Paper Manufacturing Training

 General Paper Making
 Introduction to Paper and Board Machines:::::

Description:
Paper can be defined as a flat, nonwoven network of cellulose fibers that are bonded together to
form a sheet. In the papermaking process, the sheet is formed on a fine-mesh screen from a dilute
suspension of fibers in water. This course covers the equipment and processes needed in order to
create a fully formed sheet of paper. This includes the forming and press sections, together known
as the "wet end" to the "dry end" of the machine where the paper is dried, calendered, and wound
onto large rolls of paper called reels. This course also discusses the purpose of the white water and
broke collection systems as well as different types of forming and dryer sections that are used in the
paper making process.
Learning Objectives:
-Define the terms "paper," "board," "furnish," "broke," and "white water".
-Identify the effect of each section of the paper machine on the sheet being produced.
-Identify the processes associated with each section of the paper machine.
-Describe the different types of forming sections, including Fourdrinier, cylinder, paperboard, and
twin wire.
-Describe the dryer sections on multi-cylinder and Yankee machines.
Key Questions:
The following key questions are answered in this module:
* What is typically contained in a paper making ""furnish""?

Ans: "Furnish" refers to the suspension of fibers, fillers, and chemical additives in water that is used
to produce a sheet of paper or board. Furnish components vary according to the desired sheet
properties for different paper grades.
*What is the function of the headbox on a paper or board machine?
Ans: The headbox distributes the furnish evenly onto a continuously moving fine mesh screen (also
referred to as a "forming fabric" or "wire") at one end of the machine.
*Why is it important to remove as much water as possible at the ""wet end"" of a paper or board
machine?
Ans: It is desirable to remove as much water as possible at the wet end (which consists of the
forming section and press section), because the removal of water by mechanical means costs less
than the removal of water by evaporation, which is used in the next section - the dryer section.
*What is the purpose of the white water system on a paper or board machine?
Ans: The white water system collects much of the water that is removed from the sheet on the
machine and makes it available for re-use as dilution water and shower water.
 Pulping and Paper making Overview::::
Description:
This module begins with a brief history of papermaking and a discussion on the types of fibers used
in the production of paper products. Then, it discusses the various mechanical, chemical, and semi-
chemical pulping processes used to separate the fibers in wood. It describes several pulp processing
operations, including bleaching, and ends with a description of the various sections of a paper
machine, including the forming section, press section, dryer section, and reel.
-Define the terms "pulp," "paper" and "paper grades".
-Describe the major milestones in the history of paper making.
-Differentiate between hardwood and softwood fibers.
-List in order the major operations for pulping and paper making.
-Differentiate between mechanical, chemical, and semi-chemical pulping.
-Describe the screening, bleaching and refining steps in pulp processing.
-Define and order the major sections of a paper machine.
Key Questions:
*How are softwood and hardwood fibers different from each other?
Ans: Softwood fibers tend to be long and flexible, which contributes to the strength characteristics
of paper. Hardwood fibers tend to be short and stiff, which contributes to the bulk, smoothness,
and opacity of paper.
*Why is paper that is made from mechanical pulp called "wood-containing paper"?
Ans: Mechanical pulps contain all of the constituents of wood, including the lignin, and so they are
referred to as "wood-containing."
*What is the "liquor" that is used in chemical pulping processes?
Ans: "Liquor" is the name of the water-based chemical solution that is used to cook wood chips in
chemical pulping processes.
*What happens to the chemicals in the cooking liquor after the pulping process?
Ans: The chemicals are washed out of the pulp and then they are recovered so that they can be
reused.
*Pulping and papermaking processes require a lot of steam heat. Where does this steam come from?
Ans: As part of the chemical recovery process, many organic compounds from the wood are burned
to produce steam.
 Paper Machine General Safety::::
Description:
There are many hazards associated with paper making and converting facilities. Equipment and
process hazards can be minimized by the use of safety guarding, personal protective equipment,
safety training, and standardized procedures. Personal behaviors are also important because they
play a major role in safety. This course details some common hazards and hazardous situations
found in papermaking and converting facilities and describes methods for minimizing or avoiding
these hazards.
-Describe the common dangers in a paper making environment.
-Describe injury preventative measures, including PPE, lockout/tag-out, emergency stops, and good
housekeeping.
Key Questions:
*What dangers are present in papermaking and paper converting facilities?

Ans: Pinch points, nips, sharp surfaces, hot surfaces, slips, trips, falls, airborne particles, high noise
levels, chemicals, confined spaces, water and air hoses, and fires.
*What behaviors can contribute to injuries?

Ans: Complacency due to routine, taking shortcuts to save time, and lack of focus or distractions
can contribute to injuries.
*What are the leading causes of fall injuries?

Ans: Objects left on the floor, slippery fluids on the floor, insufficient or missing railings, incorrect
ladder use, insufficient fall protection, and people being unaware of their surroundings.
*Why is paper dust hazardous?
Ans: Dust can accumulate and create a slippery surface. When airborne, it can get into operator's
eyes or cause respiratory problems. Dust is also a risk for fire or explosion.
*What precautions can be taken to avoid paper machine hazards?

Ans: Hazards can be avoided by wearing the proper PPE, following LOTO procedures, and
maintaining good housekeeping. E-stops should be used when there is imminent or actual danger to
personnel or equipment.
 Steam Theory Fundamentals::::
Description:
Steam is generated by adding enough heat energy to water to change it from a liquid to a gas phase.
Latent heat is the heat energy required to accomplish this phase change. The latent heat in the steam
can then be used to transfer heat to lower temperature surfaces. When saturated steam gives up its
heat, it changes into liquid water called condensate that is at the same temperature as the steam. This
module lists safety guidelines for steam generation and distribution systems, describes how steam
can be used to transfer heat, and describes the relationship between steam pressure and saturated
steam temperature.
-List safety hazards and safe work practices associated with steam generation and distribution
systems.
-Define the terms "latent heat," "superheat," "de-superheating," and "condensate"
-Explain how steam is created in a boiler.
-Describe how steam can be used to transfer heat.
-Explain why superheat is sometimes intentionally added to fresh steam.
-Describe direct contact and indirect contact type desuperheaters.
-Describe the relationship between steam pressure and saturated s team temperature.
Key Questions:
*What is "latent heat"?

Ans: Latent heat is the heat energy that is required to convert a liquid to a gas - for example, liquid
water to steam.
*Why is it important that steam contains latent heat?

Ans: When steam contacts a surface that is at a lower temperature than it, the steam will condense
on the surface and transfer its latent heat to that surface.
*What is superheated steam?
Ans: Superheated steam is steam that has been heated above its boiling point (for the current
pressure).
*Why is superheat sometimes added to steam, and then removed?

Ans: Steam is superheated to prevent it from condensing in steam supply piping. Once it reaches its
final destination, this superheat is often removed to encourage condensation and improve heat
transfer.
*Why is it important to try and recover the condensate from steam-heating systems?
Ans: Condensate still contains large amounts of sensible heat and it may contain boiler feed water
treatment chemicals, so it reduces costs if it can be recovered and reused.
 Paper Machine Doctors::::
Description:
Doctors are used in all sections of paper and board machines to remove excess water and
contaminants from roll surfaces. In some applications, they are also used to remove the sheet from
roll surfaces on sheet breaks or during sheet threading. Doctors must be checked and inspected on a
regular basis to ensure their continued, safe, efficient operation.
-Identify the two main functions of paper machine doctors.
-Identify and describe the safety hazards associated with roll doctors and doctor blades.
-Identify the key components of a doctor.
-Identify the purpose of the doctor components.
-Differentiate between mechanically-adjusted and self-conforming blade holders.
Identify typical locations for doctors on paper and board machines.
-Explain the importance of regular doctor and doctor blade inspections.
-Identify and describe key inspection points for doctors and doctor blades.
Key Questions:
*Why are flexible, self-conforming doctor blade holders used on some rolls?
Ans: Flexible, self-conforming blade holders utilize two fluid-filled or air-filled tubes to load the
blade against a roll surface. They maintain a uniform pressure on the blade across the machine and
automatically compensate for changes to the roll surface, including roll deflection.
*Why should you avoid increasing the load on a used doctor blade?
Ans: This can cause the blade tip to lift up, which greatly increases t he risk of the sheet wrapping
the roll.
*Why are double doctors used on some suction rolls?
Ans: The first blade removes surface water and creates a vacuum pulse that pulls water out of the
holes in the roll shell. This water is then removed by the second blade.
*Where are air doctors used on paper and board machines?

Ans: Air doctors are used on drilled and grooved surfaces to prevent the type of damage that can be
caused by contacting doctor blades.
*Why is it important to change doctor blades on a regular basis?

Ans: This is important because as blades wear, blade angles change, which makes them less efficient.
 Paper Machine Doctor Blade Components and
Troubleshooting::::
Description:
Doctors are used on paper and board machines to remove excess water and contaminants from roll
and cylinder surfaces, and to remove the sheet from these surfaces during sheet breaks and
threading. Doctors must be properly installed and maintained to ensure their continued safe and
efficient operation. It is important to examine worn blades and document wear patterns, and work
with doctor and blade manufacturers to identify problems and improve doctoring operations. This
course lists the potential causes and possible remedies for some well-known blade wear patterns. It
also lists the steps necessary to properly install a doctor.
-Identify the two main functions of paper and board machine doctors.
-Identify the main components of a doctor and describe the purpose of each component.
-Describe the two main types of doctor blade holders - rigid and self-conforming.
-List the key points involved in the proper installation of a doctor.
-Identify the potential causes and possible remedies for some well-known blade wear patterns.
-Describe safety hazards and considerations when working around paper machine doctors.
Key Questions:
*What are the two basic types of paper machine doctor blade holders?
Ans: Rigid and self-conforming. Rigid holders are fitted to the roll initially and they do not
automatically adjust. Self-conforming holders use one or two tubes to load the blade and they do
automatically adjust to match the roll surface.
*What are the three materials from which paper machine doctor blades are made?
Ans: Metals, composites (usually of resins and fibers), and plastics (usually a type of polyethylene).
*What technique can be used to detect blade wear patterns that are more difficult to observe?
Ans: Lay the worn blade on the floor next to the straight back edge of another blade for
comparison.
*What could cause a blade edge to become feathered?

Ans: A feathered edge can be caused by a low blade angle, excessive blade loading pressure, or blade
material that is too soft.
*Why is it important to not increase a blade load after a blade has been used?
Ans: This can cause the tip of the blade to lift up (called "bird mouthing"), which can lead to debris
getting trapped under the blade and sheet wrapping.
 Stock Preparation
 Thick Stock System Design:::
Description:
The thick stock system is where the papermaking process begins. In this system, pulp fibers are
blended together, refined, diluted, metered, and some additives may be added. This course discusses
the principles of the thick stock system as well as the key equipment used, how stock blending is
achieved, as well as how high density chests and stock thickeners work.
-List the four principle objectives of the thick stock system.
-Identify safety hazards and safety guidelines related to thick stock systems.
-Identify and describe key equipment used in thick stock systems.
-Identify and describe primary process flows in thick stock systems.
-Describe stock blending.
-List common features of stock storage chests.
-Describe how high density chests work.
-Describe how stock thickeners work.
Key Questions:
*Why is it important to control stock consistency in the thick stock system?

Ans: Consistency control is important because it can affect refining, sheet formation, moisture and
weight profiles, and vacuum levels on the machine.
*Where is consistency typically controlled in a thick stock system?

Ans: Consistency is measured and dilution white water is normally added at the suction of stock
pumps to help blend the stock and white water together.
*Why is pH control important in the thick stock system?
Ans: Good pH control is crucial to steady machine operation because pH plays a major role in
refining, additive efficiencies, and drainage. Also, it is easier to control machine pH when the
incoming stock pH is consistent.
*What is the purpose of savealls in thick stock systems?

Ans: Savealls (also called thickeners or deckers) are used to recover fiber and filler from white water,
thicken stock, or both. Saveall designs include gravity drum, vacuum drum, and vacuum disc.
*What is the role of the machine chest in the thick stock system?
Ans: The machine chest dampens any remaining fluctuations and supplies an uniform stock slurry to
the thin stock system.
 pH and Consistency Control for Paper Machine Stock:::
Description:
The main goal of a paper or board machine stock system is to consistently supply the desired
mixture of fibers, fillers, chemicals, and water to the paper or board making process. As part of this
goal, it is important to control two stock variables - pH and consistency. If either of these variables
is outside its desired range, the sheet produced will not meet product specifications. Having good
control of stock pH and consistency helps to produce the same quality sheet, day in and day out.
-Identify safety hazards and safety guidelines related to stock systems on paper and board machines,
including pH control systems.
-Define "consistency," "pH," "acid," "base" and "buffer".
-Identify the benefits of good consistency control.
-Identify and describe the types of consistency transmitters.
-Describe common consistency control strategies, including feedback, feed forward and cascade.
-Describe the pH scale.
-Describe pH measurement and control.
-Describe the impact of pH on wet end chemistry.
Key Questions:
*Why is it important to control consistency in a paper or board machine stock system?

Ans: Consistency affects refining, screening, and cleaning operations in the stock system, and
moisture and basis weight profiles, sheet formation, and vacuum levels on the machine, among
other things. Therefore, it can significantly impact both product quality and machine run-ability.
*How is consistency controlled in a paper or board machine stock system?

Ans: Consistency is usually controlled by adjusting a dilution water flow into a stock flow.
*What different control strategies are available to control consistencies in stock systems?
Ans: Some control strategies currently in use include feed forward, feedback, cascade, and a
combination of cascade and feed forward. The strategy used depends on the stability of the stock
flow and the dilution water supply.
*Why is it important to control pH in paper and board machine stock systems?

Ans: Soluble ions affect pH and interfere with the surface charge interactions which dominate the
interactions amongst stock constituents. Among other things, pH affects additive efficiencies,
refining, and drainage and formation on the former.
*How is pH controlled on a paper or board machine?

Ans: Acidic and caustic chemicals are typically used to control pHs on paper and board machines.
 High Density Cleaners:::
Description:
High density (or HD) cleaners are large diameter forward cleaners capable of processing several
hundred tons of fiber per day. The main purpose of high density cleaners is to separate heavy
contaminants from fibers in suspensions of fibers in water (often referred to as "stock"). This
protects downstream equipment from excessive wear and damage. They may also be used for fiber
recovery. This module will describe the operation of high density cleaners and identify typical
applications of high density cleaners in secondary fiber, pulp mill, stock preparation, and broke
systems.
-Describe how high density cleaners differ from other centrifugal cleaners.
-Identify safety hazards associated with high density cleaners.
-Identify the purpose of high density cleaners.
-Describe the operation of a "junk trap" during a dump cycle.
-Describe the purpose of the main components of a junk trap.
-Identify typical applications of high density cleaners in secondary fiber, pulp mill, stock preparation,
and broke systems.
Key Questions:
*What is the purpose of high density cleaners?

Ans: Their main purpose is to separate heavy contaminants from fibers in fiber-water suspensions in
order to protect downstream equipment from wear and damage.
*Where are high density cleaners typically used?

