STUDY ON PROCESS LAYOUT OF

PAPER MACHINE

A Mini Project Report

Submitted
By

A.Ramesh MD.Azeez
G.Devendranath N.Ranjith kumar
M.Kiran reddy

Under esteemed guidance

Mr. G V PURUSHOTHAM, Deputy Manager
ITC Ltd -PSPD, BHADRACHALAM.

Department of Mechanical Engineering

Dr. PAUL RAJ ENGINEERING COLLEGE
BHADRACHALAM - 507111.
 ACKNOWLEDGEMENTS

We wish to our beloved Principal Prof G.Amarendar Rao, M.Tech, PhD for permitting
us to carry out this project work.

We also express our profound sense of gratitude to Prof P.Srinivasulu, M.Tech, (PhD)
Head of Department Mechanical Engineering and for his kind consent in doing the
course, project and incitement towards us.

We wish to express my deep sense of gratitude to my Internal Guide, Mr. S. Raja

shekar, M.Tech for his valuable guidance and useful suggestions, which helped us in
completing the project work, in time.

Our Pleasure to mention that Shri CH. VIJAYASARADTHI, General Manager ( Paper
M/c 6 ) of Indian Tobacco Company Limited who has been a source of inspiration and
for his timely guidance in the conduct of our project work. We would also like to thanks
Mr. G V PURUSHOTHAM, Deputy Manager (Paper M/c 6) of Indian Tobacco
Company Limited, for valuable guidance in this project work.

Words are inadequate in offering our special thanks to the Project GUIDE Mr.
PURUSHOTHAM, Deputy Manager for his encouragement and cooperation in carrying
out this project work.

Finally, yet importantly, we would like to express our heart full thanks to our beloved
parents for their blessings, and wishes for the successful completion of this project.

....Project associates

CONTENTS
 Introduction

 Properties of paper

 Pulp preparation

 Pulp Processing and Chemical Recovery

 Pulp Bleaching

 Stock Preparation

 Paper manufacturing process

 Applications

 Environmental Concerns

 Conclusion

Abstract
The process for making paper has in its fundamentals not changed, although
technological advancements of the highest degree in terms of mechanization and
atomization have been achieved in the last 150 years. In our study we focus on the how
the paper is manufacture in a paper making industry, finally at the end of our study we
concluded each paper machine has unique characteristics, and one process may suffer
different pitfalls than another.
 Department of Mechanical Engineering
Dr. Paul Raj Engineering College
Bhadrachalam - 507111.
(Affiliated to JNTU-H)

Certificate
This is to certify that is a bonafied record of the project entitled “study
on process layout of paper machine” carried out by bearing roll
numbers A.Ramesh (07371A0324), in ITC Ltd-PSPD at Bhadrachalam,
during The Academic year of 2010-2011 for the Partial fulfillment of
degree in B.Tech from Jawaharlal Nehru Technological University
Hyderabad.

Prof P. Srinivasulu, M.Tech, (PhD) Mr S. Raja shekar, M.Tech

Head of the Department Internal Guide

External Examiner
 Department of Mechanical Engineering
Dr. Paul Raj Engineering College
Bhadrachalam - 507111.
(Affiliated to JNTU-H)

Certificate
This is to certify that is a bonafied record of the project entitled “study
on process layout of paper machine” carried out by bearing roll
number G.Devendranath (08375A0305), in ITC Ltd-PSPD at
Bhadrachalam, during The Academic year of 2010-2011 for the Partial
fulfillment of degree in B.Tech from Jawaharlal Nehru Technological
University Hyderabad.

Prof P. Srinivasulu, M.Tech, (PhD) Mr S. Raja shekar, M.Tech

Head of the Department Internal Guide

External Examiner
 Department of Mechanical Engineering
Dr. Paul Raj Engineering College
Bhadrachalam - 507111.
(Affiliated to JNTU-H)

Certificate
This is to certify that is a bonafied record of the project entitled “study
on process layout of paper machine” carried out by bearing roll
number MD.Azeez (07371A0301), in ITC Ltd-PSPD at
Bhadrachalam, during The Academic year of 2010-2011 for the Partial
fulfillment of degree in B.Tech from Jawaharlal Nehru Technological
University Hyderabad.

