Internship Report PM6-LINE

Internship Report
Abd u Slam (CIIT/SP08-BEC-003/LHR)
Internship Report of Packages Limited
PM-6 LINE
(OCC-PLANT, CTMP PLANT, Chemical Section and PM-6)
Submitted By
Mr. Abd u Slam (Student of CIIT Lahore)
Supervised By
Dr. Baber Ali (PM-6 Line Manager)

Engr. Khalid Mahmood (PM-6 Manager)
Engr. Adnan Yousaf (Manager OCC & CTMP)
Engr. Saqib Arif (Shift Executive PM-6)
Engr. Qaiser Iqbal (Chemical Section)
From
1st July, 2010
To
5th August, 2010
COMSATS Institute of Information Technology, Lahore. 1

Internship Report
Acknowledgement
ountless thanks to ALLAH Almighty for giving me such extraordinary

abilities and making me privileged enough to take part in such activities and all
respects and regards to Holy Prophet Hazrat Muhammad (PBUH) for giving
me the faith paving me on the right path with the essence of faith in ALLAH.
I would like to express my heartiest gratitude to:
Rana Javed Bahir, Mill Manager (BSPM), Packages Limited.

Dr. Baber Ali, PM-6 Line Manager, Packages Limited.
Engr. Khalid Mahmood, PM-6 Manager, Packages Limited.
Engr. Adnan Yousaf, Manager OCC and CTMP Plant, Packages Limited.
Engr.M. Waseem, Development Engineer PM-6, Packages Limited.
Engr. Qaiser Iqbal, Process Engineer Chemical Section, Packages Limited.
Engr. Sharjil Naushad, Shift Executive PM-6, Packages Limited.
Engr. M. Ammar Malik, Shift Executive PM-6, Packages Limited.
M. Khalil (APS-OCC), Packages Limited.
I would also like to thank my Supervisor Dr. Baber Ali, Engr. Khalid Mahmood
and Engr. Saqib Arif for their cooperation and help. They fully supported me
throughout my work. I express my heartiest gratitude to them. Their cooperation
made this project a lot much easier.
Bundle of thanks to my parents, who were and are very supportive and cooperative
at every time and always there by my side to guide me and gave me the courage
that I can do the best in my life and taught me the differ between the good and the
evil, for this be my guide in my life.

Internship Report
CONTENTS
Page No.
Acknowledgement …………………………………………………………………..02
Contents ……………………………………………………………………………..03
Executive Summary …………………………………………………………………04
Introduction ………………………………………………………………………….05
History of Paper ……………………………………………………………………..06
Producing Paper Today ……………………………………………………………...07
Making Pulp from Wood …………………………………………………....08
Making Pulp from Waste ……………………………………………………10
Manufacturing Paper from Pulp …………………………………………….11
Full Paper Making Process ………………………………………………………….13
Paper Making Machine ……………………………………………………………...17
Paper Manufacturing in Pakistan ……………………………………………………19
Paper Manufacturing in Packages Limited (Pakistan) ………………………………24
Company Profile and History ……………………………………………….24
Products ……………………………………………………………………...26
BULLEH SHAH PAPER MILLS …………………………………………………...28
The Bulleh Shah Project ……………………………………………………..28
Paper and Board Manufacturing in BSPM …………………………………..29
OCC-PLANT ………………………………………………………………………...29
Raw Materials of OCC-PLANT ……………………………………………..29
Stages in OCC-PLANT ………………………………………………………29
Block Diagrams ……………………………………………………………....30
CTMP-PLANT ……………………………………………………………………….33
Raw Material of CTMP-PLANT ……………………………………………..33
Stages in CTMP-PLANT ……………………………………………………..33
Block Diagram ………………………………………………………………..33
Chemical Section ……………………………………………………………………..34
Pulp Section Chemicals ………………………………………………………34
Types of Chemicals …………………………………………………………..35
Paper Manufacturing Process at PM-6 Line ………………………………………….36
Block Diagrams of Approach Flow System of PM-6 Line .………….............36
Block Diagram of Broke System of PM-6 ……...……………………………37
Block Diagram of Paper Manufacturing Process at PM-6 …... ………………37
Stages in Paper Manufacturing Process at PM-6…… ………………………..38
Conclusions and Problems ……………………………………………………………42
Recommendations …………………………………………………………………….42
References …………………………………………………………………………….42

Internship Report
Executive Summary
y learning Experience with Packages Limited begins with my joining from 01-
07-2010 which has completed now. My internship report contains all the
information about my work experience with the Packages Limited, which was
established in 1956 as a joint venture between the Ali Group of Pakistan and
Akerlund & Rausing of Sweden to convert paper and paperboard into packaging
for the consumer industry and commissioned its own paper mill with a production
capacity of 24,000 tones in 1968. With growing demand the capacity was
increased periodically and in 2003 was nearly 100,000 tones per year and
production capacity is increasing day by day.
As a Internee I spent good time in learning and was rewarded for my best
efforts, learnt to deal with different situations, had experience of industry’s
working environment which effects an engineer performance and attitude towards
work and had good time in learning and performing as a trainee engineer in the
PM-6 but also experienced the turbulence of the trouble times while PM-6 was
going through one of its major transition phase.
Confidence, on time decision making, consistency, hard work, team work,

seeking success out of dark, innovation, creativity, problems handling or solving
techniques and customer handling techniques are the key learning’s out of my job
and I would like to say it will be one of my best skill that would remain with me
and help me in the coming life which offer many challenges.
In short I would like to highlight this, that my working experience with

Packages Limited was very memorable and full of learning, where I found a lot of
positive changes in my life, attitude, behavior learning and problem solving skills
and behavior.

Internship Report
-Introduction:
The Paper Industry plays a very prominent role in the world economy. The Industry is
largely based on a raw material that is derived from forest crops with harvest rotations
that can approach 100 years in length. The sheer volume of timber required for the
industry's production processes is staggering. Since timber is their largest single
production cost, paper firms historically have devoted enormous amounts of capital to the
ownership and management of secure timber resources.
Especially since the end of World War II, the Paper Industry has experienced a massive
wave of technological change that has transformed its basic operating and process
management and control systems. Where earlier production processes relied on the craft
knowledge of skilled operators and superintendents, newer production processes
incorporate sophisticated sensors, information systems, and software-based process
controls. This shift, which began in the 1970s, has had far-reaching effects on the
industry's fundamental operations. Today, new paper machines are nearly 40 feet wide,
hundreds of feet long, and over two stories high. The Industry's capital-intensive pulping
and papermaking facilities, which can cost up to 1.5 billion dollars, are designed as high
tech computer-based operating systems with paper machines that run at speeds exceeding
60 miles per hour with production outputs of up to 500,000 tons per year.
This significant technological advancement in the Paper Industry has required

investments of hundreds of billions of dollars. In fact, the annual capital investment in the
US Paper Industry has ranged from 8 to 15 billion dollars per year over the last two
decades. This has required firms to develop and manage increasingly complex
relationships with external and internal suppliers of ever more complex production
equipment (including software controls). Automated process control systems also have
introduced far-reaching changes into the types of skills needed by production crews,
requiring firms to make substantial investments in the training of hourly workers and
supervisors, growing numbers of process engineers, and new organizational systems for
operations management.

