methods used to check for the alkali operation and is frequently measured. Gel point is the
sensitivity of pearl starch. One is the settling test for temperature at which liquid adhesive is transformed into
unmodified starch. (See Appendix E.) This test can be a semi-solid mass or gel. (See page 12 and Appendix C
accurate and reproducible with relatively inexpensive testing for test procedures.)
equipment. Minor deviations from the procedure, or less
than ideal conditions, may result in inaccurate results.
Microbiological Testing
There is a second, more rapid test for alkali sensitivity
Bacterial growth in starch adhesives is detrimental
that is just as accurate as the settling test. However,
because it causes molecular breakdown. If the growth
this test uses a more costly Brookfield Viscometer.
reaches a certain point, viscosity will be drastically
(See Appendix F.)
reduced, making the adhesive unusable. This growth
cannot be measured at the plant site. Typically, adhesive
Measuring Viscosity of samples are sent to a laboratory capable of measuring
Finished Starch Adhesive bacterial growth. The plants biocide supplier can assist
in arranging testing. Laboratory reports speak in terms
There is one standard for measuring viscosity Stein
of colony forming units (cfu) per gram. When the cfu
Hall seconds, which is calculated using a Stein Hall Cup.
level reaches 10,000 cfu/g, it is advisable to clean
There are, of course, some plants and manufacturers who
the system. (See page 11 and Appendix B.)
use other methods and tools for measuring viscosity.
Love Cups, Zahn Cups, Brookfield Viscometers, Norcross
Viscometers and Dynatrol Viscometers are some of the Starch Solids Concentration
other methods and tools that are used. Some have
High solids (starch) adhesives are necessary to bond high
individual charts for flowability, but most are converted
performance and recycled papers. Variation in the amount of
to Stein Hall seconds.
starch or water changes the solids content of the adhesive.
The Stein Hall Cup is a brass cylinder with a specific
Analyzers for moisture or solids measurement are
size orifice in the bottom, and two brass pins located on
available to corrugators. It is critical that the analyzers
the inside of the cylinder wall. The distance between the
be calibrated against strict standards. Generally, adhesive
two pins will hold a volume of exactly 100 ml of liquid.
samples are analyzed by outside laboratories using either
The cup is filled with adhesive and allowed to flow through
oven, infrared or microwave technologies. To determine
the opening. The elapsed time it takes the adhesive to
whether excessive water is entering an adhesive system,
move from pin to pin is the viscosity in seconds.
samples of fresh and stored adhesive are analyzed for
water content and compared. If the solids levels are
Calibrating the Stein Hall Cup equal, then no excess water has entered the system.
If water has entered the system, the solids level in
The Stein Hall Cup must be calibrated properly to give an
stored adhesive will be lower.
accurate viscosity reading. Measuring water flow from pin to
pin is the best way to check calibration. Water should flow
from pin to pin, through the orifice, in exactly 15 seconds.

17
 CORRUGATED MAKES IT HAPPEN FOR MANUFACTURING

18

Traditionally, moisture is determined with a forced air or
vacuum oven, but other devices that incorporate infrared
or microwave technologies have shown to be just as
accurate and are faster.
There are many tests for determining the quality of
combined board. Below are some of the more frequent tests.
Many of these standard tests have achieved a TAPPI
designation, which is noted next to the test name. Specific
test procedures may be obtained by contacting TAPPI.
Caliper T-411
Caliper, or thickness, is generally the first test performed
on finished board. At plant sites it is usually conducted
using a micrometer and is considered a diagnostic test
to monitor the operation of the corrugator.
Edge Crush Test (ECT) T-811
Corrugators use this test to determine the edgewise
compressive strength of their board. This test considers
the role of the medium in overall strength. A compression
machine is necessary. The ECT of a combined board is
dependent on the paper combination used.
Dry Pin Adhesion T-821
This test measures the force necessary to separate
corrugated board between the flute tips of the medium
and its linerboard facings. A special pin adhesion
attachment and compression machine is necessary.
Board
Testing
Ply Separation T-812
Ply separation determines the water resistancy of
finished board. Board samples are submerged in water
for 24 hours, removed and drained of excess water.
The linerboard facing is gently pulled apart from the
medium. If there is resistance and fiber tear, the board
is considered water-resistant.
Glue Pattern (unofficial)
For diagnostic purposes, it is often useful to soak a
sample of corrugated board in water to separate the
linerboard from the medium. Then, simply spray the inside
surface of the liner with a dilute solution of 0.1 percent
iodine-potassium iodide. The iodine solution will stain
the glue line, or starch, blue. From the pattern it may be
possible to determine how the adhesive was applied or
whether it was applied correctly.
Top to Bottom Compression T-804
This test is used to measure the ability of a corrugated
or solid fiber shipping container to resist external
compressive forces. A completed, but empty, box is
placed in a compression tester and an external force
is applied until the box fails.
Basis Weight Combined Board T-410
Basis weight is a physical measurement.
A sample of measured board is weighed on
a balance and expressed in pounds per MSF.

Wet Pin Adhesion (unofficial)

Wet pin adhesion is a variation of the dry pin test. It
tests the water resistance or waterproof characteristics of
the finished board. In the wet pin test, the board can be
submerged in water as long as 24 hours, removed and
drained of excess water. The pin adhesion test is then
conducted on the wet board. Wet pin results are much
lower than dry pin results. A range from about two to
seven lbs. per linear foot indicates water-resistant board.
Wet pin results of between 1012 lbs. per linear foot
indicate waterproof board to most corrugators.