Prof P. Srinivasulu, M.Tech, (PhD) Mr S. Raja shekar, M.Tech

Head of the Department Internal Guide

External Examiner

Department of Mechanical Engineering

 Dr. Paul Raj Engineering College
Bhadrachalam - 507111.
(Affiliated to JNTU-H)

Certificate
This is to certify that is a bonafied record of the project entitled “study
on process layout of paper machine” carried out by bearing roll
number N.Ranjith kumar (07371A0325), in ITC Ltd-PSPD at
Bhadrachalam, during The Academic year of 2010-2011 for the Partial
fulfillment of degree in B.Tech from Jawaharlal Nehru Technological
University Hyderabad.

Prof P. Srinivasulu, M.Tech, (PhD) Mr S. Raja shekar, M.Tech

Head of the Department Internal Guide

External Examiner

Department of Mechanical Engineering

Dr. Paul Raj Engineering College
 Bhadrachalam - 507111.
(Affiliated to JNTU-H)

Certificate
This is to certify that is a bonafied record of the project entitled “study
on process layout of paper machine” carried out by bearing roll
number M.Kiran reddy (07371A0313), in ITC Ltd-PSPD at
Bhadrachalam, during The Academic year of 2010-2011 for the Partial
fulfillment of degree in B.Tech from Jawaharlal Nehru Technological
University Hyderabad.

Prof P. Srinivasulu, M.Tech, (PhD) Mr S. Raja shekar, M.Tech

Head of the Department Internal Guide

External Examiner

INTRODUCTION
 Though we may take it for granted, paper is always with us, documenting our
world and reminding us of the limitless possibilities of life. Invented by the Chinese
2,000 years ago, paper has been used ever since as a communication medium. Initially,
paper was made out of fibers from mulberry bark, papyrus, straw or cotton. Wood only
emerged as the chief raw material for paper mass production as recently as the mid 19th
century.

The printed page is immediate, its message cutting across cultures; a tactile
experience that demands attention and creates desire. It is a passport to knowledge, a
storage medium, a persuasive tool and an entertaining art form. Paper is a sustainable
resource and a permanent document. It is the universal medium on which we chronicle
our every-day history. Paper carries the past. It is the canvas on which we live the present
and the blueprint upon which we design our future.

Paper touches the lives of every individual on this planet, and at Sappi, we never
stop thinking about this fact. We are proud that Sappi is the largest and most successful
producer of coated fine papers in the world. At Sappi, we are relentlessly developing new
standards for the paper industry.

Drawing on centuries of experience, and the craftsmanship and expertise of its

own people supported by 21st century papermaking technology, Sappi will lead the
industry to ensure that this creative communication medium, paper, is the best it can be!

This brochure shows how we make this first class paper. Starting with the
production of the most important raw material, wood. The pulping process converts this
wood into the most appropriate type of pulp. The paper machine then converts the pulp
into a thin base paper, which, at the end of the production process, is coated to give it a
superb flat surface and bright shade.
The process for making paper has in its fundamentals not changed, although
technological advancements of the highest degree in terms of mechanization and
atomization have been achieved in the last 150 years. Essentially, paper is manufactured
using the following main operations.

PROPERTIES OF PAPER
Basis Weight (GSM):- The weight or substance per unit area is obviously fundamental in
paper and paper board products. The Basis weight of paper is the weight per unit area.
This can be expressed as the weight in grams per square meter (GSM or g/M2), pounds
per 1000 sq. ft. or weight in kgs or pounds per ream (500 sheets) of a specific size.
REAM WEIGHT is a common term to signify the weight of a lot or batch of paper.
Control of basis weight is important as all other properties are affected. Variations in
moisture content in paper affect the gram mage.

Brightness, Whiteness and Colour:- Brightness is defined as the percentage reflectance

of blue light only at a wavelength of 457 nm. Whiteness refers to the extent that paper
diffusely reflects light of all wave lengths throughout the visible spectrum. Whiteness is
an appearance term. Colour is an aesthetic value. Colour may appear different when
viewed under a different light source. Brightness is an arbitrarily defined, but carefully
standardized, blue reflectance that is used throughout the pulp and paper industry for the
control of mill processes and in certain types of research and development programs.
Brightness is not whiteness. However, the brightness values of the pulps and pigments
going into the paper provide an excellent measure of the maximum whiteness that can be
achieved with proper tinting. The colour of paper, like of other materials, depends in a
complicated way on the characteristics of the observer and a number of physical factors
such as the spectral energy distribution of the illuminant, the geometry of illuminating
and viewing, the nature and extent of the surround and the optical characteristics of the
paper itself.

