4 Emami –Pulp & Paper Production Units at a Glance MACHINEPM # 1PM # 2PM # 3DIP # 1DIP # 3PRODUCTWRITING PRINTINGNEWSPRINTPulp-Writing printingPulp - NewsprintRAW MATERIALWASTE PAPERSDECKLE2.15 MTRS2.85 MTRS3.55 MTRSSPEED320 MPM515 MPM1120 MPMProductiongsm45 gsmCAPACITY50 TPD95 TPD250 TPD330 TPD
5 Working Principle & Maintenance Practices Maximize the machine Uptime at optimum efficiency .Achieved target & follow up for update.Spare parts management.Critical checks & recording during any available shut.To improve the awareness of the people in the area of Best Practices in maintenance.To build a positively challenging relationship across the maintenance departments.Create a learning opportunity for the development and education of maintenance people.To create an atmosphere where people will readily share experiences and information.Use modern systems for health check of machineries.
6 ABCDEFGHIJKLMNOPQRSTUVWXYZ 201450 TPD198315 TPDPAPER MACHINE 1ABCDEFGHIJKLMNOPQRSTUVWXYZPAPER MACHINE 1Hydraulic Headbox,Fourdrinier , open draw,2 straight Press, Pre-dryers,Size Press, Post dryer ,Swimming Calenderand Pope Reel
7 PM # 1 Approach Flow & Head box Benefit mmPROBLEMSUneven parent rollbuilt up for GSMvariation2. Failure of MicroJack fingersdue to forcedOperationPlainHEADBOXPATankTop Lipair ventmmHEADBOXBEFOREStandard Bend and pipePATankAFTERPr.. Scrnair ventTop LipAcceleratingBendJOB DONEApproach piping change to taper piping with Accelerating bend from std. pipingHead box Front Panel change . No. of Micro jack increase from 15 to 18Head box top lip redesign for more flexibleSlot & drill for flexibilityTaper pipeAcceleratingBendFrom PCCTo PA tankBenefitParent Roll built up improve by minimise GSM variationEliminate Micro jack failuresPr ScrnAccept to PA tank
8 PM # 1 Wire & Press Problem : Plain press Roll 630 Rigid doctoringsystemØ110 mm dia. &Stiff AngleTOP FELTØ750 , 90 ° Shore ARubber prØ740 ,100° Shore A DynarockPlain press RollØ740 ,100° Shore ADynarockØ750 , 90 ° Shore ARubberBOTTOM FELT2nd pr.BOTTOM FELT630Ø600 mm, 125 mm wide box 6/10 counter SS Couch RollProblem :Too high Draw between wire and press (23 MPM).Delayed the paper passing for Stiff angle.Paper breaks at couch lead roll for low dia. And paper drive.2nd press Doctor passing.Steam consumption high (3.30 Mt/Ton paper for low dryness after press.
9 PM # 1 Wire & Press Work done Benefit 930 Ø750 BD mm, 90 ° Shore AlØ750 BD mm, 90 ° ShoreØ750 , DynarockØ750 mm, 90 ° Shore AØ600 mm, 125 mm widebox 6/10 counterBronze Couch RollTOP FELTBOTTOM FELT2nd pressMaxiflex doctoringSystem & 2nd doctor150 mm dia. lead rollVFD drive reducestiff angle bylift up couch roll930Blind drillpress RollsWork doneBenefitCouch roll UP by 300 mm and reduce stiff angle150 dia. Couch lead roll installed with VFD dive in place 110 mm dia. rollInstalled maxi flex doctor with a 2nd doctor at 2nd press top rollBoth 1st press top & bottom Roll changed to Blind drill RollReduce Draw between wire and press from 23 MPM to 12 MPM.Paper passing time reduce .Reduce paper breaks at lead roll.Doctor passing eliminate at 2nd press rollDryness increase d to 42% from 40%.Steam consumption reduce to 2.8 MT/Ton paper from 3.3 MT.Deckle increase at Pope by 2 cm.Speed increased to 320mpm from 300 MPM.Production increase.