19
 CORRUGATED MAKES IT HAPPEN FOR DISTRIBUTION

20
 Quality Monitoring
and Control at the Adhesive Station
The fitness of the adhesive is related directly to the quality Statistical Process Control
of the bond that will be produced at the corrugator.
The first step in monitoring any of the three control
Therefore, it is critical to maintain control of several key
points (viscosity, adhesive temperature, gelatinization
characteristics of the adhesive. Adhesive temperature,
point) is to gather enough data to determine the process
viscosity and gelatinization temperatures are the critical
capability. See Figure 9 for a typical example of a chart
points to monitor and control in order to maintain
used to gather data.
consistent adhesive.
If the process is determined not to be capable in any
Many problems can be avoided and eliminated
area, the starch supplier should be called upon to provide
through the regular use of statistical process control
assistance. The process should be corrected and additional
(SPC). Development of a data collection program is
data gathered to verify the improvements and determine
recommended to achieve meaningful statistical control
if the process is capable. The goal is to keep the starch
of the process.
adhesive process in tight control.
The starch supplier can be a valuable resource. Many
Once the process is determined capable, then
suppliers offer SPC consultation or even training. Another
additional data should be collected and the mean (X),
resource for SPC training is the American Society for
upper control limits (UCL) and lower control limits (LCL)
Quality Control (ASQC).
should be calculated. The mean (X) should closely match
Generally, the SPC or Quality Control Coordinator in the the desired target. If the mean is not numerically close
plant will work closely with the starch supplier to set up to the target, then the process must be corrected. These
control and monitoring systems and determine consistent, process corrections can be as simple as an adhesive
meaningful measurement points in the system. formula change, an equipment repair or calibration.
Once again, starch suppliers should be considered
a resource for these process corrections.

21
 FIGURE 9

INDIVIDUAL AND MOVING RANGE (X & MR) CHART

CHARACTERISTICS UNIT OF MEASURE

Starch Kitchen Adhesive Viscosity Seconds (Stein Hall)
DATE 2-2 2-3 2-3 2-4 2-4 2-5 2-5 2-5 2-6 2-6 2-6 2-6 2-10 2-10 2-10 2-11 2-11 2-12 2-12 2-12 2-13 2-13 2-13 2-17 2-17
TIME 2:15 8:00 12:30 9:00 12:00 9:00 12:00 2:30 7:12 10:30 1:00 2:45 7:45 9:00 11:30 8:30 10:15 6:30 10:30 1:30 8:30 11:30 1:45 7:00 9:25
OPER. INITIALS JS
MEASUREMENT 41 42 42 47 45 39 34 43 35 41 44 31 42 43 32 37 41 37 41 43 44 35 36 32 42
PREVIOUS 41 42 42 47 45 39 34 43 35 41 44 31 42 43 32 37 41 37 41 43 44 35 36 32
MOVING RANGE 1 0 5 -2 -6 -5 9 -8 6 3 -13 11 1 -11 5 4 -4 4 2 1 -9 1 -4 10
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

50
INDIVIDUAL MEASUREMENTS

45

40
X

35

30

25
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

15

10

5
MOVING RANGES

0
MR

-5

-10

-15

NOTES:

22
 Troubleshooting
Common Corrugating Problems
DIAGNOSING VISCOSITY PROBLEMS - System: Primary/Secondary Mixing Systems,
Single Tank Mixing Systems, High Shear Mixing Systems
Adhesive viscosity is a critical parameter for quality corrugated board. It is a relatively easy
variable to control when the underlying cause of a problem is understood.

Problem: Common Causes:

Low viscosity at the mixer Not enough starch in the cooked portion of the formula
Scale out of calibration
Too much water in the cooked portion of the formula
Water leak
Water meter out of calibration
Improper measuring device
Condensate from steam lines
Condensate from steam leak
Unwanted wash water going into the mixer
Too much water in the secondary addition or secondary mixer
Water leak
Water meter not calibrated
Improper measuring device
Condensate from steam lines
Condensate from steam leak
Cooked portion too hot (+160F [71.1C])
Steam leak
Temperature controller out of calibration
Temperature gauge out of calibration (reading too low)
Finished batch too hot
Cooked portion too hot
Temperature controller out of calibration
Cooling water too warm (seasonal)
Mixer shaft overheating due to bad bearings
Improper balance between the cooked portion and cooling water
Too much shearing of the cooked portion of the adhesive
Cooked portion mixed too long
Drop time too slow or slow pump over time
Too long a time on high shear
Finished batch being mixed too long
Substituting incorrect borax (5 mol vs. 10 mol vs. boric acid)

High viscosity at the mixer
Too much starch in the cooked portion of the formula
Scale out of calibration
Too much starch in the secondary mixer
Scale out of calibration
Not enough water in the cooked portion of the formula
Water meter out of calibration
Improper measuring device
Not enough water in the secondary addition or secondary mixer
Water meter out of calibration
Improper measuring device
Cooked portion too cold
Temperature controller out of calibration
Temperature gauge out of calibration
Cooling water too cold (seasonal)
Finished batch too cold (optimum temperature 100 to 102F [37.8 to 38.9C])
Cooked portion too cold
Temperature controller out of calibration
Temperature gauge out of calibration
Cooling water too cold (seasonal)
Bulk starch too cold (seasonal)
Improper balance between the cooked portion and cooling water
Not enough shearing of the cooked portion of the adhesive
Cooked portion not mixed long enough
Too fast a drop or fast pump over time
System not left on high shear long enough
Finished batch not being mixed long enough
Incorrect amount of borax 23
Substituting incorrect borax (5 mol vs. 10 mol vs. boric acid)
 DIAGNOSING VISCOSITY PROBLEMS - Problems Common To All Systems

Adhesive viscosity is a critical parameter for quality corrugated board. It is a relatively easy
variable to control when the underlying cause of a problem is understood.

