Quality Lead Team Update Quality Lead Team Update Large Diameter - - PowerPoint PPT Presentation

Quality Lead Team Update Quality Lead Team Update Large Diameter Rolls and 60 Large Diameter Rolls and 60’ ’ Railcars Railcars Mini Mini-

• Paper Workshop on Damage

Paper Workshop on Damage Resolution Resolution

AAR AAR – – Quality Lead Team for Quality Lead Team for the Prevention of Damage to Paper Products the Prevention of Damage to Paper Products

• Review and Finalization Best Practices for Loading Roll Paper in Rail Cars –

Possible Translating the Manual Into French and Spanish – On-Line Download

• AAR Researching Data Collected Thus Far to Acquire A Weight Threshold for

Level 4 Airbags In A Horizontal Application. Weight Limits to Specify the Level of Airbag to Be Utilized In Shipments

• Loading Patterns for 60’ Cars Having 16’ Door Openings – QLT Team Recommends Only

Methods Provided in Pamphlet 39. All Other Patterns Must Go Through AAR Testing.

• Large Diameter Rolls 60” Plus In 60’ Cars Having 16’ Door Openings – Shippers Should Work

With Individual Railroad Damage Prevention Teams – Must Be AAR Tested

2009 Team Members Abitibi Consolidated - Randy Caine BNSF Railway – Jerry Jones Canadian National Railways - John Green CSX Transportation - Gary Johnson (Chairman) Forest Prod. Assoc. of Canada - David Church Brianna Hodges Georgia-Pacific Corporation - Jerome Williams Union Pacific Railroad - -Brent Lichty Norfolk Southern - Tommy Ford Packaging Corp. of America - Neal Reidenbach Glenn McDonald Weyerhaeuser - Brian Rio Whitney Nelson Transportation Tech. Center, Inc. - Mike Sandoval Canadian Pacific Railway - Louis LeBlanc

60 60” ”, 67 , 67” ”, 70 , 70” ”, 72 , 72” ”, 77 , 77” ” -

• Diameter Rolls in

Diameter Rolls in 60’ Cars Having 16’ Door Openings – – No AAR Approved Patterns No AAR Approved Patterns

BNSF working with Clearwater and Georgia Pacific on Interline moves

• Provide Loading and Securement Methods
• Origin and Destination Inspections
• Local Impact Test by Shipper & BNSF to determine effectiveness
• Petition AAR for Impact Test Upon Success of Local Testing

60” DIAMETER ROLLS

Airbag

77” DIAMETER ROLLS 175,000+ LBS

NO MATTER THE CHALLENGE WE’LL FIGURE A WAY TO HAUL IT TEAM WORK…WORKING TOGETHER TO SOLVE PROBLEMS

Mini Mini-

• Paper Workshop

Paper Workshop

“ “Moving to Damage Free Moving to Damage Free Shipments by Rail Shipments by Rail” ”

30 Years Back In Time 30 Years Back In Time

38 38-

• 40

40” ” Diameter Diameter Metal cores Metal cores – – 3 3” ” 2 2-

• 1

1-

• 2 Load Pattern

2 Load Pattern Braced by steel Braced by steel strapping strapping “ “Key Lock Key Lock” ” 58 58” ” Diameter rolls Diameter rolls 3 3” ” cores cores 1 1-

• 1 off

1 off-

• set load

set load pattern pattern

Printing Paper Pulpboard - Kraft

9' 6" 50' 6" 10'

30 Years Later 30 Years Later

38 38” ”/40 /40” ” now 42 now 42” ”, 45 , 45” ”, 50 , 50” ”, , 52 52” ”, 60 , 60” ” diameter rolls diameter rolls Metal cores to fiber cores Metal cores to fiber cores and now some plastic and now some plastic Core ID Core ID’ ’s of 3 s of 3” ”, 5 , 5” ”, 6 , 6” ” and and greater greater Variety of basis weights Variety of basis weights and widths and widths Air bags as bracing Air bags as bracing Different load patterns Different load patterns 58 58” ” still mainstay still mainstay – – some some 50 50” ” and up to 70 and up to 70” ” diameters diameters Wood blocking and now Wood blocking and now air bag braced & non air bag braced & non-

• metallic strapping

metallic strapping 58 58” ” still in 1 still in 1-

• 1 off

1 off-

• set load

set load pattern pattern

Printing Paper Pulpboard - Kraft

Equipment Changes Over the Years Equipment Changes Over the Years

Old Standard 50 Old Standard 50’ ’

– – non non-

• cushioned (some 10

cushioned (some 10” ” cushioned equipped) cushioned equipped) – – sliding doors sliding doors

The The “ “New Fleet New Fleet” ”