Bulk :- Bulk is a term used to indicate volume or thickness in relation to weight. It is the
reciprocal of density (weight per unit volume). It is calculated from caliper and basis
weight. Sheet bulk relates to all other sheet properties. Decrease the bulk or in other
words increase the density, and the sheet gets smoother, glossier, less opaque, darker,
lower in strength etc.

Dimensional Stability:- An important consequence of the absorption and de-absorption

of moisture by paper is the change in dimension that usually accompanies changes in
moisture content. Such changes in dimension may seriously affect register in printing
processes and interfere with the use of such items as tabulating cards. Uneven
dimensional changes cause undesirable cockling and curling. Dimensional changes in
paper originate in the swelling and contraction of the individual fibres. It has been
observed that cellulosic fibres swell in diameter from 15 to 20% in passing from the dry
condition to the fiber saturation point. It is impossible to be precise about the degree of
this swelling because paper-making fibres differ considerably in this property, and
because the irregular cross-section of fibres creates difficulty in defining diameter.
Change that occurs in the dimensions of paper with variation in the moisture content is an
important consideration in the use of paper. All papers expand with increased moisture
content and contract with decreased moisture content, but the rate and extent of changes
vary with different papers.

Folding Endurance (Double Folds) :- Folding endurance is the paper's capability of

withstanding multiple folds before it breaks. It is defined as the number of double folds
that a strip of 15 mm wide and 100 mm length can withstand under a specified load
before it breaks. It is important for printing grades where the paper is subjected to
multiple folds like in books, maps, or pamphlets. Fold test is also important for carton,
box boards, ammonia print paper, and cover paper etc. Folding endurance is a
requirement in Bond, Ledger, Currency, Map, Blue Print and Record Papers.

Formation :- Formation is an indicator of how the fibres and fillers are distributed in the
sheet. Formation plays an important role as most of the paper properties depend on it.
Paper that is poorly formed will have weak, thin spots and thick spots. These will affect
properties like caliper, opacity, strength etc. Paper formation also affects the coating
capabilities and printing characteristics of the paper.

Gloss :- It is the specularly and diffusely reflected light component measurement against
a known standard. Gloss is important for printing such things as magazine
advertisements. The level of gloss desired is very dependent on the end use of the paper.
Gloss and smoothness are different properties and are not dependent on each other.
Machine and Cross Direction :- Paper has a definite grain direction due to greater
orientation of fibres in the direction of travel of the paper machine. This grain direction is
known as machine direction. The cross direction is the direction of paper at right angles
to the machine direction. Some of the properties vary with the MD and CD and hence the
values are reported in both the directions. While sheeting the paper, machine and cross
direction are to be kept in mind and the sheet cutting to be done to suit the end use
requirements. Examples: 1. All printing papers are to be cut in long grain (The biggest
dimension in the grain direction). 2. Book papers fold better and the book stays open
better if the sheets are out so that the machine direction runs up and down the pages. 3.
Wrap around labels for metal cans and bottles are to be cut with the machine direction
vertical to obtain greater flexibility about the can. Long grain and Short grain : The sheet
is in long grain if the larger dimension is parallel to grain (MD) direction. The sheet is
said to be in short grain if the larger dimension is parallel to cross direction (CD).

Moisture :- Most physical properties of paper undergo change as a result of variations in

moisture content. Water has the effect of plasticizing the cellulose fiber and of relaxing
and weakening the interfibre bonding. The electrical resistance and the dielectric constant
of paper both vary with moisture content. The absorption and reflectance of certain bands
of infrared and microwave radiation by paper are affected by its moisture content. The
amount of water present in a sheet of paper is usually expressed as a percent. The amount
of water plays an important role in calendaring, printing and converting process. Moisture
control is also significant to the economic aspect of paper making. Poor moisture control
can adversely affect many paper properties.

