PAPER CALCULATION
2 Ply Paper Calculation
Each flute type has a specific factor, generally ranging from 1.1 to 1.5, based on the flute
profile:
E Flute: Approximately 1.25
F Flute: Approximately 1.15 to 1.2
For F flute, the factor typically falls around 1.15 to 1.2. However, the exact factor can vary
slightly depending on the exact flute profile, but 1.15 is often used as a standard in the
industry.
How to Use the Corrugation Factor
To calculate
the paper requirement for the fluting medium in an F flute sheet:
1. Calculate the flat area of the sheet.
2. Multiply the area by the gsm (grams per square meter) of the fluting medium.
3. Apply the corrugation factor (1.15 or 1.2 for F flute) to this result.
Calculation
Sheet Area: 0.5807 m²
Fluting Medium GSM: 150 gsm
F Flute Factor: 1.15
The weight of the fluting medium would be:
Fluting Weight=Sheet Area×Fluting GSM×Flute Factor
=0.5807 m²×150 gsm×1.15=100.49 grams per sheet
To calculate the total paper weight required for 25,000 sheets of size 25 x 36 inches with:
Top Liner: 230 gsm LWC (Lightweight Coated)
Flute Layer: F flute with 150 gsm for both the flute medium and bottom liner
Step 1: Convert Dimensions to Square Meters
The sheet size is 25 inches by 36 inches.
1. Convert to Meters:
o Length: 25×0.0254=0.63525×0.0254=0.635 meters
o Width: 36×0.0254=0.914436×0.0254=0.9144 meters
2. Calculate Area per Sheet:
Area per Sheet=0.635×0.9144=0.5807 square
Step 2: Calculate Paper Weight for Each Layer per Sheet
1. Top Liner (230 gsm):
Top Liner Weight=Area per Sheet×230=0.5807×230=133.561 grams
2. Bottom Liner (150 gsm):
Bottom Liner Weight=Area per Sheet×150=0.5807×150=87.105
3. Fluting Medium (150 gsm):
o For F flute, apply a corrugation factor of 1.15 to account for the increased
paper usage due to the fluting.
Fluting Medium Weight=Area per Sheet×150×1.15=0.5807×150×1.15=100.171 gram
s
Total Paper Weight per Sheet:
Linear Weight =133.561grams
Bottom Liner = 87.105 grams
Fluiting Medium = 100.171 grams
Total Weight per Sheet=133.561+87.105+100.171=320.837 grams
Step 3: Calculate Total Paper Weight for 25,000 Sheets
Total Paper Weight for 25,000 Sheets=320.837×25,000=8,020,925 grams=8,020.93 kg
Summary
For 25,000 sheets of 25 x 36 inches with the specified layers and gsm values, you would need
approximately 8,020.93 kg of paper.
Get the cost per unit weight for each material:
o 230 gsm LWC paper cost per kg
o 150 gsm virgin paper cost per kg
Convert area weight to kg and multiply by cost.
Glue Consumption
1. Fluting
To calculate the glue consumption for applying adhesive on the fluting of a 25 x 36 inch F
flute sheet, you can follow these steps. The glue consumption depends on factors like
the glue coat weight (gsm), sheet size, and application method.
Given Details
Sheet Size: 25 x 36 inches
Flute Type: F flute
Coating Weight (Glue Application): Up to 10 gsm (grams per square meter)
Steps for Calculating Glue Consumption
1. Convert Sheet Size to Square Meters
o Length: 25 inches = 25×0.0254=0.63525×0.0254=0.635 meters
o Width: 36 inches = 36×0.0254=0.914436×0.0254=0.9144 meters
o Total Area per Sheet (m²):Area=0.635×0.9144=0.5807 square meters
o
2. Calculate Glue Consumption per Sheet Given a coating weight of 10 gsm (grams
per square meter):
o Glue consumption per sheet (grams) = Area × Coating Weight
Glue per Sheet=0.5807 m²×10 gsm=5.807
Calculate Total Glue Consumption for Multiple Sheets To find the glue required
for, say, 25,000 sheets:
Total Glue=5.807 grams/sheet×25,000 sheets=145175 grams=145.175kg
Summary
For a 25 x 36 inch F flute sheet with a glue application of 10 gsm, you would need
approximately 5.807 grams of glue per sheet. For 25,000 sheets, this would be
about 145.175 kg of glue.
2. Top Layer Lamination
To calculate the glue consumption for 25,000 sheets with a glue application of 20 gsm
(grams per square meter), follow these steps.
