NEPA LIMITED, NEPANAGAR

STANDARD OPERATING PROCEDURE

(PAPER MACHINE)

Contents
HISTORY ..................................................................................................................................... 1
PRINCIPLE AND OBJECTIVES .................................................................................................. 2
PAPER MACHINE NO.I ............................................................................................................... 3
1. Design and Present Status ................................................................................................. 3
2. Steam & Condensate, Rope carriers and Calender: .......................................................... 4
3. Drive, winder and Controls) ................................................................................................ 5
4. Startup Procedure of Paper Machine No. 1 ........................................................................ 2
4.1.

Heating of Dryer Cylinders (3.00 Hrs.) ......................................................................... 2

4.2.

Starting Calender Section ( 1.O hrs) ............................................................................ 2

4.3.

Air Circulation .............................................................................................................. 2

4.4.

Press Felt Conditioning (2.30 Hrs) .............................................................................. 3

4.5.

Wire Section condition a Starting (1.30 Hrs) ................................................................ 3

4.6.

Caustic Washing of Press Felts and Wires (1.30hrs.) ................................................. 3

4.7.

Approach Flow System ................................................................................................ 4

4.8.

Process at wire section ................................................................................................ 4

4.9.

Press, Dryer, Calender section and Sheet reeling ....................................................... 5

5. A Brief Functional Explanation for each Major.................................................................... 6

5.1.

Head Box ..................................................................................................................... 6

5.2.

Slice ............................................................................................................................. 6

5.3.

Converflo Head Box ..................................................................................................... 6

5.4.

Wire part: ..................................................................................................................... 6

5.5.

Twln Wire Former (Machine No. l) ............................................................................... 7

5.6.

Advantage of Twin Wire Former .................................................................................. 7

5.7.

Press Part Beloit tri-nip configuration ........................................................................... 7

5.8.

Formation:.................................................................................................................... 8

5.9.

Dryer Part .................................................................................................................... 8

5.10.

Calenders ................................................................................................................. 9

5.11.

Reeler ..................................................................................................................... 10

6. Shutting (Down (Procedure). ............................................................................................ 10

PAPER MACHINE NO.II ............................................................................................................ 11
1. Design and present status: ............................................................................................... 11
2.

Startup procedure of Paper Machine no. 2 :...................................................................... 12

2.1.

Heating of Dryer Cylinders (3.00 Hrs.) ....................................................................... 12

2.2.

Starting Calender Section(6.00 hrs) ........................................................................... 13

2.3.

Air Circulation ............................................................................................................ 13

2.4.

Press Felt Conditioning (2 1/2 HRS ) .............................................................................. 13

2.5.

Wire Section condition & Starting (21/2 Hrs) ............................................................... 14

2.6.

Caustic Washing of Press Felts and Wires (11/2 HRS).................................................. 14

2.7.

Approach Flow System .............................................................................................. 14

2.8.

Process at wire section .............................................................................................. 15

2.9.

Press, Dryer, Calender section and Sheet reeling ..................................................... 15

3. Shutting (Down (Procedure). ............................................................................................ 16

M/c Chest /Head Box First Pass retention On Machine wire : .................................................... 16
WINDER CARE.......................................................................................................................... 17
WINDER CONTROL SYSTEM .................................................................................................. 21
ROLL WINDING PROBLEMS .................................................................................................... 22
PHYSICAL TEST FOR PAPER.................................................................................................. 23
SAFETY ..................................................................................................................................... 26

HISTORY

The company established in 1946.

Started production on 26THApril, 1956 with One Paper Machine, Capacity 30,000 TPA
(P.M/c No.1) M/s Pussy & Jones, USA.

A New Paper Machine (P.M/c No.2), Capacity 37,500 TPA was added in 1969, M/s
Wartsila, Finland.

Total capacity of newsprint 67,500 TPA.

Major renovation of P.M/c No.1 taken-up in 1989 in order to increase its capacity from
30,000 TPA to 50,500 TPA. (Rebuild by M/s Beloit (U.K.) through M/s Jossop & Co.,
Kolkata)

Paper Machine remained shut for renovation from 3RDApril, 1989 to 9THNov. 1989.

Production started on 9THNov. 1989 at 4.30 AM with 49 GSM paper.

PRINCIPLE AND OBJECTIVES

a. Principle:
o To achieve maximum production of paper with minimum losses to increase
productivity.
o Product as per market demand with quality.
b. Objectives:
1.

Manufacturing Paper
Continuous development making it possible to produce wider web of paper at over
increasing speed to more exacting standards quality with cost effective.

2.

To Control Losses
Such as fiber, chemicals, Energy, Water.

3.

Cost Effectiveness
Cost effectiveness of Machine clothing by proper selection and optimization.

4.

Safe working condition of crew.

5.

Housekeeping and cleanliness.

6.

In-house training which enhance Technical skill of workmen as well as supervisors {Paper
Machine: Wet end, Dry end, Calender and Winder area).

7.

Outside Training
For Technological up-gradation and other trainings related to H.R. to achieve productivity.

PAPER MACHINE NO.I

Paper Machine No.1 (M/s Pussy &Jones, USA) installed in 1955.

Renovated in 1989 by M/s Beloit (U.K.) through M/s Jessop(Kolkata).

Capacity - 50,500 TPA

1. Design and Present Status:

Design

Present status

Grade

Newsprint

Newsprint

Basis Weight

49 GSM ,

42/44 GSM

Moisture at reel

7%

5.5-6.0%

Design Speed

750MPM

Maximum operating
700MPM
Speed
Normal operating Seed 350-550 MPM
Average operating
speed
Wire width

450 MPM

410mm

5750 mm

5750 mm

Trim at reel

Speed

4950 mm (min)
4950 mm (min)
5385 mm(max)
5250 mm(max)
Modern Beloit's hydraulic thin channel converflow head box with
pulsation attenuator.
450MPM ::

Inlet Flow

35200 LPM

Slice Flow

32000 LPM

Recirculation

3200

Fan Pump

Capacity 47800LPM
Head 42M
Type 18'/20"CME

Approach Flow Head

Box
Head type

3 stage screening
4 stage centricleaning
Beloit's Hydraulic thin channel converflow Head Box with
Pulsation attenuator.
Twin wire forming section consigning of 'C frame cantilever type
Bottom-wireand top wire 'Belform' unit.
Beloit Tri-Nip press

Head Box

Wire Part
Press
part
Dryer Part
First group
Sec. group
Third group

Three mechanical groups with baby dryer.

First Dryer group Spur gears replaced with new helical gears
8 Dryers + 1 baby dryer.
14 Dryers
12 Dryers

2.

Steam & Condensate, Rope carriers and Calender:

New Cascade steam & condensate system has been provided with steam fits and rotary
siphon assemblies with differential pressure control.
System divided into following groups.
Main
group
intermediate group Wet
end (top row) group
Dry end (bottom) group

: 18 Dryers
: 8 Dryers
:4
:4+1babydryer

Dryer Drainage System

: A list of equipment used

1) Traps-Float thermostatically controlled with air bleeds
2) Separator
3) Flush tank
4) Condenser
5) Vacuum pumps

6) Pressure controller
7) Differential pressure controller
8) Automatic control valve
9) Ejectors
Rope Carriers

On machines where it is not practical or possible to hand

thread the web through the machine, a rope - nip is used
to carry through a tail before putting the lull sheet on the
machine.
This is done on large and high tier dryer sections, heavy
sheet machines & high speed machines for safer,
taste-& more positive feeding.
Two spliced endless ropes are used per section are
driven at the sheet speed by rope sheaves attached to
the revolving units free wheeling sheaves are used to
support the ropes on the return run &also to form up the
nip.
Nylon braided ropes are generally used with 12inm
diameter.

Calender Part

: Beloit fixed queen 4 roll Calender stack comprising of

& bottom Beloit controlled crown rolls.

3. Drive, winder and Controls:

New thyrister controlled section drive has' been provided
with Individual Draw control.

