1. EMAMI PAPER MILLS LTD.
Unit - Balasore
“Efforts taken at Emami Paper Mills Ltd. for Better Maintenance Practices”

2. LOCATION
North
250 KM
200 KM
BAY OF BENGAL

3. EMAMI PRODUCTION MILESTONE
PRODUCTION TPD
YEAR

4. Emami –Pulp & Paper Production Units at a Glance
MACHINE
PM # 1
PM # 2
PM # 3
DIP # 1
DIP # 3
PRODUCT
WRITING PRINTING
NEWSPRINT
Pulp-
Writing printing
Pulp - Newsprint
RAW MATERIAL
WASTE PAPERS
DECKLE
2.15 MTRS
2.85 MTRS
3.55 MTRS
SPEED
320 MPM
515 MPM
1120 MPM
Production
gsm
45 gsm
CAPACITY
50 TPD
95 TPD
250 TPD
330 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
2014
50 TPD
1983
15 TPD
PAPER MACHINE 1
ABCDEFGHIJKLMNOPQRSTUVWXYZ
PAPER MACHINE 1
Hydraulic Headbox,
Fourdrinier , open draw,
2 straight Press, Pre-dryers,
Size Press, Post dryer ,
Swimming Calender
and Pope Reel

7. PM # 1 Approach Flow & Head box Benefitmm
PROBLEMS
Uneven parent roll
built up for GSM
variation
2. Failure of Micro
Jack fingers
due to forced
Operation
Plain
HEADBOX PA
Tank
Top Lip
air vent mm
HEADBOX
BEFORE
Standard Bend and pipe PA
Tank
AFTER
Pr.. Scrn
air vent
Top Lip
Accelerating
Bend
JOB DONE
Approach piping change to taper piping with Accelerating bend from std. piping
Head box Front Panel change . No. of Micro jack increase from 15 to 18
Head box top lip redesign for more flexible
Slot & drill for flexibility
Taper pipe
Accelerating
Bend
From PCC
To PA tank
Benefit
Parent Roll built up improve by minimise GSM variation
Eliminate Micro jack failures
Pr Scrn
Accept to PA tank

8. PM # 1 Wire & Press Problem : Plain press Roll 630
Rigid doctoring
system
Ø110 mm dia. &
Stiff Angle
TOP FELT
Ø750 , 90 ° Shore A
Rubber pr
Ø740 ,
100° Shore A Dynarock
Plain press Roll
Ø740 ,100° Shore A
Dynarock
Ø750 , 90 ° Shore A
Rubber
BOTTOM FELT
2nd pr.
BOTTOM FELT
630
Ø600 mm, 125 mm wide box 6/10 counter SS Couch Roll
Problem :
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 A l
Ø750 BD mm, 90 ° Shore
Ø750 , Dynarock
Ø750 mm, 90 ° Shore A
Ø600 mm, 125 mm wide
box 6/10 counter
Bronze Couch Roll
TOP FELT
BOTTOM FELT
2nd press
Maxiflex doctoring
System & 2nd doctor
150 mm dia. lead roll
VFD drive reduce
stiff angle by
lift up couch roll
930
Blind drill
press Rolls
Work done
Benefit
Couch roll UP by 300 mm and reduce stiff angle
150 dia. Couch lead roll installed with VFD dive in place 110 mm dia. roll
Installed maxi flex doctor with a 2nd doctor at 2nd press top roll
Both 1st press top & bottom Roll changed to Blind drill Roll
Reduce 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 roll
Dryness 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 breakdown
Chrome plated
Dryer Felt Roll
Ø45
Ø 160
Rubber cover
Dryer Felt Roll
Ø 180
Ø50 10
Year
Pre dryer
Post dryer
Total
2008 5 2 7
2010 3
2012 1
2013
2014

11. PM # 1 Size Press Problem Workdone Benefit Roll life 1 month Paper
Single line shaft drive
Paper passing delay
Size solution GPL 30
Size gain less
Paper wrapping
Pneumatic loading
Nip load too low 15 kg/cm
Paper
Paper
Loading
Unloading
Loading
Unloading
30°
Workdone
Made inclined size press from horizontal
Made drive arrangement to lead out roll
Made loading
Size solution increase to 50 GPL
Nip load increase to 20 kg/cm
Benefit
Roll Life increase from 1 month to 2 month
Paper passing easy

