1. ITC LIMITED Paperboards and Specialty Papers Division
Bhadrachalam
Understanding the issue of Peel off while processing packaging grade board AT printer.
Workshop on “Technological advancements in Manufacturing Packaging Grades of Paper”

2. Myself Y. Chandra Sekhar Chemical Engineer
Learning Paper Making since 1995

3. About Us
M/s.ITC Limited is an integrated Paper and Paper Board Mill situated in Bhadrachalam, Dt.Khammam, Andhra Pradesh producing approx.1,50,000 MT of fine paper per annum (PM II, III & VI) of various grammages and applications.
 The mill was established in 1979 with recycled Board manufacturing with an annual capacity of 40,000 MT and grown to produce 5,50,000 MT as on date. The Mill has upgraded itself to expand and manufacture specialty Paper Boards and Fine Papers.
1979 Commercial production with recycled boards
1986 Coated boards – offline
1989 PM2&3 commissioned. Started producing paper
1992 Unit Bollaram – cast coated papers & boards
1997 PM4 from Valmet – LPB and Cigarette boards
2002 ECF fibre line – first in India, ahead of legislation.
2002 Merged with ITC along with Tribeni Tissues Division.
2004 Unit Kovai – Recycled boards
2004 PM5 from Voith in Oct’04 – recycled & virgin boards.
2008 Ozone Bleaching Line – first in India, ahead of legislation
2008 PM6 - Paper Machine for Copier and Writing, Printing Paper
2009 Green Boiler
2012 PM 7 – recycled and virgin boards.

4. Introduction
This project investigates the properties of the paperboard with regard to peel-off. Experiments to study the effect of sheeting speed on paperboard and defect simulation experiment in bulk packaging have been discussed. It also explores the methods to improve the scuff resistance of paperboard and relevant tests which can be used to quantify the peel-off. Lastly, it describes the equipment which can be used to upgrade the packaging methodology and stresses the need for workforce awareness and training.

5. What is Peel-off
Peel-off is the tendency of the top or bottom layer of the paperboard to roll into a cylindrical mass or quill (as shown in Figure 3) on the surface of the paperboard. When the paperboard with peel-off is passed on to the off-set printing press, it damages the blanket and subsequent paperboards which are fed for printing. This defect is found to occur in paperboards which are sheeted according to the customer requirements and is not seen in rolls.

6. Approach Discussion of problem with technical and quality personnel
Literature survey
Data collection
Analysis of properties
Analysis of finishing operations
Study of sheeting operations
Study of packaging operations
Identifying suitable tests
Identifying methods to improve board properties
Finding measures and methods to upgrade and improve packaging operations

7. Literature
Measure of the Internal Bond Strength of paper/board – Koubaa and Koran (1995)
A Method For Determination Of Delamination Toughness In Different Positions In The Thickness Direction Of Paperboard – Lundh and Fellers(2004)
Australian paper mills
Iggesund Reference Manual

8. Brain storming Peel-off occurs in paperboards of higher GSM.
The most likely reason is handling of paperboards after sheeting.
The complaints are almost equal in bundle and bulk packaging.
Product Parameters which may be related to peel-off are,
a) Plybond
b) Caliper
c) Substance (GSM)
d) Moisture
e) Roughness

9. Packaging Type Vs Type of Peel-Off
The contingency table given below summarises the peel-off type and packaging type. The analysis follows after the table.
Back Layer Top Layer All
Bulk
Bundle
All
Pearson Chi-Square = 0.042, DF = 1, P-Value = 0.838
Likelihood Ratio Chi-Square = 0.042, DF = 1, P-Value = 0.838
Result: P-value of indicates that there is no relationship between the type of packing and the type of peel-off.
A P-value of indicates that there is no relationship between the packaging type and the type of peel-off.

10. Analysis of Paperboard Properties
Analysis of board properties (complaint versus non complaint lots)
Caliper
Moisture
Ply bond
Roughness
Tools used
Box Plot
Capability Analysis
Hypothesis Testing
T test for equality of means

11. Box Plot analysis
Overall variability is same across Non-Complaint and Complaint lot

12. Capability
Capability index of complaint and non-complaints are same.

13. Test of Hypothesis & two sample T test

14. Study of Finishing Operations
Effect of Sheeting Speed on Board Properties
Sheeter speed versus plybond
Sheeter speed verusu ZDTS
Bulk Packaging Defect Simulation
Hypothesis test for good and bad ply bond, ZDTS, PPS & Bendsten TS & BS.
Two sample t test for good and bad ply bond, ZDTS, PPS & Bendsten TS & BS.

19. Hypothesis Testing Test for Equality of Variances

20. Two Sample T-Tests

21. Summery
The finishing experiments show that the sheeting operation may have some effect on the strength properties of paperboard and during bulk packaging occurrences of peel-off in paperboard have been observed. In fact, in all three simulated experiments conducted in the bulk packaging the occurrence of peel-off has been observed.

22. Conclusions
None of the paperboard properties studied is able to consistently discriminate between the paperboards with regard to peel-off.
With increase in sheeting speed there is a slight drop in the Plybond and ZDTS values of paperboards along the edges, particularly during ramp-up.
Experiment of bulk packaging defect simulation showed that restacking of sheets is the costliest operation in packaging in terms of the occurrence of peel-off. Whenever there is restacking there is a possibility of peel-off.

23. Recommendations Use of pile turner for bulk packaging.
Use of Scuff Resistance (Peeling) Test of paperboard to quantify peel-off.
Use of aqueous emulsion of polyethylene with water-soluble polyethylene oxide and similar methods should be tested for their effect in scuff resistance of paperboard.
Recording of Bulk Packaging Defect Simulation Experiment should be prepared to incorporate in training of work force as well as to sensitize customer about the handling conditions that may create peel-off in paperboard.

24. Precautions
Avoid sliding bundles of paper on top of each other. Sliding of heavy pile of paperboard over another pile increases the chances of peel-off.
During stacking lift the paperboard and place it on top of the previous stack instead of sliding it across the top face.
During all steps of handling avoid damaging the edges of the sheet.
Whenever the sheeter is shutdown all the sheets cut in the end should be checked.
Table covers of workbenches should be regularly replaced.

25. Thank You..
Thank You..