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-History of Paper:
Papyrus paper is the first paper in history. Found in the tombs and
temples of Ancient Egyptians as far back as 2700 B.C. It was made by
Ancient Egyptians from papyrus plant. The amazing part about
papyrus paper is that it's very strong, durable, and elastic and is made
naturally. The process of making this paper was rediscovered just
about 15 years ago. These pictures are 100% hand painted by artists in
Egypt today on papyrus paper; a reflection of the great civilization of
Ancient Egypt.
New evidence shows that the Chinese used old chopped-up fishing
nets to make the world's very first paper. Three hundred years later,
around 100 A.D., a Chinese scholar and government official named
Ts'ai Lun made paper out of tree bark and scraps of linen and hemp.
Even though archaeological evidence shows that paper may have been
made even a little earlier, Ts'ai Lun was the first to have his efforts
recorded. Like many inventors through the centuries, he built upon the
work of others. Because he documented his invention, Ts'ai Lun is
generally known as the man who "invented" paper.
The art of papermaking was kept a secret in China for centuries. It was not until 793 A.D.
that paper was made outside the Orient. The process slowly spread through Africa and
Europe in the 10th century, and finally reached England around 1494, two years after
Columbus sailed to America.
Finally, in 1690 the first U.S. paper mill was built at Germantown,
Pennsylvania by William Rittenhouse. The Rittenhouse mill made
about 100 pounds of paper per day. At this time, paper was made by
hand from old cotton and linen rags, which was a very slow and
labor-intensive process. As the demand for paper grew, it became
harder and harder to find enough old rags to meet the demand. It
wasn't until the late 1860s that Americans first began making paper
from wood. The table shows the dates of the earliest mills in various
countries:
Year (AD) Year (AD)

Spain (Xativa) 1150 Holland (Gennep) 1428
France (Herault) 1189 UK (Hertfordshire) 1488
Italy (Fabriano) 1260 Sweden (Motala) 1532
Germany (Nuremberg) 1389 Denmark 1540
Switzerland (Marry) 1400 Russia (Moscow) 1690
Belgium 1407 USA (Germanstown, Pa.) 1690

Internship Report
-Producing Paper Today:
Paper is made from pulp. However, this pulp can be made in a couple of different ways.
9 Making Pulp from Wood

9 Making Pulp from Waste
9 Manufacturing Paper from Pulp
Over 80 million tons of world wide paper is produced in the United States each year,
making it the highest paper manufacturer in the world.
More than 5,000 products are made from paper and papermaking by-products. In the U.S,
most paper is made from trees because wood is a renewable resource which is wisely
managed by U.S. timber companies. Paper products are categorized into five main
categories:
9 Newsprint and magazine papers

9 Printing and writing papers
9 Sanitary and household
9 Paper-based packaging materials and products
9 Other - Specialized paper

Internship Report
-Making Pulp from Wood:
Wood pulp currently represents 44% on average of the fiber used to manufacture paper
and board worldwide, of which 11% is home produced. None of these mills uses mature
fully grown trees, but rather small dimension timber, (which is no use to other
commercial users such as furniture makers and builders), saw mill waste and forest
thinning.
In the past the industry used softwoods such as spruce, pine, fir, larch and cedar almost
exclusively, but hardwoods such as birch and aspen are gaining in popularity. Fast
growing eucalyptuses have been successfully cultivated in Northern Spain, Portugal and
Brazil and provide the papermaker with very high quality pulp. Softwoods provide long
strong cellulose fibers and are used to produce papers where strength is a requirement, for
example, packaging papers. The shorter hardwood fibers provide bulk, smoothness and
opacity and are used to produce fluting medium and printings and writings.
Trees vary enormously in the time they take to reach full size. Much depends on climate
and the soil, but these figures give a rough comparison:
Tree Type Life Expectancy (years)

Willow 25 - 35 years
Sitka spruce 50 years
Douglas fir 55 - 60 years
Scots pine 70 - 80 years
Norway spruce 70 - 75 years
Oak >100 years (not used for papermaking)
When a tree trunk or thick branch is cut across, a series of dark rings can be seen. These
are annual rings which result for the seasonal growth. Each ring represents one year's
growth. The grain in timber is caused by the annual rings which show when a log is cut.
Teak, mahogany, oak, beech and elm have attractive grain and are used for furniture
making (rather than papermaking).
Wood pulp comes from trees from managed forests where more trees are planted than
harvested to ensure that demand for timber products will never outstrip supply. The forest
industry has become more aware over recent years that it has a responsibility, not only to
ensure the economic viability of its operations, but also to ensure that the requirements of
local communities are catered for. Greater care is taken to ensure that logged areas blend
in more readily with the landscape.
Certain pulp characteristics depend on the process used to reduce the wood to its
component fibers. There are three main ones:
9 Mechanical or ground wood

9 Chemical
9 Combination

Internship Report
-Mechanical Pulp:
This is a very cost effective but energy intensive process. Because the entire log apart
from the bark is used. The log is put through a grinding or refining process to separate the
fibers. Chemicals are not used, but there is a high energy use which can only partly be
offset by using the bark as fuel. Mechanical pulp retains all the natural tree substances -
sap, sulphur compounds, sugar and a lignin which binds the fibers together. Because
lignin reacts with ultra violet light, papers made from mechanical pulp tend to 'yellow'
when exposed to light. Mechanical pulps are used to manufacture newsprint and some
packaging boards.
-Chemical Pulp:
Most chemical wood pulp is made by the sulphite process. Chips from de-barked logs are
dissolved in caustic soda and sulphur by heat and pressure leaving a strong brown pulp,
colored by the effect of the chemicals on the lignin and wood sap. The pulp is commonly
known as Kraft - the German word for strong. About 20% of chemical pulp is made by
the sulphite process. Chemical pulping uses less energy than mechanical pulping. In
modern mills, recovery boiler operations and the controlled burning of bark and other
residues make the chemical pulp mill a net energy producer which can often supply
power to the grid, or steam to local domestic heating plants.
Chemical pulp, however, produces a strong liquid effluent that needs to be treated. The
term "wood free" is often used in the trade to signify that the chemical pulping process
has been used. It is not meant to be misleading and has been used for decades to mean
"free from mechanical wood" (or "ground wood free").
-Combination Pulp:
Thermo-Mechanical-Pulp (TMP) and Chemi-Thermo-Mechanical-Pulp (CTMP) are a

combination of the mechanical and chemical processes. De-barked logs are chipped in
both, and then heated to extreme temperatures to soften them before passing through
grindstones for mechanical reduction to fibers. The difference is that chemicals are
sprayed onto the chips in the CTMP process to reduce the undesirable effects of the
retained natural wood substances. The main disadvantage of this form of pulping is the
high energy demand.
The consumer often requires high quality papers which retain strength, do not discolour
during storage or go yellow when exposed to light. One of the most effective ways of
achieving all three is bleaching which has the added advantages of improving absorption
capacity and getting rid of small residues of bark or wood, as well as giving a high level
of purity, particularly important when the paper is being used for hygiene, medical or
certain food packaging purposes.