Drive

Couch Roll
Wire turning roll
Pick up Roll
1st Suction Roll
Centre Granite Roll
Paper Roll

1st Section
2nd Section

3rd Section

Baby Dryer
1st Dryer Group
2nd Dryer Group
3rd Dryer Group
Spreader Roll
Calender
Spreader Roll
Reel Drum
Reel Spool Starter

4th Section
5TH Section
6TH Section
7thSection

> Max. RPM of D.C. Motors

> Max. MPM of Master Drive
i.e. 1st group of dryer

1500 rpm
750 MPM

Winder
New Jagenberg Vari-Dur two drums Winder with thyrister drive
1.
2.
3.
4.
5.

Nominal trimmed width

Max. Operating Speed
Material Grade
Minimum slitting width
Max. re-winder dia.

5500 mm
1700 MPM
45-60 GSM
250 mm
1525 mm

Controls
1.
Micro processor based tayior MOD-30 ratio controller system in Stock
Preparation System.
2.
Accuray 1180 Micro Processor System for MD Basis Weight and
Moisture Control and Caliper measurement of finished newsprint.
3.
Auxiliary system - Level controller, Consistency controller; Pressure
controller, etc.

4. Startup Procedure of Paper Machine No. 1

After having received clearances from various concerned agencies machine is
made operative as per the following procedure:
4.1.

Heating of Dryer Cylinders (3.00 Hrs.)

i)

The process: Ensure all the steam traps & drain valve of steam line in open
condition along with drain valve of condensate separator to avoid line hammering
& gasket damage.

ii)

Dusting is done and Guide palms ate checked to be at their normal position, along
with dryer screen stretcher pressure.

iii)

Getting all the nips of dryer screens are checked then make them free of any hard
particle and foreign material to avoid damage to the screen.

iv)

Mechanical clearance for COL (central oil lubricating system) and Electrical
clearance for drive system.

v)

Upon receiving of steam clearance opening of steam valve is started,

vi)

Fresh water valve is to be open for surface condenser and preheating of dryer
cylinders is done of the dryer gets heated then dryer sections start one by one in
inching operation and then put at crawling speed. With gradual increase in steam
pressure, heating of dryer cylinders is continued. Related condensate system is
run including de-superheating At this juncture all the drain valve of steam line &
separator to be kept closed.

vii)

Movement of dryer screens is watched carefully and in case of abnormal

movement, corrective actions are initiated.

viii)

Paper carrier rope is to be checked for its evenness & proper jointing of all drier
section.

Steam and condensate system includes following pumps - 360/361,

371/372, 362, 363, 364, 365,
Exhaust Fans of Hood - 387,388,389
Meanwhile calendar and Pope reel sections are also started UTM pulper to
be made ready
This section includes following pumps & agitators. 321/322,
323/324, 325, 327, 329/330.
4.2.

Starting Calender Section (1.O hrs)

Calender section is started at crawling speed and allowed to get heated properly for nearly
1.0 hrs. If the calendar rolls are not heating .suitably, reel building may affect adversely
making hard and soft ultimately resulting in heavy rejection on this part. Reel section is
also run at crawling speed in between.

4.3.

Air Circulation

The object of air circulation is to keep the evaporated moisture and air mixture above the
dew point until it is safely out of machine room. This air is to carry away the moisture
without drip or rain from the hoods or exhaust.

All the exhaust fans should be started at the time of heating the dryers for air circulation.
Air circulation is provided to remove the vapors quickly and is accomplished by the
followings:
a)
A hood with exhausters.
b)
Hot air blowing in to the spaces between dryers.
c)
Other hot air duct system are used with contribute the helpful gain in rale of drying
in the dryer section.
d)
Safety measures:- AII fire switches, exhaust fan switches, Alarm, Steam temp.
Elec. motar guards, Air hose, pressure gauges, Rubber sheet at elect. Panels & Fire
hydrants are in workable condition.
4.4.

Press Felt Conditioning (2.30 Hrs)

A - AI1 the three press sections are thoroughly checked to see that no foreign materials
remain there in any of the nip, which may cause damage to the costly press felts.
B - All the three press felts are tightened to the optimum position if the machine has been
lying shut for a longer period of time.
At this stage P/m 17,18oil pumps to be started for getting press section drive.
C - After wetting the felts, individual press sections are run one by one in inching operation
and conditioning is done individually(interlocking bypass)
D - Having conditioning of all the three press felts, they are put together in combined mode
to run at crawling speed .Hydraulic oil pump is to be started at this juncture.(interlocking in
operation) check the sealing strip pressure of pick-up roll& suction roll.
Guiding and felt movements are given due attention during their running to avoid to
crease developing on any felt.
Press-pit is to be made ready with water &related pumps, agitators, interlocking &alarms.
(316, 317, 318 and 348 take in operation.)
E-

4.5.

Wire Section condition a Starting (1.30 Hrs)

Complete checking of wire part, ensuring no unwanted material lying on wire. Nips are
checked not to have any hard particle being these so as to avoid any chance of damage
to the wire fabric, which costs to the tune of Rs. 9 to 10 lakhs
After cleaning the filters, lubricating showers & knock down shower are to be started.
Both wires are tightened to the optimum position.
Precaution:-Auto guide palm, squirts, pressure gauges are in workable condition.
Further to this fan pump is run twice or thrice having, kept wire at stationary position with
a view to avoid any remote chance of damage to the wires due to hard particle coming
from the system.(By keeping Fan pump interlocking bypass)
Wetting and cleaning both the wires are continuing in inching operation.
Then wire is put at crawling speed (Fan pump interlocking in operation) VHP shower
for both wires are in operation with pressure 20-22 Kg/cm2 for continuous cleaning.
Wire tension is to be kept around 4.0-4.5 kg/cm.
Here load sharing of couch & WTR roll is important.
Equipment in operation 354,356,358 352
4.6.

Caustic Washing of Press Felts and Wires (1.30hrs.)

Caustic solution having 50 gpl concentrations is prepared. Press felts are washed
with showering of so prepared Caustic solution. After the caustic washing of press
Felts solution is further diluted to bring its concentration down to 20 gpl and wires
3

are treated with showering of this solution & further more cleaning is done with uhle
box shower,
Guide activities are to be closed watch after start up of wire.
4.7.

Approach Flow System

The term approach system refers specifically to the fan pump loop where in the
paper machine furnish is diluted, mixed with additives and finally screened and
cleaned before being discharged on to the paper machine forming fabric.
The stock or the stuff from machine chest (302) which is of 3.0% to 3.5%
consistency is pumped to the stuff box where a constant level is maintained. The
stock after stuff regulating valve is diluted by back water. The dilution of the stock
before the fan pump by back water is of such a magnitude as to give 0.5 to 0.6% as
consistency in the head box and an appreciable drop in freeness such low Cy and
freeness are required for sheet formation on the machine wire.
Fan Pump (303) which delivers the diluted stock to the centricleaners and then
pressure screen for screening.
Primary centricleaners accept goes to primary screen & its accept goes to head box
of the machine
Reject of primary centricleaner goes to secondary centricleaner accept of
secondary c/c goes to silo &reject goes to tertiary centricleaner. Accept of tertiary
c/c goes to reject-pit of primary centricleaner Reject of tertiary centricleaner goes to
quaternary centricleaner Accept of quaternary c/c goes to pit of secondary
centricleaner & reject in drain.
The differential pressure is important factor at this stage.
Reject of primary screen (308/309) goes to reject tank (310). It pumped to
secondary screen (311) & accept goes to inlet of fan pump .Reject goes to knotter
screen (312) & accept of knotter screen goes to couch pit & reject in drain.
Pumps 304,305,306,308/309,310,311,312 will be in operation.
Accept of pressure screen is taken to the machine head box through Attenuator,
which reduces pulsation in the stock and then to the machine wire. After having the
stock clearance machine sections are speeded up to normal operative speed. Fan
pump is started to get required head & ensuring no air in the stock flow here.
The required vacuum pumps are started.
(396, 397/398,399,400/401, 402/403,174B.)
Pump No.
396
397
398
399
400
401
174B
4.8.