Ans: They are often used in secondary fiber systems, pulp mills, paper and board machine thick
stock systems, and broke systems.
*How are high density cleaners different from other forward cleaners used in the production of
paper and board?
Ans: High density cleaners are larger in size physically, discharge their rejects intermittently rather
than continuously, and operate with higher feed stock consistencies than other forward cleaners.
*What is the purpose of the elutriation water in a high density cleaner?

Ans: A continuous stream of elutriation water is used to flush fibers out of the rejects chamber, at
the bottom of the cleaner, during cleaner operation.
*How often are the junk traps on high density cleaners emptied?
Ans: The frequency of the junk trap dump cycle and the length of the purge depends on the level of
contaminants in the stock suspension.
 Paper Machine Refining::::
Description:
Refining is one of the critical process steps in engineering the structure of paper and board as it has
a major influence on fiber quality. Refining mechanically alters the fibers by brushing, hydrating, and
cutting them. This course will describe low consistency refining as well as refining actions as they
relate to double disc refiners. It also discusses the different refiner types, key components of a
double disc refiner, typical control strategies, and the effects of refining on sheet properties.
-Describe the effects of refining on wood fibers.
-Identify safety hazards and safety guidelines associated with refiners.
-State the objectives of refining.
-Identify the different refiner types.
-Identify and describe the key components of a refiner.
-Describe the operation of refiners.
-List the typical control strategies.
-Identify the effects of refining on sheet properties.
-Explain the effects of over-refining.
Key Questions:
*What is the purpose of paper and board machine refining?

Ans: The main purpose of most paper and board machine refining is to improve certain sheet
properties, including strength and density-related properties.
*What happens to the fibers during refining?

Ans: The fiber cell walls are delaminated, allowing them to absorb more water and increasing their
flexibility. External fibrillation of the fiber surfaces increases the surface area available for bonding,
and some fiber cutting and creation of fines takes place.
*Why is it important to keep the flow rate through a refiner steady?
Ans: Flow rate determines the amount of time the fibers are available for treatment in the refiner.
Low flow can lead to fiber cutting, fiber channeling in the plate grooves, and poor strength
development. High flow can cause plugging and poor fiber development.
*Why do broke fibers and recycled fibers not respond as well to refining?
Ans: Broke and recycled fibers have already been refined and contain some shorter fibers, which
don't respond as well to refining. Also, they have been previously dried, so don't absorb water as
readily, making them more difficult to refine.
 High Consistency Refining::::
Description:
Refining is the mechanical treatment of pulp fibers to develop paper and board sheet properties.
The two main types of refining are low consistency refining and high consistency refining. This
module will examine the design and operation of high consistency refining systems.
-Identify safety hazards and safety guidelines associated with refiners.
-Differentiate between low consistency and high consistency refining.
-Identify and describe the equipment used in high consistency refiner systems.
-Describe the design and operation of high consistency refiners.
-Identify the sheet properties affected by high consistency refining.
Key Questions:
*How does high consistency refining differ from low consistency refining?
Ans: Low consistency refining increases the fibers' surface area available for bonding and several
sheet strength properties. However, it reduces freeness and drainage. High consistency refining
creates micro-compressed and curly fibers, which improve sheet stretch and porosity, as well as
some strength properties, like tear. It also reduces freeness and drainage, but to a lesser degree.
*On what paper or board grades is high consistency refining used?

Ans: High consistency refining is well-suited to the production of craft sack papers and other similar
grades which must withstand high levels of strain during use.
*At what consistency is high consistency refining performed?

Ans: High consistency refining is performed above 20% consistency, and consistencies between 30
and 40% are quite common.
*How is 30 to 40% consistency stock transported to the high consistency refiners?
Ans: Screw conveyors are typically used to move high consistency stock from the presses to the
refiners.
*What happens to the filtrate that is removed from the stock by the presses that are positioned
ahead of high consistency refiners?
Ans: This filtrate can be used to re-dilute the stock after it has been refined, before it is metered
back into the paper making process.
 Stock Approach:::::::
 Thin Stock System Design:::
Description:
The thin stock system is responsible for supplying clean, dilute stock to the headbox of a paper or
board machine. The thin stock system uses white water to dilute the stock to the proper consistency
for cleaning, screening, and delivery to the headbox. This module will list the objectives of a thin
stock system and identify how each objective is satisfied.
-Identify and describe safety hazards and safety guidelines for thin stock systems.
-List the objectives of a thin stock system and identify how each objective is satisfied.
-Explain the purpose of "cascaded" cleaning systems.
-Identify and describe key equipment.
-Identify and describe primary process flows.
-Describe the operation of centrifugal cleaners.
-Identify where chemical additives are typically added to thin stock.
-Describe how consistency is controlled in a thin stock system.
-List the objectives of thin stock screening.
-Describe operation of pulsation dampening equipment.
Key Questions:
*Why do thin stock cleaning and screening systems often use multiple stages?
Ans: The later stages are used to recover the fibers in the rejects from the first stage. This minimizes
fiber losses and improves the overall efficiency of the system.
*What is the difference between a forward cleaner and a reverse cleaner?
Ans: In both types, the denser components exit from the bottom and lighter components from the
top. Forward cleaners remove small dense contaminants, so the fibers exit from the top. Reverse
cleaners remove lightweight contaminants, so the fibers exit from the bottom.
*Why are fan pumps usually double suction pumps instead of centrifugal pumps?
Ans: Fan pumps are typically double suction pumps with low-pulse impellers to minimize pressure
pulsations in the stock going to the headbox, which can occur with regular centrifugal pumps.
*What is the difference between cleaners and screens?

Ans: Cleaners remove small contaminants based on density differences with fibers, while screens
remove larger contaminants based on size differences with fibers.
*What is the purpose of the attenuator in a thin stock system?

Ans: Attenuators use air pads to remove any remaining pressure pulsations in the stock flow to the
headbox, which is especially important for hydraulic headboxes.
 Centrifugal Cleaners::::
Description:
This course describes the purpose, design, and operation of centrifugal cleaners installed in paper
machine thin stock systems. The effect of pressure drop, feed consistency, and reject rate on cleaner
efficiency is covered, followed by a discussion on the set up and operation of a typical cascade
cleaner system.
-Describe the purpose of centrifugal cleaners.
-Describe the design and operation of forward cleaners.
-Describe the benefits of cascaded cleaning systems.
-Describe the design and operation reverse and dual cleaners.
-Describe factors that affect cleaner efficiency.
-Describe the effect that cone size has on cleaning.
Key Questions:
*What is the purpose of cleaners?

Ans: Centrifugal cleaners are used to remove contaminants and protect downstream equipment
from damage and wear.
*What are forward cleaners?

Ans: Forward cleaners separate heavy particles from pulp by centrifugal force.
*What is a cascade cleaner system?

Ans: Rejects from a set of cleaners often contain good fiber. In a cascade system, additional stages
are used to process the Primary stage rejects and recover the fibers.
*What are reverse cleaners?
Ans: Reverse cleaners separate lightweight contaminants from fibers. Lightweight contaminants
include wax, plastic, and other stickies.
*Why is pressure drop important for cleaning efficiency?

Ans: If the pressure drop is too low, the stock will rotate too slowly inside the cones and
contaminant removal will suffer. If the pressure drop is too high, the stock will pass too quickly
through the cones.
 Stock Approach - Deaeration::::
Description:
Entrained air in the dilute stock supplied to the headbox of a paper or board machine can cause
problems with drainage, foam, sheet formation, and overall process stability. Therefore, mechanical
deaeration is sometimes required. This module will identify four ways to keep entrained air out of
paper and board making processes and describe the three ways mechanical deaerators remove air
from stock.
-List and describe three forms of entrained air in stock suspensions and white water.
-Identify four ways to keep entrained air out of paper and board making processes.
-Identify the negative effects of, and potential benefits of removing, entrained air in stock.
-Identify and describe the key equipment.
-Describe the three ways mechanical deaerators remove air from stock.
-Explain why a stand-alone deaerator might be used instead of a combination cleaner/deaerator.
-Describe the function of the condenser and vacuum device in the vacuum system.
-Identify potential causes for a sudden drop in vacuum, deaerator flooding, and low vacuum or
system instability.
Key Questions:
*Are there multiple forms of entrained air?

Ans: There are three forms of entrained air that can exist in stock suspensions and white water -
free, bound, and dissolved.
*What are the differences between free air, bound air, and dissolved air?
Ans: Free air consists of larger bubbles that can be removed with time, bound air consists of smaller
bubbles that can attach to fibers and be difficult to remove, and dissolved air only presents a
problem if it converts into free or bound air.
*Is deaeration necessary on every machine?
Ans: The amount of entrained air that is tolerable in a paper or board making process depends on
many things. So, though all paper and board machines would benefit at least a little from deaeration,
not all of them use it.
*How do deaerators remove entrained air from the stock suspension?

Ans: They use three means: they use vacuum to ""boil"" the stock to remove air, they spray the
stock to expose more surface area to the vacuum, and they impinge the stock on hard surfaces to
separate the bound air from the fibers.
*Can a deaerator cause pulsations in the stock flow to a headbox?

Ans: Pulsations in the stock flow to the headbox can be caused by excessive air in the stock going to
the deaerator, an undersized or underperforming vacuum system, or low stock flows to the
deaerator, which can cause the level inside the vessel to rise and fall, leading to fluctuations in the
stock flow to the fan pump.
Thin Stock Screening::::
Description:
The purpose of thin stock screening is to remove debris from the dilute stock going to the headbox.
Screening also deflocculates the stock and protects downstream equipment. Screening systems often
use two or three "cascaded" stages in order to reduce fiber losses and improve overall debris
removal efficiency. The design and operation of a screening system must take into account the
requirements of the paper or board machine, desired sheet quality and properties, and characteristics
of the particles to be removed.
-Identify the purposes of thin stock screening.
-Identify the types of debris found in mechanic al pulps, chemical pulps, and secondary fiber.
-Identify the components and describe the operation of a vibratory flat screen.
-Identify the components and describe the operation of pressure screens.
-Explain why pressure screen holes and slots are tapered or relieved.
-Define "reject rate," "debris removal efficiency," and "long fiber removal efficiency".
-Describe the operations of cascaded screening systems.
Key Questions:
*What is the purpose of thin stock screening?

Ans: Screening removes dirt, small pieces of plastic, wood and other contaminants. It also helps
break up fiber clumps.
*What are disadvantages of vibratory flat screens?

Ans: Vibratory screens have high maintenance and foaming issues.
*How are pressure screen basket openings created?

Ans: The baskets can have drilled holes, milled slots, or welded wedge wire.
*What are typical screen opening sizes?
Ans: In thin stock systems, hole sizes range from about 1.2 to 3 mm (0.05-0.12 inch), with an open
area of 10 to 25%. Slot widths vary from about 0.2 to 0.5 mm (0.008-0.02 inch), and open area is
generally 7 to 15%.
*What debris properties affect removal efficiency?

Ans: Large, 3D particles are easiest to remove. 2D debris, such as wet strength flakes, can be
removed, but some orientations pass through the baskets easily. Small contaminants like shives are
most difficult to remove by screens.
 Pressure Screens::::
Description:
Pressure screens are used primarily to separate unwanted debris or contaminants from the desirable
fibers in papermaking pulp. This is accomplished by flowing a pulp slurry over a surface that has
many small holes or slots in it. Most of the small flexible fibers pass through the openings, and are
accepted, and the larger particles which cannot pass through the openings are held back, or rejected.
A typical pressure screen consists of a vertical cylindrical housing that contains a perforated
cylindrical screen basket. Within the basket is a spinning rotor which supports foils or protrusions
that run close to the surface of screen. Screen performance is quantified by looking at such factors
as the reject rate, debris removal efficiency, and long fiber reject rate.
-Explain the purpose of pressure screening
-Identify the major components of a cylindrical pressure screen.
-Describe how screens are kept from plugging.
-Describe why screening systems use multiple stages.
-List three measures of screening performance.
-Identify controls which affect screening performance.
-List possible causes for pressure screen process and mechanical malfunctions.
Key Questions:
*What is the primary purpose of a pressure screen?

Ans: The purpose of a pressure screen is to separate unwanted debris from desirable fiber in a pulp
stream.
*What is the purpose of the spinning rotor in a pressure screen?

Ans: The purpose of the spinning rotor within the screen basket of a pressure screen is to keep the
screen clean and increase the flow of fiber through the screen.
*What advantage is gained by using cascaded screens?
Ans: No separation process is perfect. Some good fiber is rejected with the unwanted debris in a
pressure screen. Rescreening the rejected fiber permits the recovery of the good fiber. Rescreening
multiple times is referred to as "cascading" screens, and ensures a high fiber recovery rate.
*What is a good strategy for unplugging a pressure screen?

Ans: A plugged screen can often be unplugged by reducing or stopping the accepts flow, giving the
basket an opportunity to clear itself through the rejects line, and re-opening the accepts valve.
*What could be some causes of poor accepts quality?

Ans: There are many potential causes of poor accepts quality, but some of the more common
possibilities are: low reject rate, a hole or gap in the screen basket, unusually high level of
contaminants in the feed or worn slots or holes in the basket.
 Headboxes::::::::::
 Air-Padded Headboxes::::
Description:
An air-padded headbox is a piece of equipment that is designed to deliver a constant, uniform flow
of stock to the Fourdrinier wire at the desired speed and location. The headbox has several design
elements, including a perforated plate or tube bank and rotating rectifier rolls, that are designed to
create and maintain turbulence to keep the fibers dispersed up to the slice opening. This is important
because the design and operation of the headbox are critical to the quality of the sheet produced on
the paper machine.
-Identify safety guidelines related to an air-padded headbox system.
-Identify the main functions of a headbox.
-Define "total head," "jet to wire," and "rush/drag".
-Identify and describe the main components of a n air- padded headbox.
-Describe the stock flows inside the headbox.
Key Questions:
*What are the four basic functions of a headbox?

Ans: To deliver the stock uniformly onto the forming fabric in the cross-machine direction and the
machine direction, create controlled turbulence to reduce fiber flocking and develop uniform fabric
distribution, coordinate the speed of the stock jet with the speed of the wire, and to ensure that the
flow of stock from the slice opening strikes the wire at the correct angle and location.
*What is the purpose of the headbox?

Ans: The purpose of the headbox is to distribute the stock onto the Fourdrinier wire to form the
sheet. There are several components inside an air-padded headbox that are designed to distribute the
stock evenly across the machine and generate turbulence to keep the fibers dispersed.
*What is the primary function of the flow spreading device?
Ans: The primary function of the flow spreading device is to evenly distribute the stock across the
width of the headbox and the machine. Other flow spreading devices are also in use.
*What are rectifier rolls and what do they do?

Ans: An air-padded headbox contains rotating, perforated rolls, call rectifier rolls. The stock flows
through the holes of the rectifier rolls, generating a pressure drop that dampens out large-scale
turbulence and evens out the velocity profile across the headbox width.
*How is the air pad maintained?