Opacity :- Opacity is the measure of how much light is kept away from passing through a
sheet. A perfectly opaque paper is the one that is absolutely impervious to the passage of
all visible light. It is the ratio of diffused reflectance and the reflectance of single sheet
backed by a black body. Opacity is important in Printing Papers, Book Papers, etc.
Porosity :- Because paper is composed of a randomly felted layer of fiber, it follows that
the structure has a varying degree of porosity. Thus, the ability of fluids, both liquid and
gaseous, to penetrate the structure of paper becomes a property that is both highly
significant to the use of paper. Paper is a highly porous material and contains as such as
70% air. Porosity is a highly critical factor in Printing Papers Laminating Paper, Filter
Paper, and Cigarette Paper. Bag Paper, Antitarnish Paper and Label Paper. Porosity is the
measurement of the total connecting air voids, both vertical and horizontal, that exists in
a sheet. Porosity of sheet is an indication of absorptivity or the ability of the sheets to
accept ink or water. Porosity can also be a factor in a vacuum feeding operation on a
printing press.

Sizing / Cobb :- Because paper is composed of a randomly felted layer of fiber, it's
structure has a varying degree of porosity. Thus, the ability of fluids, both liquid and
gaseous, to penetrate the structure of paper becomes a property that is both highly
significant to the use of paper. The need to limit the spreading of ink resulted in "sizing"
the paper with gelatinous vegetable materials which had the effect of sealing or filling the
surface pores. Later, the term "sizing" was applied to the treatment of paper stock prior to
the formation of the sheet, with water-repellent materials such as rosin or wax. Resistance
towards the penetration of aqueous solution / water is measured by Sizing or Cobb
values.

Smoothness:- Smoothness is concerned with the surface contour of paper. It is the

flatness of the surface under testing conditions which considers roughness, liveliness, and
compressibility. In most of the uses of paper, the character of the surface is of great
importance. It is common to say that paper has a "smooth" or a "rough" texture. The
terms "finish" and "pattern" are frequently used in describing the contour or appearance
of paper surfaces. Smoothness in important for writing, where it affects the ease of travel
of the pen over the paper surface. Finish is important in bag paper as it is related to the
tendency of the bag to slide when stacked. Smoothness of the paper will often determine
whether or not it can be successfully printed. Smoothness also gives eye appeal as a
rough paper is unattractive.
Stiffness :- Stiffness is the measure of force required to bend a paper through a specified
angle. Stiffness is an important property for box boards, corrugating medium and to
certain extent for printing papers also. A limpy and flimsy paper can cause feeding and
delivery problems in larger sheet presses. A sheet that is too stiff will cause problems in
copier machines where it must traverse over, under, and around feed rollers. Bond papers
also require certain stiffness to be flat in typewriters etc.

Stretch (Elongation) :- Stretch is the amount of distortion which paper undergoes under
tensile stress. Stretch elongation is usually expressed, as percent stretch to rupture.
Stretch can be related to the paper's ability to conform and maintain conformance to a
particular contour, e.g. Copier paper, multicolor offset printing papers, liquids packing
cartons base papers etc. It is an important property in sack Kraft papers which are used
for cement bags etc. Stretch is higher in cross direction than machine direction.

Tearing Resistance :- Tearing resistance indicates the behavior of paper in various end
use situations; such as evaluating web run ability, controlling the quality of newsprint and
characterizing the toughness of packaging papers where the ability to absorb shocks is
essential. Fiber length and interfibre bonding are both important factors in tearing
strength. The fact that longer fibres improve tear strength is well recognized. The
explanation is straight forward; longer fibres tend to distribute the stress over a greater
area, over more fibres and more bonds, while short fibres allow the stress to be
concentrated in a smaller area.

Temperature and Humidity: Conditioning of Paper :- Conditioning of paper is also of

importance in many printing and converting operations. In addition to the effect of
moisture content on physical properties, it also determines the build up of static of the
paper sheet subjected to pressure and to friction. The tendency for paper to develop static
becomes greater with increasing dryness. Cellulosic fibres are hygroscopic i.e. they are
capable of absorbing water from the surrounding atmosphere. The amount of absorbed
water depends on the humidity and the temperature of the air in contact with the paper.
Hence, changes in temperature and humidity, even slight changes, can often affect the
test results. So, it is necessary to maintain standard conditions of humidity and
temperature for conditioning.