10 PM # 1 Eliminate the Dryer felt roll breakdown Ø 160 Ø45 Chrome plated There used to be frequent breakdown of Dryer felt rolls due to journal shearing after changing from dryer felt to screen & speeding up the machine. The journal size of 45mm was replaced with 50 mm for all felt rolls with rubber cover to avoid this breakdownChrome platedDryer Felt RollØ45Ø 160Rubber coverDryer Felt RollØ 180Ø5010YearPre dryerPost dryerTotal2008527201032012120132014
11 PM # 1 Size Press Problem Workdone Benefit Roll life 1 month Paper Single line shaft drivePaper passing delaySize solution GPL 30Size gain lessPaper wrappingPneumatic loadingNip load too low 15 kg/cmPaperPaperLoadingUnloadingLoadingUnloading30°WorkdoneMade inclined size press from horizontalMade drive arrangement to lead out rollMade loadingSize solution increase to 50 GPLNip load increase to 20 kg/cmBenefitRoll Life increase from 1 month to 2 monthPaper passing easy
12 Proposed modification PM # 1Proposed Size Press45°Proposed modificationFor Further Roll Life increase and size gain we plan to installed AC VFD drive both top & bottom roll and hydraulic loading arrangementLoadingUnloading
13 PM # 1 CALENDER Before After Problem 1. Roll wear out was fast about 500 µm2. Roll changing (Grinding) Frequency- 4 month3. Parent roll not built up uniform.4. Weight loss more5. Paper smoothness not appropriate6. Roll changing time takes more - 12 hours7. Roll Edge wear out more for rigid doctoring system result Deckle shortBeforeWork Done1. Installed new 2 roll swimming calendar system in place 4 roll stack2. Installed swimming roll at bottom with hyd. loading system and heating arrangement3. Both top and bottom roll provided maxi flex doctoring systemAfterBenefit1. Roll wear out minimum 100 µm.2. Roll changing (Grinding) Frequency increase - 12 month3. Control Crown, Parent roll built uniform4. Weight loss minimum.5. Paper smoothness improve6. Roll changing takes 4 hours7. No Deckle shortage as no wear at edge for maxi flex doctoring system
15 PM # 2Vac Box bearing failures of Suction Pick up roll and Suction Couch rollBack headVacuum boxBearing AssembleDS Bearing-----ProblemFrequent failure of locking pins& Bearing failures of box brg. assembleWorkdoneBearing assemble arrangementchanged from Vac box to Drive head2. Bearing size change from23220 to 22322Stud shaft dia. change from70 mm to 85 mmBEFOREAFTERBenefi tYearPick uprollCouch rollSpeed, MPMProduction lossMT9:2534:50470.116014:5016:0049411810:0000:0050539.0050600.00515Back headVacuum boxBearing AssembleDS Bearing
16 Roll diameter increase & Maxi flex doctoring system improve press part efficiency PM # 2BEFOREProblem FaceInk deposition on the centre press surface increase downtime for cleaning and paper breaksDoctor blade life low 5-7 days onlyNarrow Nip width , Dryness of press 42%SPUØ650Grooved Ø570COUCHRollFDRWash rollCentre Press Roll Ø805-Ø825WorkdoneCentre press roll and Grooved roll diameter increase.Maxiflex doctoring system installed in place rigid doctoring system.Hole screen replace by 0.15 mm slotted screenSPUØ650Centre Press RollØ850Grooved Roll Ø590CouchFDRWASHProblem FaceNo Ink deposition on the centre press surface increase uptime and no paper breaks 3-4 days.Doctor blade life low days onlyWide Nip width , Dryness of press increase 42% to 44.5 %AFTER
17 PM # 2 FLEXIBLE doctoring system on Top Roll of PM # 2 Calender BEFOREAFTERProblem1.Doctor Loading not uniform, at Edge more.2. Wear out at edge up to 500 µm.3. Grinding frequency 4-5month.4.Roll life lessMaxiflexDoctorRigidDoctorWork done1.Replace Rigid doctoring by maxi flex doctoring system.Benefit1. No edge wear out doctor Load uniformly distributed2. Wear out only up to µm.3. Grinding frequency 8-9 month4. Roll life increase.