Location
Couch High
Press-section
Pick up High
Suction High
Suction Low
Couch Low
3rd press Uhle Box
1si& 2nd press Uhle Box

Application point
520 mmHg
450 mmHg
510 mmHg
210 mmHg
400 mmHg
300
240/260 mmHg

mmHg

Process at wire section

Paper Machine No.1 is Twin-wire former (Fourdrinier with top wire) this improves
formation by creating high shear at the nip where the top-wire is introduced. Here
4

suction couch roll and wire turning roll has separate DC drive motor. The other rolls
along with Top wire rolls are driven by wire.
In the head box the pond head is maintained which gives the required velocity for the head
box fluid (pulp slurry) which should equal the wire speed and is determined by the formula
V2 = 2gh (where: V = Velocity, g= gravitational constant, h = head). The flow of the stock
or pulp slurry comes on the wire through on adjustable orifice called slice and the flow is
regulated by its head in the slice on the rotating wire at a velocity matching the speed of
the wire. The discharge is at a forming board from where the sheet formation
commences.
The dewatering is done with aid like stationary hydrofoils with an subjected angle of 1.0 to
2.5 angle at its tips, vac. Foils, auto slice, perforated flat suction boxes where suction is
applied from vacuum system and through suction couch, which is perforated metal roll
having suction boxes which also gets suction from the vacuum system. In this case
dewatering is clone in upward and downward drainage (i.e. from top wire and bottom
wire).
The water dewatered up to the flat suction boxes is collected in to the wire pit through save
all trays. This water is known as white water or back water, it contains 'fines' which pass
through the wire along with the water. The wire on also received the wire cleaning shower
water. In wire pit a constant overflow is maintained for which, make up white water from a
different sources is added as per the need. The white water from the wire is collected in
the silo' have again constant level is maintained. The suction of the fan pump is from
silo' thus, the silo water dilutes the regulated machine chest stock from the stuff box.
The white water from the flat suction boxes and Auto slice and Transfer box of top wire is
of lower consistency is collected in seal pit and is used for make up water for centricleaner
reject tank level where again constant level is maintained. The seal pit acts as a vacuum
seal for the discharge legs of the flat boxes.
After forming the wet sheet at wire. Edges of the sheet at both the ends as it leaves the
forming wire is trimmed by high pressure water jets located over the wire between last
suction box and couch roll. The trimmed edges are comes around the couch and washed
off the wire into the couch pit beneath the wire from where it is sent to the drop chest
through Decker. ,
After forming the sheet at wire section by keeping closed watch sheet is to be completely
broken at knock down shower all possible steps are to be taken to avoid damage to wire.
4.9.

Press, Dryer, Calender section and Sheet reeling

Press section:
Dryer section:
Calender section:
Sheet reeling:

2 nd& 1st press is to be loaded at this juncture.& after getting pH in

range of 5.5- 5.8then pick-up is lowered and getting outgoing sheet
at press-pit .after checking sheet then 3rd press is loaded,
After pressing, the sheet is conveyed through the dryer section
where the residual water is removed by evaporation.
The sheet is transferred to the series of calendar rolls.
Function of Paper Machine Calender is compacting the paper web
and gives it uniform bulk and smooth surface.
Last operation cn the Paper Machine is the receiving of the paper in
roll form with moisture of 5-6% On reefer, the paper roll is pressed
to a cylinder drum rotating with constant circumferential and angular
speed (with steady speed of paper web on the machine).

Start scanner of accuray system for grammage control & steam control. The entire
interlocking are to be taken in to operation.
Winder
The winder splits the full width sheet into suitable sizes for the consumers and delivers a
roll of paper which will run on printing press with a minimum trouble or the waste.

It is usual practice to run the winder at 2.5 to 3 times the paper machine speed to give
operators the necessary time to adjust the slitters and splice breaks, remove defective
paper etc. to keep up with machine production.

5.

A Brief Functional Explanation for each Major Component of PM-I:

5.1.

Head Box

The function of the head box is to take the stock delivered by the fan pump and
transform the pipe line flow in to an even, rectangular/discharge equal in width to the
paper machine and at uniform velocity in the machine direction.

5.2.

Slice

The head box slice is a full width orifice with a completely adjustable opening to give
the desired rate of flow.
5.3.

Converflo Head Box

Converflo head box produces better formation of sheet having fibre more uniformly
distributed through the sheet thickness. It also gave excellent cross machine profile
and permits better utilisation of fourdrinier forming table. The converflo head box is a
compact, high performance hydraulic head box which does not need any air pressure
thus no need of auxiliary services such as air compressor pipe work and stone level
control, rectifier rolls and shower are also eliminated.
Beloits converflo or hydraulic head box is definitely a new concept. It has no air
cushion, no forced internal circulation and is highly adjustable. It is known hydraulic
head box because the head box is totally filled with.stock. Due to absence of an air
cushion in the head box the stock is passed through the 'surge tank' which creates as
liquid level to dampen hydraulic pulsation from the fan pump, pressure screen and
piping arrangement can adjust MD/CD ratio by using lip arrangement.
This head box provides uniform fibre dispersion across the width of the machine
through the use of tube bank to provide good sheet formation.
The relative positioning of top & bottom lip and the distance of the lip from top dead
centre of the breast roll, determine the jet angle and point of impingement on the wire.
Point of impingement as well as jet angle on the wire affects the formation of the web.
Relationship between jet speed & wire speed affects the formation and properties or
paper.
5.4.

Wire part:

The function of the wire part is to weave the fibres and de-water the stock in such a
way that paper web formed is sufficiently strong to run through the presses.
A large amount of water contained in the stock is removed in the wire part (de-watering
is costly affair; energy consumed in the wire part is 35-70% of the energy required to
drive the paper machine).
Fibre suspension in water after passing through forming board, No. of drainage
elements undergoes filtration where fibre settles and inter move with each other.
The forming medium is an endless, finely woven belt:
6

 To-day, plastic mesh fabrics are used because they provides much longer service.
The fabric travels between two large rolls, the breast roll near the head box and the
couch roll at the other end.
The various elements between the breast roll and couch roll serve the dual
functions of wire support and water removal.
The wire then passes over a series of vacuum augmented devices from low
vacuum to high vacuum.

5.5.

Twln Wire Former (Machine No. l)

Converging wire wedge over a turning radius to move surface water to the inside of
the top wire, where it is removed by vacuum.
Two sided de-watering gives the potential of a move symmetric and even material
distribution.
5.6. Advantage of Twin Wire Former
More uniform paper through better moisture distribution, basis weights distribution
and improved formation.
Less two sidedness.
Better smoothness.
Less wire marks.
Better printability.
Less venting with high tank irk.
Better ash distribution.
Stronger paper.
Uniform ink absorption on both sides of the paper.
Less ink requirement

5.7.

Press Part Beloit tri-nip configuration

Objective
The objective of the pressing is to solidity the fibre network and to achieve certain physical
properties such as, density, strength, smoothness.

Water Content

Dryness

Content of Fibre x 100 (%)

Fibre + Water

Moisture

Content of Water x 100 (%)

Fibre + Water

Many Factors in the Press Section are Important?

 The felt its evenness in MD and CD.

Conditioning.
Wear.
Contamination.
Compaction.
The roll its geometry, cover, hardness, hole pattern, balance, alignment.
The loading system - correct and evenly distributed load along the nip.
Draw in between different nip.

5.8.

Formation:

Degree of uniformity of the fibre distribution in the sheet of paper.

Importance
Better Strength

Better Opacity

Smoother Surface

Good Formation

Discussion
1.
2.

Measuring formation.
Improving formation.

5.9.

Dryer Part

After pressing, the sheet is conveyed through the dryer section where the residual water
is removed by evaporation.

On machine, the thermal energy for drying is transferred to the paper by wrapping a
series of large diameter, rotating, steam filled cylinders.