Thickness :- Thickness or Caliper of paper is measured with a micrometer as the

perpendicular distance between two circular, plane, parallel surfaces under a pressure of 1
kg./ CM2. Caliper is a critical measurement of uniformity. Variations in caliper can affect
several basic properties including strength, optical and roll quality. Thickness is
important in filling cards, printing papers, condenser paper, saturating papers etc.

Wax Pick No. (Surface Strength ):- This indicates the surface strength of the paper. This
test is important for all uncoated printing papers.

Wire side and Felt side: - Also referred as wire side and top side. The side which is in contact
with the paper machine wire during paper manufacture is called the wire side. The other side is
top side. Certain properties differ between wire and felt side and it is customary to measure
these properties on both the sides. In case of paper to be printed on one side only, best results
are obtained by printing on felt side. Postage stamps are printed on wire side and then gummed
on felt side, where the smoothness is helpful for attaining an even application.
 Cycle for paper processing

Flow diagram for paper making process

 PULP PREPARATION

There are several different methods of pulp production

to make different strengths and grades of paper. The most common classifications are chemical,
mechanical, or semi-chemical pulping techniques.

Mechanical Pulping

Mechanical pulping utilizes steam, pressure, and high temperatures instead of

chemicals to tear the fibers. The fiber quality is greatly reduced because mechanical
pulping creates short, weak fibers that still contain the lignin that bonds the fibers
together. The presence of the lignin limits the amount that the pulp may be bleached
because the lignin binds with the bleaching chemicals. Newspaper and paperboards are
typical products of the mechanical pulping process. Mechanical pulping requires
materials such as 300 series stainless steel to prevent corrosion.

Semi-Chemical Pulping

Semi-chemical pulping techniques use weak chemical solutions composed of

sodium sulfite (Na2SO3) and sodium carbonate (Na2CO3) to help digest the lignin in the
pulp. In addition to the chemical solutions, mechanical refining is used to separate the
fibers.

Chemical Pulping
 Chemical pulping uses various chemicals to produce long, strong, and stable
fibers and to remove the lignin that bonds the fibers together. The chemicals used will
vary depending on the type of chemical pulping used. In this there are two main types of
chemical pulping performed:
Kraft (sulphate) pulping
Sulfite pulping.
The corrosion rate in these processes can be significant depending on the amount and
kind of chemicals and the type of materials used.

PULP PROCESSING AND CHEMICAL RECOVERY

 To further remove impurities and recycle the cooking liquor, also known at this
stage as black liquor, the pulp is processed through a series of washes. The removal of the
black liquor takes place in washers and is necessary to reduce the chemical costs of the
liquor, generate energy from pulp residue burned in the recovery boiler, and prevent the
cooking liquor from binding to the bleach chemicals. In addition, by recycling the
cooking liquor back into the pulping process, environmental issues and costs are negated
since there are no chemicals that must be discharged from the system.

Kraft Pulping Chemical Recovery:-

To recover chemicals from the black liquor, the slurry goes through a chemical
recovery process, such as the Kraft pulping chemical recovery. The liquor passes through
evaporators, recovery boilers, and causticizers to eventually produce white liquor.

The first step of chemical recovery is the evaporation process, which increases the
concentration of solids from approximately 15 percent to more than 60 percent. The
concentrated slurry contains approximately 50 percent organic solids and 6 percent total
sulfur in the form of sodium sulfate (Na2SO4) and sodium thiosulfate (Na2S2O3) and is
placed into a recovery boiler. The organic solids are burned for energy while the
inorganic process chemicals, also know as smelt, flow through the floor of the recovery
boiler to be recausticized. Mills with high levels of closure operate at high levels of
sodium chloride (NaCl). Typically, the NaCl concentration in black liquor is
approximately 12 percent in closed systems.

Recausticizing:-

Recausticizing is the process used to transform the inorganic smelt recovered

from the recovery boiler into white liquor so that the chemicals may be recycled. the
recycled inorganic chemicals are discharged as molten smelt from the recovery boiler and
then dissolved using water to form green liquor. Any unwanted substances are
precipitated out. Lime is then added to the clarified green liquor to produce sodium
hydroxide (NaOH) from the remaining sodium carbonate (Na2CO3). The resulting
solution (white liquor) contains sodium hydroxide, sodium sulfide (Na2S), and a solid
phase of calcium carbonate (lime mud). Before the white liquor is recycled back to the
digester, the white liquor is clarified further to remove the lime mud.