18 PM # 2 HEAD BOX STEP DIFFUCER BLOCK PROBLEM : 1. Heavy leakage due to HDPE step diffuserblock crack and no sparein hand2. Repaired temporaryby isolating HorizontalMovement of Top Slice lip.3. Flow not uniform andChannelling .Heavy leakageHeadbox diffuser BLOCKCRACK
19 Manufacturing Head Box Diffuser block at Home PM # 2Manufacturing Head Box Diffuser block at HomeWork doneDiffuser Block’s Drawing, DesignDeveloped &Manufactureat home.2. Arranged 182 nos. HDPEdiffuser Nozzle by injectionmoulding at Kolkata.HDPE DIFFUSER 182 nos.BOX SS 304BenefitRun the machine at full speed and produced good quality paper.2. Paper rejection and finishingloss go down.
20 M P M Y E A R 1. 850 mm Centre press roll in place 805 mm dia 1. Head box electro polish.2. Pressure screen- may with 015 mm slot3. Uhle box slot 10 mm to 13 mmY E A R4 nos. 200 mm dia. Uhlebox in place of 150 mm with ceramicHead box lip changed2. Fan pump impeller dia increase from 365 to 380mmmm Centrepress roll in place 805 mm dia2. Centre pressMaxi flex doctor ing systemmm to 590 mm Groove° Hydrofoil1. Orthoflow
21 2014250 TPD2007205 TPDPAPER MACHINE 3Hyd.headbox, Twinwire Gap former belbie IVTrinip Ceramic Nipco Press, Dryers,Double stack Soft Calender& Pope ReelIPPTA: promotingpaper industriesgrowth
22 PM # 3 Abnormal vibrations in the forming section at wire part. BeforeHBProblem1. Too much Vibration at Forming roll.2. Restricted speed up above 1000 mpmBow rollWork doneFE analysis carried outBy IIT , Kharagpur.2. Bow roll reposition with new bracketForming rollAfterHBBenefitVibration reduce.2. Speed up the machineto 1120 MPMBow rollBEFORE VIBRATIONDRIVE END BEARINGMPMNON DRIVE END18.104.22.1689858.718.493.21AFTER VIBRATION22.214.171.12405126.96.36.199Forming roll
23 PM # 3Higher vibrations of Dryer Frames and paper breaks for sticky coming along with recycle pulpProblem :Vibration in dryer frameNo doctoring system on dryer for sticky cleaningWork doneArch type Tie connected in between dryer frameInstalled doctoring system on every dryer.BenefitVibration ReduceKeep the dryer surface clean.BEFORE:Original Dryer Frame configurationAFTER: Dryer Frame configurationwith addition of Arch Beams
24 PM # 3In house overhauling of swimming & nipco roll reduces foreign experts cost.BEFOREPreviously the Swimming rolland Nipco roll servicing wascarried out bysending the rolls to Europe.PRESENTWe have developed in housefacilities for overhauling &maintenance of same
25 Modern maintenance practices at Emami Condition monitoring system(SPM)On-line condition monitoring systeminstalled at Emami PM # 3.This on line system is very effectivefor unplanned stoppage, fire safety.The bearing changed as per onlinecondition symptom on planned andunplanned as followsYear Planned Unplanned(downtime) Condition monitoring on off line: Offline bearing conditions are alsomonitored regularly and 20%bearing consumption cost reduces sincelast 5 yearsProactive maintenanceRegularly monitoring the lubricantquality prevent downtime in Nipco rollSwimming roll and COL system rolls and cylinders bearingsSCREW PRESS MOTORDRIVE ENDDATETORQUELR/HRHORVERTAXIALMINMAX44/3188.8.131.521/251.9184.108.40.2061.16
27 Horizontal slot screen Horizontal Hole screen Power Saving in DIP 1PROBLEM1. Power consumption too highPARTICULARSHorizontal slot screenHorizontal Hole screenVertical slot screenVertical hole screenSlot/Hole size0.15 mm slotdia 1.8/2.20.15mm slotdia 1.4mmBasket sizeØ740 x 600Ø500 x 430Ø495 x 500Ø495 x 495% of Open area4.295.712.7Rotating element weight Kg580275270 Rotor dia733496490Rotor rpm571763440715Tip velocity m/sec22201118Inlet Consistency (% )%%%3-3.5%BKW75391531Motor KW904518.537Motor rpm150014551450Motor FLC157813566Motor RLC128742555Running KW774433Work DoneStudy individual powerconsumption trend ofequipment's in DIP plants.Identified screeningsection consumingmore powerSelect appropriateequipment and installed4. Power consumption reducefrom 121 KW to 48 kw.