Problem: Common Causes:

Low viscosity at the storage tanks
High viscosity at the storage tanks
Low viscosity adhesive coming from mixer
Finished batch temperature too high
Temperature of cooked portion too high
Bad temperature controller
Insufficient amount of cooked starch in primary portion
Bulk scales out of calibration
Temperature of the adhesive too high
Temperature viscosity control (TVC) system set too high
TVC controller out of calibration
Adhesive returning from machine at an elevated temperature
Finished batch temperature too high
Bad bearings on the agitator causing the shaft to overheat
Bad bearings on the supply/return pump
Storage tank agitators running continuously
Agitator timers not operating properly
TVC system controller malfunctioning
Poor heat transfer from TVC coils
TVC water too hot
TVC coils coated with gelled adhesive
TVC water too cold
TVC circulation pumps not operating
Unwanted water in adhesive
Wash water coming back from corrugator
TVC coil leaking inside storage tank
Over-shearing of the adhesive
High rpm supply and return pumps
Too many elbows in the supply and return lines
Supply and return line pipe diameter too small
Pipe size reductions in supply and return lines
Partially open valves in supply and return lines
Air pressure too high on air diaphragm pumps
Old adhesive (stored too long)
Adhesive treated with resin (WPA) mixed with domestic adhesive
Low solids adhesive formula
Microbiological contamination of adhesive
High viscosity adhesive coming from the mixer
Adhesive viscosity "growing" in storage
Too much caustic in the formula
Scale out of calibration
Caustic meter out of calibration
Not enough borax in the formula
Scale out of calibration
Borax timer set improperly
Wrong type of borax (5 mol vs. 10 mol)
Adhesive cold
TVC system not operating properly
Loss of steam pressure in the plant
Finished batch temperature should be 100 to 105F
Storage tank agitators not operating properly
Alkali-sensitive starch

24
 DIAGNOSING VISCOSITY PROBLEMS - Problems Common to All Systems
Adhesive viscosity is a critical parameter for quality corrugated board. It is a relatively easy
variable to control when the underlying cause of a problem is understood.
Problem:
Low viscosity at the machine
High viscosity at the machine
Viscosity decrease after overnight
or weekend storage
Common Causes:
Excessive adhesive temperature in the starch pan (between 110-120F)
Incorrect storage tank temperature
Incorrect TVC water temperature
Starch feed and return line exposed to steam lines
Insulate these lines for better temperature control
Starch feed line running over top of single facer
Increase starch flow through the pan
Adhesive temperature increases the longer it remains in the pan
Higher temperatures lower the viscosity
Water dripping into the starch pan
Condensate from steam showers
Partially open valves in the starch feed and return lines
Flow restriction will create shear causing a drop in viscosity
Air pumps feeding or returning adhesive running at high PSI levels
Bad Viking pump (weak suction) creates too much shear
Pumps not sized properly for the corrugator
Plant has doser
Recirculating the adhesive causing a drop in viscosity
Low viscosity adhesive coming from the storage tanks
Low adhesive temperature
Cold weather outside causing the temperature drop
Very high temperature in the starch pan (in excess of 120F [48.9C])
Pressurized machine running high solids over 30%
Excess heat inside the chamber causing water loss
Chemicals in formula are out of ratio (borax to caustic)
Steam leak directly into the pan
Steam leak blowing into a starch line
Poor agitation or no agitation of the adhesive held in storage
High viscosity adhesive coming from the storage tanks
Clean-up water returned to storage tanks
Agitators/circulating pumps left running
Circulating lines full of water
TVC system not working properly
Water leak from the TVC coil
Temperature of the adhesive too high
Insufficient amount of cooked starch in the formula to hold viscosity properly
Primary portion of the formula is overcooked
Bacteria
25
 DIAGNOSING TYPICAL GEL TEMPERATURE PROBLEMS

Problem: Common Causes:

Gelatinization temperature too high Not enough caustic in the adhesive

Scale out of calibration
Caustic meter set too low
Caustic meter out of calibration
Too much borax in the adhesive
Scale out of calibration
Borax timer not working properly
Too much starch in the adhesive
Scale out of calibration
Too much water in the adhesive
Water meter out of calibration
Mixer scale out of calibration
Substituted incorrect borax formula (5 mol vs. 10 mol vs. boric acid)
Borax too old (dry, becomes more concentrated)
Caustic soda beads too old
Liquid caustic too old
Caustic stratified in storage tank sending low concentrations of caustic
Wrong concentration of liquid caustic (See Appendix D)
Adhesive stored too long
Addition of resin into adhesive
Wrong or defective thermometer used by starch person
Do not use an electronic or dial thermometer
Test is performed improperly or by different people

Gelatinization temperature too low Too much caustic in the adhesive

Scale out of calibration
Caustic meter set too low
Caustic meter out of calibration
Not enough borax in the adhesive
Scale out of calibration
Borax timer not working properly
Borax discharge tube plugged
Not enough starch in the formula
Scale out of calibration
Substituted incorrect borax in the formula (5 mol vs. 10 mol vs. boric acid)
Problem with caustic soda
Liquid caustic too cold
Liquid caustic crystallized in storage tanks sending high
concentrations of caustic
Wrong concentration of liquid caustic (See Appendix D)

