The Critical Steps Needed For A Successful Machine Installation BY RICHARD H. ETRA Over the course of my long career, I have seen excellent machines fail to live up to expectations because of mis- steps in their installation and startup. A good layout, expe- rienced and motivated personnel, and a generous budget may be insufficient to prevent costly downtime, inefficient operation, and production errors. Here are some do’s and don’ts to help make your project run smoothly, efficiently, and successfully. Planning for a successful machine startup begins with the purchase contract. Insist that machine specifications and capabilities such as registration tolerances and speed curves have been clearly defined in the contract. Then identify representative items that will demonstrate that the machine is capable of operating within these specifica- tions over a range of product sizes and configurations. It is important to include challenging products such as those with unusual flutes, grades, etc. specific to your operation. Define an acceptance trial in the purchase contract, spec- ifying dimensional tolerances, run speeds, etc. for these items. Also, include a schedule for delivery, installation, and startup, and negotiate a penalty for late startup. As with any project, schedule the tasks based on a re- alistic timeline, paying particular attention to the task se-
quence and critical path. Solicit input from all vendors and contractors and get their buy-in for this schedule. Be sure to review it frequently and adjust as necessary, keeping all players aware of revisions to ensure that material and per sonnel arrive when needed during the installation and startup phases. Next on the list is to review ink, adhesive, and tooling specifications with your suppliers well in advance of the installation. Purchase tooling from vendors who have ex- perience with your type of machine and whose tooling has a proven track record of performance. Once you have experience with your machine, you can experiment with lower-cost vendors, but don’t complicate your startup with problems resulting from your tooling manufacturer’s inex- perience or quality. Be sure sheet suppliers – either your corrugator or sheet feeder – understand your requirements concerning bottom and tie sheets, bale heights, and other consider- ations that can affect prefeeder performance and waste. Additionally, your sales force, customer service, and suppliers must be educated as to tooling requirements. If you have been using 0.250-inch plates and are switch- ing to thin plates used by most state of the art equipment, or have been using Matthews mounting strips and your new machine uses proprietary strips, be sure everyone is aware of these facts, and that existing plates may be un- suitable for your new equipment.
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• Machinery selection • Plant layout • Project Management • Consulting
A true corrugated industry veteran with nearly 50 years’ experience, Richard Etra can help you with every aspect of box plant operation. Contact Richard today for a no-cost consultation: email: richard_etra@etracorrugatedsolutions.com ph: 917-647-9520
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October 20, 2025
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