12. Proposed modification
PM # 1
Proposed Size Press
45°
Proposed modification
For Further Roll Life increase and size gain we plan to installed AC VFD drive both top & bottom roll and hydraulic loading arrangement
Loading
Unloading

13. PM # 1 CALENDER Before After Problem
1. Roll wear out was fast about 500 µm
2. Roll changing (Grinding) Frequency- 4 month
3. Parent roll not built up uniform.
4. Weight loss more
5. Paper smoothness not appropriate
6. Roll changing time takes more - 12 hours
7. Roll Edge wear out more for rigid doctoring system result Deckle short
Before
Work Done
1. Installed new 2 roll swimming calendar system in place 4 roll stack
2. Installed swimming roll at bottom with hyd. loading system and heating arrangement
3. Both top and bottom roll provided maxi flex doctoring system
After
Benefit
1. Roll wear out minimum 100 µm.
2. Roll changing (Grinding) Frequency increase - 12 month
3. Control Crown, Parent roll built uniform
4. Weight loss minimum.
5. Paper smoothness improve
6. Roll changing takes 4 hours
7. No Deckle shortage as no wear at edge for maxi flex doctoring system

14. 2014
95 TPD
1996
60 TPD
PAPER MACHINE 2
Hydraulic Headbox, Fourdrinier wire,
Close draw, Bi-nip press,
Dryer , Swimming Calendar
and Pope Reel
IPPTA: promoting
paper industries
growth
PRODUCT
NEWSPRINT
RAW MATERIAL
RECYCLE
DECKLE
2.85 MTRS
SPEED
515 MPM
GSM 45
PRODUCTION
95 TPD

15. PM # 2
Vac Box bearing failures of Suction Pick up roll and Suction Couch roll
Back head
Vacuum box
Bearing Assemble
DS Bearing
-----
Problem
Frequent failure of locking pins
& Bearing failures of box brg. assemble
Workdone
Bearing assemble arrangement
changed from Vac box to Drive head
2. Bearing size change from
23220 to 22322
Stud shaft dia. change from
70 mm to 85 mm
BEFORE
AFTER
Benefi t
Year
Pick up
roll
Couch roll
Speed, MPM
Production loss MT
9:25
34:50
470.1
160
14:50
16:00
494
118
10:00
00:00
505
39.00
506
00.00
515
Back head
Vacuum box
Bearing Assemble
DS Bearing

16. Roll diameter increase & Maxi flex doctoring system improve press part efficiency
PM # 2
BEFORE
Problem Face
Ink deposition on the centre press surface increase downtime for cleaning and paper breaks
Doctor blade life low 5-7 days only
Narrow Nip width , Dryness of press 42%
SPU
Ø650
Grooved Ø570
COUCH
Roll
FDR
Wash roll
Centre Press Roll Ø805-Ø825
Workdone
Centre press roll and Grooved roll diameter increase.
Maxiflex doctoring system installed in place rigid doctoring system.
Hole screen replace by 0.15 mm slotted screen
SPU
Ø650
Centre Press Roll
Ø850
Grooved Roll Ø590
Couch
FDR
WASH
Problem Face
No Ink deposition on the centre press surface increase uptime and no paper breaks 3-4 days.
Doctor blade life low days only
Wide Nip width , Dryness of press increase 42% to 44.5 %
AFTER

17. PM # 2 FLEXIBLE doctoring system on Top Roll of PM # 2 Calender
BEFORE
AFTER
Problem
1.Doctor Loading not uniform, at Edge more.
2. Wear out at edge up to 500 µm.
3. Grinding frequency 4-5
month.
4.Roll life less
Maxiflex
Doctor
Rigid
Doctor
Work done
1.Replace Rigid doctoring by maxi flex doctoring system.
Benefit
1. No edge wear out doctor Load uniformly distributed
2. Wear out only up to µm.
3. Grinding frequency 8-9 month
4. Roll life increase.