26
 DIAGNOSING CORRUGATING EQUIPMENT AND BOARD QUALITY PROBLEMS
Board quality begins at the single facer. To insure that good quality board is being produced
at high speeds, it is critical to maintain the single facer in good mechanical condition.
Problem:
Soft Board:
This causes poor pin adhesion,
low top-to-bottom compression
and poor print quality
Washboard Appearance:
This problem usually occurs once
the board has cured and causes a
poor printing surface and brittle
edges during conversion
Dry Board, Zipper Board:
Creates waste, low pin adhesion
and poor top-to-bottom
compression
Leaning Corrugation:
This causes low board caliper,
poor pin adhesion, poor top-
to-bottom compression, poor
printing surface
Slipping Board - General
Slipping Board:
This problem is produced
by a surface bond only and
delaminates after curing
Common Causes:
Excessive adhesive application
Operator error
Low machine temperature
Over conditioning of the medium
Wet paper - medium or liners
Excessive rider roll pressure at double backer glue machine, crushing flute tips
Uneven roller pressure in hot places or cooling section of double backer
Board cut off knife pressure too high
Low viscosity of the adhesive
Low solids of the adhesive
Water sprays being used to help control warp
Hot plates not level
Incorrect roller pressure in the cut off section or stacking section of the machine
Heavy adhesive application at single facer or double backer
Adhesive viscosity too low
Adhesive solids too low
Wet paper (roll stock stored outside)
Excessive heat applied to lightweight liners
Glue roll set to wrong paper speed
Over-dried liners
Adhesive application at single facer or double backer too light
Water penetrates medium too quickly
Low viscosity adhesive
Medium with fast water drop
Low solids adhesive
Too much borax in the formula
Glue roll in double backer at wrong speed (paper comes apart easily in one
direction, but has good fiber pull in the other direction)
Too much heat application at single facer or double backer
Slow machine speed
Adhesive gel temperature too low
Poorly formed flutes (highs and lows)
Slipping of the board coming through the machine
Misalignment of corrugator rolls
Excessive wear on corrugator rolls
Pressure between corrugator rolls too low
Top and bottom belts traveling at different speeds
Excessive rider roll pressure at double backer glue station
Adhesive application at single facer or double backer
Drag through hot plate
Excessive tension on double facer
Loose or worn belts
Belt rollers lift
Top and bottom belts traveling at different speeds
Treatment or finish of bottom liner causing excessive drag on the hot plates
Excessive drag on single face web
Loose or worn corrugator belts in double facer
Hot plate rollers are up
Rollers in pulling section of the double facer are up
Corrugator belts traveling at different speeds
Coating on bottom liner creating drag
27
 DIAGNOSING CORRUGATING EQUIPMENT AND BOARD QUALITY PROBLEMS
Board quality begins at the single facer. To insure that good quality board is being produced
at high speeds, it is critical to maintain the single facer in good mechanical condition.
Problem:
Dry Streak:
Poor bonding, low top-to-bottom
compression of finished carton
"Cracker" Board:
This problem is identified by a
cracking sound when flexed
Light Glue Pattern at Double Backer:
Brittle or zipper board appearance
Light Glue Pattern at Single Facer:
Delaminates, poor bonding
Foaming of Adhesive in Pans:
Poor bonding and high
starch consumption
Adhesive Between Flutes:
This problem creates warp
problems, high starch consump-
tion, poor bonding and overall
poor quality
28
Common Causes:
Dirty fingers on the single facer
Worn fingers - flat spot on tip
Finger running too close to lower roll
Too much vacuum pressure on a vacuum style single facer
Dirty cleanout prongs
Water jacket malfunctioning
High adhesive viscosity
Poor lateral adjustment of corrugating roll
Tension on medium too high
Slippage between single facer web and double backer line
Light glue application
Glue solids too low
Excessive unglued or high-low corrugations
Excessive borax in formula
Liners too hot
Medium too dry
Too much drag on medium
Slow machine speed
Low gel temperature
Glue roll and paper machine speeds synchronized
Poorly formed flutes
Low glue roll setting
Rider roll set too high
Glue roll speed too fast
Smooth glue roll
Dirty or worn glue roll
Low viscosity adhesive
Too much drag on single facer web
Glue roll too far from corrugating roll
Smooth glue rollnot transferring enough adhesive
Glue roll settings too low
Dirty or worn glue roll
Improper pressure roll setting
Poorly formed flutes (highs and lows)
Air in starch lines
Leak in pumps
Wiper blade improperly installed or dirty wiper blade on metering roll
Flexo waste water used for adhesive make-up
Resin in the adhesive
Adhesive viscosity too low
Not using antifoam with adhesive made with High Shear system
High corrugating speeds
Starch setting too high
Low viscosity adhesive
Low solids adhesive
Improper adhesive formula
Rider roll set too low at double backer
Improper glue roll speed
Bad wiper blade on metering roll
Skip clutch not holding glue roll
Bad glue on metering roll
Adhesive blown off the flute tips when running a jet assist for heavy-weight board
Long tack adhesive
 DIAGNOSING CORRUGATING EQUIPMENT AND BOARD QUALITY PROBLEMS
Board quality begins at the single facer. To insure that good quality board is being produced
at high speeds, it is critical to maintain the single facer in good mechanical condition.
Problem:
White Glue Line:
Delaminates after curing, low pin
adhesion, poor top-to-bottom
compression
Spotty Glue Application on the
Single Face Side:
Poor bonding, low pin adhesion,
low top-to-bottom compression
Adhesive Sets Up on Fingers:
High starch consumption,
poor bonding, low pin
adhesion, poor top-to-bottom
compression, low production
speeds
Loose Edge on the Single Face Side:
Poor quality board, high
waste, low production speeds
Loose Edge on the Double
Back Side:
High waste, low production
speeds, poor print quality
Common Causes:
Insufficient gelatinization
Gel temperature too high
Incorrect temperature at pressure roll, corrugator rolls or hot plates
Low boiler pressure
Low viscosity
Wet paper
Roll stock stored outside
Glue roll motor problem
Finger set too low
Worn finger
Medium not properly conditioned
Medium not forming properly
Medium sticking to corrugator roll
Excessive drag on medium
Water dripping on medium
Dirty corrugator rolls
High/low calibrated medium
Bad glue roll/metering roll
Gel temperature of adhesive too low
Adhesive viscosity too high
Temperature in glue pan too high
Improperly conditioned medium
Paper temperature too high
Fingers worn
Cleanout fingers too loose or tight against glue roll
Incorrectly set taper speed
Water jacket not functioning properly
Poor flow of the adhesive through the starch pan
Wet paper roll
Adhesive improperly applied to medium
Not enough brake on medium
Fingers improperly adjusted
Dirty corrugating rolls
Lack of pressure on roll
Wet liner edge
Medium wider than liner
Improperly set slitter knife
Roll stand out of parallel
Wrap arms on the medium or liner out of parallel
Large difference in paper temperature from one side of the machine to the other side
Starch dam out of adjustment at single facer
Sheet guide compressing flutes
Wet streak on liner edge
Worn corrugator belt
Worn rollers in hot plates
Wet paper roll
Dirty hot plates
Low adhesive solids
Too much heat
Improperly set slitter knife
Low viscosity
Roll stand out of parallel
Wrap arms on the medium or liner out of parallel
Bridge guides too tight
Large difference in paper temperature from one side of the machine to the other side
Not enough flutes in contact with glue roll
Starch dams out of adjustment
29
 DIAGNOSING CORRUGATING EQUIPMENT AND BOARD QUALITY PROBLEMS

Board quality begins at the single facer. To insure that good quality board is being produced
at high speeds, it is critical to maintain the single facer in good mechanical condition.