Ans: The air pad inside the head box is maintained by a source of pressurized air. The source can be
mill compressed air or a dedicated air compressor for the headbox. The pressurized air is piped to
the top of the headbox and regulated to maintain the stock level inside the headbox.
 Hydraulic Headboxes - Stock Jet Geometry for Roll
Type Gap Formers::::
Description:
This course describes the role of the headbox in the paper making process, and then defines the
critical features of the stock jet geometry for a hydraulic headbox installed on a modern tissue
machine or twin-wire paper machine. It discusses the importance of sheet formation and then
describes the stock jet geometries that affect sheet formation and other sheet properties. Lastly, it
covers some common headbox adjustments and other equipment settings that can affect the stock
jet geometry.
-Describe the purpose of the headbox in the paper making process.
-Define the terms "jet length," "jet angle," and "jet impingement".
-Identify the jet length, jet angle, and jet impingement in a stock jet diagram.
-Describe the impact of stock jet geometry and sheet formation on the appearance and strength
properties of the sheet.
-Describe the effects of the slice opening and fan pump speed on stock jet geometry.
Key Questions:
*Why is sheet formation so important?

Ans: Formation is important because it affects the appearance and performance of the sheet. It
affects appearance in that a well-formed sheet will look very even, and it affects performance
because the distribution of fibers directly affects the distribution of fiber-to-fiber bonds which hold
the sheet together. If formation is poor, there will be thin, weak spots which will fail under load.
*What is the "stock jet geometry"?

Ans: The term "stock jet geometry " refers to a set of measurable, observable physical characteristics
of the stock jet after it exits the headbox.
*Which stock jet geometries are important for a roll type gap former?
Ans: Jet length, jet angle, and jet impingement are all important.
*Why is it important to have a short free jet length?

Ans: A short free jet length reduces the time available for the fibers to re-flocculate before the sheet
sets, and if there are multiple layers, it minimizes mixing between the different layer furnishes.
*Should the angles between the jet and the fabrics be low or high?
Ans: The jet angles should be low because if the jet is directed too much into either roll, water can
start "pumping" around the roll, which can disrupt sheet formation.
 Hydraulic Headboxes - Stock Jet Geometry for
Fourdriniers::::
Description:
A hydraulic headbox is designed to deliver a uniform, low consistency stock stream to the
Fourdrinier wire. It is important to monitor the geometry of the stock jet because it greatly impacts
the appearance and performance of the sheet. Only by understanding the variables that affect the
stock jet, and how the jet geometry affects sheet properties, can one begin to make adjustments to
the headbox to optimize sheet quality.
-Describe the purpose of the headbox in the paper making process.
-Define the terms "hydraulic," "jet impingement angle," "jet landing point," "sheet formation," "jet-
to-wire ratio," and "rush/drag".
-Describe the impact of stock jet geometry and sheet formation on the appearance and strength
properties of the sheet.
-Identify and describe common headbox adjustments and settings that affect the stock jet geometry.
-Describe the effects of the slice opening and fan pump speed on stock jet geometry.
Key Questions:
*What is the jet impingement angle?

Ans: On a Fourdrinier machine, it is the angle between the stock jet and the wire as the jet strikes
the wire.
*Why is the stock jet geometry so important?

Ans: Stock jet geometry is important because it affects sheet formation, and sheet formation affects
both the appearance and the performance of the sheet.
*What is the difference between "pressure forming" and "velocity forming"?
Ans: Pressure forming occurs with very high jet angles, where the stock jet is forced down into the
wire. Velocity forming occurs with low jet angles, and the stock jet lands more gently on the wire.
*What is the "jet-to-wire ratio"?

Ans: It is the ratio of the stock jet speed and the wire speed, and it greatly affects the orientation of
the fibers in the sheet.
*What is the "L/b ratio" and why is it important?

Ans: It is the ratio of the horizontal spacing to the vertical spacing between the slice lip and apron
lip. It is important because it affects the jet landing point and the jet impingement angle.
 Hydraulic Headboxes - Multi-Layer Headboxes::::
Description:
This course covers the purpose and objectives of a headbox on a paper machine, and the advantages
of a multi-layer hydraulic headbox. The purpose or function of the major components, and how
they all work together to fulfill the objectives of the headbox, is also discussed. Major components
described include the stock inlet headers, dilution profiling system, recirculation lines and valves,
internal turbulence-inducing elements, slice opening, and various stock jet adjustment mechanisms.
Lastly, it includes some protection and care guidelines for the headbox and forming fabrics.
-Describe the purpose and objectives of the headbox on a paper machine.
-Describe the advantages of a multi-layer headbox.
-Identify and locate the major components of a multi-layer headbox.
-Identify stock and recirculation flows.
-Describe the available adjustments to the headbox.
-Identify protection and care guidelines for the headb ox and forming fabrics.
Key Questions:
*Why are multi-layer headboxes increasingly popular?

Ans: Because they allow for efficient fiber usage and optimization of desired sheet properties.
*Are the stock systems for multi-layer hydraulic headboxes and non-layered headboxes the same?
Ans: No. Because the different layers can have different furnish compositions, each layer has its own
stock preparation and delivery system.
*What are the advantages of dilution profiling systems over traditional slice lip adjusters?
Ans: Dilution profiling systems eliminate the cross-flows in the stock jet and fiber orientation
variability that were caused by slice lip adjustments.
*What is the purpose of the tubes, chambers, drilled plates, and flat sheets or vanes in hydraulic
headboxes?
Ans: These items induce turbulence in the stock flows to keep the fibers separate and help break up
flocs before the stock reaches the forming fabrics.
*What happens when the slice opening is widened slightly?

Ans: The pressure inside the headbox initially drops, so the fan pump speeds up to increase the
headbox pressure, which increases the total flow through the headbox. The end effect is a drop in
the headbox consistency.
 Forming::::::
 Sheet Formation::::
Description:
Formation is a property of the sheet that is based on the overall uniformity of the fiber distribution
in the sheet. Sheet formation is important because it affects both the appearance and the
performance of paper and board products. At the end of this module, you will be able to identify
three mechanisms available to minimize flocculation and describe the differences between
mechanical and chemical fibers related to fiber length, refining response and sheet strength.
-Define "formation" and "floc".
-Identify three mechanisms available to minimize flocculation.
-Describe the differences between mechanical and chemical fibers related to fiber length, refining
response and sheet strength.
-Describe how the stock delivery system affects sheet formation.
-List the three directions of fiber orientation in a sheet of paper or board.
-The three directions of fiber orientation in a sheet of paper or board.
-Define "jet-to-wire ratio" and "rush/drag".
-Describe the terms "rushing" and "dragging".
-Describe how common chemical additives c an affect sheet formation.
-Describe how forming section components can affect sheet formation.
Key Questions:
*How does a paper or board machine's stock delivery system affect sheet formation?
Ans: The shear forces created by agitators, pumps, valves, cleaners, and screens in the stock system
help keep the fibers dispersed in the dilute stock suspension and prevent flocs from forming before
the stock reaches the headbox, which ultimately improves formation.
*How does headbox design influence sheet formation?
Ans: Rectifier rolls, tube banks, converging channels, and other internal headbox elements are
designed to create turbulence and shear. This helps keep the fibers dispersed until they reach the
forming zone.
*Why aren't all headboxes run at lower consistencies, since this helps keep the fibers separate and
improves formation?
Ans: The headbox consistency can only be lowered until the drainage capacity of the former has
been reached. If it is lowered further, the sheet will be too wet going into the press section.
*Does the addition of starch affect sheet formation?

Ans: Starch is sometimes added to stock to increase sheet strength properties and improve drainage
and retention. This can improve formation to a point, but over-use can lead to foam in the stock,
which hurts formation and drainage.
*How can the forming section influence sheet formation?

Ans: Breast roll shake mechanisms, formation showers, dandy rolls, foil box angles, and vacuum
levels on the former can all affect sheet formation.
Forming Fabric Design::::
Description:
Paper machine forming fabrics are designed to retain as much fiber and other furnish components
as possible while allowing water to drain through them as quickly as possible. These fabrics are
typically produced from monofilament strands or yarns that are woven together in a pattern that can
be classified by their fabric style (or weave); mesh, count, and diameter; surface topography; and air
permeability. This module discusses how each of these characteristics affect final sheet quality.
-Identify machine direction and cross direction.
-Describe safety guidelines while working near forming fabrics.
-List the four factors that should be considered during forming fabric selection.
-Describe fabric styles (single, double, triple layer).
-Describe mesh, count, and yarn diameter.
-Describe surface topology.
-Describe air permeability.
-State the importance of p roper fabric guiding and tensioning.
Key Questions:
*What are the two main jobs of a forming fabric?

Ans: To retain as much fiber and other furnish components as possible, and to allow water to drain
through as quickly as possible.
*What are the most common fabric styles or weaves used in forming fabrics?
Ans: The most common fabric styles are single layer (one MD and one CD strand), double layer
(one MD and two CD strands), double layer with support shute (one MD and three CD strands),
and triple layer (two MD and three CD strands).
*What is the difference between "mesh" and "count"?
Ans: Mesh refers to the number of MD yarns per inch of fabric, while count refers to the number of
CD yarns per inch of fabric.
*Why can't air permeability (which measures air flow) be used alone to predict the drainage capacity
of a fabric?
Ans: Because it does not take into account the impact of the fibers and furnish on drainage. Surface
topography and fabric construction both affect furnish retention and so can also affect the
dewatering capacity of the fabric.
*How can you tell if a forming fabric is misaligned?

Ans: Most forming fabrics are manufactured with a colored stripe across their width. If this stripe is
not straight, this means that the fabric is skewed or misaligned.
 Forming Fabric Tensioning and Guiding::::
Description:
The forming section can contain one or more fabric loops, and each loop has its own set of support
rolls and cleaning showers. The purpose of a forming fabric is to dewater and support the sheet as it
forms, and carry the formed sheet to the next section of the paper machine. The purpose of the
tensioning and guiding systems is to keep the fabric running at the proper tension and centered on
the machine. This module will discuss the purpose and operation of forming fabric tensioning and
guiding systems.
-Identify typical guidelines for working around the forming section of a paper or board machine.
-Describe the purpose of a forming fabric.
-Explain how fabric tension specifications are determined.
-List some problems associated with improper wire tension.
-Identify the purpose of fabric guiding system components, including the guide palm, autoguide and
manual guide.
-Explain the basic principle of fabric guiding.
Key Questions:
*In addition to furnish retention and dewatering capacity, what else is required of a forming fabric?
Ans: The forming fabric must be able to withstand the wear caused by stationary elements and
vacuum devices on the former.
*Relatively high fabric tension is desirable because it improves drainage and reduces slippage on
driven rolls. However, what happens if the tension is too high?
Ans: Excessive fabric tension can reduce drainage capacity by narrowing the openings in the fabric,
damage the wire seam, or cause roll deflections and warping, which can lead to ridges in the fabric.
*What is the problem with low fabric tension?
Ans: Very low fabric tension can cause slippage at the driven forming section rolls, and wire flexing
at the gravity foils and vacuum boxes. This can lead to wire abrasion, and guiding and speed control
issues.
*What is the purpose of seam straightening?

Ans: A skewed seam or colored stripe on the forming fabric indicates a misalignment in the forming
section. Straightening the seam evens out the fabric tension, which evens out the dewatering
capacity of the fabric across the machine.
*What is the basic principle of fabric guiding?

Ans: The fabric will move or ""steer"" toward the end of the roll that it contacts first.
 Fourdrinier Design and Operation::::
Description:
A Fourdrinier is a type of forming section or former on a paper or board machine. It serves three
main functions: to drain and recover white water from the stock suspension to form a sheet, to
deliver the formed sheet to the press section at the highest possible consistency, and to optimize
sheet formation to create a strong, uniform, high quality sheet of paper or board. Knowing the
design and principles of the Fourdrinier is essential to proper sheet formation.
-Identify safety and wire protection guidelines for the Fourdrinier.
-Describe the three main functions of the Fourdrinier in the paper or board making process.
-Identify and describe the three zones on a Fourdrinier.
-Identify and describe the functions of the major Fourdrinier components.
Key Questions:
*What exactly is a Fourdrinier ""wire""?

Ans: Contemporary wires are fabric loops that are woven from polyester monofilaments, and
traditional textile variables (weave pattern, yarn count, and yarn diameter) allow them to be
customized to each machine and grade mix.
*Why are different devices used on a Fourdrinier to remove water from the sheet?
Ans: Vacuum levels increase on the Fourdrinier table because water becomes increasingly difficult to
remove from the sheet. Foil boxes help remove water early on, and flat boxes with slotted covers are
used later because they provide better sheet support at higher vacuum levels.
*Why must Fourdrinier wires be stretched or tensioned?

Ans: Constant tension on the wire allows the wire to maintain its retention and drainage
characteristics as it ages and stretches. Tension is also required to properly drive the wire.
*How do guide rolls work?
Ans: Guide rolls work on the principle that when a wire contacts a roll, it will ""steer"" toward the
end of the roll that it contacts first.
*What is the purpose of the separators on the drive side of a Fourdrinier?

Ans: The air-water mixture pulled from the sheet into each vacuum box is pulled first into a
separator, which separates the air from the water. The air flows out the top to the vacuum source,
and the water exits from the bottom to a seal pot or tank.
 Paper Machine Twin-Wire Formers::::
Description:
A twin-wire former captures the stock jet in the converging nip formed between two fabric-covered
rolls. These are also sometimes referred to as "gap" formers. There are four types of twin-wire
formers - blade, roll, hybrid and roll/blade. Each has its own challenges and strengths. With twin-
wire formers, it is especially important to define the desired sheet properties, and then work with
equipment and fabric suppliers to configure, control and operate the design that is selected.
-Identify the issues which led to the development of twin-wire formers.
-Identify and describe the four basic types of twin-wire formers, including blade formers, roll
formers, hybrid formers and roll/blade formers.
-List advantages and disadvantages for each type of twin-wire former.
-Describe the challenges presented by twin-wire formers.
-Describe the advantages of twin-wire formers.
Key Questions:
*What are some benefits of twin-wire formers over Fourdrinier formers?

Ans: Twin-wire formers reduce sheet two-sidedness, wire instability, and the length of the forming
section. Also, twin-wire formers double the drainage area and can run at higher speeds.
*What are some potential problems presented by twin-wire formers?

Ans: Space limitations restrict the addition of more water-removal de vices. Fibers can build up
preferentially on the two fabric surfaces, which increases the likelihood of sheet de-lamination.
Fabric selection is critical and there is a high potential for fabric and equipment damage because the
fabrics operate in close proximity.
*What is a roll former?
Ans: Roll formers are characterized by the stock jet being captured in a long nip created between
two fabrics traveling together around a perforated suction forming roll.
*What is a blade former?

Ans: Blade formers are characterized by a stock jet impinging into a gap between two forming
fabrics which are fored together by a number of fixed blades in a vertical forming section.
*What is a roll/blade former?

Ans: Roll/blade formers try to combine the advantages of roll and blade formers and avoid their
problems. Two forming fabrics wrap around a perforated suction roll then there is a blade section to
provide additional pulsed drainage.
 Multi-ply Forming::::
Description:
Multi-ply forming was first introduced in 1830 when two cylinder formers were combined to
produce a two-ply sheet. Equipment designs have changed over the years, however, the multiple
cylinder former design is still in use. Multi-ply sheets can contain a different stock mixture in each
layer, which has several potential benefits, including those related to fiber costs, machine speeds, and
sheet properties. Therefore, multi-ply forming has expanded from mostly paperboard grades to
tissue and other paper grades.
-Describe the history of multi-ply forming.
-List the goals of multi-ply forming.
-Describe the three basic methods of multi-ply forming.
-Describe the design and operation of cylinder formers.
-Identify and describe the different types of equipment used to produce multi-ply sheets.
-Identify the challenges of multi-ply forming.
Key Questions:
*How can multi-ply forming reduce costs?