18. PM # 2 HEAD BOX STEP DIFFUCER BLOCK PROBLEM : 1. Heavy leakage due to
HDPE step diffuser
block crack and no spare
in hand
2. Repaired temporary
by isolating Horizontal
Movement of Top Slice lip.
3. Flow not uniform and
Channelling .
Heavy leakage
Headbox diffuser BLOCK
CRACK

19. Manufacturing Head Box Diffuser block at Home
PM # 2
Manufacturing Head Box Diffuser block at Home
Work done
Diffuser Block’s Drawing, Design
Developed &Manufacture
at home.
2. Arranged 182 nos. HDPE
diffuser Nozzle by injection
moulding at Kolkata.
HDPE DIFFUSER 182 nos.
BOX SS 304
Benefit
Run the machine at full speed and produced good quality paper.
2. Paper rejection and finishing
loss 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 slot
3. Uhle box slot 10 mm to 13 mm
Y E A R
4 nos. 200 mm dia. Uhlebox in place of 150 mm with ceramic
Head box lip changed
2. Fan pump impeller dia increase from 365 to 380mm
mm Centre
press roll in place 805 mm dia
2. Centre press
Maxi flex doctor ing system
mm to 590 mm Groove
° Hydrofoil
1. Orthoflow

21. 2014
250 TPD
2007
205 TPD
PAPER MACHINE 3
Hyd.headbox, Twinwire Gap former belbie IV
Trinip Ceramic Nipco Press, Dryers,
Double stack Soft Calender
& Pope Reel
IPPTA: promoting
paper industries
growth

22. PM # 3 Abnormal vibrations in the forming section at wire part.
Before HB
Problem
1. Too much Vibration at Forming roll.
2. Restricted speed up above 1000 mpm
Bow roll
Work done
FE analysis carried out
By IIT , Kharagpur.
2. Bow roll reposition with new bracket
Forming roll
After HB
Benefit
Vibration reduce.
2. Speed up the machine
to 1120 MPM
Bow roll
BEFORE VIBRATION
DRIVE END BEARING
MPM
NON DRIVE END
13.
10.1
3.32
985
8.71
8.49
3.21
AFTER VIBRATION
7.5
4.3
1.8
1058
3.5
2.3
1.53
Forming roll

23. PM # 3
Higher vibrations of Dryer Frames and paper breaks for sticky coming along with recycle pulp
Problem :
Vibration in dryer frame
No doctoring system on dryer for sticky cleaning
Work done
Arch type Tie connected in between dryer frame
Installed doctoring system on every dryer.
Benefit
Vibration Reduce
Keep the dryer surface clean.
BEFORE:
Original Dryer Frame configuration
AFTER: Dryer Frame configuration
with addition of Arch Beams

24. PM # 3
In house overhauling of swimming & nipco roll reduces foreign experts cost.
BEFORE
Previously the Swimming roll
and Nipco roll servicing was
carried out by
sending the rolls to Europe.
PRESENT
We have developed in house
facilities for overhauling &
maintenance of same

25. Modern maintenance practices at Emami
Condition monitoring system(SPM)
On-line condition monitoring system
installed at Emami PM # 3.
This on line system is very effective
for unplanned stoppage, fire safety.
The bearing changed as per online
condition symptom on planned and
unplanned as follows
Year Planned Unplanned(downtime)
 Condition monitoring on off line: 
Offline bearing conditions are also
monitored regularly and 20%
bearing consumption cost reduces since
last 5 years
Proactive maintenance
Regularly monitoring the lubricant
quality prevent downtime in Nipco roll
Swimming roll and COL system rolls and cylinders bearings
SCREW PRESS MOTOR
DRIVE END
DATE
TORQUE
LR/HR
HOR
VERT
AXIAL
MIN
MAX
44/35
2.19
2.21
2.3
31/25
1.92
1.3
1.25
1.31
1.16