Description of Drying Process

The wet web from the press section containing 58-60% moisture is passed over a series
of rotating steam heated cylinders usually 1.5 m diameter where water is evaporated and
carried away by ventilation air.
The wet web is held tightly against the cylinder by a synthetic fabric called dryer
felt/screen.
The fabric also serves to support and guide the sheet through the dryer section.
Steam enters the dryer via the hollow Journal, passes in to the spider and emerges in to
the dryer through the two steam ports. Condensate, which is remaining, is picked up by
the hopper/shoe and passed via the vertical siphon pipe into the central passage way of
the spider and out through the hollow journal to the steam fit.
Siphon shoe is screwed to the dryer wall by two sets crews.
These screws are screwed and that the joint between the dryer head and the siphon is still
intact (little maint. Required).
The vertical siphon pipe is held captive in the spider by dog point screw but should be fairly
good slide.
Fit in the base of the shoe, to cater for expansion and contraction of the pipe and dryer.

Draw

The paper maker uses the adjustment of draw between sections to correct sheet
release problems.

By pulling a little faster from 2nd press, the sheet can be made to release from a 1st
press top roll at lower point and provide safer running prevent blowing and wrinkling.

On the dry end of machine, percentage of moisture will effect the shrinkage of the
sheet and thus draw required.

5.10. Calenders

Function of Paper Machine Calender is compacting the paper web and gives it
uniform bulk and smooth surface.

Finish and calliper depends on calendering.

Paper going to the calender should have 5% moisture.

Dry paper ( 3 - 4 % moisture) does not get proper smoothness through the calenders
because it is stiff.

Too high moisture is not good because it blackens the paper sheet.

Smoothing action of calender rolls is due to slippage of polished rolls out of which
only one roll is driven.

Glaze and smoothness of paper is due to the smoothness of the roll which should be
hard and polished.

In order to get good machine finish and glaze it is necessary to have uniform moisture
across the deckle, good look through, good condition of calender rolls.

Thickness reduction is an objective with newsprint which is important for reel building.

5.11. Reeler

Last operation on the Paper Machine is the receiving of the paper in roll form.

On reeler, the paper roll is pressed to a cylinder drum rotating with constant
circumferential and angular speed (with steady speed of paper web on the
machine).

Roll of the paper rotates under the action of circumferential force (friction force)
between the roll and cylinder drum.

With considerable rise in -oil diameter its rotational speed constantly reduce and
circumferential speed is steady and equal lo circumferential speed of the cylinder
drum.

Compact and uniform reeling is obtained.

6. Shutting Down (Procedure).

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Check chest level and decides exact moment of shut down.

Break paper at couch runs to couch pit, until the substance on the wire is too thin.
Shut off stuff.
Shut off fan pump and other pumps.
Turn wire sprays to fresh water.
Clean of the wire by hose.
Check the wire thoroughly.
Clean breast roll, couch roll, wire return roll, doctors and trays.
Stop the wire.
Stop all vacuum pumps.
Hose out all the white water tanks and boxes, looking especially for slime etc.
Boil out Head box. Clean lips of head box.
Shut down the main drive with aid of electrical department.
Before stopping the wire, it is thoroughly examined over every inch of its surface. If
there are any pitch/ink spots they must be removed, as it is extremely difficult to remove
them when the wire is moving at production speed. After the final check wire may stop.

Press Part & Dryer Part

> Turns off steam (steam valve gradually shut keeping required steam pressure in dryer
so as to get optimum differential pressure for removal of condensate).
> Shut off air supply fan and exhaust fan for hood.
> Lower speed of the cylinders.
> Cylinder doctors lifted and cleaned.
> All loose paper removed.
> Lower speed of the press section.
> The whole of the press section, rolls, trays, press pit, etc. cleaned off.
> Run VHP shower for pick up roll and suction roll for about 2 hours for cleaning the
roll.
> Whole the press section is inspected for condition of guides, roll surface, etc.
> Stop press section; loose the felts/raise top rolls.
> After removal of condensate from the cylinder and steam valve shut.
> Inspection of guides, roll surface, etc.
> Stop dryer section.

PAPER MACHINE NO.II

Paper Machine No.ll (M/s Wartsila, Finland) installed in 1969 with the capacity 37,500 TPA.

1. Design and present status:

Grade
Basis Weight
Moisture at reel
Design Speed
Maximum
operating Speed
Wire width
Trim at reel

Newsprint
52 GSM

Capacity
Head Box

37500 MT
Pressurized type with inlet manifold . Three rectifier
rolls with 20-25 MM dia perforations &53-55%open
areas.
Sliceconvergent&divergent. 1.Speed range = 150
M/min -400 M/min
2.Flow volume=32000 L/min
3.Pond side = 5590 MM
4.Inlet system-manifold with side inlet
5.Lip material material -S.S. (AISI-304)
Make JMW
TYPE = 2.22-507
Capacity=35000 LPM
Head=15 mtr
Rpm=750
Run-out type with both the suction couch roll &
drive-roll .Being cantilevered
Forming board, table rolls with deflectors and flat
suction

Fan Pump

Wire Part
Dewatering
Element
Boxes
Press Part

Dryer Part

Rope carriers

500MPM
400MPM
5700 mm
5335 mm (min)

Vaccum pickup.
Inclined suction press with granite roll top one,
straight Through suction press with granite roll top.
Presses are pneumatic loaded.
1.36 paper dryers + 1 sweat cylinder.
2.3rd steam group cylinders =15-36
3.2nd steam group=5-14
4.1st steam group cylinder =1-4
Felt drying group=10 cylinders-.>bypass.
Three mechanical groups with baby dryer .The
condensate siphon is rotary type. The condensate
system consists of three flash tanks with auto level
controller.
On machines where it is not practical or possible to
hand thread the web through the machine, a rope nip is used to carry through a tail before putting the full
sheet on the machine.
This is done on large and high tier dryer sections,
heavy sheet machines & high speed machines for
safer, faster &more positive feeding.
Two spliced endless ropes are used per section are
driven at the sheet; speed by rope sheaves attached
to the revolving units freewheeling sheaves are
used to support the ropes on the return run &also to

Newsprint
44/48 GSM

285/300MPM
5741 mm
5250 mm
(min)

Hood
Calender Part
Reel
Drive

Line Shaft Motor

Main Line Shaft

Type
Make
Max. Width
Trim Width
Max.Unwind Dia
Max. Rewind Dia
Smallest Slitting
width
Roll wrapping
Machine
Designed for
Paper rolls
Controls

form up the nip.

Nylon braided ropes are generally used with 12mm
diameter. :
Semi closed type hood
Calender comprises of 6 rolls acting by their own
weight
Pope Reel with all reeling operations being controlled
Pneumatically = 2000MM dia (max)
Mechanical drive is for a speed of 200 to 400 M/min.
Crawling speed = 25 M/min .
Draw is controlled with fu help of cone pully's driven
by Belts
Mechanical part of the drive
Main Line shaft
Reduction gear units.
600<W, RPM=1000, v=440 make AEG
Reduction, gear units for:
Wire Turning Roll
1stPress
2nd Press
1st Dryer Group
2nd Dryer Group
3rd Dryer Group
Calender Reel
Winder :
25 E
Jagenberg Wartsilla
1500 mpm
5200 mpm
1800 mpm
1500 mpm
400 mpm
Finishing House :
Wartsilla make 700-1200 mm dia and 420-1700 mm
long.

Electronic head controller , consistency controller

,electronic steam controller etc.

2. Startup procedure of Paper Machine no. 2:

After having received clearances from various concerned agencies machine is
made operative as per the following procedure:
Ensure clutches of all sections in off-mode. Then start line shaft motor
2.1.

Heating of Dryer Cylinders (3.00 Hrs.)

i)
ii)
iii)
iv)
v)

The process:-Ensure steam traps & drain valve of steam line in open
condition along with drain valve of condensate separator to avoid line
hammering & gasket damage.
Dusting is done and Guide palms are checked to be at their normal
position, along with dryer screen stretcher pressure.
Getting all the nips of dryer screens are checked then make them free of
any hard particle and foreign material to avoid damage to the screen.
Mechanical clearance for COL (central oil lubricating system) and Electrical
clearance for drive system.
Upon receiving of steam clearance opening of steam valve is started,

vi)

vii)
viii)

Fresh water valve is to be open for surface condenser and preheating of

dryer cylinders is done of the dryer gets heated then dryer sections start one
by one in inching operation and then put at crawling speed. With gradual
increase in steam pressure heating of dryer cylinders is continued. Related
condensate system is run including de-superheating At this juncture all the
drain valve of steam line & separator to be kept closed.
Movement of dryer screens is watched carefully and in case of abnormal
movement, corrective actions are initiated.
Paper carrier rope is to be checked for its evenness & proper jointing of all
drier section.
Steam and condensate system includes following
pumps: 184A/B, 185, 186, PD12A/B, 272A, 272B
Exhaust Fans of Hood. 250,251,252,253
Meanwhile calender and Pope Reel sections are also
started Pulper to be made ready
This section includes following pumps &
agitators. 154,112,130,111 A/B

2.2.