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For many years chlorine was used because of its efficiency. In recent years however it
has been discovered that alternative bleaches such as chlorine dioxide or oxygen have a
lower impact on the environment and they are now increasingly being used throughout
the industry.
-Making Pulp from Waste:
The global use of waste paper in the production of paper and board is increasing. It
reached about 85 million tones in 1990. A further increase in the utilization of recycled
paper is anticipated.
As forests in the UK account for only 10% of the total land area compared with 25% to
80% elsewhere in Europe, waste paper has been the backbone of the UK paper industry
for many years. It is seen as an essential resource and at present represents 55% of the
fiber used by the UK paper and board industry.
Recycling paper however does not, as many believe, create a perfect cycle allowing paper
to be made, used and then made again. For instance there are limits to paper recovery.
Paper is lost from the cycle when used for permanent applications like record keeping,
destroyed in use or contaminated. Cellulose fibers cannot be recycled indefinitely. Virgin
fibers need to be continuously added to the cycle to replace exhausted fibers as this
diagram shows.
Utilizing waste paper nevertheless makes sound

economic and environmental sense, particularly if
the only alternative is to send paper to landfill.
Recycling however should not be seen as a
panacea for the environment. It too is an industrial
process with environmental implications which,
like all industry, waste paper mills have to
endeavor to minimize.
The recovery of waste paper begins with its

collection. It then has to be sorted by hand into
some 10 different groups of paper, all suitable for
different tasks. It is obviously much more
efficient if paper can be separated at source and
this in fact is what the public is doing by
depositing their newspapers and magazines in
special supermarket skips. Office paper recycling
schemes are becoming more common and
separate bins are installed so that the 'non-
recyclables', such as envelopes and fax papers,
can be separated from the valuable office grades.

Internship Report
Much of the paper sent to the mill will contain contraries and must be processed to
remove all unwanted materials (such as pins, staples, and adhesive tape) the paper will
have to be cleaned and contaminates disposed of. Depending on the final intended use,
inks will be dispersed or removed by de-inking.
Uses for the contraries or 'sludge' are being developed by waste paper using mills; some
use de-inked sludge to generate energy, others are developing uses such as composting
and brick-making thus reducing disposal to landfill.
-Manufacturing of Paper from Pulp
If you tear a piece of paper you will see a number of minute 'whiskers' sticking out from
the line of the tear. These are the fibers, they are very small in size (not much more than a
millimeter in length) and there are millions of them in any piece of paper. Paper is made
from cellulose, trees being the main source of cellulose fiber (or wood pulp). Besides
wood pulp, paper can be made from other materials such as cotton, flax, esparto, straw,
hemp, manila and jute. Some of the pulp properties depend upon the process used to
separate the fibers from the timber. The main processes are called mechanical and
chemical.

Internship Report
If the pulp mill is close to the paper mill, i.e. it is part of an integrated mill; the liquid
pulp is pumped direct to the paper mill. Otherwise, after straining, the pulp is dried and
packed into bales. The trees used in papermaking are mainly grown in Scandinavia,
North America and Canada. They are cone-bearing for example, spruce, pine or fir
(softwoods), and leaf-bearing trees such as birch, beech or eucalyptus (hardwoods).
Waste paper is a very important source of fiber for the papermaking industry. It is called
secondary fiber to distinguish it from the fiber obtained directly from wood (sometimes
called primary fiber). Before waste paper can be turned into pulp it must be collected,
sorted, graded and baled. It is then transported to the mills where further processes are
carried out to remove unsuitable materials (contraries) e.g. Paperclips, staples and plastic.
It is then broken down into pulp and sometimes printing ink is removed from the slurry
(see de-inking).
The wire can travel at speeds of up to 2000m/minute. By the time it reaches the end of
this section the fibers have become a sheet of paper, though very moist and having little
strength. It then passes to the press section. This consists of a number of sets of heavy
rollers through which the moist paper is conveyed, on thick felts. Even at this stage the
paper 'web' is still weak and moist.
It then passes to the dry end which consists of a large number of steam heated drying
cylinders, up to 100 or more on large paper machines. Part of the way down the bank of
drying cylinders is the size press. It is here that a solution of water and starch can be
added to the sheet in order to further improve the surface. Beyond the drying cylinders
comes the calender, which consists of a stack of polished iron rollers mounted one on top
of the other. Its function is to polish or glaze the surface of the paper as it passes between
the rollers.
Still traveling at up to 2000m/minute the paper now comes off the machine ready for
winding into large reels, each of which may contain up to 20 tones of paper. These reels
are later either cut into sheets or slit into smaller reels according to the type of paper and
the customer's requirements.
A separate process is the coating of the paper with china clay and then polishing it
through the calender. This makes 'art' paper, the glossy kind used for pictures. There are 3
main kinds of modern coating processes; blade coating, air knife coating and roll coating.
Blade coating is often done `off' the paper machine, as is air knife coating. But roll
coating is done 'on' the paper machine and can either be a complete coating or a first coat
followed by 'off-machine' coating by the blade or air knife process.

Internship Report
-Full paper making process:
9 Timber
9 De-Barker
9 Chipping Machine
9 Chemical Pulping Process
9 Mechanical Pulping Process
9 Hydrapulper
9 Blend Chest
9 Waste Paper
9 De-inking
9 Refining
9 Screening and Cleaning
9 Papermaking Machine
9 Conversion and Printing

Internship Report
-Timber:
Timber used for papermaking comes from well managed forests where more trees are
planted than harvested to ensure sustainable growth. Papermakers usually use only the
parts of the tree that other commercial industries don't want - such as saw mill waste and
forest thinning.
-De-Barker:
Bark is stripped from the logs by knife, drum, abrasion, or hydraulic barker. The stripped
bark is then used for fuel or as soil enrichment.
-Chipping Machine:
Stripped logs are chipped into small pieces by knives mounted in massive steel wheels
(used in chemical pulping process). The chips pass through vibrating screens, whereby
undersized chips, dust etc and oversized chips are rejected. Accepted chips are then
stored in huge bins ready for the next process.
-Chemical Pulping Process:
Chips from the storage bins are fed into a digester to which chemicals have been added.
The woodchips are then 'cooked' to remove lignin. Lignin is the binding material which
holds the cellulose fibers together. The chips are 'cooked' by heat and pressure in caustic
soda and sulphur. The chemical process is energy self-sufficient as nearly all by-products
can be used to fire the pulp mill power plant. The chemical pulping process produces
lower fiber yield than mechanical pulping, typically 50-60%.
-Mechanical Pulping Process:
Mechanical pulp yields over 90% of the wood as fiber is produced by forcing debarked
logs, about two meters long, and hot water between enormous rotating steel discs with
teeth that literally tear the wood apart. Alternatively, logs can be pressed against
grindstones and therefore this process is also known as ground wood pulp.
Trees contain up to 30% lignin, a material which is sensitive to light and degrades, and
turns brown in sunlight, which explains why papers made from mechanical pulp will
discolor. An example of this is newsprint. Newsprint is designed to have a short life span,
and if left for a long period of time will lose its whiteness and strength. The special
advantages of mechanical pulp are that it makes the paper opaque and bulky.