26. 2014
54TPD
2005
48 TPD
Deinking Plant 1
WE SHALL OVERCOME

27. Horizontal slot screen Horizontal Hole screen
Power Saving in DIP 1
PROBLEM
1. Power consumption too high
PARTICULARS
Horizontal slot screen
Horizontal Hole screen
Vertical slot screen
Vertical hole screen
Slot/Hole size
0.15 mm slot
dia 1.8/2.2
0.15mm slot
dia 1.4mm
Basket size
Ø740 x 600
Ø500 x 430
Ø495 x 500
Ø495 x 495
% of Open area
4.2 9
5.7
12.7
Rotating element weight Kg
580
275
270 
Rotor dia
733
496
490
Rotor rpm
571
763
440
715
Tip velocity m/sec 22 20 11 18
Inlet Consistency (% ) % % %
3-3.5%
BKW 75 39 15 31
Motor KW 90 45
18.5 37
Motor rpm
1500
1455
1450
Motor FLC
157 81 35 66
Motor RLC
128 74 25 55
Running KW 77 44 33
Work Done
Study individual power
consumption trend of
equipment's in DIP plants.
Identified screening
section consuming
more power
Select appropriate
equipment and installed
4. Power consumption reduce
from 121 KW to 48 kw.

28. DIP # 1
BEFORE MODIFICATION in SCREENING SECTION POWER CONSUMPTIN WAS 121 KWH/MT F paper
Fine screen feed chest & pump
Constant level chest & pump
Coarse Hor. Hole
screen 45 kw
Fine Hor. Slot screen
90 KW
Diabolo slot
Diabolo hole
Mac cell
POWER
520 KWH/PAPER
Fine screen feed chest & pump
Constant level
chest & pump
HD cleaner
Coarse Ver hole
screen 37 KW
Fine Ver. slot screen
18.5 KW
Diabolo slot
Diabolo hole
Mac cell
AFTER MODIFICATION in SCREENING SECTION POWER CONSUMPTIN IS 48 KWH/MT F paper
POWER
360 KWH/PAPER

29. ABCDEFGHIJKLMNOPQRSTUVWXYZ
2014
330 TPD
Deinking Plant 3
2007
300 TPD
ABCDEFGHIJKLMNOPQRSTUVWXYZ

30. Reduction of Screw press vibration in of Deinking Plant:
DIP # 3
Problem
Too much vibration at DS screw for polished screw surface .
Coupling failure.
Basket damaged.
Production hampered for
frequent stoppage for
roughening the polished screw surface.
Work Done
Tungsten carbide coated body plate
welded on polished screw surface
Benefit
Eliminate excessive vibration at DS screw
Coupling & Basket not failed/damage
since body plate installed.
Frequent roughening not require
SCREW PRESS
DRIVE END
NON DRIVE END
AFTER
TORQUE
HOR
VER
AXIA
56%
1.02
0.51
0.59
1.17
0.79
0.97
0.78
0.38
0.29
0.84
0.4
0.35
BEFORE
54%
5.5
2.6
1.3
3.7
4.7
3.5
26/12/2013
55%
6.5
4.2
4.3
5.1

31. DIP # 3 Cost Reduction on Reject Plastics Handling in Deinking Plant:
Problem
Work done
Benefit
Dirty House keeping
A heavy duty Bale press installed
Clean House keeping
More Man power (40 nos.)
Two conveyor installed which carry the reject plastic to bale press directly from source
Less Manpower (10 nos.)
Higher moisture ( 60%) in plastics.
Less moisture (20%) in plastics
SAVINGS IN PLASTICS HANDLING BY INSTALLATION OF BALE PRESS & NEW CONVEYING SYSTEM
Sl.No.
PARTICULARS
PREVIOUS
PRESENT
SAVINGS of Manpower
UNIT PRICE (Rs.)
Total Savings (Rs.)/Day
Total Savings Lacs/Month 1
Manpower engaged in Power plant for Baling & feeding Plastics 34 10 4
Manpower engaged in DIP#3 & DIP 1 plant for shifting Plastics to Power plant/Day 6
Total Manpower 40 30
200
6000
1.8 7
Transportation charge
1044
0.24 9
Total Savings per month
7044
2.04
Total Savings per Annum in Lacs
24.48

32. Conclusion
Frequent 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

33. Thank you