Ans: For high basis weight grades; multi-pl y forming can run at higher speeds than are possible with
single-ply forming. Also, more economical furnish components can be used in some layers, and
expensive components can be concentrated in the layers where they can make the most impact.
*What are three basic ways that a multi-ply sheet can be formed?
Ans: A multi-ply sheet can be formed by forming additional layers on top of an existing sheet,
separately forming multiple layers and then combining them together while they are still moist, or
using a multi-layer headbox.
*What are some of the downsides of multi-ply forming?
Ans: Additional equipment must typically be installed an d operated to prepare and deliver different
furnishes to the different layers. Also, bonding between the plies or layers can be a problem.
*What kinds of products are made using multi-ply forming?

Ans: Multi-ply forming was originally used to produce heavy weight grades, but it is now used to
produce a wide range of products, including tissue and towel, and printing and writing, grades.
*How can cylinder formers be used to produce a multi-ply sheet?

Ans: A cylinder former forms a sheet on its mesh-covered surface and then transfers it to an
absorbent felt that is pressed against it. When multiple cylinder formers are arranged in series with a
single felt, each additional former adds another layer to the sheet that is forming on the felt.
 Wet Edge Control::::
Description:
Deckles run along the wire edges adjacent to the headbox to keep the stock on the wire until it has
dewatered sufficiently. Curling boards and water jet deckles can help minimize the formation of
deckle wakes. Edge showers are used to keep the deckles, curling boards and wire edges clean and
lubricated. Trim squirts are used to trim off the edges at the end of the former and establish the
sheet width into the press section. They must all be installed and positioned properly to minimize
wear and prevent edge profile and edge transfer issues. This module will describe the function and
operation of each of these devices.
-Identify where sheet formation is established on a paper or board machine.
-Describe the relationship between sheet formation and sheet properties.
-Describe why wet edge control is important and identify sheet properties affected by edge control
issues.
-Identify and describe the functions of deckle boards, curling boards, edge showers, and trim squirts.
Key Questions:
*Why do sheet breaks on a paper or board machine often originate at the sheet edges?
Ans: The edges of the sheet tend to have issues with formation because the stock flow abruptly cuts
off at the edges, which can lead to poor formation at the edges and cause sheet breaks.
*What is the purpose of deckle boards?

Ans: They keep the stock from flowing off the edges of the wire.
*Why have water jet deckles replaced deckle boards on many paper and board machines?
Ans: Water jet deckles use a curtain of water to contain the stock. Because there are no longer
boards for the stock to deflect off of, this minimizes the formation of deckle waves or wakes.
*Why is the position of the end deckles on forming section suction boxes so critical?
Ans: If they are too far in, this can cause wet sheet edges. If they are too far out, air will be sucked in
to the box at the edges, reducing the overall vacuum level. Also, they should be staggered to reduce
wire edge wear.
*What is the purpose of curling boards?

Ans: Curling boards help contain the stock on the wire at a low angle, which helps prevent the
formation of deckle wakes.
 Wet End Edge Trimming::::
Description:
At the beginning of the forming section of a paper or board machine, deckles and curling boards
keep the stock on the wire until it has sufficiently dewatered and solidified. At the other end of the
former, the trim squirts trim off the edges of the sheet before it transfers to the press section. This
establishes the sheet width all the way to the reel. The deckles and trim squirts must be set up
correctly, and the trim squirt nozzles and water supply system must be regularly monitored to ensure
the cleanliness of the edge cuts and trouble-free sheet transfer into the press section.
-Define sheet "formation".
-Explain why wet end edge trimming is important on a paper or board machine.
-Identify and describe the functions of deckle boards, trim squirts, and wire cleaning showers.
-Identify the trim squirt system parameters that are important to monitor during production.
-Identify and describe the equipment (showers) used to remove the trimmed edges from the wire.
Key Questions:
*Why are the edges of the sheet removed at the end of the forming section?
Ans: The sheet edges are removed because they tend to have issues with formation, which can cause
sheet breaks to originate at the edges.
*Why is the shower water supplied to the trim squirts filtered?

Ans: Trim squirt nozzles have very small orifices which are pro ne to plugging, so it is critical that
the water supply be clean and free of debris.
*On machines with multiple trim squirts or multi-orifice nozzles on both sides, why is the alignment
of the nozzles or orifices so critical?
Ans: If they are not aligned properly, the edge cuts can be too thin or too wide, which can lead to
issues with edge separation and even sheet breaks.
*Why do edge showers often follow the trim squirts?

Ans: If the edge stock is not removed from the wire, s tock would tend to stick to it, which could
lead to problems with buildup, deposits, and sheet transfer.
*Which wet end components of a paper or board machine are actively involved in establishing the
sheet edges?
Ans: The deck les, curling boards, and trim squirts all help establish the sheet width and sheet edges.
 Wet Pressing::::::
 Wet Pressing Theory::::
Description:
This module begins with a description of the objectives of the wet pressing process on a paper
machine. Then, it discusses how water is removed from the sheet in press roll nips. It explains the
purpose of a wet felt in wet pressing and how wet felts are designed. This module will give you a
better understanding of how water is removed from the sheet during the wet pressing process.
-Describe the three objectives of wet pressing.
-Identify and describe the pressing phases in a press nip.
-Identify the key process and equipment variables that impact wet pressing.
-Identify the sheet properties impacted by wet pressing.
-Explain how to minimize sheet rewetting.
-Describe the purpose and design of wet felts.
-Explain how uhle boxes aid in water removal at the press.
-Explain how steam boxes aid in water removal at the press.
-Describe the types of rolls used in wet presses.
Key Questions:
*What are the objectives of wet pressing?

Ans: Wet pressing removes water from the sheet, consolidates the sheet, and improves the wet
strength of the web so it can remain intact in open draws.
*How does wet pressing affect sheet properties?

Ans: Pressing increases density, surface smoothness, and dry and wet strength properties. Bulk,
caliper, and stiffness typically decrease.
*What are the phases of water removal in presses?
Ans: Water removal can be divided into compression and expansion phases.
*What is the purpose of the wet felt?

Ans: Wet felts act as a transfer device or belt to move the wet sheet without damage, absorb water
from sheet, and maintain an even, smooth surface for the wet sheet.
*What types of rolls are used for pressing?

Ans: Wet pressing can be accomplished by using solid rolls, variable crown rolls, suction rolls, and
shoe presses.
 Paper Machine Suction Rolls and Roll Covers::::
Description:
Though their design and construction are very similar, suction rolls perform several different
functions on paper machines, depending on their position. They can be used to remove water from
the sheet, transfer the sheet, improve dewatering in a press nip, dewater a felt, stabilize the sheet, or
pull steam into the sheet. Roll cover selection should take into account the functions of the roll and
the operating conditions.
-Explain the purpose of suction rolls in the forming and press sections of a paper or board machine.
-Identify and describe the function of key components of a suction roll.
-Explain the importance of proper vacuum box and end deckle positioning in suction rolls.
-List the various types of roll cover materials and their typical applications.
-Explain the benefits of grooved and blind-drilled roll covers.
Key Questions:
*Where are suction rolls typically located on a paper or board machine?

Ans: Paper and board machines are typically equipped with multiple suction rolls in the forming and
press sections.
*What are suction press roll shells constructed from?

Ans: Suction roll shells are typically constructed of bronze or stainless steel.
*What is the flushing shower in a suction roll used for?

Ans: The flushing shower is used when the paper machine is down to clean and flush stock build up
out of the vacuum box and the holes in the roll shell.
*What are the most common roll cover materials?
Ans: Rubber and polyurethane are the two most common roll cover materials. Rubber is very
versatile, while polyurethane is tough and wear resistant. These materials can be designed for use in
many different applications.
*Where are ceramic roll covers used?

Ans: Ceramic roll covers are extremely wear resistant and have very good release properties. They
are often used on center press rolls.
 Wet End Steam Boxes::::
Description:
On a paper machine, the sheet dryness after pressing is important because it is more economical to
remove water by mechanical means at the wet end than by evaporation in the dryer section. One
way to increase after-press dryness is to increase the temperature of the sheet when it is pressed.
Increasing the sheet temperature reduces the viscosity and surface tension of the water contained in
the sheet. This reduced viscosity makes it easier for the water to travel out of the sheet, which
increases the dewatering capacity of the press. A common way to raise the sheet temperature is to
apply steam with a steam box on the wet end of the paper machine.
-Describe the purpose of wet end steam boxes.
-Explain the relationship between sheet temperature and wet end water removal.
-Differentiate between profiling and non-profiling steam boxes.
-Describe steam box heat transfer.
-List the variables that affect steam box efficiency.
-List the benefits of steam boxes.
Key Questions:
*What is the purpose of a steam box?

Ans: Steam boxes are used to increase the after-press dryness of the paper by increasing the
temperature of the sheet.
*What is the difference between a profiling and non-profiling steam box?

Ans: Profiling steam boxes are divided into sections across the width of t he machine. The steam
flow to each section can be adjusted to produce a uniform CD (cross direction) moisture profile.
Non-profiling steam showers apply steam evenly across the entire width of the machine, so while
they do improve dewatering, they cannot address moisture streaks.
*Why are steam boxes usually positioned over vacuum boxes or opposite vacuum rolls?
Ans: Vacuum helps pull the steam through the sheet so that it condenses in the sheet and not just
on the surface. The goal is to have a uniform sheet temperature.
*What variables affect heat transfer efficiency?

Ans: Steam box heat transfer is affected by basis weight, sheet permeability, sheet moisture, and
initial sheet temperature. Heat transfer is also affected by steam flow, the distance to the sheet,
vacuum level and position, and the dwell time.
*What is the impact on total machine drying efficiency?

Ans: Even though steam boxes use steam, total paper machine steam consumption usually
decreases. For every pound of steam used in the press section, up to 3 pounds less steam is needed
in the dryer section.
 Roll Presses::::
Description:
Roll presses are often used on paper and board machines to mechanically remove water from the
sheet. They also consolidate and flatten the sheet, increase wet sheet strength, and improve final
sheet strength characteristics. This module will give you a better understanding of roll presses and
how they function in press sections of paper machines.
-Identify the purpose of a roll press on a paper or board machine.
-Describe the pressing phases in a roll press nip.
-Identify and describe roll cover materials used in roll presses.
Describe a typical roll press arrangement.
-Describe the purpose of a roll crown.
-Describe swimming-type and shoe-type deflection- compensated rolls.
Key Questions:
*Why is the sheet frequently separated from one or both felts soon after a press nip?
Ans: To minimize "rewetting," wherein the sheet reabsorbs some water from the felt or felts.
*Are press rolls usually solid rolls?

Ans: In a conventional roll press, the roll surfaces can be solid, blind-drilled, grooved, or blind-
drilled and grooved.
*What are the limitations of fixed crown rolls?

Ans: A "fixed crown" roll has a crown ground in to the roll face, and it is only appropriate for a
single nip loading. On machines where nip loadings vary because different grades are made, a
variable crown roll may be a better choice.
*Are controlled-crown rolls used in top or bottom roll positions?
Ans: Controlled-crown rolls can be used in both top and bottom roll press positions. In bottom
positions, they typically have softer covers that are grooved or blind-drilled to enhance water
removal.
*How do controlled-crown rolls create the crown?

Ans: CC rolls use hydraulic pressure in a sealed chamber or applied to cross-machine cylinders to
create the crown.
 Shoe Presses::::
Description:
Shoe presses are used in the production of many different grades of paper and board. They differ
from conventional roll presses in that they offer a significantly longer nip width and dwell time.
Shoe presses offer many different benefits, including higher dryness to the dryer section, improved
bonding and sheet strength properties, and increased bulk. Understanding the design and operation
of shoe presses will help with day-to-day operations and troubleshooting.
-Describe the major difference between a shoe press and a conventional roll press.
-List the benefits of shoe presses.
-List the major components of a shoe press, including the stationary press beam, hydraulically-
loaded shoe, sleeve or belt, roll heads and journals, and dedicated hydraulic system.
-Identify the functions of the major components.
Key Questions:
*What is the main advantage of a shoe press over roll press?

Ans: With the increased nip width, the dwell time (the amount of time that the sheet is exposed to
the nip pressure) is up to 10 times longer.
*On which grades are shoe presses used?

Ans: Shoe presses were initially used on machines producing heavier weight grades, like board and
corrugating medium. They are now used effectively in making printing, writing, and tissue, as well as
container board and carton board, grades.
*What are shoe press sleeves made out of?

Ans: Most shoe press sleeves are made from a woven substrate with a coating of polyurethane,
which may be grooved, blind drilled, or smooth.
*What are the functions of the hydraulic fluid in a typical shoe press?
Ans: The hydraulic fluid is used to pressurize the shoe loading pistons, provide lubrication for the
shoe-to-sleeve interface, and provide cooling.
*Does the entire shoe press rotate during press operation?

Ans: No. The roll journals, heads, and sleeve rotate around the stationary support beam and press
shoe assembly.
 Felt Tensioning and Guiding::::
Description:
The felt guiding system is responsible for keeping the press felt centered on the rolls in its felt run.
The felt tensioning system is responsible for maintaining a constant, uniform tension in the felt. This
module will provide you with a better understanding of how felt tensioning and guiding systems are
operated and their value to an effective wet pressing operation.
-Describe the purpose of felt guiding.
-Explain the principles of felt guiding.
-Identify and describe the main components of a felt guiding system.
-Explain why felt tension is important.
-Identify and describe the equipment used for felt tensioning.
-Explain how felt stretchers can be used to straighten the seam.
Key Questions:
*Why is it important for press felts to be centered on the machine?

Ans: To completely cover the sheet width to ensure uniform water removal in the press nips. Also,
to keep the felts from running off the front or back of the machine.
*What is the basic principle of fabric guiding?

Ans: The basic principle of fabric guiding is that the felt moves or "steers" toward the roll end that it
contacts first.
*By what mechanism does the movement of the guide palm cause the autoguide to move?
Ans: The guide palm movement closes or opens a bleed air valve, which increases or decreases the
air supply pressure to an air bag which moves the autoguide end of the guide roll.
*What is the purpose of the hand guide or manual guide?
Ans: Its purpose is to keep the autoguide end centered in its travel. This ensures that the autoguide
always has some adjustment available in both directions.
*What is the recommended roll wrap (in degrees) for a felt guide roll?
Ans: Guide rolls need to have a roll wrap of 25 to 35 degrees to ensure sufficient friction for the roll
to move the felt.
 Felt Cleaning and Conditioning::::
Description:
Felt cleaning and conditioning systems use mechanical and chemical means to keep press felts clean
and open during press operation. Showers and uhle boxes are positioned in the felt runs to remove
contaminants from and dewater the felts. This helps maintain the dewatering capacity of the felts,
and improves the overall cleanliness and runnability of the press section. This module will discuss
the cleaning and conditioning equipment used on a paper or board machine.
-Describe the function of a press felt.
-Explain the importance of proper felt cleaning and conditioning.
-Identify and describe the equipment used for wet felt cleaning and conditioning.
-Describe the function/ purpose of the wet felt cleaning and conditioning equipment.
-Describe the best practice locations for wet felt uhle boxes and showers.
-Describe the different shower types.
Key Questions:
*Why are press felts usually replaced?

