Packaging Board Slide No.

Training Session on Packaging Board

Plant Process

Presenter : S. Kannan
Date : 28.10.2015
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What we discuss in next hour

 Machine configuration

 Products

 Technology

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Why Packaging with paperboard

 Light weight, convenient and easy to open.

 Recyclable

 Extremely Cost effective

 Can be used for wide range of substrates

 Easy to pack, fill and transport

 Communicate the Brand Image

 Disposed easily, without any adverse impact to the

environment

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Configuration

• Machine 2nd Hand, SAPPI, South Africa

• Started in Feb 2007
• Rebuild in Feb 2011
• Capacity
• GSM Range
• Product
• Speed
• Deckle
280 TPD
180 – 430(Base/Coated)
Tufcote&Ultima
210 – 340 MPM
260 cms at Pope reel
254 cms (Coated)

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Configuration
 Three wire + 1 top former
 New concept approach flow(Hydro mix)
 Hydraulic head box
 3 press, Binip – Jumbo – Nipco(Smoothening)
 MG
 Inclined size press
 Eco cal calender
 3 Combi blade Coaters, 2 on top and 1 on bottom
 IR dryers in all 3 coaters
 Softnip calender

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Rebuild activities
Increasing production from 60000 MT to 84000 MT/Annum

9 Nos of new ACS800 Multi Drives added(ABB)

9 Nos. drive upgrade from shaft mounted to silent drive

New Master reel installed from VOITH

New Reel turn up system from IBS

5 Nos. vacuum tail threading system

EOT crane from Demag

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Products

Tufcote Ultima

Tufcote Ultima
CCB CBL
Endura CBU
Tufpak PNT
FBL JCC
WAD IV
FBU

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Products
Tufcote

Ultima

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Tuffcote

 Composition:
 Top Layer : HW Chemical Pulp
 Filler Layer BCTMP+Broke
 Back Layer : HW Chemical Pulp
 Coating :
 Precoat
 Top Coat
 Back Coat
 GSM Range : 190-430 GSM

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Ultima

Composition:
 Top Layer : HW Chemical Pulp
 Filler Layer : BCTMP+Broke+HW Chemical pulp
 Back Layer : HW Chemical Pulp
 Coating :
 Precoat
 Top Coat
 Back Coat
 GSM Range : 180-400 GSM

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Tufcote- End Uses

 Food and beverages

 Cigarettes

 Pharmaceutical

 Personal & Health care products

 Cosmetics & Toiletries

 Electronic & Entertainment Products

 FMCG

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Ultima - End Uses

 Advertising of promotional material
 Publication Covers
 Tags and Inserts
 Personal & Health Care products
 Cosmetics & Toiletries
 Greeting cards and Posters
 Wedding cards
 Pharmaceutical
 Book covers
 Playing cards
 FMCG

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Applications

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Applications

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Critical Properties
1) Caliper
2) Stiffness
3) Roughness(PPS)
4) Pre & Post Print Gloss
5) Glueability
6) Shade
7) IGT
8) No Physical Defects

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Sections
 SFT
 Stock Preparation
 Wire Part
 Press Part
 Dryer Section
 Coating
 CCK
 Finishing House

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SFT

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SFT-A

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SFT-B

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SFT-C

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SFT
 Secondary fibre treatment plant consists of 3 streets SFT –
A,B&C respectively

 SFT-A : Continuous pulper for slushing Bleached hardwood

chemical pulp(Imported&JKPM pulp) with 75 TPD capacity@5%
consistency

 SFT-B: HD pulper for slushing BCTMP pulp with 120TPD

@15%consistency

 SFT-C: HD pulper for slushing BCTMP/Softwood chemical pulp

with 120TPD @15%consistency

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STOCK PREPARATION

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Stock Preparation
• 3 Streets for pulp processing – TL, ML & BL Streets.

• Refining : Total 5 nos. DDR – 24”,3no & 2 Triconic

• : TL - 1 No. Triconic from Pilao
– : ML - 2 Nos. (3Nos) DDR from
SAPPI
– : BL - 1 No. Triconic from Pilao
– : Broke -1No Deflaker from
Parason
– : Swing - 1 No. can be used for
TL&BL.
– M/C stage screening : 2 stage screening for TL,ML&BL

• M/c stage cleaning : 3 stage Centri-cleaners for TL &BL

• Disc Filter : Common for all 3 layers

• Broke Tower : 1000 M3

• White water tower : 1000 M3

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HYDROMIX

Hydromix is latest technology being used in the board plant

which substitutes the white water silo. It is a long L shaped
tube. The inner surface of hydromix is mirror finished to
avoid turbulence in the flow. As there is continuous flow of
in the hydromix, it reduces the slime formation when
comparing to the silos.