Starting Calender Section(6.00 hrs)

In the mean while, calender section is started at crawling speed and allowed to got
heated proper for nearly 6.0 hrs. The calender section being provided only with
pneumatic system, takes more time for getting heated up in comparison to the
calender section of Paper Machine No.I. If the calendar rolls are not heating
suitably, reel building may affect adversely making hard and soft ultimately resulting
in heavy rejection on this part. Reel section is also run at crawling speed in between.

2.3.

Air Circulation
The object of air circulation is to keep the evaporated moisture and air mixture
above the due point until it is safely out of machine room. This air is to carry away
the moisture without drip or rain from the hoods or exhaust.
All the exhaust fans being started at the time of heating the dryers tor air circulation.
Air circulation is provided to remove the. vapours quickly and is accomplished by
the followings:
a)
b)
c)
d)

A hood with exhausters.

Hot air blowing in to the spaces between dryers.
Other hot air duct system are used with contribute the helpful gain in rate of
drying in the dryer section.
Safety measures;-AII fire switches, exhaust fan switches, Alarm,Steam temp.
Elec. motar guards, Air hose, pressure gauges, Rubber sheet at elect.
Panels & Fire hydrants are in workable condition.

2.4. Press Felt Conditioning (2 1/2 HRS )

Both the press felts are thoroughly checked to see that no foreign materials remain
there in any of the nip, which may cause damage to the costly press felts.

Both press felts are tightened to the optimum position if the machine has been lying
shut for a longer period of time.

After wetting the felts press sections are run in inching operation and conditioning is
done.

After conditioning of both pres felts they are put in crawl mode.

Guiding and movement of felts are given due attention during their running to
avoid, crease developing on any felt.

2.5.

Wire Section condition & Starting (21/2 Hrs)

Complete checking of wire part, ensuring no unwanted material lying on wire. Nips
are checked not to have any hard particle being these so as to avoid any chance of
damage to the wire fabric, which costs to the tune of Rs. 9 to 10 lakhs

Wire is wetted and cleaned well then tightened up to the optimum position.
Precaution:- Auto guide palm, squirts,
pressure gauges are in workable
condition.

After cleaning the filters, lubricating showers, trim showers & knock down shower
are to be started.

Cleaning is continued again in inching operation. Then wire is put at crawling

speed.
VHP shower for wire is in operation with pressure 11-12 Kg/cm for continuous
cleaning.
Wire tension is to be kept around 4.0-4.5 kg/cm. Here load
sharing of couch & WTR r&ll is important
Equipment in operation 117,118,119,120,230/233
2.6.

Caustic Washing of Press Felts and Wires (11/2 HRS)

Caustic solution having 50 gpl concentration is prepared. Pick up felt is washed with
showering of so
prepared caustic solution. After the caustic washing of pickup up
press felt start uhle box shower for more cleaning. Solution is further diluted to bring its
concentration down to 20 gpl and wire is treated with showering of this solution. After
caustic treatment all showers should be started.
Guide activities are to be closely watched after start up of wire.
2.7.

Approach Flow System

The term approach system refers specifically to the fan pump loop wherein the paper
machine furnish is diluted, mixed with additives and finally screened and cleaned before
being discharged on to the paper machine forming fabric.
The stock or the stuff from machine chest (108 A/B) which is of 3.0% to 3.5 % in
consistency is pumped to the stuff box where a constant level is maintained The stock
after stuff regulating valve is diluted by back water The dilution of the stock before the
fan pump by back water is of such a magnitude as to give 0.5 to 0.6% as consistency in
the head box and an appreciable drop in freeness such low cy and freeness are required
for sheet formation on the machine wire.

Fan Pump (114) which delivers the diluted stock to the pressure screens 146,147,148 for
screening. Accept of screens goes to head box of the machine. ,
Reject of pressure screens (146,147,148) goes to reject tank. It is pumped to inlet of Fan pump
through pump (116A/B).
Pumps 115,117,118,119,120,230/233,159,116, 200A, 200B, 201
operation.

will

be in

Accept of pressure screens is taken to the machine head box through SFV. Head box delivers
the steady and constant stock with minimum pulsation rate to the machine.
After having the stock clearance machine sections are speeded up to normal operative speed.
Fan pump is started to get required head & ensuring no air in the stock flow here.
The required vacuum pumps are started before putting the wire in run mode.
(170,171,172,173,174A.)
Pump No.

Location

Vacuum at

170
171
172
173
174A

2.8.

application point
320 mmHg
300 mmHg
240 mmHg
300 mmHg
300 mmHg
150
to 200
mmHg

Couch High
Pickup High
Upper Uhle Box
Couch Low
Suction Roll I & II Hi
Flat Boxes(1,2,3,4,5)

Process at wire section

Paper Machine No.2 is T Fourdrinier. Here suction couch roll and wire turning roll and wire
return roll has separate DC drive motor.
In the head box the pond head is maintained which gives the required velocity for the head box
fluid (pulp slurry) which should equal the wire speed and is determined by the formula V2 = 2gh
(where: V = Velocity, g= gravitational constant, h = head). The flow of the stock or pulp slurry
comes on the wire through on adjustable orifice called slice and the flow is regulated by its head
in the slice on the rotating wire at a velocity matching the speed of the wire. The discharge is at
a forming board from where the sheet formation commences.
The dewatering is done with aid like forming board, table rolls, fiat suction boxes where suction
is applied from vacuum system and through suction couch, which is perforated metal roll having
suction boxes which also gets suction from the vacuum system. In this case dewatering is done.
The water dewatered up to the flat suction boxes is collected in to the wire pit through save all
trays. This water is known as white water or back water. It contains 'fines' which pass through
the wire along with the water. The wire pit also received the wire cleaning shower water. In wire
pit a constant overflow is maintained for which, make up white water from a different sources is
added as per the need. The white water from the wire is collected in the 'silo' have again
constant level.is maintained. The suction of the fan pump is from the 'silo' thus, the silo water
dilutes the regulated machine chest stock from the stuff box.
The white water from the flat suction boxes of wire is of lower consistency is collected in seal pit.
ancl is used for make up water for accept tank level where again constant level is maintained.
The seal pit acts as a vacuum seal for the discharge legs of the flat boxes.
After forming the wet sheet at wire, edges of the sheet at both the ends as it leaves the forming
wire is trimmed by high pressure water jets located over the wire between last suction box and
couch roll. The trimmed edges are comes around the couch and washed off the wire into the
couch pit beneath the wire from where it is sent to the drop chest through Decker.
After forming the sheet at wire suction by keeping closed watch sheet is to be completely
broken at knock down shower ail possible steps are to be taken to avoid damage to wire.
2.9.

Press, Dryer, Calender section and Sheet reeling

Press section:

2 nd& 1st press is to be loaded at this juncture &after getting pH in range of

5.5- 5.8then pick-up is lowered and getting outgoing sheet at press-pit
,after checking sheet.Then 3rd press is loaded.

Dryer section:

After pressing, the sheet is convened through the dryer section

where the residual water is removed by evaporation.

Calender section: The sheet is transferred to the series of calender rolls.Function of

Paper Machine Calender is compacting the paper web and
gives it uniform bulk and smooth surface.
Sheet reeling:

Last operation on the Paper Machine is the receiving of the

paper in roll form with moisture of 5-6%.On reeler, the paper roll
is pressed to a cylinder drum rotating with constant

15

circumferential and angular speed (with steady speed of

paper web on the machine).

3. Shutting Down (Procedure):

Check chest level and decides exact moment of shut down.