Ans: Press felts are usually replaced because they have either filled with contaminants or have
compacted to the point that their dewatering capacity is insufficient.
*How many showers and uhle boxes are typically used on each press felt?
Ans: A typical system utilizes 3 or 4 showers on each wet felt, followed by one or two uhle boxes.
*Where are the lubricating showers installed in press felt runs?

Ans: A lube shower is usually installed ahead of each uhle box to help reduce wear on the felt and
box cover, and also act as a seal at the uhle box. They should spray into the ingoing nip.
*Why are high pressure needle jet showers on press felts oscillated from front to back?
Ans: They are oscillated in the cross-machine direction to evenly distribute the water an d prevent
damage to the felts; these showers should be interlocked to shut off if the oscillator or press section
stops.
*Where are uhle boxes typically positioned?

Ans: Uhle boxes are usually located on the face- or sheet-side of the felt after the press nip and all
major showers.
 White Water and Filtrate Systems:::::::
 White Water System Design::::
Description:
The purpose of a white water system is to collect and reuse as much white water as possible, in
order to minimize fresh water usage and effluent losses. At the end of this module, you will be able
to identify the three main objectives of a white water system, identify major components of the
short and long white water circulation loops, and identify the purpose or function of each major
white water system component.
-Identify safety hazards and their related guidelines for white water systems.
-Identify the three main objectives of a white water system.
-Define "rich white water," "lean white water," "short circulation loop," and "long circulation loop".
-Describe the criteria used to size white water storage chests.
-Identify major components of the short and long white water circulation loops.
-Identify the purpose or function of each major white water system component.
-Identify and describe the primary process flows of each major white water system.
Key Questions:
*What is the difference between rich and lean white water?

Ans: The white water removed from the sheet early on the former tends to contain more solids
(fibers, fines, and fillers), and so it is often called "rich" white water. Water removed later on the
former is often referred to as "lean white water" because it contains fewer solids.
*Where is rich white water collected?

Ans: Rich white water is typically collected in a wire pit, or a wire tray and flume, and directed to a
silo.
*Where is lean white water collected?
Ans: Lean white water that is removed from the sheet by suction boxes in the forming section and
press section is often piped to a separator on the back side of the machine.
*What is clarified white water used for?

Ans: Clarified white water is used for shower water and dilution water.
*What are the objectives of the white water system?

Ans: The white water system should provide adequate quantities and qualities of white water to all
points in the process, maximize reuse of white water in order to reduce fiber and energy losses and
minimize effluent loads, and minimize fresh water makeup, as fresh water must be heated up to
process temperatures and may require pH adjustment.
 White Water Clarification::::
Description:
White water clarification refers to the removal of fiber fines and other solids from paper or board
machine white water. The clarified white water can then be reused for showers, stock dilution, and
make down of certain chemicals. This module will list the purposes of white water clarification and
describe the operation of disc filters, rotary drum filters, and DAF systems.
-List the purposes of white water clarification.
-Identify and describe the components of disc filters.
-Identify and describe the components of rotary drum filters.
-Identify and describe the components of DAF systems.
-Describe the operation of disc filters.
-Describe the operation of rotary drum filters.
-Describe the operation of DAF systems.
-Identify devices used to remove smaller solids from smaller water flows.
-Identify hazards and safety guidelines related to white water clarification equipment.
Key Questions:
*What are the benefits of white water clarification?

Ans: Clarification benefits include reduced water us age, sewer flows, energy costs, and raw material
cost.
*What types of equipment are used to clarify white water?

Ans: Disc filters, rotary drum filters, dissolved air flotation systems, filters, and strainers can all be
used for white water clarification.
*What is a saveall?
Ans: Saveall is a not her name for a disc or drum filter.
*What does DAF mean?
Ans: DAF stands for Dissolved Air Flotation. It is a clarification process that removes suspended
solids from water using air.
*What are filters and strainers used for?

Ans: Filters and strainers are usually used for additional clarification of lower white water flows, such
as shower water.
 White Water Circulation Loops::::
Description:
The collection and reuse of white water in paper and board making processes reduces fresh water
usage, sewer losses and loads, and energy usage. The primary white water circulation loop, or short
circulation loop, quickly returns white water removed from the stock on the former to the thin stock
system and headbox. The secondary white water loop, or long circulation loop, collects the excess
white water, clarifies it, and supplies dilution, shower, and make-down water back to the process.
This module will identify and describe the components and main functions of the primary and
secondary white water circulation loops.
-Define the terms "white water" and "closed system".
-Describe the benefits of collecting and reusing white water in paper and board production
processes.
-Identify the components and two main functions of the primary white water circulation loop.
-Identify and describe the components of the secondary white water circulation loop.
-Identify the uses of secondary white water.
-Identify and describe the primary process flows.
Key Questions:
*What are the benefits of reusing white water?

Ans: Reuse of white water reduces the fresh water usage, sewer loads and losses, and energy usage.
*What is the purpose of the short circulation loop?

Ans: To dilute the stock to the desired headbox consistency and to prevent foam and entrained air
from entering the thin stock system.
*Where is white water added to thick stock?
Ans: The primary cleaner pump or fan pump receives the thick stock flow, plus dilution white water
from the silo, and pumps the resulting mixture through the thin stock system.
*How is white water in the long (secondary) loop clarified?

Ans: The white water in the long circulation loop is typically clarified by a disc saveall, drum saveall,
or dissolved air flotation (DAF) unit to separate the fibers and fines from the water.
*What is secondary white water used for?

Ans: Clarified white water in the secondary circulation loop is typically used as machine shower
water, dilution water for consistency control to various stock pumps, dilution and sluicing water to
pulpers, and make-down water for chemical systems.
 Strainers and Filters::::
Description:
Strainers and filters are devices that mechanically remove solids from flowing fluids. Strainers are
often employed in pipelines to protect downstream equipment, such as heat exchangers, pumps,
compressors, flowmeters, spray nozzles, turbines, and steam traps, from the detrimental effects of
sediment, rust, pipe scale, and other extraneous debris. This module will list the functions of
strainers and filters and describe Y strainers and duplex, twin, back-flushing, automatic self-cleaning,
and scraper basket strainers as well as surface and depth type filters.
-Identify the functions of strainers and filters.
-Define "strainer" and "filter".
-Differentiate between strainers and filters.
-Describe the design and operation of Y strainers and duplex, twin, back-flushing, automatic self
cleaning, and scraper basket strainers.
-Describe surface type and depth type of filters.
-Identify and describe the following types of filters: cartridge, bag, hydraulic, panel, oil and air filters.
Key Questions:
*What is the difference between a strainer and a filter?

Ans: Technically speaking, a filter is any device that separates solids from a fluid, so a strainer is a
filter. However, in industry, the term "strainer" is used for devices that use a perforated metal plate
or wire mesh screen to remove larger particles, while "filter" is used for devices with more
substantial filter media that remove smaller particles.
*What is the difference between a duplex strainer and a twin strainer?

Ans: Both have two basket strainers so the flow can be alternated between them to allow for online
cleaning. Duplex strainers use shared internal valving and experience higher pressure drops, while
twin strainers have separate external control valves and lower pressure drops.
*How can the cleaning cycle be initiated for an automatic self-cleaning strainer?
Ans: It can use a differential pressure switch, timer, pushbutton start, or a combination of these.
*What is a surface filter?

Ans: Surface filters trap particles on one side of the filter media and have limited holding capacity.
Coffee filters are surface filters.
*What is a depth filter?

Ans: Depth filters use a porous filtration medium which captures the particles throughout its depth.
Home air filters are usually depth filters.
Dissolved Air Flotation (DAF) Systems::::
Description:
Dissolved air flotation (DAF) is a water treatment process that removes suspended solids from
water using air. This separation is achieved by dissolving air into water under pressure, and then
releasing the air at atmospheric pressure in a flotation tank. This module will describe common
applications of the dissolved air flotation (DAF) process and the main steps of the DAF process.
-Describe common applications of the Dissolved Air Flotation (DAF) process.
-Describe the main steps of the DAF process.
-Describe the equipment utilized in a DAF system.
-Identify chemicals commonly used as coagulants and flocculants in DAF systems.
-Describe coagulant and flocculant chemicals used in DAF systems.
-Identify hazards associated with DAF system.
Key Questions:
*How are tiny fiber fines removed from suspension in a dissolved air flotation system?
Ans: Tiny fibers attach to small air bubbles and are carried to the surface of the DAF clarifier.
*What types of chemicals are added to the DAF process to assist in particle separation?
Ans: Coagulants and flocculants can be added to DAF units in order to increase their separation
efficiency.
*What is the purpose of prescreening ahead of DAF units?

Ans: Prescreening the feed stream to a DAF unit reduces the solids loading on the unit.
*Where in the DAF unit is new feed added?

Ans: Incoming feed is released at the bottom of the unit, giving a chance for dissolved air bubbles to
form and collect suspended particles as they rise.
*What happens to the separated material that floats to the top of a DAF unit?
Ans: Separated material is skimmed from the surface of the DAF unit. If the unit is treating paper
machine white water the float may be recycled.
 DAF System Chemicals and Chemistry::::

Description:
Dissolved air flotation (DAF) is a water treatment process that removes suspended solids from fresh
water, process water, or wastewater. Coagulant and flocculant chemicals can be added to the feed
water to aggregate and join together the small solid particles to form larger flocs or bundles and
improve solids removal. This training module describes how these chemicals work in the DAF
process.
-Define and describe "coagulation".
-Define and describe "flocculation".
-Describe the functions of dissolved air, pH control chemicals, coagulants and flocculants in DAF
systems.
Key Questions:
*What is the term for an aqueous suspension of particles that are too small to settle out under the
influence of gravity?
Ans: An aqueous suspension of particles that are too small to settle under the influence of gravity is
called a colloidal suspension.
*How are tiny fiber fines removed from suspension in a dissolved air flotation system?
Ans: Tiny fibers attach to small air bubbles and are carried to the surface of the DAF se parathion
vessel.
*What do flocculants do in a colloid?

Ans: Flocculants combine microflocs formed by coagulation into larger aggregates of flocs.
*What do coagulants do in a colloid?

Ans: Coagulants neutralize the electrical surface charge on colloidal particles which allows them to
combine to form microflocs.
*If both chemicals are used, in what order should coagulant and flocculant chemicals be added to a
suspension?
Ans: When coagulants and flocculants are used together, coagulants should be added to the
suspension first.
 Paper Machine Dryers:::::::::::
 Paper Machine Drying::::
Description:
On conventional paper and board machines, the energy required to dry the sheet to the desired
moisture target at the reel is supplied by a series of rotating, steam-heated, dryer cylinders. These
cylinders, or "cans," are grouped into multiple drive sections, which go progressively faster in order
to adjust for machine direction stretch and to maintain sheet tension. This module will provide a
general overview of the drying section of a paper machine.
-Describe the design and operation of a typical multi- cylinder dryer section.
-List the objectives of paper machine drying.
-Define the terms "latent heat," "boiling point," "evaporation," "condensation," "superheated," and
"blow through steam".
-Identify, describe, and state the purpose of dryer syphons, dryer fabrics, pocket ventilation systems,
hood makeup air and exhaust systems, and blow boxes.
-Describe heat transfer and mass transfer during sheet drying.
-Describe the three phases of drying - sheet heating, constant r ate, and falling rate.
-List the factors that affect sheet drying.
-Identify and describe single-tiered and double-tiered dryer sections.
-Explain the purpose of blow-through steam.
-Describe the two ways blow-through steam can be recovered for reuse.
-Identify and describe safety hazards and safety guidelines for multi-cylinder dryer sections.
Key Questions:
*What is the purpose of dryer fabrics on multi-cylinder machines?

Ans: Dryer fabrics improve heat transfer and help control cross-ma chine direction shrinkage and
sheet distortions by holding the sheet tightly against the can surfaces. They also drive dryer cans on
some machines.
*What is the purpose of dryer hoods?

Ans: Originally, hoods were used to improve machine room conditions. They have evolved and their
current purpose is to improve control of air flows, temperatures, and humidites around the sheet as
it dries.
*What are single-tiered dryer sections?

Ans: Single-tiered dryer sections have one level of heated dryer cans, plus one level of rolls. They
typically utilize a serpentine-shaped "unirun" fabric that supports the sheet through the entire
section.
*Why are single-tiered dryer sections often followed by double-tiered sections?

Ans: Because only one side of the sheet contacts the dryers in single-tiered sections, they are often
followed by double-tiered sections to make the two sides of the sheet more equal in appearance.
*What is the purpose of pocket ventilation systems?

Ans: Pocket ventilation, or PV, systems introduce hot dry air across the machine in dryer pockets to
keep the air around the sheet from becoming saturated and improve drying. This helps ensure a flat
moisture profile at the reel by maintaining uniform humidities across the machine.
 Paper Machine Alternative Drying System::::
Description:
On most conventional paper and board machines, the energy required to dry the sheet to the desired
moisture target at the reel is supplied by a series of rotating steam-heated dryer cylinders or cans.
This module briefly covers the principles behind this system of drying. It will discuss applications
where this system is not the best choice, and where alternative drying techniques can be used. These
alternatives include: Yankee drying, through-air drying, infrared drying, impulse drying, and air
impingement drying.
-Identify and describe the major components of a multi-cylinder dryer section.
-Describe the principles of operation of multi-cylinder dryer sections.
-List some the drying alternatives to multi-cylinder drying.
-List the advantages and disadvantages of multi- cylinder drying.
-Describe the process and typical components for Yankee drying.
-Identify typical products in which Yankee drying is applied.
-Describe the process and typical components for through-air drying.
-Identify typical products in which through-air drying is applied.
-Describe the process and typical components for impulse drying.
-Identify typical products in which impulse drying is applied.
-Describe the process and typical components for infrared drying.
-Identify typical products in which infrared drying is applied.
-Describe the process and typical components for air flotation drying.
-Identify typical products in which air flotation drying is applied.
Key Questions:
*What are some of the weaknesses of conventional multi-cylinder dryer systems?

Ans: Multi-cylinder dryer systems have relatively low drying rates so require a lot of space, they
respond rather slowly to control changes, and they inherently offer poor control of cross-machine
moisture profiles.
*Can Yankee dryers be used in the production of non-tissue grades?

Ans: Yankee dryers can also be used to produce machine-glazed (MG) papers. On these machines,
there is no dryer coating, steam pressures and temperatures are lower, and additional dryers are
necessary to assist in sheet drying.
*How does through-air drying increase the bulk, softness, and water absorbency of the sheet?
Ans: Through-air drying machines do not employ any wet pressing, so the sheet is never crushed.
*Infrared drying is not usually very economical, so why is it used at all?

Ans: Infrared dryers are small so they are sometimes used to add incremental drying capacity. They
can also provide additional control over cross-machine moisture profiles, or non-contact drying for
paper coatings.
*What is air impingement drying?