Given Details
Sheet Size: 25 x 36 inches
Glue Application Rate: 20 gsm
Quantity: 25,000 sheets
Step 1: Convert Sheet Size to Square Meters
1. Convert inches to meters:
o Length: 25 inches = 25×0.0254=0.63525×0.0254=0.635 meters
o Width: 36 inches = 36×0.0254=0.914436×0.0254=0.9144 meters
2. Calculate the total area per sheet in square meters:
Area per Sheet=0.635 m×0.9144 m=0.5807 square meters
Step 2: Calculate Glue Consumption per Sheet
Given a glue application rate of 20 gsm:
Glue per Sheet=Area per Sheet×Glue Application Rate=0.5807 m2×20 gsm=11.614 grams pe
r sheet
Step 3: Calculate Total Glue Consumption for 25,000 Sheets
To find the total glue required:
Total Glue=11.614 grams per sheet×25,000 sheets=290,350 grams
Convert grams to kilograms:
=290,350 grams
Summary
For a 25 x 36 inch sheet size with a glue application of 20 gsm and a quantity of 25,000
sheets, you would need approximately 290.35 kg of glue.
Power Consumption
For Corrugation :
To calculate the total power consumption required to convert 25,000 sheets of 25x36
inches at a machine speed of 60 meters/min and a power rating of 120 kW, let’s break it
down.
Given Data:
Power Requirement: 120 kW
Machine Speed: 60 meters/min
Sheet Size: 25 x 36 inches
Quantity: 25,000 sheets
Step 1: Calculate the Length of Paper Required for 25,000 Sheets
1. Convert the sheet length from inches to meters:
o Length = 25 inches = 25×0.0254=0.635 meters25×0.0254=0.635meters
2. Total Length of Paper for 25,000 Sheets:
Total Length (meters)=25,000×0.635=15,875 metersTotal Length (meters
)=25,000×0.635=15,875meters
Step 2: Calculate the Time Required to Process 25,000 Sheets
1. Time Required at 60 meters/min:
Time Required (minutes)=Total Length Machine Speed=15,87560≈264.58 minutes
2. Convert Time to Hours:
Time Required (hours)=264.5860≈4.41
Step 3: Calculate Total Power Consumption
1. Power Consumption:
Total Power Consumption (kWh)=Power Requirement×Time Required (hours)
=120 kW×4.41 hours≈529.2 kWh
Summary:
The total power required to convert 25,000 sheets of 25x36 inches at a machine speed of
60 meters/min with a power rating of 120 kW is approximately 529.2 kWh.
For Lamination
To calculate the power required to convert 25,000 sheets of 25 x 36 inches on a Litho
Laminator machine that has a power requirement of 28.5 kW and operates at a speed of 140
meters/min, we can follow these steps:
Given Data:
Power Requirement: 20 kW
Machine Speed: 180 meters/min
Estimate production Speed : 140 meters/min
Sheet Size: 25 x 36 inches
Quantity: 25,000 sheets
Step 1: Calculate the Area of One Sheet
1. Convert the sheet dimensions from inches to meters:
o Length: 25×0.0254=0.63525×0.0254=0.635 meters
o Width: 36×0.0254=0.914436×0.0254=0.9144 meters
2. Calculate the area of one sheet:
Area of One Sheet=0.635×0.9144=0.5807 square
Step 2: Calculate the Total Area for 25,000 Sheets
1. Total area of 25,000 sheets:Total Area=0.5807 m²×25,000=14,517.5 m²
Step 3: Calculate the Time Required to Process 25,000 Sheets
1. Machine Speed: 140 meters/min
2. Length of Each Sheet: 25 inches = 0.635 meters
The number of sheets that can be processed per minute is:
Sheets per Minute=Machine SpeedLength of One Sheet=140 meters/min0.635
meters≈220.16 sheets
The time required to process 25,000 sheets:
Time Required (minutes)=25,000 sheets
220.16 sheets/min≈113.6 min
Step 4: Calculate the Power Consumption
Since the machine requires 28.5 kW of power to operate, the total energy consumption
over 113.6 minutes can be calculated as follows:
1. Power Consumption (kWh):Power Consumption=28.5 kW×113.6 minutes60≈53.87
kWh (unit)
Summary:
The total power required to convert 25,000 sheets of 25x36 inches at a machine speed
of 140 meters/min on a Litho laminator machine with a power rating of 28.5 kW is
approximately 53.87 kWh.
PRODUCTION TIME
Corrugation
The time required to process 25,000 sheets:
Time Required (minutes)=25,000 sheets
78.74 sheets/min≈317.5 minutes
Lamination
The time required to process 25,000 sheets:
Time Required (minutes)=25,000 sheets
220.16 sheets/min≈113.6 min