Break paper at couch runs to couch pit, until the substance on the wire is too thin.
Shut off stuff. (108A/ 108B)
Shut off fan pump and other pumps.
Slow down the line shaft speed up to crawl speed.
Turn wire sprays to fresh water.
Clean of the wire by hose.
Check the wire thoroughly.
Clean breast roll, couch roll, wire return roll, doctors and trays.
Stop the wire.
Stop all vacuum pumps.
Hose out all the white water tanks and boxes, looking especially for slime etc.
Boil out Head box. Clean lips of head box. '

Before stopping the wire, it is thoroughly examined over every inch of its surface. If
there are any pitch/ink spots they must be removed, as it is extremely difficult to
remove them when the wire is moving at production speed. After the final,check wire
may stop.

Press Part & Dryer Part:

The whole of the press section, rolls, trays, press pit, etc, cleaned off.
Run VHP shower for pick up roil and suction roll for about 2 hours for cleaning the
roll.
Whole the press section is inspected for condition of guides, roll surface, etc.
Stop press section; loose the felts/raise top rolls.
Turns off steam (steam valve gradually shut keeping required steam pressure in
dryer so as to get optimum pressure for removal of condensate.
Shut off air supply fan and exhaust fan for hood.
Cylinder doctors lifted and cleaned.
All loose paper removed.
After removal of condensate from the cylinder and steam valve shut.
Inspection of guides, roll surface, etc.
Stop dryer section.
Stop calendar part after cleaning,
All calender rolls opened by lifting device. t
All doctors kept in off-mode.
Stop reel section.
At last stop main line shaft motor.

M/c Chest /Head Box First Pass retention On Machine wire:

S.NO. PARTICULARS

UNIT

1
2
3
4
5
6

%
ml
%
ml
%
%

M/c chest consistency

M/c chest freeness
Head box consistency
Head box freeness
Wire Tray Consistency
First pass Retention on
machine wire

16

TEST RESULTS
M/C 1
M/C 2
3.5
2.2
164
173
0.603
0.416
83
100
0.164
0.100
72.8
75.96

WINDER CARE
Today's paper machine winder is a hard worked piece of equipment. As paper machine widths
and speeds increase and customer quality requirements become more stringent, the demands on
the winder are increased. Normally the winder is the last process before shipping, and the
appearance and quality of product is largely dependent upon the winder operation. The winder
can be fitted with various devices to give correct roll structure to the developing reels and, to
ensure repetitive quality, winder maintenance is very important. Of course, same reels may be
rejected for other than winder faults, for example basis weight, calliper, colour, finish, etc., and
these faults will have to be corrected in the previous process. There are, however, a number of
reel quality faults which can be attributed to winder performance and operation.
A few of the more common faults are:1.
Poor roll structure.
2.
Poor edges, steps etc.
3.
Slitter dust and fuzz.
4.
Edge square ness.
5.
Stuck rolls
6.
Spliced rolls (winder breaks).
7.
Winder bursts and cracks
There are, of course, other winder faults derived from one or more of the basic faults described.
The vast majority of winder faults can be minimised by running adjustments, well planned
maintenance, and settings of the various control devices. All operating parts are subject to wear
and loss adjustment and if these conditions are progressively allowed to develop the quality of
the reels of paper will slowly deteriorate, with more reject reels being returned by the customer.
A regular inspection should be made of the main operating elements of the winder as well as
piping and hose connections. Make certain, there are no leaks and that use of controls obtains
proper response. All limit switches should be checked weekly for proper operation. These are
installed to ensure safety of operation and should never be bypassed for any reason.
The winder in total comprises a number of sections which are:1. Unwind section.
2. Slitting section.
3. Web control section.
4. Web Tension Section.
5. Roll Structure Section.

UNWIND SECTION :
The function of the unwind station is to support the machine reel on its spool and to transmit the
braking required in the sheet for sheet tension.
The regenerative unwind employs a D.C. drive. The drive motor to help accelerate the reel of
paper up to speed and then regenerates to provide braking and tension during full speed
operation and deceleration. Typical unwind of the mechanical brake drum bearings run in oil
baths. Once a week check the oil level in the bearing housings and when required top up with a
high grade oil with a viscosity of 500-700 seconds at 38C. Every six months remove drain plugs
at the bottom of the housings and flush out with flushing oil and refill.
The disc brake assembly usually consists of two brake calipers which straddle the disc. The
caliper units are designed to require minimum of attention, they are fitted with swiveling lining
shoes to ensure full pad contact with the disc. Adjustment for liner wear is not required during the
life of the liners.

17

When wear has reduced the pads to the minimum permissible thickness of 5mm, the liners must
be replaced. These are supplied with friction pads bonded to the liner backing plates.
SLITTING SECTION :
Shear Type slitters are used for all paper grades although special circumstances score type
slitters are used on specialty grades such as crepe tissues and glassine, but the shear slitter is
developing to cover all grades. The slitter section can use various types of shear slitter and
support tables. Some of the most popular types (a)
Bands on roll.
(b)
Motor driven.
The support tables are either stationary guard boards or rotating rolls. The bottom slitter bands
are double edged and to cut accurately at high speed should be changed at regular intervals and
re-sharpened. No hand dressing is permissible and any bands with snicks or chips must be
removed. When fitting new slitter bands check them for run out and wobble, both should be within
0.05 mm - 0.10 mm to give quality cuts at high speeds.
Check that the bands are proud of the support table the amount varying from 1.5 mm to 3 mm
dependent on sheet weight. If trouble such as wrinkling or snap-offs is occurring in the slitter
section, check hat the support tables are parallel to the slitters, also that all slitters are free and in
good condition.
TOP SLITTERS:
The top slitter has two preset angles and if slitter problems persist these angles should be
checked and corrected. Check the top dovetail periodically for damage and clean off dust, etc.
Periodically for damage and clean off dust, etc. Periodically check the diaphragms for air leaks
and sticking, and check the loading springs for load and distortion. Ideally every 10 to 14 days,
remove the hub assembly, remove retaining rings, press out the bearings and clean and inspect
the bearings. Renew where necessary and lubricate with a few drops of anti-drip type oil with
oxidation and corrosion inhibitors, viscosity should be about 500 SSU at 38C. Do not allow worn
bearings to be left in operation as this will upset the blade cutting angles with subsequent
deterioration of cut quality. Check that spring loading pressure are kept to a minimum and the
correct setting device is used by the operators, who sometimes increase the knife loading
compensate for dull blades.
It is worthwhile to assess the number of blades changed per shift and to have racks located near
the winder with a sufficient quantity of sharp blades ready for the operator. A typical shear slitter in
operation is shown.

WEB DRIVEN SLITTER :

Developments have been made in slitter design in the past few years in order to
Obtain higher quality slitting and reduce down time for slitter setting.
The web driven slitter which, as the name implies, the slitting components are driven
by the web instead of by separate drive motors. Web driven slitter offer improve slit quality,
reduction in dust, re-sharpening of blades minimized , safety (blades have square edges), slitters
only rotate when driven by web so they only wear when working.
A further development has been made in the mounting of the slitter assemblies which are now
carried across the machine on antifriction ball slides for easier lateral movement.
The anti-friction ball bushings are self-aligning and the clearance between the ball bushing and the
shaft can be adjusted by an adjusting screw. A slight amount of pre load is usually acceptable but
care must be taken to avoid too much pre-load which could cause rough operation and damage the
shaft.
Since the bushings are lightly loaded and operating in dusty atmosphere lubrication is not
necessary. Any damage to the shafts should be removed with a fine stone.

18

Problems associated with all types of slitters are:a)

Fuzzy edges,
b)
Cracks at edges,
c)
Inter-weaving,
d)
Snap-offs,
e)
Slitter 'rings',
This can be attributed to blunt knives, worn top bearings, out of alignment of slitter section and
bottom slitter knife speed too low.
WEB CONTROL SECTION :
The control of the web through the winder is jointly shared by the tension system and the spreader
system. In this section we will deal with the spreading devices. There are basically three alternative
types as follows
1.
2.
3.

