EMAMI PAPER MILLS LTD.
Unit - Balasore
“Efforts taken at Emami Paper Mills Ltd. for
Better Maintenance Practices”
LOCATION
250 KM
200 KM
BAY OF BENGAL
EMAMI PRODUCTION MILESTONE
900
Chart Title
pm-1
800
pm-2
pm-3
bm-4
total
PRODUCTION TPD
700
600
500
400
363
390
400
350
300
235
250
255
92
95
48
50
200
100
0
15
1983
20
1990
85
60
25
1996
95
65
30
2001
YEAR
110
70
40
2005
83
45
2008
2011
2014
2015
Emami –Pulp & Paper Production Units at a Glance
MACHINE
PRODUCT
PM # 1
WRITING
PRINTING
PM # 2
NEWSPRINT
PM # 3
NEWSPRINT
RAW
MATERIAL
DIP # 1
PulpWriting
printing
DIP # 3
Pulp Newsprint
WASTE PAPERS
DECKLE
2.15 MTRS
2.85 MTRS
3.55 MTRS
SPEED
320 MPM
515 MPM
1120 MPM
Production
50-150 gsm
45 gsm
45 gsm
CAPACITY
50 TPD
95 TPD
250 TPD
50 TPD
330 TPD
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.
1983
15 TPD
PAPER MACHINE 1
2014
50 TPD
PAPER MACHINE 1
o
o
o
o
o
o
Hydraulic Headbox,
Fourdrinier , open draw,
2 straight Press, Pre-dryers,
Size Press, Post dryer ,
Swimming Calender
and Pope Reel
ABCDEFGHIJK
LMNOPQRSTU
VWXYZ
Approach Flow & Head box
PM # 1
15 nos. @ 150 mm
Plain
PA
Tan
k
HEADBOX
Top Lip
air vent
PROBLEMS
1. Uneven parent roll
built up for GSM
variation
2. Failure of Micro
Jack fingers
due to forced
Operation
18 Nos. @ 120 mm
BEFORE
PA
Tan
k
AFTER
air vent
Pr..
Scrn
Accelerating
Bend
JOB DONE
3.
Top Lip
Slot & drill for flexibility
Accelerating
Bend
Pr
Scrn
F
r
o
m
P
C
C
2.
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
T
o
P
A
t
a
n
k
1.
HEADBOX
Accept to PA
tank
Benefit
1. Parent Roll built up improve
by minimise GSM variation
2. Eliminate Micro jack failures
PM # 1
Wire & Press
Ø110 mm dia. &
Stiff Angle
Rigid doctoring
system
TOP FELT
Plain press Roll
Ø750 ,
90 °
Shore A
Rubber
pr
Ø740 ,
100°
Shore A
Dynarock
Ø750 ,
90 °
Shore A
Rubber
630
Ø740
,100°
Shore A
Dynarock
BOTTOM FELT
Ø600 mm, 125 mm wide box
6/10 counter SS Couch Roll
Problem :
1.
2.
3.
4.
5.
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.
2nd pr.