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Top Layer

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Middle Layer

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Bottom Layer

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Chemicals
Sizing: PAC&Catsize
RDA : Percol
Tinting : Pigment Dyes&OBA
Biocide
Descaling
DSR
Coagulant
Felt passivation
Defoamer
Alkaline boil out
Spray starch
Caustic

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Wire Part

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Wire Part
 Top&Bottom layer: Hydaulic head box from SAPPI

 Middle layer : Hydraulic head box from Voith

 Vacuum pumps and vacuum fans

 65% is processed through middle layer

 25% is processed through top layer

 10% is processed through bottom layer

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Wire&Press Part

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PRESS SECTION

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Press Part
 Binip press with one suction roll,one PU and one micro rock
roll(50-70 N/MM)
 Jumbo press with both aquawell rolls(50-150 N/MM)

 Nipco press with PU and microrock rolls(40-80 N/MM)

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Dry End

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Drying
Total dryer groups: 13
1st and 2nd group are Uni-run

MG : Dia 5.0 Meters

: Single Touch roll

Size press : Inclined (M/s Servall)

Hard nip : Steam heating

Coaters : Pre coat – Blade (SAPPI)

: Top coat – Blade (BMB)
: Back coat – Blade(SAPPI)

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Drying

• Drying at coating with IR dryers.

• Softnip calender

• Pope Reel : Hydraulic

• Tambour roll : Rubber lined.

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Dryers&Rewinder

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COLOUR COATING KITCHEN

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CCK
 Dispersing machine to prepare coating solution for
Pre,top and back coat

 Cooker to prepare oxidised starch for size press

application
 Dissolver to prepare spray starch

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CCK
 Chemicals used in CCK:
 Hydra gloss clay
 Carbitol 60& Carbitol 90
 SBR latex
 Acrylic latex
 Pigment Dyes&OBA
 Caustic
 Dispersing agent
 Antifoam
 Lubricant
 Crosslinker
 CMC
 Biocide
 Surface sizing
 Acid,alkaline and neutral boilout

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REWINDER

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Rewinder
• Output Dia - 1- 1.5 m
• Max. Speed - 1200 m/min
• Core ID - 3’’,6’’&12’’
• No. of slitting knives - 8 Nos.
• Reel width - Minimum : 40 cm
Maximum :180 cm

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CONVERTING SECTION

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Finishing House

• Four Pasaban(Spain) Synchrofly Sheeters- accurate

cuts for direct feeding to the printing machine
• Average Sheeting capacity :210 TPD
• Maximum speed : 300mpm
• Minimum width reel : 40cm
• Maximum width reel : 180cm (90*2)
• Minimum chopping : 45cm
• Maximum chopping : 160cm

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Finishing House
• PACKING

• The packing is carried out in 4 different ways

• Bulk packing (Sheet order)

• Ream packing (Sheet order)

• Bundle packing (Sheet order)

• Reel Packing (Reel order)

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Finishing House
• BULK PACKING

It is the direct packing of the pallet where the pallet height

should not exceed 1.5m. The pallet will be shrink wrapped in
shrink wrapping machine by using 30 microns thick stretch film.
• REAM PACKING

Every 100 sheets are taken from the pallet and packed in the
ream packing machine using 40 microns thick shrink film.

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Finishing House
• BUNDLE PACKING

To pack the composite reams upto 65-70 kg, this is done

using 80 microns thick shrink film.

• REEL PACKING

In reel packing, the reel will be stretch wrapped on the

stretch wrapping machine using 30 microns thick stretch
film.

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DESPATCH SECTION

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DESPATCH SECTION

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Finishing House

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Software
• QCS by Honeywell - Total 5 scanners (measurement&control)
- Before MG(Surface moisture )
- Before Size press(moisture,basis weight)
- Before Precoater(Base gsm&moisture)
- Before Top coater(Precoat weight)
- Before Pope reel(gsm,caliper,moisture)
• Equipped with DCS control from Yokogawa
• 141 AC external multi drives from ABB having Auto tension control
system
• Break sensors from press part to pope reel
• CCTV cameras for break analysis
• Hole detector to detect blotches

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Some Key Customers

• West North
• Parksons Kumar Printers
• TCPL Janas
• Borkar South
• Navneet Kamsree
• Print man Global
• Nobel
• Yamir Packaging
• Temple packaging
• M K Print

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End of presentation…..

Thank you for your valuable attention

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