The ParAlign team aligned over 100 rolls across two print lines, overcoming the unique challenges of working with legacy equipment at one of Tetra Pak’s older facilities.
Summary
Faced with the challenge of working on both a legacy print line and a newer, more compact setup, the ParAlign service team used their expertise to make precise adjustments at the facility despite tight spaces and frame instability. By the end of the service appointment, both lines were performing at optimal levels.
- Over 100 rolls aligned across two print lines
- Addressed alignment issues on older, hard-to-reach equipment
- Achieved 0.2 mm tolerance on the legacy line
- Resolved the paper crinkling issue, restoring high-product quality
Background
For Tetra Pak, a global leader in food processing and packaging solutions, maintaining the highest standards across their facilities in over 160 countries is a daily priority. Every machine in each facility has a part to play in upholding their commitment to quality. That’s why the company approaches maintenance with extreme care and high expectations.
When a scheduled shutdown was planned at their facility in Denton, Texas, the Tetra Pak team seized the opportunity to evaluate two crucial print lines and address any issues that could affect their performance. Knowing that even minor misalignments could escalate to disrupt production and quality, they brought in the ParAlign Roll Alignment Services team to check every roll and alignment.
The ParAlign team had already helped resolve similar challenges at the Tetra Pak Mexico facility, so they arrived in Texas with knowledge of the equipment in use and the experience to handle any misalignment quickly and effectively.
Challenges
At the Texas facility, one of the older sites within the organization, the ParAlign team was tasked with working on two print lines — one of which had never undergone a full alignment check. This older print line, which had fewer parts and critical rollers in tight, hard-to-reach spaces, required extra care for accurate measurements and adjustments to be carried out. Additionally, years of repairs and modifications had caused some components to shift, affecting the overall alignment.
The newer print line presented its own set of challenges, as even minor adjustments to one roller could impact the alignment of others due to the tightly packed setup of its frames and components.
Both lines called for a high degree of precision and adaptability from the team.
Implementation
Modern Alignment for an Older Print Line
Pinpointing the problem: Two specialists from the ParAlign services team used the device’s advanced inertial technology, which relies on highly accurate ring laser gyroscopes, to measure the rolls on the print line. By selecting a critical roll as a reference point (the most important roll is used as a zero point) they measured the position of 94 subsequent rolls in both horizontal and vertical directions. This let the team identify precisely how much each roll needed to move to achieve proper alignment.
Instant Printout for Quick Adjustments: Unlike competitors, ParAlign provides immediate results after each measurement, allowing the team to print out an overview of the alignment conditions of all the rolls. This served as a practical guide for the facility mechanics to make adjustments to each one. With this reference, the technicians used dial indicators and shims to reposition the rolls — shims for vertical alignment and jacking bolts for horizontal alignment.
Example of a ParAlign Alignment Conditions Report
Correcting frame instability: The frame for the unwinder section had previously been rewelded after breaking four times before the ParAlign adjustment. The rewelding was found to have made the frame asymmetrical, causing crinkling in the paper. Adding to the challenge was the fact that there was no replacement frame available as the machine was no longer manufactured. This meant the team had to be extra careful when they had to adjust the rolls to account for the uneven frame. They performed several rounds of re-measurement, gradually achieving the best possible alignment with every adjustment. Shims were added to improve stability.
Closing in on precision: “Considering how old the line was and how long it had gone without adjustments, we were able to get it within a 0.2 mm tolerance,” says Lily Meuninck, ParAlign Service Technician. Aligning this first print line took four days.
Precision Work on the New Print Line
After completing work on the older line, the ParAlign team turned to the newer print line. The rolls and frames were positioned very close together, so even a small adjustment — like moving one part by 0.4 millimeters — could affect the alignment of other parts. “Further movement would have thrown off multiple rolls and taken days to correct,” explains Meuninck.
Therefore, the frame of the chill rollers was moved to reduce misalignment as much as possible. Ultimately, the chill rollers were left in a place that was closer to the ideal tolerance.
The facility’s technicians and the ParAlign team worked closely together over three days, making small, careful adjustments to have the line properly aligned by Friday. That way, the facility team didn’t need to come in on a Saturday or Sunday and could enjoy their well-earned weekend break.
Results
When the alignment on both print lines was completed, ParAlign specialists were able to share a report of the work performed, showing a clear improvement in tolerance levels and eliminating the crinkling issues in the paper. The successful alignment of these lines meant that the facility could continue producing high-quality packaging without disruption.
Based on these results, Tetra Pak Texas plans to have the ParAlign service team return for an alignment on the laminator machine soon. One alignment was enough to see the difference — and plan for the next.