28 DIP # 1BEFORE MODIFICATION in SCREENING SECTION POWER CONSUMPTIN WAS 121 KWH/MT F paperFine screen feed chest & pumpConstant level chest & pumpCoarse Hor. Holescreen 45 kwFine Hor. Slot screen90 KWDiabolo slotDiabolo holeMac cellPOWER520 KWH/PAPERFine screen feed chest & pumpConstant levelchest & pumpHD cleanerCoarse Ver holescreen 37 KWFine Ver. slot screen18.5 KWDiabolo slotDiabolo holeMac cellAFTER MODIFICATION in SCREENING SECTION POWER CONSUMPTIN IS 48 KWH/MT F paperPOWER360 KWH/PAPER
30 Reduction of Screw press vibration in of Deinking Plant: DIP # 3ProblemToo much vibration at DS screw for polished screw surface .Coupling failure.Basket damaged.Production hampered forfrequent stoppage forroughening the polished screw surface.Work DoneTungsten carbide coated body platewelded on polished screw surfaceBenefitEliminate excessive vibration at DS screwCoupling & Basket not failed/damagesince body plate installed.Frequent roughening not requireSCREW PRESSDRIVE ENDNON DRIVE ENDAFTERTORQUEHORVERAXIA56%1.020.510.591.170.790.970.780.380.290.840.40.35BEFORE54%220.127.116.11.74.73.526/12/201355%18.104.22.168.1
31 DIP # 3 Cost Reduction on Reject Plastics Handling in Deinking Plant: ProblemWork doneBenefitDirty House keepingA heavy duty Bale press installedClean House keepingMore Man power (40 nos.)Two conveyor installed which carry the reject plastic to bale press directly from sourceLess Manpower (10 nos.)Higher moisture ( 60%) in plastics.Less moisture (20%) in plasticsSAVINGS IN PLASTICS HANDLING BY INSTALLATION OF BALE PRESS & NEW CONVEYING SYSTEMSl.No.PARTICULARSPREVIOUSPRESENTSAVINGS of ManpowerUNIT PRICE (Rs.)Total Savings (Rs.)/DayTotal Savings Lacs/Month1Manpower engaged in Power plant for Baling & feeding Plastics34104Manpower engaged in DIP#3 & DIP 1 plant for shifting Plastics to Power plant/Day6Total Manpower403020060001.87Transportation charge10440.249Total Savings per month70442.04Total Savings per Annum in Lacs24.48
32 ConclusionFrequent breakdown of Dryer felt rolls on PM#1 was eliminated by changing the journal size from 45mm to 50 mm for all felt rolls.By increasing the lead roll diameter & with VFD arrangement Paper breaks at couch roll in PM#1 reduced.PM#2 machine speed increased from 470 mpm to 515 mpm by in house modifications in suction couch & suction pickup roll, adding wire table dewatering element & installing maxi flex doctoring system at centre press roll resulting increase in Production by 2000 MT/Annum.Reduce power consumption at Deinking plant#1 by 165 KW/ton of finish paper after changing Horizontal screen by Vertical screen in both Hole & fine screening stage.In-house plastic handling system reduces the manpower & nuisance in the Plant.In house overhauling of swimming & nipco roll Eliminated supervision and experts cost Rs. 10 lacs / annum.The deinking plant poire is being rebuild at our workshop which saves around 2.5 Lac/ year