Ans: Air impingement drying involves blowing hot dry air onto a wet sheet. Yankee dryer hood
systems involve this type of drying, and air impingement is also used in flotation dryers.
 Dryer Felt System Operations::::
Description:
moisture target at the reel is supplied by a series of rotating steam-heated dryer cylinders or cans that
are grouped together into drive sections. Each drive section is equipped with one or two dryer felts
to hold the sheet tightly against the heated dryer cans. This improves heat transfer to maximize
drying, and also helps control cross-machine direction shrinkage and other sheet distortions. This
course discusses the importance of dryer felts, how they operate, typical installation steps, felt
guiding components, and the safety hazards that are present around dryer felt systems.
-List the main operating requirements for paper and board machine dryer felts.
-Describe typical dryer can arrangements, felt runs, and locations of single-tiered and double-tiered
dryer sections.
-List the major steps required to install a new dryer felt.
-Identify which felt seam types are less likely to mark the sheet.
-Identify and describe typical felt guiding system components.
-Explain how felts are guided and tensioned.
-Explain how seams are straightened.
-Describe common felt contaminants and how they can be removed.
-Identify safety hazards and safety guidelines related to dryer felt systems.
Key Questions:
*Why does a dryer "felt" look less like a felt and more like a regular woven fabric?
Ans: Modern dryer felts are woven to be as porous as possible to allow water vapor to escape.
Felted materials do not allow enough air and water vapor to pass through.
*Are different styles of dryer felts used in the different dryer sections on a paper or board machine?
Ans: Felts closer to the wet end, where the sheet is wetter and weaker, are often more tightly woven
in order to "pump less air" and prevent sheet flutter and sheet breaks.
*What is the purpose of a positioner?

Ans: The purpose of the positioner is to keep the autoguide centered so that it can make
adjustments in both directions at all times.
*Why is it important for the felt stretch roll to have a lot of "wrap"?
The high roll wrap ensures that the stretch roll movements serve only to change the felt length, and
do not affect fabric guiding.
*Why are the bottom felts often missing in later dryer sections?
Ans: The sheet is mostly dry in later dryer sections, and the absence of a bottom felt makes them
somewhat self cleaning during threading and sheet breaks.
 Dryer Felt Design:::::
Description:
moisture target at the reel is supplied by a series of rotating steam-heated dryer cylinders or cans that
are grouped together into drive sections. Each drive section is equipped with one or two dryer felts
to hold the sheet tightly against the heated dryer cans. This improves heat transfer to maximize
drying, and also helps control cross-machine direction shrinkage and other sheet distortions. On
many machines, dryer felts also drive some of the cans. This course covers the design and
construction of dryer felts.
-List the functions of a dryer felt.
-Identify appropriate machine locations for single-tier and double-tier felt sections.
-List the typical properties desired of a dryer felt.
-Differentiate between woven, spiral, and needled dryer fabrics.
-Describe the impact of dryer felt permeability and surface roughness on the product and on the
drying process.
-List common materials of construction for modern dryer fabrics.
-Describe the different yarn types used in dryer felts.
-Explain why dryer felts are heat set by the manufacturer.
-Identify and describe dryer felt edge treatments.
-Identify safety hazards and safety guidelines related to dryer felts.
Key Questions:
*What is a "unirun" felt run?

Ans: "Unirun" felts have a serpentine shape to support and transport the sheet around all of the
cans in a section, which is especially important for the wetter, weaker sheet in early dryer sections.
*Why are there two names: dryer felts and dryer fabrics?
Ans: They were originally called "dryer felts" because they were constructed of wool and cotton, and
more closely resembled felted fabrics. Today, they are more often called "dryer fabrics" because
faster machine speeds require more permeable fabrics.
*How are the dryer fabrics used in early dryer sections different from the fabrics used in later dryer
sections?
Ans: Gene rally speaking, dryer fabrics with lower permeabilities are used in earlier felt sections to
"pump less air" and improve stability and support for the wetter, weaker sheet.
*Why are surface characteristics important for dryer fabrics?

Ans: Surface characteristics are important because a rough surface can mark the sheet. It can also
carry along more "boundary layer air," which can lead to sheet flutter and even sheet breaks.
*Why are dryer fabrics heat set by the manufacturer before they are delivered?
Ans: "Heat set" means that the fabrics are subjected to high temperatures for a period of time. This
improves their mechanical stability during use.
 Paper Machine Cascade Steam Systems::::
Description:
Paper and board machines use steam-heated dryer cylinders to dry the sheet to its final moisture
target. In a cascade steam system, fresh steam is typically introduced to the main steam group and
then it is cascaded upstream to the intermediate and wet end steam groups. This arrangement
automatically stair steps steam pressures (and steam temperatures) upwards as the sheet travels
through the dryer section and moisture becomes harder to remove. This module describes the steam
and condensate flows and controls for cascade steam systems. It also discusses their advantages,
limitations, and safety hazards and guidelines.
-List the main objectives of a paper or board machine dryer section.
-Identify and describe the purpose of dryer cans, dryer felts, dryer hoods, drive sections, and steam
groups in a dryer section.
-Explain how thermo-compressor systems and cascade steam systems allow steam to be reused in
dryer sections.
-Describe the differential pressure controls that are used within and between steam groups in a
cascade steam system.
-Identify and describe blow-through steam flows in a typical cascade steam system.
-Identify and describe safety hazards and safety guidelines related to paper machine cascade steam
systems.
Key Questions:
*What is a "cascade steam system"?

Ans: In a cascade steam system, fresh steam is introduced to one of the later steam groups, and the
flash and blow-through steam from the condensate tank is cascaded back through the previous
steam groups, in order.
*Is a cascade steam system the only system that re-uses the flash and blow-through steam from the
steam groups?
Ans: No, thermo compressor steam systems also re-use the flash and blow-through steam, except
they re-use it within each group.
*Why do cascade steam systems sometimes use condensers and vacuum pumps?
Ans: Because there are several pressure drops as the steam cascades through the groups, the
condensate header for the wet end group is often under vacuum. A condenser can be used to supply
vacuum to this condensate header. A vacuum pump is sometimes used to remove air and other
NCGs from the system.
*How do cascade steam systems make control of the moisture at the reel more difficult?
Ans: Fine steam pressure adjustments, such as those used for reel moisture control, are difficult to
achieve because a change to one pressure will cause several other pressure changes.
*How do cascade steam systems automatically account for the decrease in drying rate that occurs as
the sheet dries on a paper or board machine?
Ans: "Drying rate" is the rate at which water ca n be removed from the sheet. In a cascade steam
system, because the steam cascades from the dry end to the wet end, steam pressures and
temperatures automatically stair-step upwards as the sheet dries. This naturally compensates for the
decrease in drying rate.
 Paper Machine Thermocompressor Steam Systems::::
Description:
Paper and board machines use steam-heated dryer cylinders and multiple steam groups to dry the
sheet to its final moisture target. In a thermo-compressor steam system, each steam group has a
thermo-compressor that uses high pressure motive steam to pull flash and blow-through steam from
the section condensate tank and boost it to a more useful pressure. This steam is supplied to the
section steam header where makeup steam is added to control the steam pressure going to the cans.
This module will cover the components and operation of a thermo-compressor steam system.
-List the main objectives of a paper or board machine dryer section.
-Identify and describe the purpose of dryer cans, dryer felts, dryer hoods, drive sections, and steam
groups in a dryer section.
-Explain how thermo-compressor steam systems and cascade steam systems allow steam to be
reused in dryer sections.
-Identify and describe the components of a thermo-compressor.
-Identify and describe steam and condensate flows in a typical thermo-compressor steam system.
-Identify and describe safety hazards and safety guidelines related to paper machine
thermocompressor steam systems.
Key Questions:
*What is a steam group on a paper or board machine?

Ans: A steam group is a set of dryer cans that are supp lied steam at a controlled pressure from a
single steam header, and typically discharge all of their condensate to a single common condensate
header.
*What is a thermo-compressor?
Ans: A thermo-compressor is a device that uses high pressure "motive" steam to pull in lower
pressure steam in order to boost it to a more useful steam pressure so it can be re-used.
*How does a thermo-compressor like a valve?
Ans: Because the size of the nozzle opening ca n be changed by an actuator, which changes the flow
of motive steam and therefore the amount of lower pressure steam that is pulled in, a
thermocompressor basically acts like a valve.
*Why is that thermo-compressor steam systems can respond more quickly to production rate
changes than cascade steam systems?
Ans: Thermo-compressor systems allow for independent control of the steam pressures in the
groups so the system response is faster.
*How do thermo-compressor steam systems account for the decrease in drying rate that occurs as
the sheet dries on a paper or board machine?
Ans: Steam header pressures (and therefore temperatures) are often lower toward the wet end and
higher toward the dry end to compensate for the decrease in drying rate.
 Paper Machine Dryer Hood Air Systems::::
Description:
Paper and board machine dryer hood air systems have two main goals: remove the water vapor
evaporated from the sheet in the dryer section and control the temperatures, humidities, and air
flows in the dryer pockets across the full machine width. A properly designed and operated hood air
system will increase the drying capacity of the machine, improve the reel moisture profile, reduce
steam requirements, and improve the runnability of the dryer section. This module will cover the
components and operation of paper machine dryer hood air systems.
-List the objectives of a dryer hood air system.
-Describe heat transfer and mass transfer during the sheet drying process.
-Identify and describe open and closed hoods.
-Identify and describe the components of a typical modern hood air system.
-List the goals and benefits of a hood air system.
-Explain how hood supply and exhaust air flows are typically regulated.
-Describe the functions of pocket ventilators, anti-blow boxes, and vacuum rolls in dryer sections.
-List common uses for the heat recovered from hood exhaust air.
-Explain how humidity is measured.
-List and describe the indicators that can be used to evaluate hood air system performance.
-Identify and describe safety hazards and guidelines for paper machine dryer sections.
Key Questions:
*What is the difference between "open" hoods and "closed" hoods?

Ans: Open hoods have walls and a roof, but are open at the operating level. Closed hoods have
movable walls at the operating level to fully enclosed the dryers, and totally closed hoods are also
enclosed at the basement level.
*What are the advantages of closed hoods?
Ans: Lower exhaust air flows so exhaust fan requirements are lower and heat recovery is possible.
Also reduced building heating load because they have dedicated supply air systems.
*For a machine with closed hoods, should the supply air flow be equal to the exhaust air flow?
Ans: Modern hoods should have 65% to 75% of the exhaust air flow supplied as dry heated air. The
remainder is supplied by infiltration around the hood seals and doors to prevent hot humid air from
escaping into the machine room.
*How can the heat that is recovered from hood exhaust air be used?
Ans: It can be used to preheat the hood supply air, heat process water, or heat ventilation air to the
building.
*Can hood performance be evaluated somewhat easily?

Ans: Yes. Hood performance indicators include the hood supply air flow, hood supply air
temperature, and hood exhaust air humidity, which are all measurable.
 Size Presses::::
Description:
Surface sizing is commonly used on grades of paper and board that will be coated and/or printed.
The traditional purposes of surface sizing have been to improve the sheet's resistance to the
penetration of fluids and to improve certain sheet properties. Traditionally, a starch-based sizing
solution is applied to both sides of a fully dried sheet in a two-roll nip at a "size press" that is located
between drying sections. This course discusses the design and functions of a size press.
-List the two traditional purposes of surface sizing.
-List some of the materials that can be used in surf ace sizing solutions.
-Identify and describe pond-style size press designs, including vertical, horizontal, and inclined size
presses.
-List sheet variables that affect the performance of pond-style size presses.
-List sizing solution variables that affect the performance of pond-style size presses.
-List equipment variables that affect the performance of pond-style size presses.
-Identify and describe film-type size press designs.
-List the advantages of film-type size presses over pond-style size presses.
-Identify and describe safety hazards and safety guidelines for size presses.
Key Questions:
*What is the purpose of surface sizing?

Ans: The purpose is to improve the sheet's resistance to the penetration of fluids like ink, and
improve certain sheet properties, such as surface strength, internal bond, stiffness, and porosity.
*Where is surface sizing usually applied to the sheet?

Ans: Traditionally, surface sizing is applied at a "size press" that is located between drying sections,
though it can also be applied at a calender stack.
*How is cationic starch different from regular starch?
Ans: Cationic starch is starch that has been treated to produce cationically-charged starch that better
adheres to the anionically-charged fibers in the sheet.
*Where is surface sizing usually applied to the sheet?

Ans: It is the weight of surface size picked up by the sheet per unit area. You must know the sheet
weight before and after the size press in order to calculate it.
*Why do sheet breaks often occur at the size press?

Ans: Because the sheet is re-wetted at the size press, there is an increased possibility of sheet breaks
here, especially if there is a weak spot or hole in the sheet.
 Dry End Equipment::::::::
 Carrier Ropes - Procedures and Maintenance::::
Description:
Carrier ropes are used on paper and board machines to thread a narrow section of the sheet from
the wet end to the dry end of the machine along the tending side. Once the tail has been threaded
the full length of the machine, the sheet is widened out to its full width. A safe and efficient carrier
rope system requires proper design and set up, proper operation and maintenance, and safe behavior
by personnel. This course discusses the proper operation and maintenance. It covers routine
inspection items, rope cleaning precautions and techniques, shut down maintenance, rope
replacement (with and without the old rope on the machine), putting a rope back on a sheave, safely
dealing with sheave failure, and rope splices.
-Describe the purpose of carrier ropes on a paper machine.
-Identify the major components of a safe and efficient carrier rope system.
-Describe routine inspections for a carrier rope system.
-Describe the precautions and techniques for rope cleaning.
-List in order the steps for rope replacement.
-List in order the steps for putting a rope back on a sheave.
-List in order the steps for dealing with sheave failure.
-Describe some of the actions which should be performed on the system during a shutdown.
Key Questions:
*How often should carrier ropes and rope runs be inspected?

Ans: The condition of the ropes and rope runs should be checked on all levels every few hours.
*What should be done during these regular inspections?
Ans: Remove broke or debris that is safe to remove during this check. Also look for problems such
as wobbling or slow moving sheaves, and listen for squealing and clattering which could indicate
bearing problems.
*What is the safest technique for pulling loose tail from a rope run?
Ans: Pull tails from rope runs upstream at about a 45° angle. If your grip on the tail is lost, this
ensures that the ropes will pull the tail away from you, not toward you. And don't grip the tail too
tightly, as you may need to release it quickly if it gets pulled in.
*When preparing to replace a rope, why is it a good idea to leave the old rope in place until the new
rope is ready?
Ans: The new rope can be tied to the old rope, and the old rope can be used to thread the new rope
correctly through the rope run.
*If a rope does break and come off the machine, what tools can be used to help thread a new rope
through the rope run?
Ans: A magnet, magnetic belt, or rubber hose can be used to thread the rope around the dryer cans
or from dryer felt nip to dryer felt nip.
 Carrier Ropes - Design and Operation::::
Description:
Carrier ropes were introduced over a hundred years ago to address the safety hazards and time
requirements associated with threading a paper machine by hand. While carrier ropes are much
safer, many hazards still exist. To keep a carrier rope system operating safely and efficiently, it is
important to understand the elements of proper design and operation. The information presented in
this module will help you to identify existing issues with your carrier rope system and provide
guidance on the possible changes needed to alleviate them.
-Identify and describe the equipment in a carrier rope system.
-Describe a typical rope path through a dryer section.
-Describe the design considerations for sheaves, including layout, alignment, wear, and material.
-Describe the major factors in rope selection.
-State the importance of proper rope tension
Key Questions:
*What is a "dog leg" in a carrier rope system?