Internship Report
-Hydrapulper:
When the bales of wood pulp or waste paper arrive at the paper
mill they are loaded onto a conveyor and passed into a circular
tank containing water. This has a very powerful agitator at the
bottom which breaks up the bales into small pieces. The pulp
mass created begins to look like thick porridge. This machine
is known as a Hydrapulper. It operates automatically and when
the disintegrating process is complete it discharges the pulp
into large storage tanks.Hydrapulpers used mainly for handling
waste paper are fitted with special devices for removing
unwanted contraries such as wire, plastic, paper clips, staples
etc.
-Blend Chest:
The stock passes to a blend chest where numerous chemicals

can be added to obtain the required characteristics to the
finished paper. Dyes are also added, as necessary, to color the
paper. Dyes fix themselves to the cellulose fibers and are fast
to light and water. Each grade of paper and board requires a
very accurate blend of pulps and additives and the properties
of the paper are continually monitored by computers during
manufacture.
-Waste Paper:
Waste paper is collected from Waste Paper Banks and Commercial collections. When
you deposit your used papers into a waste paper bank, you are sorting the paper into
grades before the merchant collects it. This is why you can only put certain papers into a
particular bank. Many offices have in place an office recycling scheme. Again the waste
paper is usually segregated ready to be collected. Waste paper currently represents 67%
of the raw material used in the UK to make paper and board. The waste paper merchant
collects the used paper which is then sorted by hand into different grades. Paper not
suitable for recycling is removed. The waste paper merchant will then bale the waste
paper ready to be taken to the paper mill.
-De-inking:
Before printed paper, such as office waste and newspapers, can be recycled into high
quality paper products the ink needs to be removed, otherwise it will be dispersed into the
pulp and a dull grey paper will result. There are two main processes for de-inking waste
paper known as washing and flotation.

Internship Report
1. Washing
The waste paper is put into a pulper with a large quantity of water and broken down into
slurry. Contaminants or 'contraries' such as staples and plastic are removed by wire mesh
machines and a mechanical action. Most of the water containing dispersed ink is drained
off from the pulp through slots or screens that allow small particles through, but not the
pulp. Water can be added to rinse the fibers and drained to remove more of the ink.
Adhesive particles known as 'stickies' are removed by fine screening.
About 80% of the original fiber is recovered by this process (though it will depend on the
type of washing equipment being used) with the remaining 20% of ink, clay, filler,
plastics etc. left behind.
De-inking by washing has been used with great success on 'wood free' waste grades to
produce pulp for writing papers and tissue; and on old newspapers to produce a stock for
newsprint manufacture. It is more effective than the flotation process at removing smaller
ink particles.
2. Flotation
Again the waste paper is made into slurry and the contaminants are removed. Then
special surfactant chemicals are added which makes a sticky froth on the top of the pulp.
Air bubbles are blown through the pulp and these carry the ink to the surface. As the
bubbles reach the top foam layer is formed that traps the ink. The foam must be removed
before the bubbles break or the ink will go back into the pulp. Because the ink is removed
from the flotation machine in a concentrated form, the flotation system does not require a
large water treatment plant.
When the flotation method is used to de-ink old newspapers, around 30% used magazines
are usually added. The clay present in coated papers can improve de-inking efficiency as
the ink attaches itself to the clay particles before floating to the surface. The flotation
method is more able, than the washing method, to remove larger ink particles. Yields
from flotation de-inking are quoted as 90 - 95% but filler is not removed to the same
extent as in the washing process. Once the pulp has been de-inked it is ready to be made
into paper.
The most common performance measurements of the de-inking process are paper
brightness (measured by a brightness meter) and the number of ink specks on a sheet
surface (measured by visual inspection using a magnifying lens). However, the
mechanical properties of the paper, such as tear strength, also need to be determined.
Paper recycling is increasing, there are approximately 420 de-inking mills world-wide
(120 having been completed in the past 4 years).
Newsprint, writing and office papers, and tissue are made from de-inked recycled paper
and research is continuing to further improve the de-inking process.

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-Refining:
The cellulose fibers pass through a refining

process which is vital in the art of papermaking.
Before refining, the fibers are stiff, inflexible and
form few bonds. The stock is pumped through a
conical machine which consists of a series of
revolving discs. The violent abrasive and bruising
action has the effect of cutting, opening up and
declustering the fibers and making the ends
divide. This is called fibrillation. In this state, the
fibers are pliable and have greater surface area,
which significantly improves the fiber bonding.
The properties of the paper are directly related to
the refining process. Refining used to be called
beating.
-Screening and Cleaning:
Pulps contain undesirable fibrous and non-fibrous materials, which should be removed
before the pulp is made into paper or board. Cleaning involves removing small particles
of dirt and grit using rotating screens and centrifugal cleaners.
-Papermaking Machine:
STEAM
DRYER EXHAUST DRYER
FELT
COUCH FELT
APRON/
ROLL DRYER
SLICE
DRUM
DANDY
HEAD
ROLL
BOX HOOD
TABLE
ROLLS
DRY
PAPER
BREAST
ROLL
FOILS SUCTION
SUCTION
FORMING ROLLS
BOXES
WIRE
FOURDINIER WET DRYERS
(WET END) PRESSES (DRY END)

Internship Report
The Paper Machine is a very large piece of machinery. A typical machine is about the
length of two football pitches and around 4 meters wide. It can run up to speeds of
2000m/minute or 60miles/hour. The machine itself consists of 7 distinct sections. The
flow box, wire, press section, drier section, size press, calendar and reeling up.
The first section of the machine is called the 'Wet End'. This is where the diluted stock
first comes into contact with the paper machine. It is poured onto the machine by the flow
box which is a collecting box for the dilute paper stock. A narrow aperture running across
the width of the box allows the stock to flow onto the wire with the fibers distributed
evenly over the whole width of the paper machine.
The machine is operated by computer control. The computer will monitor the paper for
moisture content, weight etc and computer screens will show pictures of the process and
should any adjustments need to be made, an alarm will sound.
Machine Flow Box Control Room

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-Conversion and Printing:
Once the paper is made, a great deal of it is converted into a product. Converters
specialize in transforming reels and sheets of paper and board into a vast array of finished
products for distribution such as boxes, cartons and stationery. Converters sell their
products to the public or to other manufacturers.
Not all paper and board is processed by converters. Some papermakers do their own
converting, for example, the manufacturers of soft tissues market their own products and
sell directly to the public. The printing industry converts large quantities of paper and
board, much of which reaches the customer as newspapers, magazines or books.
Paper Manufacturing in Pakistan

History
9 History
9 Types of paper
9 Paper manufacturing
9 Paper making processes
9 Corrugated Packaging
9 Environmental Impact
9 Pakistan Paper Sector (Current Scenario)
9 Production and Cost of Production and Cost of Production
9 Imports of paper in Pakistan
-History:
Paper board manufacturing unit all demands were met through imports. The first paper
making industry in the sub-continent was set up in Delhi and Lahore in 1956. Lahore at
that time had a production capacity of 500 tons per annum. Due to ill planned growth;
many of the units were closed in the 80’s and 90’s.dfdhe 80’s and 90’s.
-Types of Paper:
9 Writing and printing paper

9 Corrugated Paper (Fluting)
9 Test Liner
9 Kraft and Water proof liner
9 White duplex coated
9 Uncoated board
9 Tissue paper
9 Chip board

Internship Report
-Paper manufacturing:
Raw materials are
9 65% local grass and wheat straw.