Problem: Common Causes:

Highs and Lows - Flutes Not Fingers set too low

Glued - Single Face Side/ Pressure between corrugating rolls too low
Double Back Side Dirty rolls
Corrugating medium too wet
Glue roll angled improperly
Too much drag on the single face web at the double back glue line
Excess drag on medium
Low caliper medium
Medium surface temperature too high
Improper brake pressure on medium

Problem: Common Causes (All Machines):

High and Low Corrugation: Medium improperly conditioned

Low pin adhesion, poor top-
to-bottom compression,
poor print surface, overall
poor quality
Lack of steam
Proper steam (wet)
Surface temperature of medium too high
Improper pressure on corrugating rolls
Worn or old rolls
Glue roll out of parallel
Roll stand out of parallel
Rider roll out of parallel at double backer glue station
Improper pressure on rollers in hot plates
Improper brake on single face web
Excess drag on medium
Low caliper medium

Common Causes (Finger Machines):

Fingers improperly adjusted, worn, old or dirty

Common Causes (Vacuum Machines):

Low vacuum settings

Bad seals
Plugged holes/slots in corrugated roll

Common Causes (Pressure Machines):

Improper pressure
Leaky cabinet seals
Plugged holes/slots in corrugating roll

Blisters: Fingers worn, old, dirty

Poor quality, poor print Fingers adjusted improperly
surface, low pin adhesion, Incorrect heat in corrugator rolls, pressure rolls, hot plate section
poor top-to-bottom Poor quality paper
compression Wet paper
Medium not properly conditioned
Low viscosity adhesive
Liner too hot
Medium too hot
Medium or liner out of calibration
Wet streaks in the medium or liner
Dirty or worn glue roll
Improper brake pressure on single face liner
Worn corrugator rolls

30
 DIAGNOSING WARP PROBLEMS

Warp is generally caused by moisture or tension imbalance.

Problem: Common Causes / Corrective Actions:

Normal Warp (Side-to-Side Up Warp)
Operating Footnote: If the moisture
content of the single facer liner roll is
greater than 2 percent over that of the
double backer liner roll, then the roll
should be changed. Preheaters on the
machine can only remove 1 to 2 percent
moisture from roll stock. Should the
moisture imbalance be greater than
2 percent, warp will occur.
Reverse Warp (Down Warp)
Operating Footnote: If the moisture
content of the double back roll is greater
that 2 percent over the single-face liner
roll, then the roll should be changed.
A difference of 2 percent or more in
moisture between the single-face liner and
the double back liner will create warp.
Caused by moisture in the single facer liner
Add more heat (increasing warp) to the single face web
at the double backer glue machine
Reduce heat (decreasing warp) to the double facer liner
at the double backer glue machine
Increase single facer liner warp on the 36-inch
preheater at the single facer
Increase the warp on the medium preconditioner
Decrease steam shower into the medium
Reduce the amount of single face web on the bridge
Increase machine speed
Reduce the amount of adhesive used at the single facer
Increase the amount of adhesive used at the double backer
Lift some ballast rolls in the hot plates
Caused by moisture in the double facer liner
Increase heat to the double facer liner (increase wrap on the
36-inch preheater)
Decrease the heat in the single facer web at the double
backer glue machine (decrease the wrap on the 36-inch preheater)
Increase the steam shower on the medium
Lower all rollers in the hot plate section
Check steam pressure in the hot plates and increase if possible
Increase the amount of single face web on the bridge
Reduce the speed of the machine
Reduce the amount of adhesive at the glue machine
Increase the amount of adhesive at the single facer
Add small amount of moisture to the top corrugator belt (use steam
spray across the entire belt)
Use water spray on single face web

Operating Footnote: If th e moisture content of the double back roll is greater that 2 percen t over the single face liner roll, then the r oll should be changed.
A difference of 2 per cent or more in moisture between the single face liner and the double back liner will create warp.

31

Warp is generally caused by moisture or tension imbalance.
Problem:
S Warp (combination of
normal and reverse warp):
This warp is usually caused
by variations in moisture
(wet streaks) across the web
in a roll of liner or medium,
or by machine conditions
which apply variable amounts of
heat or adhesive across the web
Operating Footnote: If the machine is
equipped with a water spray, this is
usually the best way of controlling the
S warp. The water spray should be used
on the single face side of the web only.
Machine Direction Warp
(End-To-End Warp):
The end-to-end warp can be either up or
down, but is always in the machine direction
End-To-End Warp
End-To-End "Down" Warp
Operating Footnote: The corrugator crew
may find the only way to control this type
of warp will be with machine speed.
The higher the speed, the less drag they
see, because at higher machine speed
they can operate with less brake.
Cross Machine Direction (CD)
Side-To-Side Warp:
This is a warp that usually is
found within a few hours after
the board is run. The problem
is moisture and tension along
with the temperature in the
working area
Operating Footnote: The corrugator crews
should have a good understanding of the
adhesive system within their machine and
also understand the proper use of water
sprays. Using the adhesive and water
sprays properly is the best way to control
this type of warp.
32
DIAGNOSING WARP PROBLEMS
Common Causes / Corrective Actions:
Wet streak in roll liner or medium
Thin streak or edge in roll of liner will warp in opposite direction to wet streak
Loose edge in roll of liner does not hug preheater
Wet edge in liner due to outside storage
Out of level or out of square machine condition preventing liner from contracting
preheater firmly across the web
Single face glue roll or doctor roll (glue roll and transfer roll) out of parallel
Improper crown between single face glue roll and doctor roll loose, worn or dirty in
some areas
Scraper blade on single face or double back doctor roll loose, worn or dirty in some areas
Single face glue or doctor roll (glue roll and transfer roll) galled
in some areas or pitted on ends
Double backer rider roll out of parallel
Double back glue roll and doctor roll out of parallel
Applicator roll out of parallel to the corrugating roll
Hydraulic lift of the glue mechanism not functioning correctly at the single facer;
partially blocked steam shower
Distorted steam chests causing uneven board temperatures across the machine
Possible roll stand out of parallel
Tension greater in one liner than in the other
Tension greater on the single face liner than on the double back liner
Single face liner is pulling back on the sheet
"Drag" on the top liner, usually from a drag belt on the bridge
Preheater locked down not turning, adding tension to the single face web going
into the double facer
Running with too much brake on the single face liner at the single facer
Running with too much paper on the bridge
Running with too much brake on the medium pulling back on the single face web
Incorrect tension on web; increase tension
Tension greater on the double back liner than on the single face liner
"Drag" on the bottom liner usually caused by a bad break on the roll stand;
preheater locked down not turning, adding tension to the bottom liner
Dirty hot plates adding drag
Need to lubricate double face liner, especially when running coated liners
Wrap arm or roller out of parallel giving uneven contact pressure in the double facer
Out of round glue roll at the single facer, applying adhesive light and heavy
Machine speed from time to time will cause the adhesive to be applied heavy and light
Rollstock with wet streaks or moisture content higher than normal
 DIAGNOSING WARP PROBLEMS