BOTTOM FELT
Wire & Press
TOP FELT
150 mm dia. lead roll
VFD drive reduce
stiff angle by
lift up couch roll
Blind
drill
press
Rolls
Ø750 BD
mm, 90 °
Shore A
l
Ø750 ,
Dynaro
ck
Ø750
mm, 90
° Shore
A
930
Ø750 BD
mm, 90 °
Shore
Ø600 mm, 125 mm
wide
box 6/10 counter
Bronze Couch Roll
Work done
1. Couch roll UP by 300 mm and
reduce stiff angle
2. 150 dia. Couch lead roll installed
with VFD dive in place 110 mm
dia. roll
3. Installed maxi flex doctor with a
2nd doctor at 2nd press top roll
4. Both 1st press top & bottom Roll
changed to Blind drill Roll
PM # 1
Maxiflex doctoring
System & 2nd doctor
BOTTOM FELT
l
2nd press
BOTTOM FELT
Benefit
1. Reduce Draw between wire and press from 23 MPM to
12 MPM.
2. Paper passing time reduce .
3. Reduce paper breaks at lead roll.
4. Doctor passing eliminate at 2nd press roll
5. Dryness increase d to 42% from 40%.
6. Steam consumption reduce to 2.8 MT/Ton paper from
3.3 MT.
7. Deckle increase at Pope by 2 cm.
8. Speed increased to 320mpm from 300 MPM.
9. Production increase.
Eliminate the Dryer felt roll breakdown
PM # 1
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
Ø 160
Ø45
Chrome plated
Dryer Felt Roll
Ø 180
Ø50
Rubber cover
Dryer Felt Roll
Year
Pre dryer
Post dryer
Total
2008
5
2
7
2010
3
2
5
2012
1
1
2
2013
0
0
0
2014
0
0
0
10
PM # 1
Size Press
Problem
1.
2.
3.
4.
5.
6.
7.
8.
Roll life 1 month
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
NIP load size press pm1
20
nip load kg/cm
Paper
15
Nip load(
Kg/cm)
10
5
Paper
0
0
Loading
1
2
3
4
5
6
air pressure kg/ cm sq
Unloading
NIP load size press pm1
Workdone
Benefit
1. Roll Life increase from 1 month to 2
month
2. Paper passing easy
Loading
Unloading
25
nip load kg/cm
30°
1. Made inclined size press from
horizontal
2. Made drive arrangement to lead out
roll
3. Made loading
4. Size solution increase to 50 GPL
5. Nip load increase to 20 kg/cm
20
15
Nip load(
Kg/cm)
10
5
0
0
1
2
3
4
5
air pressure kg/ cm sq
6
PM # 1
NIP load size press pm1
nip load kg/cm
Proposed Size Press
35
30
25
20
15
10
5
0
0
10
15
20
25
30
35
40
Hyd Pressure kg/ cm sq
45°
Proposed modification
1. 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
CALENDER
Before
After
PM # 1
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
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
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
1996
60 TPD
PAPER MACHINE 2
Hydraulic Headbox, Fourdrinier wire,
Close draw, Bi-nip press,
Dryer , Swimming Calendar
and Pope Reel
PRODUCT
NEWSPRINT
RAW
MATERIAL
RECYCLE
DECKLE
2.85 MTRS
SPEED
515 MPM
GSM
45
PRODUCTION
95 TPD
2014
95 TPD
IPPTA: promoting
paper industries
growth
PM # 2
Vac Box bearing failures of Suction Pick up roll and Suction Couch roll
Back
head
DS
Bearing
Vacuum box
Bearing
Assemble
Problem
1. Frequent failure of locking pins
& Bearing failures of box brg. assemble
Workdone
-----
BEFORE
AFTER
Back
head
Vacuum box
Bearing
Assemble
DS Bearing
1. Bearing assemble arrangement
changed from Vac box to Drive head
2. Bearing size change from
23220 to 22322
3. Stud shaft dia. change from
70 mm to 85 mm
Benefi t
Year
Pick up
roll
Couch
roll
Speed,
MPM
Producti
on loss
MT
2008-09
9:25
34:50
470.1
160
2009-10
14:50
16:00
494
118
2010-11
10:00
00:00
505
39.00
2012-13
00:00
00:00
506
00.00
2013-14
00.00
00.00
515
00.00
Roll diameter increase & Maxi flex doctoring system improve
press part efficiency
PM # 2
BEFORE
Problem Face
Groo
ved
Ø570
SP
U
Centre
Press
Roll
Ø805Ø825
Ø6
50
F
D
R
1.
CO
UC
H
Roll
2.
3.
W
as
h
ro
ll
Workdone
1.
2.
3.
Groo
ved
Roll
Ø590
SPU
Centre
Press Roll
Ø850
Ø650
FDR
AFTER
Couch
WA
SH
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%
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
Problem Face
1.
2.
3.
No Ink deposition on the centre press surface
increase uptime and no paper breaks 3-4 days.
Doctor blade life low 15-17 days only
Wide Nip width , Dryness of press increase 42%
to 44.5 %
PM # 2
FLEXIBLE doctoring system on Top Roll of PM # 2 Calender
BEFORE
AFTER
Rigid
Doctor
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 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 50-75 µm.