9 25% based on waste paper.
9 10% imported pulp.
9 Other raw materials include bagasse, rice straw and cotton waste.
-Paper making processes:

There are three main procedures for paper making.
9 Pulp manufacturing
9 Bleaching
9 Paper manufacturing
-Pulp manufacturing:
This includes a mild chemical pretreatment of wheat straw in slightly alkaline sodium
sulphite liquor at temperature ranging from 160 to 190 degree Celsius. After this cooked
pulp is washed thoroughly to get rid of the sodium sulphite.
-Bleaching:
The bleaching process is used to improve the pulp brightness. Chlorine, Sodium
Hypochlorite and Chlorine Dioxide are used as a bleaching agent.
-Paper manufacturing:
For the conversion of pulp into a continuous sheet of paper, the bleached blended pulp
together with the filling materials is passed over a wire with a series of presses and driers.
-Corrugated Packaging:
Corrugated packaging is a rigid sort of packaging that is used generally in our daily lives
named “CARTONS”.
-Environmental Impact:
Pulp and paper industry of Pakistan is considered to be one of the most polluting
industries because of Waste water, air emissions, and solid waste and other health risks.

Internship Report
-Pakistan Paper Sector:

There are about 100 units in the organized installed capacity of 650,000 tons per annum.
The organized sector comprises of 26 paper manufacturing units with 575,000 tons of
production capacity. About 70% of the units are located in Punjab, 20% in Sindh and
10% in NWFP.
Contribution to GDP 0.36%

Employment 100,000
Skilled unskilled labor ratio 30:70
Total Investment Rs. 30 billion
Per Capita Consumption 3.79 KG
Technology:
Low tech is 93%

Intermediate is 7%
High tech is ---
Source of machinery: Finland, Sweden, Italy, Germany and Korea
Local production as a %age of global production: 0.1%
-Cost of Production:
Cost of Production
Raw material
Labor
Fuel & Energy
Overheads

Internship Report
-Production of Paper in Pakistan:
Production of Paper in Pakistan
450
400
350
300
250
Production of Paper in
200 Pakistan(000 tonnes)
150
100
50
0
2002-03 2003-04 2004-05 2005-06
-Paper Imports of Pakistan:
Writing and Printing Paper 10,905 tons Rs. 481,622

Paper and Ordinary Board 25,412.23 tons Rs. 1,051,957
Duplex Board 83,119 tons Rs. 3,072,403
Wrapping and Packing
39,696 tons Rs. 1,282,416
Paper
News Print 95,221 tons Rs. 2,782,516
Specially 10,738 tons Rs. 1,417,262
Pulp 63,167 tons Rs. 2,385,892
-Percentage Imports of Paper in Pakistan:
Country 2001-02 2002-03 2003-04

USA 28.98 51.33 40.49
Canada 31.25 12.15 32.35
Indonesia - 0.95 -
Sweden 15.83 16.98 10.5
Russian Federation 0.26 - -
Others 23.68 18.59 16.66

Internship Report
Paper Machinary Imports
30,000
25,000
20,000
15,000
Machinery(Value in $000)
10,000
5,000
0
2000 2001 2002 2003 2004
Production of Paper Mills ( p.a )
Name of Mills Installed Capacity Production

Packages Limited 85,000 81,000
Century Paper & Board Mills Ltd. 85,000 79,000
Paramount Paper & Board Mills 45,000 3,770
Flying Board & Paper Product 30,000 21,763
Mandiali Paper & Board Industry 24,000 22,410
Taj International Ltd. 8,500 7,060
Olympia Paper & Board Mills 7,500 6,620

Pioneer Board Mills 6,000 5,500
Shamsi Paper & Board Mills 6,000 4,980
Rehman Classica (Pvt) Ltd. 5,000 4,120

Internship Report
Paper Manufacturing in Packages Limited (Pakistan)
-Company Profile and History:
Established in 1956 as a joint venture between the Ali Group of Pakistan and Akerlund
and Rausing of Sweden, Packages Limited provides premium packaging solutions for
exceptional value to individuals and businesses. We are the only packaging facility in
Pakistan offering a complete range of packaging solutions including offset printed
cartons, shipping containers and flexible packaging materials to individuals and
businesses world-wide. Our clientele includes illustrious names such as Unilever and
Pakistan Tobacco Company, who have been our customers for over 50 years. We employ
over 3000 people and had sales of over US $ 100 million in 2004.
Listed on all three stock exchanges in Pakistan, Packages Limited has maintained a long-
time credit rating of AA. Our joint ventures and business alliances with some of the
world's biggest names reflect our forward-looking strategy of continuously improving
customer value through improvements in productivity.
Packages has always been at the forefront of new developments in packaging research
and has pioneered several innovations, including the use of wheat straw as a raw material
for paper and board manufacture. Our on-site paper and board mill, established in 1968,
has constantly increased its production capacity. A new plant with even greater
capabilities is planned for the near future.
Since 1982, Packages Limited has had a joint venture with Tetra Pak International in
Tetra Pak Pakistan Limited to manufacture paperboard for liquid food packaging and to
market Tetra Pak packaging equipment.
Packages commissioned its own paper mill with a production capacity of 24,000 tones in
1968. The mill produces paper and paperboard based on waste paper and agricultural by-
products like wheat straw and river grass. With growing demand the capacity was
increased periodically and in 2003 was nearly 100,000 tones per year.
In 1993, a joint venture agreement was signed with Mitsubishi Corporation of Japan for
the manufacture of Polypropylene films at the Industrial Estate in Hattar, NWFP. This
project, called Tri-Pack Films Limited, commenced production in 1995 with equity
participation by Packages Limited, Mitsubishi Corporation, Altawfeek Company for
Investment Funds, Saudi Arabia and the public. Packages Limited owns 33% of Tri-Pack
Films Limited's equity.
In 1994, Coates Lorilleux Pakistan Limited, in which Packages limited, has 55%
ownership, commenced production and sale of printing inks.

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In 1996, a joint venture agreement was signed with Printcare (Ceylon) Limited for the
production of flexible packaging materials in Sri Lanka. Packages Lanka (Private)
Limited commenced production in 1998. Packages Limited now owns 79% of this
company.
In 1999-2000, Packages Limited successfully completed the expansion of the flexible

packaging line by installing a new rotogravure printing machine and expanded the carton
line by adding a new Lemanic rotogravure inline printing and cutting creasing machine.
A new 8-color Flexographic printing machine was also installed in the Flexible Business
Unit in 2001. Packages Limited has also started producing corrugated boxes from its
plant in Karachi from 2002.
In 2003, Packages entered into an agreement with Vimpex of Austria to provide

management and technical assistance to help in the operation, production optimization
and capacity expansion of a paperboard mill in Syria. A team from Packages is currently
providing these services and is close to optimizing mill production.
Over the years, Packages has continued to enhance its facilities to meet the growing
demand of packaging products.
PACKAGES LIMITED
TOTAL SALES 2005
FLEXIBLE LINE
CARTON LINE
30%
Rs 2,537 MILLION 21%
Rs 1,674 MILLION
TISSUE PAPER CORRUGATED LINE