Warp is generally caused by moisture or tension imbalance.

Problem: Common Causes / Corrective Actions:

Twist Warp (Combination of Roll stand out of level

End-to-End and Side-to-Side Warp): Preheater out of level
Twist warp is caused by Splice roll out of level
uneven tension or stress Roll stand, preheater out of square to the machine
across the web of any or all Dirt on wrap roll or preheater
components during the Bridge web guide out of level, out of square or off center
combining process Crown breaker roll in double back glue machine out of level
Double back glue machine rider roll out of level
Top double back belt pulls unevenly across web
Loose or tight edge in roll of liner
Operating Footnote: Twist warp is seen
Uneven or diagonal stresses in roll liner
more often on machines that run a two
piece top corrugator belt. One belt will be
running faster than the other adding stress
to the web. If the twist warp occurs off
the machine, a wet streak will be noticed
in one of the liners.

Post Warp (warp observed Check liners for wet streaks

several hours or days later):
The degree of this type of
warp will depend greatly on
the way the sheets were
stacked and the location of
the stack. About the surest
way to minimize in-storage
warping has proved to be
producing as dry as possible
board on the corrugator,
using as little adhesive as
possible, and using preheaters
to their fullest capacity
Reduce web tension on the single face side
Reduce break drag on all roll stands
Preheaters should be free turning
Hot plate section should be clean and free of dirt build up
Adhesive formula should have the proper solids for the mix within the plant
If the machine uses a two piece belt, check the speed of the belts
Sheets must be stacked properly
Board coming off the machine should be dry and firm
Should have proper storage area for the finished sheets

Operating Footnote: When sheets warp after

they leave the corrugator, moisture is most
likely the problem. The sheets coming off
the machine will be wet or damp to the
touch. Storing finished sheets near open
doors and windows, or loading the sheets
into a cold truck before they have properly
cured, will cause warp.

33
 Appendix A

Equivalent Amounts of Borax for Starch Formulations

English Units, lb Metric Units, kg

10 Mol 5 Mol Boric 10 Mol 5 Mol Boric
(decahydrate) (pentahydrate) Acid (decahydrate) (pentahydrate) Acid

20 15.50 12.33 9.0 7.0 5.5

21 16.00 13.00 9.5 7.2 5.9
22 16.75 13.50 10.0 7.6 6.2
23 17.50 14.25 10.5 8.0 6.5
24 18.25 14.75 11.0 8.4 6.8
25 19.00 15.50 11.5 8.8 7.1
26 19.75 16.00 12.0 9.2 7.4
27 20.50 16.67 .
12.5 9.6 7.7
28 21.25 17.25 13.0 9.9 8.0
29 22.00 18.00 13.5 10.3 8.3
30 23.00 18.50 14.0 10.7 8.6
31 23.75 19.00 14.5 11.1 8.9
32 24.50 19.75 15.0 11.5 9.2
33 25.25 20.25 15.5 11.8 9.6
34 26.00 21.00 16.0 12.2 9.9
35 26.75 21.50 16.5 12.6 10.2

Table courtesy of TAPPI

34

Microbiological Growth/Control in
Corrugating Adhesives
For 666 Gallon Primary Secondary Units
Step 1 Primary mixer
Fill mixer with 150 gallons of water and heat to 130F
[54.4C]. Add 15 pounds of a commercially available
industrial strength cleaner and agitate for 30 minutes.
DO NOT discard the solution. Proceed to Step 2.
Step 2 Secondary mixer
Fill mixer with 300 gallons of water and heat to 130F
[54.4C]. Add 30 pounds of a commercially available
industrial strength cleaner and agitate for 30 minutes.
Add the solution in the primary mixer into the secondary
mixer. Pump the combined solutions into the storage tank
and through the circulation lines for 30 minutes. Dispose
of solution in an appropriate manner.
Step 3 Primary mixer
Fill mixer with 150 gallons of water (DO NOT HEAT). Add 2
quarts of commercial household bleach and agitate for 15
minutes. DO NOT discard the solution. Proceed to Step 4.
Step 4 Secondary mixer
Fill mixer with 300 gallons of water (DO NOT HEAT).
Add 1 gallon of commercial household bleach and agitate
for 15 minutes. Add the solution in the primary mixer into
the secondary mixer. Pump the combined solutions into
the storage tank and through the circulation lines for an
additional 15 minutes. Dispose of the solution in an
appropriate manner.
Step 5 Flush all mixers, tanks and lines thoroughly with
clean water to remove all trace amounts of chemicals.
For 666 Gallon No-Carrier &
Single Tank Mix Systems
Step 1 Mixer
Fill mixer with 350 gallons of water and heat to 130F
[54.4C]. Add 45 pounds of a commercially available
industrial strength cleaner and agitate for 30 minutes.
Pump the solution to the storage tank and through the
circulation lines for 30 minutes. Dispose of the solution
in an appropriate manner.
Appendix B
Step 2 Mixer
Fill mixer with 350 gallons of water (DO NOT HEAT). Add 6
quarts of commercial household bleach and agitate for 15
minutes. Pump the solution into the storage tank and
through the circulation lines for an additional 15 minutes.
Dispose of the solution in an appropriate manner.
Step 3 Flush all mixers, tanks and lines thoroughly with
clean water to remove all trace amounts of chemicals.
For 300 Gallon High Shear Systems
Step 1 High shear mixer
Fill mixer with 300 gallons of water and heat to 130F
[54.4C]. Add 39 pounds of a commercially available
industrial strength cleaner and agitate for a full 15
minutes with the high shear ON. Pump solution into the
storage tank and through the circulation lines for 30
minutes. Dispose of the solution in an appropriate manner.
Step 2 High shear mixer
Fill mixer with 300 gallons of water (DO NOT HEAT). Add 5
quarts of commercial household bleach and agitate for 10
minutes. Pump the solution into the storage tank and
through the circulation lines for an additional 15 minutes.
Dispose of the solution in an appropriate manner.
Step 3 Flush all mixers, tanks and lines thoroughly with
clean water to remove all trace amounts of chemicals.
Note for all systems: Growth can occur in an empty
section of pipe or on the underside of tank covers.
Using proper discretion, the solutions can also be used
to clean the starch pans at the machine.
35
 Appendix C