3. Grinding frequency 8-9 month
4. Roll life increase.
HEAD BOX STEP DIFFUCER BLOCK
PM # 2
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
PM # 2
Manufacturing Head Box Diffuser block at Home
Work done
BOX SS 304
1. Diffuser Block’s Drawing, Design
Developed &Manufacture
at home.
2. Arranged 182 nos. HDPE
diffuser Nozzle by injection
moulding at Kolkata.
Benefit
HDPE DIFFUSER 182 nos.
1. Run the machine at full speed
and produced good quality
paper.
2. Paper rejection and finishing
loss go down.
PM # 2
PM # 2 Speed UP ( in MPM)
520
510
500
500
505
510
490
477
MPM
480
470
460
460
450
440
430
YEAR
2008-09
1. 4 nos. 200 mm
dia. Uhlebox in
place of 150 mm
with ceramic
2009-10
1. Head box lip
changed
2. Fan pump impeller
dia increase from 365
to 380mm
2010-11
1. Head box electro
polish.
2. Pressure screenmay with 015 mm slot
3. Uhle box slot 10 mm
to 13 mm
2011-12
1. 850 mm Centre
press roll in place
805 mm dia
2. Centre press
Maxi flex doctor
ing system
3. 570 mm to 590
mm Groove
4. 0.5° Hydrofoil
2012-13
1. Orthoflow
PAPER MACHINE 3
2007
205
TPD
Hyd.headbox, Twinwire Gap former belbie IV
Trinip Ceramic Nipco Press, Dryers,
2014
Double stack Soft Calender
250 TPD
& Pope Reel
IPPTA: promoting
paper industries
growth
PM # 3
Abnormal vibrations in the forming section at wire part.
Before
Bow roll
Forming roll
HB
After
Bow roll
Problem
1. Too much Vibration at Forming roll.
2. Restricted speed up above 1000 mpm
Work done
1. FE analysis carried out
By IIT , Kharagpur.
2. Bow roll reposition with new bracket
Benefit
1. Vibration reduce.
BEFORE VIBRATION
DRIVE END BEARING
13.
10.1
3.32
MPM
985
NON DRIVE END
8.71
8.49 3.21
AFTER VIBRATION
Forming roll
HB
7.5
4.3
1.8
1058
3.5
2. Speed up the machine
to 1120 MPM
2.3
1.53
PM # 3
Higher vibrations of Dryer Frames and paper breaks for sticky
coming along with recycle pulp
Problem :
BEFORE:
Original Dryer Frame configuration
1. Vibration in dryer frame
2. No doctoring system on dryer for sticky cleaning
Work done
1. Arch type Tie connected in between dryer frame
2. Installed doctoring system on every dryer.
AFTER: Dryer Frame configuration
with addition of Arch Beams
Benefit
1. Vibration Reduce
2. Keep the dryer surface clean.
In house overhauling of swimming & nipco roll reduces
foreign experts cost.
PM # 3
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
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)
2011
33
7
2012
17
2
2013
16
0
2014
6
1
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
DATE
06-112014
06-042014
06-032014
TORQUE
DRIVE END
HOR
VERT
LR/HR
44/35
31/25
31/25
AXIAL
M
IN MAX MIN MAX MIN
MAX
2.19
2.21
2.3
1.92
1.3
2.21
1.25
1.31
1.16
2005
48 TPD
Deinking Plant 1
2014
54TPD
WE SHALL
OVERCOME
Power Saving in DIP 1
KW/MT F paper
600
519.6
478.33
500
456
364
359
355
2011-12
2012-13
2013-14
400
PROBLEM
1. Power consumption too high
300
200
100
0
2008-09
2009-10
PARTICULARS
2010-11
Horizontal
slot screen
0.15 mm slot
Horizontal
Hole screen
dia 1.8/2.2
Vertical
slot screen
0.15mm slot
Vertical
hole screen
dia 1.4mm
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
270
Rotor dia
733
496
490
490
Rotor rpm
571
763
440
715
Tip velocity m/sec
22
20
11
18
1.6 -1.8 %
2.5-2.6%
0.8-2.0%
3-3.5%
BKW
75
39
15
31
Motor KW
90
45
18.5
37
Motor rpm
1500
1500
1455
1450
Motor FLC
157
81
35
66
Motor RLC
128
74
25
55
Running KW
77
44
15
33
Slot/Hole size
Basket size
Inlet Consistency (% )
Work Done
1. Study individual power
consumption trend of
equipment's in DIP plants.