Ans: A "dog leg" release transfer refers to a rope transfer sheave setup that facilitates the dropping
of loose tails and broke after a transfer point during threading. This improves threading and carrier
rope life.
*If a carrier rope needs to change direction on a sheave, how should the sheave be set up?
Ans: The rope should enter the sheave square to the groove and exit on the required angle. The
straight-on entry angle helps keep wads and broke from rolling the rope out of the sheave. The exit
angle should be within the groove profile to minimize rope abrasion on the sheave edges.
*What is the most common cause of premature rope failures?
Ans: Poor sheave condition is the most common cause of premature rope failures. Secondary
grooves worn in the root of the sheave will abrade the length of the rope, and especially hammer
and wear the splice (which tends to be slightly bigger around than the rope) as it passes through.
*Why is rope tension reduced after threading?

Ans: Rope tension should be reduced after threading to allow the ropes to recover from the higher
threading tension and help them maintain their natural elasticity. It also helps minimize rope wear by
reducing the effects of abrasion.
*Why are carrier ropes sometimes coated or treated?

Ans: Size press and coater sections tend to use coated or treated rope to combat the effects of the
chemicals present in these sections.
 Tail Threading::::
Description:
Every time a paper or board machine is started up after a shutdown, and following wet end sheet
breaks, it is necessary to rethread the sheet from the forming section to the reel. After dry end sheet
breaks, the sheet must be threaded through some portion of the machine. This module will describe
the sheet threading process on a paper or board machine and the main components of a carrier rope
system, including rope sheaves, rope tensioners, and rope drives.
-Describe the sheet threading process on a paper or board machine.
-Identify the purpose of tail threading equipment.
-Recognize the safety hazards and safety guidelines associated with tail threading equipment.
-Identify and describe the main components of a carrier rope system, including rope sheaves, rope
tensioners, and rope drives.
-Identify and describe tail cutter and tail breaker equipment.
-Identify the function of tail cutters and tail breakers.
-Identify and describe threading devices, including belt conveyors, threader pans and chutes, and air
showers/ nozzles.
-Describe the operation of threading devices, including belt conveyors, threading chutes, and air
nozzles.
-Identify and describe the main components and primary flows of common tail threading systems.
Key Questions:
*How can ropes be used to thread a paper or board machine?

Ans: Carrier rope systems are comprised of multiple sections, each containing 2 or 3 ropes which
travel together along the sheet path. During threading, a ""tail"" (a narrow section of the sheet) is
pinched and carried along between the ropes in each section.
*How are carrier ropes driven?
Ans: They can be driven by the driven rolls or dryer cans in their section, or by a separate rope drive
in their return run.
*Doesn't that take a lot of rope? What happens if you run out of rope?
Ans: Carrier ropes consist of endless loops which travel along the sheet path with the tail through
their section, and then separate and return to the beginning of the section. On their return run, they
are tensioned and sometimes driven.
*How is the tail transferred between rope sections?

Ans: Each rope section can be set up to release the tail directly into an ingoing rope nip in the next
rope section, or an auxiliary device (an air shower or belt conveyor) can be used to transfer the tail.
*Why is rope tension reduced after threading?

Ans: Reducing the rope tension after threading allows the ropes to recover and maintain their
elasticity.
 Carrier Ropes – Safety::::
Description:
The purpose of a carrier rope system is to help thread a narrow section of the sheet, called the
"tail," from the wet end to the dry end of a paper machine. Once the tail has been threaded the full
length of the machine, the sheet can be widened out to its full width. When working around a carrier
rope system, it is important to keep in mind that the ropes have the ability to cause considerable
personal injury. Following standard procedures and recommended techniques, while maintaining a
healthy respect for the ropes, will minimize the potential for accidents and injuries.
-Identify the dangers associated with carrier ropes.
-State the importance of proper respect for carrier rope systems.
-Identify the major hazards when working around a carrier rope system.
Key Questions:
*What are the three main dangers associated with carrier rope systems?
Ans: A paper machine carrier rope system poses three major dangers above and beyond those
inherent to the paper machine: nip points, burns, and rope breakage.
*What is a nip point?

Ans: A nip point is created wherever a moving or rotating object contacts another moving, rotating,
or stationary object and creates a pinch point. Nip points are places where clothing, tools, and body
parts can be grabbed and drawn into the machinery.
*Where are nip points and pinch points located in carrier rope systems?
Ans: Rope systems introduce a number of new nip points, including rope -to-rope nips, rope-to-
sheave nips, rope-to-dryer can nips, and tensioner sheave carriage nip points.
*Why is it important to approach an area that contains carrier ropes cautiously?
Ans: There is always a chance of rope breakage, and if a rope breaks, it can easily get tangled in an
adjacent rope and create a hazard. The fact that the ropes move so quickly and have the power of
the entire paper machine behind them presents a considerable possibility for injury.
*If you must cross under a rope, how should you proceed?
Ans: Stop before you cross and observe the rope run. Watch long enough to see the entire length
pass by and look for rope damage or an unusual rope movement. Look in both directions to make
sure that the rope is properly moving through the sheaves. Listen for any unusual noises, like
squeaky sheave bearings, and the sheet break horn. If everything appears normal, pass under the
rope run quickly.
 Calendering - Hard Nip::
Description:
Hard nip calendering is used to smooth the surface and control the caliper or thickness of the sheet
before it is wound onto a reel. Some sheet compaction or pressing also occurs. At the end of this
module, you will be able to describe the purpose of hard nip calendering and describe the main
components of a hard nip calender.
-Describe the purpose of hard nip calendaring.
-Identify sheet and calender operating variable s that affect calendering.
-Describe the differences between single-nip and multi-nip calender stacks.
-Identify the safety hazards associated with calender stacks.
-Identify and describe the main components of a hard nip calender.
-Explain how roll deflection can be used to control the caliper profile of the sheet.
-Explain how zone profiling can be used to adjust the caliper profile of the sheet.
Key Questions:
*Why are multi-nip calender stacks with 3 or more rolls used on some paper grades?
Ana: Multi-nip calender stacks are used in the production of smooth, high gloss paper grades, like
magazine paper.
*What is a "queen roll"? What is a "king roll"?

Ans: In single-nip calender stacks, the top roll is called the "queen roll" and the bottom roll is called
the "king roll." In multi-nip stacks, the "king roll" is at the bottom and the next roll up+G186 is
often called the ""queen roll.""
*What adjustment can be made at the calender stack to "fix" soft edges at the reel without changing
the nip load?
Ans: Soft edges at the reel indicate low caliper at the edges. If one of the calender rolls is a variable
crown or controlled crown (CC) roll, increasing the roll deflection will increase the caliper at both
edges without changing the overall nip load.
*What if only one edge is soft?

Ans: If only one of the edges of the reel is soft, there are two options: either decrease the load on
that edge, or decrease the load on the other edge AND decrease the roll deflection in the variable
crown or controlled crown (CC) roll.
*What is "zone profiling"?

Ans: Zone profiling works by deforming one of the calender rolls (often the king roll) to adjust the
nip pressure at multiple cross-machine positions. The localized nip pressure variation is achieved by
increasing or decreasing the diameter of the "zone-controlled roll."" Hot or cold air and nozzles, or
induction heaters, can be used to heat or cool the zones and change the roll diameter by zone.
 Calendering - Wet Stack::::
Description:
Calendering is a process used in the production of paper and board to smooth the surface and
control the caliper or thickness of the sheet. Some sheet compaction or pressing also occurs. Wet
stack calendering uses moisture to enhance calendering results. Wet calender stacks must be
followed by dryers to remove the added moisture before they can be wound onto the reel.
-Describe the purpose of wet stack calenders.
-Identify the safety hazards associated with ca lender stacks.
-Describe the wet stack calendering process.
-Identify and describe the main components of a wet calender stack.
-Describe the design and operation of deflection compensated rolls in wet stacks.
Key Questions:
*Why is it called "wet stack" calendering?
Ans: In a wet stack, water is added to the sheet surface in one or more nips. This added moisture
improves the transfer of the smooth calender roll surface to the surface of the sheet, so it enhances
calendering results.
*How is the water applied to the sheet on a wet calender stack?

Ans: "Water boxes" are positioned at one or more nips. They contain heated water which contacts
the sheet briefly to moisture only the sheet surface, in order to concentrate the calendering action on
the surface.
*Can anything be added to the water that is used to moisten the sheet?
Ans: Dyes, lubricants, and binders like starch can be added to the water going to the water boxes, if
desired.
*How are wet calender stacks loaded?
Ans: Stack loading is typically provided by the weight of the rolls, which means that the nip loads
increase from top to bottom. Jacking bolts or compensators may be provided on the ends of the
upper rolls to adjust edge loads, if necessary.
*Are variable crown rolls used in wet calender stacks?

Ans: To maintain uniform cross-machine nip pressure profiles in a wet stack, the king roll and queen
roll (if there is one) are either fixed crown or variable crown rolls. Fixed crown rolls are designed for
a single nip loading, while variable crown rolls can be adjusted for different nip loadings.
 Dry End QCS Scanner::::
Description:
The QCS scanner is a device located just before the reel that provides continuous measurement of
key dry sheet properties. This module will describe safety guidelines for working around a dry end
QCS scanner, how QCS scanners operate, and different types of sensors used.
-Describe safety hazards and safe work practices associated with a dry end QCS scanner.
-Explain how QCS scanners operate.
-Identify and describe the type of sensors used to measure moisture, weight, and caliper.
-Explain how moisture, weight, and caliper profile issues are handled by the control system.
-List the benefits of improved profiles.
Key Questions:
*What variables are typically measured by dry end QCS scanners?

Ans: Commonly measured variables include moisture, basis weight, and caliper. Both machine
direction and cross-machine direction results are reported.
*Can I work safely around a dry end QCS scanner that contains a radioactive measuring device?
Ans: Even though they are shielded and emit only very low levels of radiation, avoid working on or
near the scanner heads for an extended period of time in order to minimize your exposure risk. Only
qualified technicians should clean or work on the sensors and scanner heads.
*Where are caliper adjustments made on the machine?

Ans: Caliper profile adjustments can be made at a calender stack, either by changing a roll deflection
or using a zone profiling system.
*Are any of the profiled variables related to each other?
Ans: Typically, there are interactions between the profiled variables. For example, if there is a high
weight zone, that zone will mostly likely experience high moisture. There may also be a caliper issue
in that zone.
*What are the benefits of flatter sheet profiles?

Ans: A dry end QCS scanner system can yield benefits in costs, sheet quality, and machine
productivity. Improved runnability is related to all of these, and is perhaps its biggest benefit.
 Paper Machine Reel Systems::::
Description:
The purpose of the reel section (or simply the "reel") is to wind the continuous sheet produced on a
paper or board machine onto a spool to produce jumbo rolls called "parent reels" that are ready for
further processing. It basically completes the paper or board production process. This module
describes the operation, functions, and main components of a pope reel system.
-List the purpose of a paper or board machine reel section
-Identify the safety hazards associated with paper and boa rd machine reel systems.
-Describe the operation of a pope reel system.
-Identify and describe the main components of a pope reel.
-Identify the functions of the main components of a pope reel system.
-Identify and describe common turn-up systems.
-Identify and describe common tail threading systems.
Key Questions:
*How is the parent reel speed controlled if it is not driven?

Ans: The building parent reel is held against and driven by t he driven reel drum, whose speed is
matched to the rest of the paper or board machine.
*What is ""double nip loading""?

Ans: "Double nip loading" occur s when both the primary arm hooks and the secondary arms are in
contact with the spool, after the primary arms have set the spool on the rails and the secondary arms
have loaded. A time-delay pressure switch is typically used to keep the double loading to a minimum.
*Why are reel drums grooved?

Ans: Reel drums are often spiral grooved to allow the boundary layer air traveling with the sheet to
evacuate and allow the sheet to lay flat on the drum.
*How are reel spools started?
Ans: A driven rubber tire or belt accelerates the empty spool in the primary arms up to, or just
above, the current machine speed before the spool is lowered to its turn-up position, on top of the
reel drum.
*Why are ""bubble"" turn-up systems only used on lower weight grades?
Ans: A bubble-type turn-up system uses a pocket of air blown in under t he sheet just ahead of the
reel to transfer the sheet to a new spool. The air ""bubble" is caught up in the reel drum/spool nip
and the rotating spool pulls and tears the sheet. This works better on lighter weight sheets, which
tear more easily.
 Web Guiding and Spreading::::
Description:
Web guiding and spreading are two elements of web control that are used in web producing
processes. On paper and board machines, several fabric loops require web control to keep them
running correctly on the machine. Web control is also used on the sheet after it has been dried to
ensure the success of dry end and winder operations. This module will discuss web guiding first, and
then web spreading.
-Define "traction" and "tension".
-Describe the purpose of guiding and spreading devices in paper and board production processes.
-List safety guidelines associated with web guiding and spreading devices.
-List ways to improve traction between rolls and the sheet.
-State the law of "normal entry".
-Explain how the web guiding an d spreading equipment operates.
-Explain how to adjust guiding and spreading equipment to address a given situation.
Key Questions:
*Which web or webs are guided and spread on a paper or board machine?
And: On paper and board machines, fabric loops require web guiding and spreading to keep them
running correctly, and the sheet requires guiding and spreading at the dry end and winder to ensure
the success of dry end and winder operations.
*I've heard that guide rolls must be ""in traction"" with the sheet in order to properly guide the
sheet. What does that mean?
Ans: "In traction" mean s that the sheet and guide roll surfaces are in contact and moving at
approximately the same speed.
*What is the ""law of normal entry"" for webs?
Ans: This law states that a web will seek entry to a roll at 90 degrees to the roll's axis at each point of
contact. This is how a spreader roll's bow causes the web to be directed outward, toward the roll
ends, when it is set up with its bow pointing downstream.
*How should bowed spreader rolls be oriented?

Ans: Pointing the bow in the downstream direction utilizes the law of normal entry and spreads the
web outward, but bowed rolls are sometimes rotated into or out of the web to compensate for a
baggy center or slack edges.
*Where are dual spreading devices used?

Ans: Dual spreading devices are sometimes used after slitters to separate the slits and then straighten
their paths.
 Paper Coating Operations::::
Description:
Paper coatings can be used to enhance the printability, visual properties or functionality of a sheet
of paper board. Coating formulas vary widely because there are many different grades of coated
paper and board with very different end uses. This module will identify the main purposes of paper
and board coatings and describe the three most common coater designs.
-Identify the main purposes of paper and board coatings.
-List the three main categories of coating ingredients.
-Identify and describe the three most common coater designs.
-List the three main objectives of coating equipment.
-List the advantages and disadvantages of air-knife, blade and roll coaters.
-Describe the three most common methods of drying paper coatings.
Key Questions:
*Why are there so many different coater designs?