Testing The Gelatinization Temperatures

Introduction
With a few pieces of simple equipment and a little
practice, the gel temperature of a starch adhesive can
be measured quickly, accurately and reproducibly.
Procedure
1. Fill a container (beaker) with water to within 1/2 inch
of the top, place on a hot plate and heat to between
170F and 180F [76.7C and 82.2C].
(DO NOT BOIL THE WATER.)

Equipment 2. While the water is heating, pour the starch adhesive

to be tested into the test tube (fitted with a test
a tube holder or clamp) to a level of 1 to 2 inches,
or approximately 1/3 of the tube volume. Insert the
thermometer as shown to the left.
b 3. When the water has reached temperature, turn the
hot plate OFF and place the tube in the hot water
(as shown). Immediately begin stirring the adhesive
c with the thermometer, being careful to wipe the side
of the tube to prevent localized heating and gelling.
4. As the temperature rises, the adhesive will begin to
d thicken as the gel point is approached (usually between
139F and 152F [59.4C and 66.7C]). The temperature
rise will pause (level off) for a few seconds at the
e actual gel value, then continue upward. RECORD the
temperature in degrees, where the leveling occurred.
f (NOTE: If the water is too hot, the temperature pause
will be shorter and often more difficult to detect.)
5. The test requires some skill; it is suggested that the
g test be repeated and an average value reported.

Recommendations
1. Periodically, check the accuracy of the thermometer
by placing it in boiling water. It should read exactly
212F [100C].
a. Glass thermometer calibrated in degrees Fahrenheit (F)
(See Recommendations 1 & 2 on thermometers) 2. Glass thermometers are recommended over metal
dial-type thermometers.
b. Heat stable glass test tube
c. Test tube holder or suitable clamp
d. Heat stable glass beaker or other suitable container
e. Starch adhesive to be tested
f. Hot water at proper temperature (see Procedure)
g. UL approved hot plate, bottle warmer, etc.

36
 Appendix D

Specific Gravities and Concentrations of Caustic Soda Solutions

Based on International Critical Tables

Lbs. of
%NaOH %Na2O Sp. Gr. Deg. Baum Lbs. NaOH Solution
@ 60/60F @ 60/60F Per Gal. Per Gal.
[15.6C] [15.6C] @ 60F [15.6C] @ 60F [15.6C]

2 1.55 1.023 3.3 .17 8.53

4 3.10 1.045 6.2 .35 8.71
6 4.65 1.067 9.1 .53 8.90
8 6.20 1.089 11.9 .73 9.08
10 7.75 1.112 14.6 .93 9.27
12 9.30 1.134 17.1 1.13 9.45
14 10.85 1.156 19.6 1.35 9.64
16 12.40 1.178 21.9 1.57 9.82
18 13.95 1.201 24.3 1.80 10.01
20 15.50 1.223 26.4 2.04 10.20
22 17.05 1.245 28.5 2.28 10.38
24 18.60 1.267 30.6 2.53 10.56
26 20.15 1.289 32.5 2.79 10.75
28 21.70 1.310 34.3 3.06 10.92
30 23.25 1.332 36.1 3.33 11.11
32 24.80 1.353 37.8 3.61 11.28
34 26.35 1.374 39.5 3.89 11.46
36 27.90 1.394 41.0 4.19 11.62
38 29.45 1.415 42.5 4.48 11.80
40 31.00 1.435 44.0 4.78 11.96
42 32.55 1.454 45.3 5.09 12.12
44 34.10 1.473 46.6 5.40 12.28
46 35.65 1.492 47.8 5.72 12.44
48 37.20 1.511 49.0 6.05 12.60
50 38.75 1.530 50.2 6.38 12.76
52 40.30 1.549 51.4 6.72 12.91

37
 Appendix E

Alkali (Caustic) Sensitivity Settling

Method Field Test For Corrugators

This test has been designed for testing unmodified corn
starch at the corrugators site. For best results, the
components should be weighed. Empirical information
can be obtained if the containers are calibrated and
marked with the component weights. The largest variable
is the length of time the starch is in contact with the
caustic solution prior to mixing. That time must be kept
to a minimum to get a valid reading. It is easy to get a
false negative result.
Equipment
250 ml bottles with caps
100 ml graduated cylinders
Test Procedure
1. Weigh 145 g of test solution into one 250 ml bottle.
2. Weigh 50 g starch into another 250 ml bottle. If starch
is being added to a marked bottle, it should be tamped
to get proper amount.
3. Quickly pour starch into bottle with test solution.
4. Quickly cap the bottle and shake for 3 to 5 minutes.
It is important that steps 3 and 4 be done quickly.
5. Pour the starch slurry without delay into the graduated
cylinder up to the 100 ml mark and put a piece of
aluminum foil over the top as a cap.
6. Let the graduated cylinder stand for 24 hours.