2. Identified screening
section consuming
more power
3. Select appropriate
equipment and installed
4. Power consumption reduce
from 121 KW to 48 kw.
BEFORE MODIFICATION in SCREENING
SECTION POWER CONSUMPTIN WAS 121
KWH/MT F paper
DIP # 1
Diabolo slot
Mac cell
Diabolo hole
POWER
520 KWH/PAPER
Coarse Hor. Hole
screen 45 kw
Constant level chest & pump
Fine Hor. Slot screen
90 KW
Fine screen feed chest & pump
AFTER MODIFICATION in SCREENING SECTION
POWER CONSUMPTIN IS 48 KWH/MT F paper
Mac cell
POWER
360 KWH/PAPER
Diabolo slot
Diabolo hole
HD cleaner
Constant level
chest & pump
Coarse Ver hole
screen 37 KW
Fine screen feed chest & pump
Fine Ver. slot screen
18.5 KW
2007
300
TPD
Deinking Plant 3
2014
330 TPD
ABCDEFGHIJKL
MNOPQRSTUV
WXYZ
Reduction of Screw press vibration in of Deinking Plant:
Problem
1. Too much vibration at DS screw for polished
screw surface .
2. Coupling failure.
3. Basket damaged.
4. Production hampered for
frequent stoppage for
roughening the polished screw surface.
Work Done
1. Tungsten carbide coated body plate
welded on polished screw surface
Benefit
1. Eliminate excessive vibration at DS screw
2. Coupling & Basket not failed/damage
since body plate installed.
3. Frequent roughening not require
SCREW PRESS
DRIVE END
HOR VER AXIA
NON DRIVE END
HOR VER AXIA
AFTER
TORQUE
06-04-2014
06-03-2014
BEFORE
01-09-2014
26/12/2013
56%
56%
1.02
0.78
0.51
0.38
0.59
0.29
1.17
0.84
0.79
0.4
0.97
0.35
54%
55%
5.5
6.5
2.6
4.2
1.3
2.6
3.7
4.3
4.7
5.5
3.5
5.1
DIP # 3
Cost Reduction on Reject Plastics Handling in Deinking Plant:
Problem
Work done
DIP # 3
Benefit
Dirty House keeping
A heavy duty Bale press installed
More Man power (40
nos.)
Two conveyor installed which carry
Less Manpower (10 nos.)
the reject plastic to bale press directly
from source
Higher moisture ( 60%)
in plastics.
Clean House keeping
Less moisture (20%) in
plastics
SAVINGS IN PLASTICS HANDLING BY INSTALLATION OF BALE PRESS & NEW
CONVEYING SYSTEM
UNIT
Total
Total
PREVI PRESE SAVINGS of PRIC
Savings
Sl.No.
PARTICULARS
Savings
OUS
NT Manpower E
Lacs/Mo
(Rs.)/Day
(Rs.)
nth
Manpower
engaged in Power
1
34
10
plant for Baling &
feeding Plastics
Manpower
engaged in DIP#3 &
4
DIP 1 plant for
6
0
shifting Plastics to
Power plant/Day
6
Total Manpower
40
10
30
200
6000
1.8
Transportation
7
1044
0.24
charge
Total Savings per
9
7044
2.04
month
10
Total Savings per Annum in Lacs
24.48
Conclusion
1. 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.
2. By increasing the lead roll diameter & with VFD arrangement Paper breaks
at couch roll in PM#1 reduced.
3. 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.
4. 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.
5. In-house plastic handling system reduces the manpower & nuisance in the
Plant.
6. In house overhauling of swimming & nipco roll Eliminated supervision and
experts cost Rs. 10 lacs / annum.
7. The deinking plant poire is being rebuild at our workshop which saves
around 2.5 Lac/ year