Supplying complete Industrial package from Gears, Shafts, Gear Boxes, Corrugating Rollers, Single facers, Corrugation plants, Machined Components
Corrugman : Could you brief us about BKG?
Raghav Thapar : BKG Corrugating Rolls was established in 1963 by Mr. Bal Kishan Thapar. It started as a manufacturer of industrial gears and later expanded into high-precision grinding and corrugating rollers. Over the years, the company has played a significant role in the Indian packaging industry by introducing high-quality corrugating rollers at competitive prices. BKG has continuously innovated to develop flute profiles that meet diverse customer needs, ensuring superior performance and efficiency in corrugated board production.
CM : What are your company’s mission & vision?
RT : BKG operates with a strong commitment to technological advancements and innovation, aiming to provide high-quality solutions to its customers. The company focuses on building long-term relationships with clients, suppliers, and industry professionals to foster growth and trust.
Mission : To be a global leader in manufacturing high-precision corrugating rollers and packaging industry equipment, offering technologically advanced and cost-effective solutions.
Vision : To achieve global recognition for Indian manufacturing by delivering high-quality products and services that meet international standards. BKG is dedicated to environmental responsibility and sustainable practices, ensuring a cleaner and greener production approach.
” BKG was the first company in India to introduce elite quality Corrugated Rollers at competitive prices “
CM : Can you provide an overview of the products offered by BKG Corrugating Rolls, and which are the key products?
RT : BKG Corrugating Rolls offers a diverse range of products designed for the corrugation and packaging industry. Their key products include:
- Pressure Rollers: Ensure uniform pressure application during the corrugation process, leading to consistent flute formation.
- Doctor Rollers: Remove excess adhesive from the applicator roll, ensuring precise glue application.
- Glue Applicator Rolls: Engineered for accurate and consistent adhesive application, offering corrosion resistance and long-term durability.
- Chrome Plated Corrugated Rolls: Provide enhanced surface hardness and corrosion resistance, extending the lifespan of the rollers.
- High Precision Tungsten Carbide Corrugated Rolls: Feature exceptional wear resistance and longevity, making them essential for high-speed corrugation operations.
These products are integral to optimizing efficiency and ensuring high-quality output in the corrugation process.
CM : What are the key advantages of BKG’s high-precision rollers with anti- friction coatings compared to traditional surface-treated rollers?
RT : BKG’s high-precision rollers with anti-friction coatings, such as tungsten carbide, offer several advantages over traditional rollers:
- Enhanced Durability: Tungsten carbide coating increases hardness, significantly reducing wear and extending roller lifespan.
- Improved Performance: Anti-friction properties reduce energy consumption and heat generation, improving operational efficiency.
- Consistent Quality: Precision engineering and coatings ensure uniform flute formation and adhesive application, leading to higher-quality corrugated boards.
These advantages make BKG’s rollers a reliable choice.
CM : BKG offers rollers with customized surface profiles for different applications. How do these variations impact the strength and performance of corrugated boards?
RT : Customized surface profiles allow the corrugation process to be tailored to specific requirements, impacting board strength and performance in the following ways:
- Flute Geometry: Different flute profiles (A, B, C, E, F) affect the board’s strength, cushioning, and printability. Choosing the right profile ensures optimal performance.
- Material Compatibility: Custom profiles accommodate various paper grades and thicknesses, optimizing bonding and structural integrity.
By offering tailored surface profiles, BKG ensures that manufacturers can produce corrugated boards that meet precise strength and durability standards.
CM : BKG specializes in advanced surface treatment techniques for rollers. What factors influence the precision and longevity of these components?
RT : The precision and longevity of BKG’s rollers depend on several key factors:
- Material Selection: High-quality base materials enhance roller durability and resistance to operational stress.
- Coating Application: Advanced techniques in tungsten carbide coating ensure uniform coverage, increasing wear resistance.
- Precision Engineering: CNC machining and parabolic crowning techniques optimize pressure distribution and reduce uneven wear, ensuring long-lasting performance.
These factors contribute to the superior quality and extended lifespan of BKG’s surface-treated rollers.
CM : How does BKG’s precision-engineered components contribute to minimizing structural damage to the corrugated medium at high-speed operations?