12% 18%
Rs 953 MILLION PAPER & BOARD AND Rs 1,486 MILLION
PRE-PRESS
19%
Rs 1,513 MILLION
TOTAL SALES Rs 8,163 MILLION

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P A C K A G E S L IM I T E D
IN V E S T M E N T 1 9 9 4 -2 0 0 4
E NV IR O NM E N T
14%
C AP A C IT Y
T E C HN O L O G Y 52%
34%
T O T A L IN V E S T M E N T = U S $ 1 4 0 M
-Products:
9 Paper & Board
9 Carton Business Unit
9 Corruwal Business Unit
9 Flexible Business Unit
9 Consumer Products
-PAPER & BOARD:
Packages are producing high quality paper and board since

1965 using environment friendly manufacturing processes.
We specialize in making a variety of duplex boards and
paper. Our products are tested for high performance in
terms of strength, stiffness and gloss. From coffee cups to
the books we read, from Tetra Pak juice containers to huge
shipping containers, paper and board products touch our
lives in a thousand ways every day.
-Paper: Packages produce

9 high gloss writing paper
9 machine glazed / special poster paper
9 liner for shipping cartons
9 corrugating medium paper (Fluting)
9 wood-free writing/printing paper

Internship Report
Paper quality and weight is determined by the client's specific requirements and Packages
ensures this is carried out to the exact specifications provided. Paper is available in the
following weights:
Type of Paper Weight (g/m2)

Test liner 110-200
Corrugated medium Paper/Fluting 100-175
Wrapping Paper 70-90
High gloss writing paper 58-68
Poster Paper 40-90
-Board:
Packages manufacture several types of board. Food Board, a basic raw material in liquid
food packaging, is being manufactured since 1979 for Tetra Pak Pakistan Limited. This
material is used in making aseptic packaging for milk, cream, oil, fruit juices and other
perishable food items. Some board products are:
9 liquid packaging board

9 food grade board
9 duplex board / chipboard
9 bleached board
9 tobacco board and cardboard
9 liner board
Board is available in the following weights:
Type of White Board Weight (g/m2)

Bleached Board 195 - 205
Duplex Board 150 - 450
Cardboard 160 - 250
Liquid Packaging Board 150 - 290

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BULLEH SHAH PAPER MILLS
The Bulleh Shah Project: In 2005, Packages Limited started a new pulp and paper mill
project in Kasur located 50 km south of Lahore. The greenfield site spread on 42 hectares
is known as Bulleh Shah Paper Mill coined after a famous Pakistani poet from this
region.
B U L L E H S H A H P A P E R M IL L S P R O JE C T
O V E R A L L O B JE C T IV E
T o I n c r e a s e o u r P r o d u c t io n C a p a c it y t o M e e t F u t u r e
M a rk e t D e m a n d
W h it e : 1 0 0 ,0 0 to n s / a n n u m
B ro w n : 8 7 ,0 0 0 to n s / a n n u m
W r itin g / P r in t in g P a p e r : 1 1 5 ,0 0 0 t o n s / a n n u m
T o t a l – 3 0 2 ,0 0 0 T o n s / A n n u m
E s tim a te d T o ta l P r o je c t C o s t U S D 2 5 0 M
The greenfield site comprises of two modern paper machines PM6 and PM7 that will
enable us to increase our paper and paperboard production from 100,000 to 300,000 tones
per year. PM6 already in operation since 2007 manufactures container board.
PM-6 LINE

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Paper and Board Manufacturing in BSPM
O C C -P L A N T C T M P -P L A N T
P A P ER & B O A R D
P M -6 / P M -7
C H E M IC A L S
-OCC-PLANT:
OCC (Old Corrugated Container) is a plant in which pulp is produced from waste paper
and board.
-Raw Materials of OCC-PLANT:

9 Virgin Fiber
9 Imported Wood Pulp
9 UBKP ( Un-Bleached Kraft Pulp )
9 BKP ( Bleached Kraft Pulp )
9 OCC-Imported
9 OCC-Local
9 Tetra Trim
9 Newspaper
-Stages in OCC-PLANT:
There are six stages in OCC-PLANT
1. Slushing
2. Coarse Screening
3. Centri Cleaning
4. Fine Screening
5. Thickening
6. Reject Handling

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Slushing
Accept from Drum Screen Drum
Screen
Accept from Poir Screen Reject
Chute Drain
Accept Detreasing Accept Poir Screen
M (Contaminax) 6mm
Pulper Feed Conveyor
Pulper Reject Contaiminax
Junk Trap Drain
Pulper Screen
Accept from both Rufclone (Pulp)
Accept
Pulper
Pump
M Gear Box HD Cleaner No.1 HD Cleaner No.2

(Rufclone) (Rufclone) Dump Tank
A A
B B
Reject Drain from both Rufclone ( To Mill Effluent Collection)
Coarse Screening
Prim ary Coarse Prim ary Coarse Accept

Dump Tank Pum p Screen Feed Pum p Screen
Chest (2 mm )
Reject
Reject Secondary Coarse Accept

Reject Handling Coarse Screen
Screen Coarse Screen HD
Tank ( DAF ) Accept Chest
(2 mm ) Cleaner
Reject
Accept from Secondary Coarse Screen

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Centri Cleaning
Accept from Primary Cleaner Accept from Secondary Cleaner Accept from Tertiary Cleaner
Accept from Quaternary Cleaner

Coarse Screen
Accept Chest Pump Primary Cleaner Secondary Cleaner Tertiary Cleaner
Reject Reject Reject
Quaternary Cleaner
Primary Fine
Primary Cleaner
Screen Stand
Accepts
Pipe
Reject
To Reject Tank ( DAF )
Fine Screening
Accept Short Fiber
Disc Filter
Primary Fine
Primary Fine
Screen Stand Pump Screen
Pipe Light Reject Light W eight
Cleaner
Heavy
Reject
Accept Long Fiber
Disc Filter
Accept Secondary Fine
Screen
Light Reject Reject Tank
(DAF)
Heavy
Reject Reject
Reject Tank (DAF)
Pulp Fine Screens Dewatering Cloudy Chest
Rejects Thickener W ater Remove (W ater)
Tertiary Fine
Screen
Tertiary Fine
Pulp Hydraflaker Feed Accept Screen Feed
Pump Hydraflaker Pump
Chest Chest
Tertiary Fine Screen Feed Pump

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Thickening
Primary Fine OCC Short Fraction from Disc Filter Shower

Screen Accept Motor
Chest Main Short Fiber MC
Drive Pulp Standpipe
Screw
Motor
Water Water
Pump
Cloudy Filtrate Chest Clear Filtrate Chest
Shower
Secondary Fine OCC Long Fraction from Disc Filter Motor Short Fiber OCC
Screen Accept HD Storage Tank
Chest Main (500 m3)
Drive Pulp
Screw
Motor
Water Water Long Fiber MC

Standpipe
Cloudy Filtrate Chest Clear Filtrate Chest
Long Fiber OCC

HD Storage Tank Pump
(500 m3)
Reject Handling
Reject Tank Turbo Washer Accept Secondary Coarse

