Continuous Improvement
Purpose of this Guide is to provide information and knowledge required for performing product change from 1312RE to 1312FR without stopping board-line in aim to improve machine efficiency, increase product output and improve profitability of the business.
Continuous Improvement
There is a number of factors affecting this particular product change that must be considered in order to make it successful. The most important are:
Continuous Improvement
Good preparation, communication and cooperation between operators on the “wet” side of the Board-line is essential for success of the change. Some advanced planning and changes could prove to be the factor determining success or failure of the change.
Continuous Improvement
All above temperatures are for the air flowing through the Dryer – NOT FOR THE BOARD ITSELF. Board temperature is much lower due to the evaporation process. Generally speaking – board is protected form calcination as long as there is moisture inside the core and evaporation is not finished.
Continuous Improvement
Case Study No. 1
Continuous Improvement
Case Study No. 2
Continuous Improvement
Everywhere in the world QUALITY is our reference!
Change from 1312RE to 1312FR without stopping Board-line is a very complex change and one with a
high degree of risk of producing some product that is not within our quality standards and specifications.
There are many variables involved and too many situations where control might be lost. It is very important
to be able to identify faulty product and prevent it from reaching market place.
Continuous Improvement
It is our goal to operate our plant efficiently.
IT IS OUR IMPERATIVE TO OPERATE OUR PLANT SAFELY.
Continuous Improvement
Our process is ever changing and advancing as we progress and some changes to this Guide might be necessary to be able to keep up with that progress. This Guide is therefore not a finished project but rather work in progress.
Any suggestions about how to improve our efficiency in performing this product change are encouraged and welcome
Energy consumption reduction & Environmental Management
Heat Recovery System installed in Altona Plant
Three years ago, the Altona Plant received funding to install a ‘heat recovery system’ under the Victorian Sustainable Energy Authority’s Business Energy Efficiency Initiative. This new energy-saving technology will help the plant to reduce greenhouse pollution by 1,600 tonnes – the equivalent of removing 370 cars from Victoria’s roads.
The heat recovery system also can recover some of the evaporated water and re-introduce it back into the process. The estimated recovery rate now is 2.5 mega litres per annum. The heat recovery system also has the potential to save up to eight percent of the site’s natural gas consumption – resulting in energy cost savings of up to $80,000.00
Energy consumption reduction & Environmental Management
Water loss reduction in Plasterboard Manufacturing
In plasterboard production, water serves two important functions. While some water is required to set the plaster, the majority is to give enough fluidity to the plaster slurry as it is being formed.
This excess water must be removed in the drying process, hence the term water loss. The challenge is to use less water in the forming process, while still maintaining
the favourable properties of the finished product.