Test Solution Observation

From dry caustic: Read the bottom of the clear water layer. The reading
13.3 g caustic should be less than 70 ml if the starch is not alkali
8.1 g 10 mol borax (caustic) sensitive.
1434.0 g distilled water

From 50 percent caustic:

26.6 g 50 percent caustic
8.1 g 10 mol borax
1421.0 g distilled water

38

Alkali Sensitivity, Viscometric:
Unmodified Starch
Principle
Starch granules that are heat damaged and no longer
exhibit birefringence in aqueous suspension tend to swell
more readily in aqueous alkali than intact granules.
Measured incremental viscosity in dilute alkali at room
temperature is related to enhanced viscosity of corrugated
board adhesive formulations.
Scope
This procedure was developed specifically for unmodified
corn starch and may not be used with modified starches
without further study.
Equipment
Beaker: Griffen low form, 400 ml capacity
Brookfield Viscometer: Model LV equipped with a
laboratory stand and UL Adapter with spindle SPOO.
Stirrer: Stainless steel 3-blade propeller, 5 cm
diameter, on a 0.8 x 31.0 cm shaft
Stopwatch
Weighing Paper
Reagents
1 percent (w/v) aqueous sodium hydroxide (NaOH)
Procedure
The test is run at room temperature (about 77F [25.0C]).
Transfer 150 ml of 1 percent NaOH and 50 ml of distilled
water to the 400 ml beaker. Position the stirrer in the
beaker and mix the solution at 600 rpm. Weigh 100 g (see
note 1) of starch on the weighing paper. Add the starch to
the agitated alkaline solution as quickly as possible but
avoid lumping (see note 2) and start timer. Transfer 16.0 ml
of slurry to the UL Adapter and measure viscosity at 30 rpm.
Appendix F
Calculation
(Unless the viscometer reads cps directly)
Alkali Sensitivity, cps = Scale Reading x 0.2 (See note 3)
Notes
1. Variation in the normality of the sodium hydroxide
solution and the moisture content of the sample can
have a significant effect depending on the alkali
sensitivity. As the alkali sensitivity increases, the
effects of these variables increase. Decreasing the
sodium hydroxide normality from 0.25 to 0.24
decreases the measured alkali sensitivity by about
1.7 cps at 14 cps and about 0.1 cps at 5 cps. Reducing
the sample moisture content from 11.0 to 10.0 percent
increases the measured value by 0.6 cps at 14 cps and
0.2 cps at 5 cps.
2. The addition is generally done in 5 to 10 seconds to
avoid gelatinization of the intact granules.
3. As an alternative procedure, 200 ml of 0.1875 N NaOH
can be used in place of the combination of 50 ml water
and 150 ml 0.250 N NaOH. However, this change will
eliminate the ability to adjust the formulation for
variations in sample moisture content. The 0.1875
N NaOH can be obtained commercially as a special order.
4. The equipment, reagents and method are all
available from:
Shape Products
1127 57th Avenue
Oakland, CA 94621
(800) 444-0015
www.shapeproductsonline.com
39
 Glossary

Amylose Hybrid A corn variety forming more linear Recycle In corrugating this refers to the reuse of
starch molecules paper products

Borax A crystalline compound used to control starch Pearl Unmodified starch

swelling and provide additional adhesive tack

Shear Mechanical action of breaking down starch

Double Backer Second glue station of corrugator; adhesive
single face web glued to liner to form finished board

Single Facer First glue station of corrugating

Carrier Starch Primary portion of adhesive machine; medium is fluted and bonded to liner

Caustic Soda Alkaline substance that causes starch Starch Complex carbohydrate from corn, potato, rice
granules to swell; also called sodium hydroxide or tapioca processing

Feed Gluten Co-product of processed corn Steepwater Water in which corn has been soaked or
steeped during the initial stages of the corn wet milling
refining process
Gelatinization Point at which adhesive begins to
thicken and develops bonding properties
Viscosity Term used to describe adhesive flowability

Germ Product of processed corn; usually further

refined into corn oil Waxy Maize A corn variety producing predominantly
branched, chained starch molecules

Glue Roll Component of corrugating machine;

transfers starch to flutes at double backer or single facer Wick Penetrate

High Ring Crush High performance paper having a

ring crush value of 2 pounds for every pound of basis weight

Liners The flat paperboard portion applied to the

fluted medium by applying adhesive to each flute tip

Medium Fluted portion between the liners, which

when combined with the liners, makes corrugated board

Modified Starch A starch modified chemically

or mechanically

40
41
Your global resource
Corn Products International, Inc., with international operations spanning 16 countries
and 34 plants, is one of the largest corn refiners in the world and the leading refiner in
Latin America. Our entire organization is dedicated to one mission: to be your preferred
resource in product quality and service dependability on a global basis.

Corporate Headquarters Toronto CPIngredientes, S.A. de C.V.

Corn Products U.S. Casco, Inc.
5 Westbrook Corporate Center 401 The West Mall, 2nd Floor
Westchester, IL 60154 Etobicoke, Ontario M9C 5P7
United States Canada
(800) 443-2746 (416) 620-2300 (Toronto)
www.cornproductsus.com (514) 694-4700
(Montreal/Eastern Canada)
www.casco.ca
Av. Mariano Otero #1249, Floor 9
Torre Atlantico
Rinconada del Basque
44530 Guadalajara, Jalisco
Mexico
(33) 3884-9000 ext. 3520
www.cpimex.com

CUSTOMER SERVICE CENTER (800) 443-2746

Corn Products U.S. is a business unit of Corn Products International, Inc. 021-CM-99
Printed in the USA June, 2006 Quantity: 2,500
Casco Inc. and CPIngredientes are affiliates of Corn Products International, Inc. 2006, Corn Products International, Inc.