Pump 2mm Screen
(DAF)
Impellers Accept Chest
Reject
Accept
KUFFRATH (DAF)
THICKENER Pulp + Water Feed Tank
Reject
Dewatering
Cloudy Chest
By Press
Or KUFFRATH
Back Water PRESS Reject Drain
Tank Water
Loading of Reject

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-CTMP-PLANT:
CTMP (Chemi-Thermo Mechanical Pulp) is a plant in which pulp is produced from the
straw with the help of combination of the mechanical operations and chemical processes.
CTMP is a branch of mechanical pulp. Yield of pulp is about 80%.
-Raw Material: Straw is used as a raw material
-Stages in CTMP-PLANT:
9 Dry Cleaning
9 Wet Cleaning
9 Dewatering
9 Cooking
9 Defiberlisation
9 Washing
9 Refining
9 Screening
9 Disc Filter
9 Storage
Dust to Bag Filter CTMP-PLANT Block Diagram
Overflow
Straw Dry Cleaning Unit Feed Hydropulper
Accept Dry Silo Mixing Tank
Belt
Store Straw+Water (Agitator)
M M
Heavy Reject
Drain
Steam Caustic Pump
Digesting Pin Drum

Defiberator Lignin Tubes (Calculated Pressed Straw By Pass
Screw Drainer
(Fiber Separate) Softening P=6.5 bar Amount of Bin Screw
Removing Tr=38 mint Straw transfer)
Reject from Screen Water

Drain
Twin Roll Press Water

Refiner Remove Final Chest
Screen Accept Disc Filter
(Fibrillation Storage
0.3mm (Thickening)
Operation) Lignin Tank
Liquor Remove Remove

Internship Report
-Chemicals Section:
Different chemicals are used in paper manufacturing process.
-Pulp Section Chemicals:
Sizing chemicals are used in pulp section.
Objectives are
9 To control cobb value

9 To improve printing ability
9 To control of ink absorption rate
Chemical Name Form Nature PH

High Phase Size Liquid Acidic 2Æ3
Top Sizer Liquid Basic 10
Dipole L125 Liquid Basic 10
Delta Size Paste Basic 10
Rosin Paste Acidic & Alkaline 3 Æ 3.5 & 10 Æ 11
FFSOREZE Solid( Powder) Basic 11
-Alum: Alum is used

9 To control the PH of Pulp (Decrease).
9 To Increase the effects of sizing chemicals.
9 To Increase the dryness of paper and used as retentionate.
9 To decrease the penetration of water.
-Starch: Starch is used

9 To control the bursting strength of paper because starch has adhesive nature.
9 Cationic starch is used in wet pulp and act as retentionate.
9 TB starch is used in size press for paper coating which increases the value of SET
and bursting index and also increases the smoothness of paper.
9 The use of starch at the wet end of the paper machine improves paper strength.
Unmodified starch has a neutral charge and is still being used via pulper addition
or by "starch spraying." Cationic starches ranging from D.S. about 0.010 to 0.040
with electrical affinity to cellulose fibers and fillers are the wet end product of
choice as it improves retention.

Internship Report
-Dyes:
Dyes are used for shading of paper and depend on the customer requirement. Dyes are
introduces in machine/blend chest and also increase printing ability. For white & printing
paper “Violet Dye” is used.
Example: Indosole brown, Bismark brown and Carta brown
-OBA (Optical Brightness Agent):

9 OBA used in white paper.
9 OBA controls the brightness and whiteness of paper.
9 Board Æ 75% OBA
9 Printing Paper Æ90% to 100% OBA and standard OBA is >94%
-Fillers:
9 Fillers are used as filling agent (To fill the very small pores of paper).
9 Increase the weight of paper.
9 Increase whiteness, smoothness and brightness of paper.
9 Increase the opacity of paper.
-Polymers:
9 Polymers are long chain molecules.
9 Polymers used as retentionate.
9 Polymers increase the head box consistency and reduce wire water consistency.
9 Retain the pulp (very fine fibers).
-Bio sides:
9 Bio-Sides are used to control the growth of bacteria and slime.

9 Bio-Sides are used as anti-scaling agent (to control scaling).
-Sulphuric Acid:
9 Sulphuric acid is used to control the PH of pulp.
Anti-Foamers:
9 Anti-foamers are used to reduce foam particles formation in white water.

Internship Report
Paper Manufacturing Process at PM-6 Line

Approach Flow System of PM-6 Line
Short Fiber Long Fiber

HD Storage HD Storage
Tank Tank
Pum p Pum p
Short Fiber Long Fiber

Low Density Low Density
Chest Chest
Refiner
Pum p Pum p Refiner Accept Pum p
Chest
Top Layer Back Layer

Pum p Blend Chest Blend Chest Pum p
Top Layer Back Layer

Machine Machine
Chest Chest
Back Layer
Approach flow System of PM-6 Line Top Layer
Machine Machine
Chest Chest
Pump Accept from Back Layer Accept from Top Layer Pump
Secondary Screen Secondary Screen
SILO SILO
(Back) (Top)
Pump L.R L.R L.R Pump
H.R L.R
Back Layer H.R Top Layer
Head Tank Head Tank
Primary Screen Primary Screen
(Back) (Top)
0.25 mm ( Slots) 0.25 mm ( Slots)
Accept Accept
Pulse Pump Pump Pulse

Elimination Elimination
Tank Tank
(Back) Back Layer Top Layer (Top)
Secondary Screen Secondary Screen
0.25 mm ( Slots) 0.25 mm ( Slots)
Head Box H.R Tertiary Screen H.R Head Box

(Back) Head Tank (Top)
Accept Tertiary Screen Reject to OCC

Internship Report
Broke System of PM-6
Under Machine
Broke Towers
Pulpers
Wet Broke Blend Chest

Broke
Dry Broke
Blend Chest
HD Cleaner
Deflaker
Paper Manufacturing at PM-6
Pipelines
Pulp Towers PM-6 Line
Blend
Chest
Pulp
1:Machine 3:High Pressure

2:Silo 4:Head Box 5:Wires Section
Chest Screen
9:After Dryers 8:Size Press

7:Dryers Section 6:Press Section
Section Coating Section
10:Calendering 11:Pope Section 12:Rewinder Market

Section ( Winding on Machine) Section

Internship Report
Stages in Paper Manufacturing Process at PM-6
1. Machine Chest
2. Silo
3. High Pressure Screens
4. Head Box
5. Wire Section
6. Press Section
7. Dryers Section
8. Size Press Section
9. After Dryers Section
10. Calendering Section
11. Pope Section
12. Rewinder Section
-Machine Chest: It contains pulp with high consistency (2.5% to 3.5%).