Sulfite Pulping Chemical Recovery:-

An alternative process is sulfite pulping chemical recovery. The chemical

recovery system of sulfite pulping differs from that for the Kraft process discussed
previously. The magnesium-based and calcium-based recovery systems are the most
corrosive recovery systems for sulfite pulping. Pitting and crevice corrosion under scale
deposits are the major corrosion concerns. The sulfite pulping process contains greater
amounts of sulfite (SO3), hydrogen sulfide (H2S), and hydrochloric acid (HCl) than those
used in the Kraft pulping process. Because of the presence of these corrosive species, the
internal portions of the recovery boilers and the evaporators are generally constructed of
reinforced plastics,

PULP BLEACHING
 Pulp bleaching is performed on the pulp in order to increase its brightness. Bleaching is
an extremely corrosive process that is executed under acidic conditions with strong oxidants
such as chlorine, chlorine dioxide, sodium hydroxide, and hydrogen peroxide.

Traditional Bleaching Techniques:-

The bleaching process as normally having three to five stages in which the pH of
the pulp is alternated between acid and alkaline conditions. During the acid cycle,
chemical reactions between the bleach and the lignin bonds turn the pulp lighter in color.
During the alkaline cycle, the reaction products from the acid stage are removed.

Environmentally Friendly Techniques:-

In recent years, less chlorine and more sodium hydroxide have been used for
bleaching. Currently, chemical pulps and the de-inking of secondary fibers are the
primary users of chlorine bleaching techniques. The European paper and pulp industry
has demonstrated success in using a totally chlorine-free bleaching process for selected
pulp grades.
STOCK PREPARETION
 After bleaching, the pulp is processed into (liquid) stock that can be transferred to
a paper mill. This processing is performed to get the required paper product and quality
specified. It can include blending various pulps together, beating and refining, dispersion
in water, and the addition of any wet additives such as resins, waxes, fillers, or dyes for
coloring.

Wood is a renewable resource that consists mainly of cellulous, lignin, and a

small portion of terpenes, resins, and fatty acids. The breakdown of wood is 45%
cellulose and 30% hemi-cellulose. It also contains 23% lignin, which is a resinous
material that binds the cellulose fibers together. It has less than 5% substances like
terpenes, resins and fatty oils and acids.

Many pulp mills have a paper mill adjacent to them; therefore, transferring the
products is not costly. The pulp mills, which produce market pulp, dry the pulp and
transfer it by truck, train, or ship. The equipment used to store and transport the pulp can
undergo crevice corrosion and pitting; therefore, they are usually completely or at least
partially clad with stainless steel.

PAPER MANUFACTURING PROCESS

Head box operation

Di scharge a uniform flow of pulp stock on to the moving wire. The Paper stock at this
point in the process is 99% water and 1% fiber. The Fan Pump forces the Paper stock through
a set of nozzles in the head box onto the “wire” mesh . The fan pump speed is a major factor in
the basis weight and formation of the sheet of paper.

Forming Section

A typical flat former is a continuous rotating wire (today this is plastic) mesh that
removes water from the paper by sucking it out of suspension. Multi-layer paper
machines and paper board machines include additional forming sections (one forming
section for each layer of paper).

Wire

Once the suspension has left the headbox and comes into contact with the wire,
the paper fibres move to the wire as a result of their natural flow resistance, thus forming
a layer of fibres on the wire which accumulates towards the top of the stock. At the same
time, water drains away at the bottom, and this combination of processes leads to two
different forms of sheet formation, depending on the freedom of motion of the fibres in
the suspension: through filtration and by means of thickening . It also known as a four
driner a moving fabric that forms the fibers in to that mat as the drains out of the mat.

Presses

Pressing is done to remove water, compacts the web and improves strength. A press
section works by using felts and vacuum devices to remove water.. The press section can
comprise of two or more presses. The still wet web of paper is transferred from the wire of the
wet end onto the felt at the couch roll, and is then carried through the presses on the felts; the
texture and character of the felts may vary depending on the various surface structures which
can be applied here. Sometimes a linen pattern or other types of surface structure are
introduced to the paper depending on the grade of paper being made. The main function of the
press is to continue to remove water from the pulp fibers and to smooth the surface
characteristics of the felt and wire sides (top and bottom sides) of the paper web running the
length of the machine.