– – 50 50’ ’, 60 , 60” ” and 62 and 62’ ’ inside length inside length – – high cube high cube – – high capacity cars high capacity cars – – 15 15” ”, 18 , 18” ” and 20 and 20” ” cushion units cushion units – – Plug doors Plug doors – – Multi Multi-

• use car

use car – – Strap cars Strap cars

Bracing, Dunnage & Packaging Bracing, Dunnage & Packaging

Air bags Air bags – – both paper and both paper and poly poly Non Non-

• metallic strapping

metallic strapping Riser material Riser material Contour Filler Material Contour Filler Material Honeycomb Filler Material Honeycomb Filler Material Improved Wrappers and Improved Wrappers and Headers Headers

Flat Spot Gouged

The The “ “Original Original” ” Damage Types Damage Types

Crushed Core Wet Damage Edge Damage Chaffed Rolls

Gouged Split Edge Out-of Round Flat Spot T r a n s i t B u r s t Crushed Core C

• n

c e a l e d Chafe W e t T

• r

n T e l e s c

• p

e d T r a n s i t C r e p e Starred C

• n

t a m i n a t i

• n

2 Things Have Remained Constant 2 Things Have Remained Constant

Rolls are “ROUND” Boxcars Aren’t

Resolving Damage Issues Resolving Damage Issues

Water damage Water damage

– – Inspect car before loading Inspect car before loading – – Utilize approved load Utilize approved load pattern, bracing method and pattern, bracing method and doorway protection doorway protection

Gouged rolls Gouged rolls

– – Inspect car Inspect car – – Remove protruding objects Remove protruding objects – – Inspect handling equipment Inspect handling equipment

Flat spots Flat spots

– – Inspect rail equipment Inspect rail equipment – – Utilize approved pattern and Utilize approved pattern and bracing method bracing method – – Provide side wall protection Provide side wall protection

Edge damage Edge damage -

• chaffing

chaffing

– – Consistent diameters in Consistent diameters in same stacks same stacks – – Load tightly each end and Load tightly each end and use approved bracing use approved bracing method method – – On multi On multi-

• layer loads; break

layer loads; break the strata line each end of the strata line each end of load load

Crushed cores Crushed cores

– – Utilize approved load Utilize approved load pattern and bracing method pattern and bracing method – – Change pattern Change pattern ……… ………

TBOX 665003 TBOX 665002

Flat Spots Flat Spots – – Transit Burst (Crepe) Transit Burst (Crepe)

Doorpost

Condition of sidewalls and endwalls can magnify problem

Flat Spots Flat Spots – – Transit Burst (Crepe) Transit Burst (Crepe)

Contact Points How To Reduce or Eliminate

Additional Protection at Sidewalls Additional Protection at Sidewalls

½” ½” folded folded honeycomb honeycomb material at material at contact contact points of points of rolls and rolls and sidewalls. sidewalls.

Transfer of forces thru honeycomb into doorpost roll

Positioned off floor Maybe an improvement ……………

Other means to resolve flat spots, Other means to resolve flat spots, transit burst (crepe) transit burst (crepe)

Reject cars that have excessive bowed Reject cars that have excessive bowed

• sidewalls. Damage can actually happen during
• sidewalls. Damage can actually happen during

loading operations! Excessive? loading operations! Excessive? Change load pattern that will result in fewer rolls Change load pattern that will result in fewer rolls contacting sidewalls contacting sidewalls Reduce lengthwise void that air bags is being Reduce lengthwise void that air bags is being used to fill lengthwise void. used to fill lengthwise void. Load off sidewall Load off sidewall – – but still maintain tight but still maintain tight lengthwise load lengthwise load

CAR “A” CAR “B” How many rolls in each car? How many rolls are contacting sidewalls in each of these cars?

Change your pattern Change your pattern

Crushed Cores, Edge Damage or Crushed Cores, Edge Damage or Water damage Water damage

60' 9" 10' 9' 6"

Other Tips to Consider Other Tips to Consider… ….. ..

Fine Paper, Newsprint or Printing Paper should be loaded in cushioned equipped cars only. Does load pattern match car size – may not be able to load a 9’ 2” car with same pattern as a 9’ 6” width car. If load/doorway type requires doorway protection – is car equipped for securing straps? What about your customer?

– Can they accept high cube cars – Some older facilities can not accept plug door cars.

If your customer is critical – choose the best car to meet they needs.

How do I resolve my damage issues? How do I resolve my damage issues?

Gather Data and Analyze Gather Data and Analyze – – What type of damage (photos) What type of damage (photos) – – Location of damage (photos) Location of damage (photos) In rail car In rail car Customer Customer Is my load plan AAR approved Is my load plan AAR approved Pre Pre-

• loading car inspections

loading car inspections Bring in your rail carrier damage prevention Bring in your rail carrier damage prevention representative representative Visit your customer Visit your customer