Consistency: Amount of fibers per 100ml of H2O
Units: gm / 100ml of H2O
Example: 2.5% Consistency means 2.5 gm of fiber / 100ml of H2O
-Silo: In this section, tower containing water are available which are used to dilute the
pulp from 2.5% - 3.5% to < or equal 1%.
-High Pressure Screen: In this section high pressure screen are used to final
removal of all unwanted material. Usually slots type screen are used of 0.25mm slot size.
-Head Box:
After screening the stock arrives at the head box. The
purpose of the head box is to deliver a uniform
suspension of unformulated fibers across the width of the
machine. The head box is the receptacle on the wet end of
the paper machine in which the pulp, or stock, is evenly
distributed onto the wire which looks like a sheet or web.
-Wire Section: In this Section water is removed (dewatering) and in wire section 20%
dryness is achieved. There are four parts of wire.
9 Forming Board
9 Hydrofoils
9 Vacuum foils
9 Suction Boxes

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Forming board:
Forming board is a part of wire at which evenly distributed pulp falls on wire.
Hydrofoils:
A hydrofoil blade for use in a paper making machine wherein a plurality of variously
angulated surfaces is provided for producing turbulence having controllable scale and
intensity while independently controlling the rate of dewatering.
Vacuum Foils:
A type of ving under the wire in the wire section of a paper machine creating a vacuum
pulse to eliminate water from the stock (fiber/water slurry).
Suction Boxes:
Suction boxes located beneath an endless forming wire in a papermaking machine are
mounted on resilient supports, and are coupled to vibrators which impart movement to
the suction boxes with components in the longitudinal direction of the forming wire and
in the vertical direction, and of such resultant direction and amplitude that the suction-
boxes at least in their highest position contact the underside of, and move in the same
direction as, the forming wire.
F O R M IN G W IR E
F O IL B L A D E
FO IL
FO RM E D
C E R A M IC
F IB E R M A T
ST O C K FRE E BLA D E F O R M IN G
S U S P E N S IO N W IR E
REM OVED
WATER
LOW
PRE SSURE R E S IN
BOD Y
SUPPO RT

Internship Report
-Press Section:
After the paper web is produced, the

water must be removed from it by
pressing the sheet removes the water
by force. Once the water is forced
from the sheet, felt (not to be confused
with the traditional felt) is used to
collect the water. When making paper
by hand, a blotter sheet is used. In this
section water is further removed
(dewatering) by pressing the web.
Web is passed between two moving
press rolls and web is press between
them. Then water is extracted with the
help oh high vacuum. In the press
section 45% dryness is achieved.
-Dryer Section:
In this section drying of web is done to our requirement usually 92% dryness is achieved
in dryer section. Drying involves using air and or heat to remove water from the paper
sheet. In the earliest days of papermaking this was done by hanging the paper sheets like
laundry. In more modern times, various forms of heated drying mechanisms are used. On
the paper machine, the most common is the steam-heated can dryer. These dryers can
heat to temperatures above 200°F (93°C) and are used in long sequences of more than 40
cans. The heat produced by these can easily dry the paper to less than 7% moisture when
the paper sheet enters the paper machine Dryer Section; it is about 50% water. It must be
dried to less than 10% water for a finished product. The most common Dryer Sections
include Steam Cylinders and Air Dyers. Infrared Dryers are most commonly used on
coating lines.
ST E AM FILLE D AIR
H O OD D RYE R CANS BLOW E RS
DRY E R
FE LTS
PAPE R W E B
D RY E R SECT IO N

Internship Report
-Size Press Section:

The size press is an important tool for
increasing paper strength because addition
levels much higher than by wet-end addition.
It is also important because relatively
inexpensive native starches may be applied. In
order to improve whiteness, smoothness and
gloss of paperboard, one or more layers of
coating are applied. Coatings are usually made
up of Pigment, binders and additives.But
usually coating of starch is done in this
section in order to improve the bursting
strength of paper.
-After Dryer Section:
After size press section web becomes wet again so in order to dry the web, after dryer
section is used and 92% dryness is achieved.
-Calendering Section:
A calender consists of a number of rolls, where
pressure and heat is applied to the passing
paper. Calenders are used to make the paper
surface extra smooth and glossy. It also gives it
a more uniform thickness. The pressure applied
to the web by the rollers determines the finish of
the paper.A calender refers to the use of two
rolls, or calenders, that squeeze paper in order to
smooth the surface. Often a sheet/web is run
between a series of calenders that squeeze the
sheet in several directions, smoothing the
surface in every possible direction.
-Pope Section:
A paper machine pope section refers to the roll

on to which the paper is wound when it comes
off the last dryer of the paper machine. In this
section Winding of web or sheet of dry paper
made on machine.

Internship Report
-Rewinder Section:
Rewinders rewind the roll off the original winder.

Because it is difficult to retain perfect consistency
of thickness and grain when the sheet is being
wound on directly off the machine onto the first
winder, rewinding the sheet can help even out
stretches and crooked sheets and other
imperfections.
-Problems:
9 Lack of competitive Infrastructure and technological base.

9 Economies of Scale
9 Non-availability of raw and auxiliary materials at the competitive prices.
9 Restrictive local demand and competitive factors for export market.
9 Tariff and local duties irregularity.
9 Dumping of cheap products.
-Recommendations:
9 The government should enhance competitiveness by bringing the prices low down
to international prices.
9 Duty should be reduced on the imported raw material (including wood pulp,
chemicals, waste paper, plant and machinery).
9 Development institutions should be made at macro levels for the pulp and paper
industry.
9 An incentive package should be introduced to revitalize the projects in
difficulties.
.
-References:
9 Paper and Pulp By CASEY

9 Paper and Pulp Technology By BERRT
9 http://en.wikipedia.org/wiki/Paper_machine
9 http://individual.utoronto.ca/abdel_rahman/paper/index.html
9 http://en.wikipedia.org/wiki/Papermaking
9 http://www.paperonweb.com/pmake.htm
9 http://www.pulpandpaper-technology.com
9 http://www.hqpapermaker.com/paper-history
9 http://www.scribd.com/doc/23204983/Paper-Board-Industry

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What is the full paper making process?

What are the main sections of a paper making machine?

What are the main sections of a paper making machine?

Internship Report

Abd u Slam (CIIT/SP08-BEC-003/LHR)

Internship Report of Packages Limited

Mr. Abd u Slam (Student of CIIT Lahore)

Dr. Baber Ali (PM-6 Line Manager)

1st July, 2010

5th August, 2010

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ountless thanks to ALLAH Almighty for giving me such extraordinary

I would like to express my heartiest gratitude to:

Rana Javed Bahir, Mill Manager (BSPM), Packages Limited.

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Confidence, on time decision making, consistency, hard work, team work,

In short I would like to highlight this, that my working experience with

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This significant technological advancement in the Paper Industry has required

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Year (AD) Year (AD)

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-Producing Paper Today:

9 Making Pulp from Wood

9 Newsprint and magazine papers

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-Making Pulp from Wood:

Tree Type Life Expectancy (years)

9 Mechanical or ground wood

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Thermo-Mechanical-Pulp (TMP) and Chemi-Thermo-Mechanical-Pulp (CTMP) are a

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-Making Pulp from Waste:

Utilizing waste paper nevertheless makes sound

The recovery of waste paper begins with its

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-Manufacturing of Paper from Pulp

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-Full paper making process:

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-Chemical Pulping Process:

-Mechanical Pulping Process:

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The stock passes to a blend chest where numerous chemicals

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The cellulose fibers pass through a refining

-Screening and Cleaning:

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Machine Flow Box Control Room

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-Conversion and Printing:

Paper Manufacturing in Pakistan

9 Writing and printing paper

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Raw materials are

9 65% local grass and wheat straw.