RT : BKG’s precision-engineered components ensure smooth and damage-free high-speed operations by:
- Accurate Flute Formation: Precisely machined corrugating rolls maintain consistent flute profiles, preventing structural weaknesses.
- Optimized Pressure Distribution: Techniques like CNC-regularized parabolic crowning provide uniform pressure, preventing stress points that could damage the corrugated medium.
- Enhanced Surface Coatings: Anti-friction coatings reduce heat generation and wear, preserving the integrity of the corrugated medium during high-speed operations.
These features ensure that structural damage is minimized, even under demanding production conditions.
CM : How does production speed affect shaping in corrugated boards using BKG components, and what adjustments ensure quality?
RT : Production speed significantly influences the shaping and overall quality of corrugated boards. As speed increases, maintaining precise flute formation becomes more complex due to variations in heat, pressure, and adhesive setting times.
BKG’s high-precision corrugating rolls are designed for efficiency at different speeds, ensuring consistent flute profiles and superior board quality. To maintain high quality during high-speed production, key adjustments include:
- Temperature Control: Maintaining stable heat application to facilitate proper fluting and adhesive bonding.
- Adhesive Application: Adjusting viscosity and application rates to ensure sufficient bonding without excess adhesive usage.
- Tension Settings: Keeping optimal paper tension to prevent warping and maintain uniform flute formation.
Regular equipment maintenance and real-time monitoring further enhance quality control, ensuring precision even at elevated speeds.
” BKG was the first company in India to introduce elite quality Corrugated Rollers at competitive prices. Right from its formative years, BKG has been spearheading growth and loyal commitment to its customers “
CM : BKG manufactures components designed for precise adhesive application. How do adhesive viscosity and chemical balance impact bonding strength in the corrugation process?
RT : Adhesive viscosity and chemical balance play a crucial role in the bonding strength of corrugated boards.
- Viscosity Control: Proper viscosity ensures adequate penetration of adhesive into paper fibers, creating a strong bond. Excessively thick adhesive may result in uneven spread, while overly thin adhesive may be absorbed too quickly, leading to weak bonds.
- Chemical Balance: The formulation affects setting time, tackiness, and moisture resistance. An optimized composition ensures proper curing and long-term durability.
BKG’s precision-engineered glue applicator rolls ensure a consistent and controlled adhesive application, adapting to different adhesive properties to maintain optimal bonding strength.
CM : What are the key differences between natural and synthetic bonding agents in corrugation, and how does BKG optimize their application?
RT : Natural adhesives, such as starch-based adhesives, are biodegradable and cost-effective but may require additives for enhanced water resistance and strength. Synthetic adhesives, typically polymer-based, offer faster setting times and superior moisture resistance but can be more expensive and less eco-friendly.
BKG’s advanced glue applicator rolls are designed to handle both types of adhesives efficiently. The rollers allow precise adjustments in application thickness and patterns, ensuring uniform bonding strength. This flexibility enables manufacturers to select adhesives that align with their product requirements and sustainability initiatives.
CM : BKG emphasizes the importance of controlled thermal treatment during the corrugation process. What key factors must be managed in this stage?
RT : Controlled thermal treatment is essential for achieving proper flute formation and adhesive curing. Key factors to manage include:
- Temperature Settings: Ensuring optimal heat levels in corrugating rolls and hot plates to facilitate fluting and bonding without damaging the paper.
- Heat Distribution: Maintaining uniform heat across the rollers to prevent inconsistencies in flute shape and adhesive performance.
- Dwell Time: Controlling the duration of heat exposure to ensure proper adhesive curing while avoiding excessive drying of the paper.
BKG’s corrugating rolls incorporate advanced heat treatment capabilities, ensuring precise control over these factors for consistently high-quality corrugated boards.
CM : May we know about your aim and business focus? goal in the Industry?
RT : BKG aims to expand its footprint in the global corrugation industry by continuously upgrading its technology and manufacturing capabilities. The company is focused on offering innovative, sustainable, and cost-effective solutions to meet the evolving demands of the packaging industry. Its goal is to strengthen its presence in international markets and contribute to the advancement of the corrugation sector by providing superior quality products.
CM : How is technology advancing in the Indian corrugation industry?
RT : The industry is embracing automation, digital printing, and sustainable materials for better efficiency, customization, and eco-friendliness. Companies like BKG are leading with innovative corrugation solutions.