D'

Bar
Mount hope type roll
POS Z Spreader

The selection of the various types is dependent on duty, paper types, etc.
'D' Bar (spreader type)
The standard 'D' Bar assembly should be mounted as closely as possible to the rear main drum and
it is important to ensure that the assembly is at 90 to the sheet. Periodically clean and free off all
adjusting screws and check the bar for wear and uniformity. Occasionally the bar takes a
permanent set with humps, etc. due to local adjustment as opposed to the uniform bow it should
have - if this occurs replace the 'D' bar. The minimum bow and minimum penetration are the ideal
setting to prevent interweaving and over stressing the sheet. However, due to some unknown
reason, the only way operators adjust a 'D' bar is into the sheet and periodically the bar should be
reset following the detailed description in manual.
An alternative design of 'D' bar spreader is available where the 'D' bar can be adjusted by
pneumatic actuators, which reduces time required for setting and enables the controls to be
positioned remotely from the 'D' bar if desired. Maintenance is confined to regular inspection to
check for air leaks or signs of wear especially 'O' rings and seals for deformation and general
ageing.

MOUNT- HOPE TYPE ROLLS :

The mount hope type spreader is used where a stationary spreader would mark the sheet.
This roll should be greased at both ends once a week. Periodically inspect the surface of the
roll and clean with a cloth dampened with paraffin or something similar. If there are signed of
checking or glazing, sand the roll down with a belt sander or by hand with a sandpaper
block. If the roll is badly scuffed, return the roll to the manufacturer. Inspect the surfaces
carefully - any cuts or cracks can affect the spreading effect of the roll. In the event of a
wrap-up do not allow operators to cut the layers of paper from the roll, clear the last few
layers by hand by rotating the roll. Every two years or so return the roll to the manufacturers
for overhaul. Periodically check condition and tension of drive belts to ensure the roll is
running at the correct without belt slip.

19

Pos Z SPREADER :
The Pos 'z' spreader is a new design of spreader for the spreading and separation of narrow
multi-webs. The spreader consists of two vari-bow stationary rolls with a series of small
holes across the face to float the sheet. Periodically check the air blower system and inspect
the roll face to ensure the sheet is floating and not contacting the roll body. Clean and check
rotating screws for freeness.

WEB TENSION SECTION :

The web tension control is an essential feature in the production of quality reels and can be
various types, operating on air, hydraulics or electrical signals Here are some of the more
common types in use today
a)
Bleed hole system
b)
Electric load cell system
BLEED HOLE SYSTEM (Paper machine no.2) :
With the bleed hole system the sheet tension is controlled by the amount of back pressure
from the sensing holes mounted in the before Slitter Guard board; after some time the
sensing holes tend to block with debris from the sheet. Once a month check the air lines for
possible leaks and check for breaks in the nipples under the guard board and at the same
time clean the guard board bleed holes using the procedure as per instruction leaflet in
manual.
ELECTRIC LOAD CELL SYSTEM (Paper machine no. 1) :
The electric load cell is a maintenance free piece of equipment and does not normally
require inspection. Any error or malfunction usually requires special set-up and calibration
procedures. The only maintenance checks would be to check tightness of mounting bolts,
etc. of the load cells and paper rolls, and tightness of cable plugs in individual load cells.
WINDER MAINTENANCE :
All chains and sprockets on the winder should be inspected for wear once each month at
which time a coating of light mineral oil should be applied at all bearing points.
When ordering new chain specify to manufacturer that chains are being used as a pair and
should be supplied "matched length". Never replace just one chain.
The alignment of the rider roll and core shafts with the main drums is very important for
producing quality reels, once each month the rider roll and core shaft should be checked for
level with the winder drums.
On rider rolls with automatic rider roll programming, once per week check the alignment of
the cam and pressure regulator and check locking screws. Any movement of the cam on its
shaft can upset the relieving programme. A rider roll relieving system that is not operating
correctly can impair the roll structure dramatically and the faults in the reel can quite often
be observed. Defects such as telescoping, starring, negative tension band and loose
centres can be observed. It is, therefore, very important to maintain the relieving system in
first class order and to check the programme periodically. Always ensure the rider roll
chains are lubricated as dry chains can affect the nip loading. Check the operating cylinders
for free movement and correct piston sealing and ensure the lubricators are full and set
correctly. This should be done more frequently than other systems due to the cylinder size
and operating time cycle.

20

WINDER CONTROL SYSTEM

PNEUMATIC SYSTEM
All the cylinders should be checked for proper lubrication once each week Oil reservoirs
should be filled with S.A.E. No. 10 oil and the needle valve adjusted to allow 3 to 5 drops per
minute to enter into the system. Check for air leaks and damage to pipelines and flexible
hoses. Check the correct operator of the air cylinders and if seal leakage is suspected test
the cylinder with gauges in both lines and if faulty renew seals as quickly as possible.

HYDRAULIC SYSTEM :
The use of hydraulics is becoming more popular and to ensure trouble-free operation,
periodic checks should be made of the various components. Once every week check the oil
level in the tank. Check the condition of the oil and its temperature. Drain and flush the oil
tank every 6 months. Every week check the oil filters and replace when necessary. Check
the system for leaks and rectify as soon as possible. Leaking hydraulic units soon become a
dirty looking piece of equipment

21

ROLL WINDING PROBLEMS

Problems
SOFT STARTS
(LOOSE CORES)
Offsets
Dishing
Interweaving
Bursts
Wrinkles
Vibration
(Roll bounce)
Starring

Possible cause
Rider roll pressure too low. Tension application too late.Drum
differential load incorrect.
Insufficient tension, sticking slides, loose slides, fast
unwindoscillation, fast acceleration or deceleration, altering
tension in mid roll, mal functioning tension control system
Insufficient tension, improper rider roll relieving program,
widevariation of sheet caliper.
Insufficient tension, Incorrect adjustment of lD' bar spreader,
Loose or dull slitters, Bouncing roll on drums, misaligned rotating
components, wide variation of sheet caliper.
Too much rider roll load, too much tension, too large roll
diameterbuildup wide variation of sheet calliper
Insufficient tension, misaligned rolls, too much imbalance in drum
torque division.
Too much imbalance in drum torque, paper grade (bulky sheets),
outof round rolls (starts), mechanical imbalance in rider soil or
drums.
Improper rider roll (or nip) programming, too much sheet tensionat
outer diameters, too much sheet tension at outer diameters,
inoperative tension system, too little tension during build up,
operating tension on "manual" without relieving brake pressure
as roll builds up.

ROLL FORWARDING TO FINISHING HOUSE

After winding rolls are sent to finishing house for reel packing, labeling and weighing.

Physical Test for Paper

The following tests are carried out in paper testing lab after each reel taken out from paper
machine.

Newsprint IS Specification 11688 -1999

S. No.
1
2
3
4
5
6
7
8

Particulars
Basis weight
Thickness
Tear factor
Breaking length (MD)
Breaking length (CD)
Brightness
Opacity
Smoothness
Porosity

Unit
g/m2
Micron
Mtrs
Mtrs
%
%
Ml/min
Ml/min

IS Specifications
40-52
56-90 +-4 %
45.9
3570
1530
52
90
250/300
800

Basis weight:
Basis weight is the weight per unit area of the paper and boards. Basis weight affects all
physical properties. Uniformity in the weight is also important. Moisture variation affects
basis weight considerably. Basis weight is expressed in Grams per square meter (g/m2).
Thickness:
Measurement uses a thickness gauge with a paper sheet or a pad of sheets compressed
with a given pressure between two parallel plates. The preferred pressure is 100
kPa(ISO-534). Uniform thickness is very important for printing papers.
Thickness of paper is expressed in micron ()
Bulk :
Apparent density is the mass per unit volume of the paper calculated as the ratio between
basis weight and thickness. Bulk = 1/density i.e.Thickness in micron/Basis weight
expressed as cm3/g.
Moisture :
The moisture content of paper is dependent on the relative humidity of the air in contact
with it. Determination of moisture content of paper involves weighing a sample of paper
before and after drying at 105 + 2C in hot air oven.
Moisture is expressed in %.
Ash Content :
Determination of the ash content of paper involves igniting the sample at 900 0C or
preferably at 525 0 C if the filler consists of CaC03 that decomposes at higher temperature.
It is defined as the amount of residue of material left after incineration.
Ash is expressed in %.