Dryers

The web of paper enters the drier section with water content of approximately 65%, The drier
section consists of a series of driers, These are used to remove residual water by evaporation
will paper sheet is moves over a rollers. It is done by two processes,

Wet-End Operations:-

Using a paper production machine the processed pulp is converted into a paper
product at the beginning of this stage, the water content of the paper is greater than 99
percent. The most common machine utilized is the Fourdriner paper machine. In the wet-
end operation, the slurry of pulp is deposited onto a continuously, moving belt that
suctions the water from the slurry using gravity, vacuum chambers, and vacuum rolls.
The continuous sheet then moves though additional rollers that compress the fibers and
remove the residual water.

Dry-End Operations:-

Following the pressing of the wet-end operations, the continuous sheet is

compressed by steam-heated rollers to allow the fibers to begin bonding together.
Coatings are then applied to add to the surface appearance before the sheet is spooled for
storage.

Size press
 The simplest form of refinement is surface treatment in the size press which is
integrated in the paper machine. Here, starch is applied to strengthen the paper surface.
At the same time, this “closes” the surface of the paper, thus preventing problems like
dusting or picking from occurring in the later printing process. In many cases, treatment
in the size press is used to prepare the paper for the subsequent process of coating. The
size press consists of a pair of soft rolls, often coated with rubber, which press against
each other as the paper web is guided through the nip between the rolls. The size solution
is transferred to the paper through this nip, which also serves to control the dose of sizing
being applied. In the size press, the quantity of applied pigments is limited.

Calendaring & Reeling

The calendar section, the final section, consists of calendar stacks with a winding
mechanism for gathering the paper web onto a roll as it leaves the end of the paper
machine. The calendaring section of the paper machine gives the desired finish to the web.

Calendaring compacts the sheet and increases smoothness. A higher degree of smoothness
usually results in better printability. Calendar stacks consists of smooth rolls of varying
configurations. Items such as roll compositions, whether or not steam is used in the rolls, the
number of rolls and the types of control over these rolls all vary from paper machine to paper
machine. The paper leaving from the calendar stack is wound into a large roll of paper referred
to as the "parent roll". Parent rolls are wound to the specific diameter needed to produce
subsequent "sets" of smaller diameter reels to satisfy customer requirements. After that they
sent to a converting station where the paper will be either slit into smaller rolls or
where it may be sheeted for use in offset printing.

Winding
Winders convert parent rolls into customer requested reels of
specific width and diameter. They also make the removal of defective paper possible,
and are designed to control the amount of tension wound into rolls.
Applications
 Paper of different QUALITY, different GSM and GRADE can be used for various
purposes like:

  For all Commercial Printing Business Communication, Publications,

Diaries, Books and Stationary.

 For Calendars, catalogues, Annual Reports, Advertising, Brochures &

Pamphlets.


Environmental Concerns

The number of trees and other vegetation cut down in order to make paper is
enormous. Paper companies insist that they plant as many new trees as they cut down.
Environmentalists contend that the new growth trees, so much younger and smaller than what
was removed, cannot replace the value of older trees. Efforts to recycle used paper (especially
newspapers) have been effective in at least partially mitigating the need for destruction of
woodlands, and recycled paper is now an important ingredient in many types of paper
production.

The chemicals used in paper manufacture, including dyes, inks, bleach, and sizing, can
also be harmful to the environment when they are released into water supplies and nearby land
after use. The industry has, sometimes with government prompting, cleared up a large amount
of pollution, and federal requirements now demand pollution free paper production. The cost of
such clean-up efforts is passed on to the consumer.
Diagram that shows how the paper is made

 
 Conclusion

For papermakers who want to realize these flow sheets on existing machines, it is
important to implement the previously mentioned items one change at a time to reduce
machine downtime. Furthermore, gradual implementation permits operators to become
accustomed to each modification.

Finally, each paper machine has unique characteristics, and one process may
suffer different pitfalls than another. A progressive implementation and follow-up
procedure ensures the success of the project. TJ