Quantifying Surface Elevation Variance along Score Lines Using Optical Profilometry
Optical profilometry quantifies score elevation variance down to sub-micron resolution, identifying die wear and coating micro-fractures before carton assembly.
Line Speed Jam Rate
Operational Loss
Machine stops on a high-speed packaging or printing line can severely reduce the total output and increase the waste rate of the substrate. This operational frequency, measured as the line speed jam rate, records the number of material blockages that occur per hour of operation at different speed levels. An elevated line speed jam rate often points to inconsistencies in the stiffness or thickness of the paperboard being used.
If the line speed jam rate remains high, it can erase the profitability of high-volume runs.
Causative Factor
As the run speed increases, the physical forces on the paperboard rise, which can trigger feeding or folding failures. The line speed jam rate is closely tied to the coefficient of friction of the board’s surface and the accuracy of the die-cut creases. If the board is too slick, it slips in the rollers, while a board that is too rough will cause feeding errors.
Keeping these properties within a narrow range minimizes the downtime.
Diagnostic Testing
Logging stop events automatically allows the control system to calculate the line speed jam rate in real time. This information helps supervisors identify which board batches or machine sections are causing the interruptions. Regular monitoring ensures that the converting process maintains high efficiency without sacrificing carton quality.