Folding Endurance :
Folding endurance or folding strength is the ability of a strip of paper to resist breaking
when folded under a certain load. The folding strength is expressed directly as the number
of double folds that the paper can withstand. Folding strength relates to the tensile
strength, elasticity and elongation of the paper. Higher tensile strength and elongation of a
paper shows higher folding strength.
Folding strength indicates the effect of paper aging. It is important test in testing endurance
of banknote paper.
Folding endurance is the paper's capability of withstanding multiple folds before it breaks.
It is defined as the number of double folds that a strip of 15 mm wide 100 mm length can
withstand under a specified load before it breaks. It is important for printing grades
where the paper is subjected to multiple folds like in books, maps, or pamphlets.

BURSTING STRENGTH :
Bursting strength is defined as the hydrostatic pressure in kilopascals or pounds per
square inch psi, required to produce rupture of the material when the hydrostatic pressure
by a fluid is increased at a controlled constant rate of 95 5 mL / min (approximately 0.75
kg/ cm2) through rubber diaphragm to a circular area, 30.5 0.05 mm(1.20 inch diameter)
Formula -

Bursting Strength * 1000

Burst Factor = ---------------------------------------------------------------------------------------Basis Weight (g/m2)

TEARING STRENGTH :
ScopeThe method specifies a methodology for determination of the internal tearing resistance
of paper, i.e. the mean force required to continue the tearing of an initial cut in a single
sheet of paper. Tearing strength is the work done in continuing the tear through a fixed
distance 43 mm. Tear factor is 100 times the tearing resistance divided by the grammage
(basis weight) of the paper.
Principle:
An initial cut is made in single sheet of paper or an initial cuts are made in several sheets
(Normally four). Normally four sheets are torn through a fixed distance using a pendulum
to apply the tearing force. The work done in tearing the test piece is measured by the loss
in potential energy of the pendulum. The scale is calibrated to indicate the average
tearing force. The internal tearing resistance of the paper is determine for the average
tearing force and the number of sheets in the test piece.
Formula Reading in mN * 0.102 X100
Tear Factor = ---------------------------------------------------------------------------------------------Basis Weight (g/m2)

TENSILE STRENGTH:

Tensile strength is defined as the maximum force per unit width that a paper strip can
resist before breaking when applying the load in a direction parallel to the length of the
strip. In the tensile strength tester, the test piece is stretched to the point where rupture
occurs. The maximum tensile force the test piece can withstand before it breaks and the
corresponding elongation of the strip are measured and recorded.
Formula Reading in Kg * 1000
Tensile Strength = ------------------------------------------Basis Weight (g/m2)

Reading in Kg * 66666.6
Breaking Length = ---------------------------------------------
Basis Weight (g/m2)

Smoothness:
Smoothness is concerned with the surface contour of paper, it is the flatness of the
surface under testing conditions which considers roughness, liveliness, and
compressibility. In most of the uses of paper, the character of the surface is of great
importance. It is common to say that paper has a "smooth" or a "rough" texture. The
terms "finish" and "pattern" are frequently used in describing the contour or appearance
of paper surfaces. Smoothness in important for writing, where it affects the ease of travel
of the pen over the paper surface. Finish is important in bag paper as it is related to the
tendency of the bag to slide when stacked. Smoothness of the paper will often determine
whether or not it can be successfully printed;' Smoothness also gives eye appeal as a
rough paper is unattractive. Smoothness is measured as rate of flow of air across the
lateral surface of the paper.
Porosity:
Paper is composed of a randomly felted layer of fibre, it follows that the structure has a
varying degree of porosity. Thus, the ability of fluids, both liquid and gaseous, to
penetrate the structure of paper becomes a property that is both highly significant to the
use of paper. Paper is a highly porous material and contains as such as 70% air. Porosity
is a highly critical factor in Printing Papers Laminating Paper, Filter Paper, Cigarette
Paper, Bag Paper, Anti tarnish Paper and Label Paper. Porosity is the measurement of
the total connecting air voids, both vertical and horizontal, that exists in a sheet. Porosity
of sheet is an indication of absorptivity or the ability of the sheets to accept ink or water.
Porosity can also be a factor in a vacuum feeding operation on a printing press Porosity is
measured by the resistance of paper to passage of air under standard condition.
Formation :
Formation is defined as the small scale variation of the mass (Fibre) distribution within
the sheet. Scanner scan the field of view and report the result as non-uniformity index
(NUI).

Brightness:
Brightness is the percentage of blue light reflected of a sample measured at an effective
wavelength of 457nm. It is the measurement of reflectance factor of a test specimen to
blue light of specific and spectral and geometric characteristics. Reflectance factor
requires an instrument' employing 45 0 illumination and 00 viewing geometry (450 - 0 0
directional reflectance). Magnesium oxide is considered as 100 % Bright.

25

Opacity:
Opacity is the measure of how much light is kept away from passing through a sheet. A
perfectly opaque paper is the one that is absolutely impervious to the passage of all
visible light. It is the ratio of diffused reflectance and the reflectance of single sheet
backed by a black body. Opacity is important in Printing Papers, Book Papers, etc. The
opacity of paper is influenced by thickness, amount a n d kind of filler, degree of bleaching
and coating etc. Opacity is the ratio as percentage of single sheet luminous reflectance
factor to the intrinsic luminous reflectance factor of the pad of paper. Important in book
printing where both sides of paper are printed.
Opacity is expressed in - %.
Safety:
Only you can think safety either you're at home, at work or at play. The safe way either
work or play is the best way. Then you won't waste beautiful days recovering from an
injury that you could have prevented with just a little common sense.
Accidents - Especially some accidents have long lasting consequences. There's just too
much at stake to take chances.
Safety is very simply not having accidents. We must all train ourselves to look at
everything we do for the possibility of an accident. This accident potential is especially
present in the things that are usually overlooked.
The following elements are important for a job.
1. Awareness is always important.
2. Good housekeeping practices are necessary. Such common cases thinks as good
housekeeping practices are extremely important. Grease or oil spilled on the floor can be
beginning of the bad fault.
3. Use personal protective equipments. Using the protective equipments available to
reduce frequency and severity of held eye and foot injuries is again just a common sense
approach to safety. Hard hats, safety glasses and safety shoes have prevented many
injuries.
4. Proper use of tools and equipments are essential Tools and materials strewn around
make unsafe obstacle course. Tagging and lockout before maintenance work preventive
many reasons,
5. Wearing clothing must be suitable for the job. Use poorly fitted clothing can get caught
in machinery or tools and each an invitation to disaster.
6. Use of sign and color codes. Painting serves as a constant reminder to every one of
the potential hazards around moving machinery. Signs a n d color code painting are an
important part of any safety programs. Too many signs and too many color coding can be
fatiguing and distracting.
7. Entering stock chest, storage tanks or large vessels of any kind presents special
hazard. Such vessels/chest should never be entered without properly venting or
ventilating the vessel/chest before any one enters. Uses an air pack to provide a supply
of good air - you don't get at second chance.
8. Maintenance work inside of dryers presents some special problems. Wnen a man is
working inside a dryer, he should always have a buddy that stays immediately outside the
dryers and does not leave for any reason
9. It is also recognize that guarding every point where a person can possibly injured
without making the machine inoperable presents all of us with serious problems.

Paper making machineries is large and heavy. Moving components of that machinery
requires a little more than the usual amount of care. Equipments to lift these chains or
ropes used to make a lift should be inspected before each lift to be certain they are
26

completely reliable. If the lifting job at hand is close to the rated capacity of the
equipment, the crane or hoist should also be carefully inspected before making the lift.
People working on unfamiliar equipments or in strange surroundings are always the most
vulnerable to accident. They should be instructed in safe working practices and potential
hazardous before they start the work. People that have been in the job for some time
should take a few minutes to look at their activities to be sure they have not developed
unsafe habits.

------------ X -------------

Manager
(Paper Machine)

27