Ans: The coater design used must take into account properties of the base sheet, properties of the
coating mixture, number of sides to be coated, number of coats on each side, and the desired final
coated sheet properties.
*Why is some coating done on-machine and some off-machine?

Ans: There are advantages and disadvantages to each method. In general, on-machine coating is
better suited to light to moderate coating applications with less stringent quality requirements. Most
coaters can be used either way.
*Which type of coater is best at filling in low spots in the sheet to create a smooth printing surface?
Ans: Because blades are quite rigid, blade coaters do a rather good job of filling in low spots on the
sheet, at the expense of the uniformity of the coating layer thickness.
*What is a ""contour coater""?
Ans: Air-knife and roll coaters are ""contour coaters."" This means that they create a coating layer
with a relatively even thickness that follows the contour of the sheet surface.
*Why are other types of dryer equipment, besides steam-heated dryer cans, used to dry paper
coatings?
Ans: Dryer cans dry by contacting the sheet. The coated side of the sheet must be sufficiently dried
before it contacts a dryer can to prevent sticking or picking of coating on the dryer surface.
 Paper Coating Ingredients:::::
Description:
Paper and board grades are sometimes coated to improve the printability, visual properties, or
functionality of the sheet. Coating formulas typically contain three categories of ingredients:
pigments, binders and additives. Pigments improve printing and optical properties of the sheet,
binders adhere the pigment particles to each other and to the sheet, and additives either assist in the
coating process or enhance sheet properties. This module describes common coating formulas and
coating ingredients.
-List the sheet properties that are enhanced by paper coating.
-List the three main ingredient categories used in paper coating mixtures.
-Describe the purpose of pigments, binders, and additives in coating mixtures.
-Describe the functionality of the more common paper coating pigments and binders.
-Identify and describe common coating additives.
Key Questions:
*Why are some paper and board grades coated?

Ans: Paper and board grades can be coated to enhance printability, visual properties (brightness,
opacity, gloss), or functionality (ink holdout, glueability) of the sheet.
*What does a typical paper or board coating mixture contain?

Ans: Some coating mixtures contain 10 or more ingredients. A typical print-grade coating formula
might contain 83% pigment, 13% binder and 4% additives (by percent of dry weight). These
ingredients are typically dispersed in water.
*What is the purpose of pigments in coating mixtures?
Ans: Pigments used in paper and board coatings govern the final optical and printing properties of
the sheet. They do this by providing brightness, whiteness, smoothness, and opacity.
*Why do some coating mixtures smell like latex paint?

Ans: Latex can be used as a binder in coating mixtures and also in latex paints. Binders hold pigment
particles to each other and to the sheet, help fill voids between pigment particles, and influence the
viscosity and water retention of the solution.
*Anti-foamers and defoamers can be used to control foam in coating systems. What is the
difference?
Ans: Anti-foamers prevent foam from forming, while defoamers help eliminate foam after it has
formed.
 Broke Systems:::::::
 Broke System Purpose and Operation::::
Description:
"Broke" refers to partly or fully manufactured paper or board that is discarded from paper or board
making, converting, and finishing processes. It also refers to the stock made by repulping these
materials. Broke is continuously being produced, and it is the job of the "broke system" to collect
this valuable resource, process it, and make it available for reuse. Because broke can amount to well
over 5% of a machine's total production, broke is an important fiber source and the broke system is
an essential part of the paper making process, from both financial and operational perspectives.
-Describe the purpose of the broke system for a paper or board machine.
-List safety hazards and safety guidelines for broke systems.
-Identify how broke usage affects machine operations.
-Explain why broke consistency control is important.
-List ways to control contamination in broke systems.
-List sources of wet and dry broke.
-List the main differences between wet broke and dry broke repulpers.
-List the functions of repulper showers.
-Describe how operators maintain control of broke systems.
Key Questions:
*Why is it important to feed broke back into the system in a controlled manner?
Ans: Broke behaves differently than virgin fiber - it holds less water, so dries mo re easily. However,
it can negatively affect sheet quality and machine runnability, so the amount used needs to take into
account all of its effects.
*Why is wet broke easier to repulp than dry broke?
Ans: Wet broke is more easily rewetted and repulped because its moisture content is already much
higher.
*What are the differences between under-machine repulpers at the wet end and dry end?
Ans: Dry end repulpers are usually of heavier duty construction so they can handle large s labs of
broke. They are usually larger to allow for the extra retention time needed to properly slush dry
broke.
*How much broke storage should a paper or board machine be equipped with?
Ans: Ideally, a broke storage system would be able to handle around 2 hours of full machine
production, though in reality it is usually much less.
*Why is it important to control consistency during repulping?

Ans: Repulpers are designed to create a vortex that draws broke down to the rotor blade. If the
consistency is too low, there will be excessive turbulence, but if the consistency is too high, the
suction effect of the vortex will be weakened.
 Broke Repulpers::::
Description:
Broke is an important byproduct of the paper making process that is reclaimed and recycled back
into the furnish. Broke is generated at various points around a paper machine and so repulpers are
positioned in both under-machine and off-machine locations to collect, repulp, and pump the broke
back to the stock system for reuse in the paper or board making process. This course covers the
safety hazards around broke repulpers, off-machine repulper designs, the broke repulping process,
as well as repulper consistency control.
-Safety hazards and safety guidelines.
-Purpose of broke repulpers.
-Sources of broke.
-Typical repulper components.
-Purpose of repulper compone nts.
-Repulping process.
-Biocides and Fungicides.
-Consistency control.
-Vat level control.
Key Questions:
*List some common sources of broke to off-machine broke repulpers.

Ans: Trim and waste from converting operations, loose dry broke, and broke rolls that have been
cut down by a guillotine.
*What are the major components of an off-machine broke repulper?

Ans: A vat, one or two driven agitators or rotors, an extraction plate a t each rotor, one or more
pumps, piping, and consistency and level controls.
*How is broke typically fed to off-machine broke repulpers?
Ans: By blowers, fork trucks, and/or belt conveyors.
*How is consistency typically controlled in an off-machine broke repulper?

Ans: A consistency control loop utilizes a signal from a consistency transmitter on a recirculating
stock line to adjust dilution water flows to the vat and pump suction in order to maintain the
consistency at or near a set point.
*How is the vat level typically controlled in an off-machine broke repulper?

Ans: A level transmitter on the vat sends a signal to a level controller which controls an automatic
makeup water valve position.
 Under-Machine Repulpers::::
Description:
Most paper and board machines are equipped with at least three under-machine repulpers. These
repulpers collect and process wet and dry broke from the machine during normal operation and also
during startups and sheet breaks. The three most common under-machine repulpers are located
under the couch roll, press section, and reel. Some machines have another repulper located under
the winder. This module describes the purpose, locations, and components of under-machine
repulpers.
-Purpose of under-machine repulpers.
-Safety hazards and safety guidelines.
-Couch Pits.
-Press Pits.
-Reel / Dry End Repulpers.
-Repulping process.
-Winder Repulpers.
-Typical components.
-Process flows.
Key Questions:
*What is the purpose of under-machine repulpers?

Ans: To process the broke generated during the production of paper or board so that the fibers and
other valuable components of the sheet can be reused.
*Where are under-machine repulpers normally located?

Ans: Under the couch roll at the end of the forming sect ion, under the press section, under the reel,
and sometimes under other major machine sections and/or the winder.
*What are the typical components of an under-machine repulper?
Ans: A vat, showers, one or more agitators, and one or more pumps.
*What type of broke is collected in a couch pit?

Ans: Wet edge trim during normal production, and the full sheet during startups and sheet breaks.
*What is the purpose of the ventilation/exhaust system on a reel repulper?

Ans: To create a partial vacuum in the broke chute.
 Broke System Inventory Management::::
Description:
There are two types of broke generated on a paper or board machine: continuous and event related.
Broke is continuously generated as wet edge trim, winder trim, dressing from reels, and cull rolls.
Event-related broke comes from sheet breaks and machine startups and shutdowns. Large quantities
of broke can be generated during these events that end up going to under machine repulpers, such
as the couch pit, press pit, and dry end repulper. It is important to recover and reuse as much of this
valuable fiber resource as possible.
-Describe the two types of broke generated on paper and board machines.
-List safety hazards and safety guidelines related to broke systems.
-Explain why it is important to recover broke for reuse.
-Describe the sources of broke to typical under machine repulpers.
-Identify the components of a typical under machine repulper.
-Explain the importance of consistency and level control in repulper vats.
-Explain the importance of broke and dilution white water inventory management.
Key Questions:
*Why is it important to maintain broke storage chest levels in the 25 to 35% range during normal
operations?
Ans: This helps ensure sufficient storage capacity during process upsets, such as sheet breaks,
threading, and start ups.
*Why is broke often thickened so that it can be stored at a higher consistency?

Ans: The removal of water on broke thickening equipment increases the storage capacity of the
broke chests.
*Why is it important to control the level in repulper vats during slushing?
Ans: This allows the rotor to effectively circulate and slush the broke, using the least amount of
energy and minimizing repulping time.
*Why are dry end repulpers typically of heavier construction than other under-machine repulpers?
Ans: Dry end repulpers are normally of heavier construction because they must often handle slabs
from reels and cull rolls.
*Why is it important for the seal pit liquid level to be kept above the dropleg openings from a drum
or disc thickener?
To make sure that the dropleg opening is not exposed to air, which would cause the thickener to
lose vacuum.
 Broke Cleaning and Screening::::
Description:
"Broke" refers to partly or fully manufactured paper or board that is discarded from paper or board
making, converting, and finishing processes. It also refers to the stock made by repulping these
materials. Broke is continuously being produced and it is the job of the "broke system" to collect
this valuable resource and supply it back to the paper or board making process for reuse. Many
broke systems include cleaning and screening stages just before the broke fiber is returned to the
machine furnish. The purpose of broke cleaning and screening systems is to remove contaminants
from the broke stream, break apart fiber flakes and bundles in the broke to improve sheet
uniformity and minimize fiber losses, and return a clean, consistent flow of broke to the machine
furnish.
-List the functions of broke cleaning and screening systems.
-List safety hazards and safety guidelines related to broke systems.
-Explain the purpose of high density cleaners, broke deflakers, and broke screens in broke systems.
-Describe process flows in a typical broke cleaning and screening system.
-Describe the operation of a high density cleaner junk trap.
-Explain how a two-stage screening system works.
-Explain why consistency control is important in broke cleaning and screening systems.
-Describe why it is important for broke to be metered consistently into the machine furnish.
Key Questions:
*Why would you need both cleaners and screens? Don't they both remove contaminants from
broke?
Ans: Broke systems often use both high density cleaners and pressure screens. HD cleaners remove
heavy contaminants, while screens remove large contaminants and help break up fiber flakes.
*What are the process flows for a typical broke system?
Ans: Typically, broke is pumped from a broke storage chest to a high density cleaner, through a
deflaker, and on to a broke screening system, before it is blended back in to the machine furnish.
*Why is it important to control broke consistency?

Ans: Consistency swings can negatively affect the machine-direction weight profile. Also, if the
consistency is too high, this can cause pressure screens to mat over and plug.
*How does broke fiber differ from virgin fiber?

Ans: Broke fiber has already been screened, cleaned, refined, and perhaps chemically treated or
dried. Therefore, it does not hold water as well or respond as well to refining.
*Where is broke typically added back to the paper or board making process?
Ans: Broke is typically reintroduced to the process at the blend chest or machine chest in the thick
stock system.
 Finishing:::::::
 Paper Machine Winding Basics::::
Description:
There are two basic winding processes in the paper industry: reeling and winding. The reeling
process is used to produce very large rolls of paper or board, called "parent reels," at the dry end of
a paper machine. The winding process converts the large parent reels produced on the paper
machine into customer-sized rolls that are ready for converting or shipping. This training module
covers the winding process. The equipment used for this process is called the "winder."
-Describe the purpose of the winder.
-List in order the steps that occur during winding.
-Describe the desired roll set characteristics.
-Identify the sections and main components of a conventional two-drum winder.
-List and differentiate between the major winding variables.
-Describe the relationship between paper properties and winding.
-Describe wound-in-tension and residual tension
-Describe other winder designs.
Key Questions:
*What are the TNTs of winding?

Ans: The structure of finished roll sets is largely dependent on three winding variables - sheet
tension, nip load, and winding torque. These are often referred to as the TNTs of winding -
Tension, Nip and Torque.
*Why are there spreading devices both before and after the slitters on a winder?
Ans: Spreading devices straighten the sheet before the slitters to ensure good quality cuts and then
keep the slit sections separate as they enter the winding section. They help prevent the sheet from
weaving back and forth between adjacent rolls in the roll set.
*Where is sheet tension controlled on a typical two-drum winder?

Ans: During winding, the sheet is tensioned by the driven drums in the winding section and a
mechanical brake or regenerative brake motor in the unwind section. The braking force is used to
control sheet tension.
*What is the difference between wound-in-tension and residual tension?

Ans: Wound-in-tension is the amount of tension present in the sheet as it is being wound. Once a
roll set has been built, the wound-in-tension converts to residual tension. Residual tension is usually
positive in the outermost layers of the roll, and negative or negligible in the center and middle.
*Why do winders run at such high speeds?

Ans: Because there is usually one winder per machine and a winder may only run 50% of the time
(due to parent reel changes, slitter adjustments, maintenance, blade changes, and repairs), a winder
must run at least twice as fast as the paper machine in order to keep up with production.
 Paper Machine Winder Slitting::::
Description:
The purpose of a winder is to convert the large diameter, machine-width parent reels of paper or
board produced on a paper or board machine into finished roll sets ready for converting or
shipping. Winder slitters are used to cut parent reels into various roll widths and trim off the edges
of the sheet in order to meet customer requirements. This module will describe common slitting
methods and recognize safety guidelines applicable to winder slitters and slitter sections.
-Explain the purpose of the winder slitting process.
-Identify and describe hazards and safety guideline s applicable to winder slitters and slitter sections.
-Describe common slitting methods and identify the method most often used during winder slitting.
-Describe the advantage of individually driven bottom slitters over a driven bottom slitter carrier
roll.
-Describe slitter setup parameters.
-Describe automatic slitter positioning systems.
-Describe slitter variables which influence slit quality.
Key Questions:
*Why are bottom slitters driven slightly faster than the sheet?
Ans: The over speed prevents buckling and bunching up of the sheet at the entrance to the slitters.
*There are several different slitting methods - water jet, razor, score/crush, and shear. Which is the
most common?
Ans: Shear slitting is the most common method used on paper and board machine winders because
it gives high quality cuts on a wide range of grades at relatively high speeds.
*Why is each bottom slitter driven instead of mounting all of the bottom slitters on a driven carrier
roll?
Ans: Because the carrier roll diameter must increase as the winder speed and machine width
increase, in order to control vibrations, individual motor slitters have become more popular.
*They are often referred to as ""knives,"" but only the top slitters look sharp. How do most slitters
cut the sheet?
Ans: On most winders, the top slitters are sharp circular blades and the bottom slitters are bands.
The top blade slightly overlaps the bottom band and is loaded from the side to cut the sheet using a
shearing action, like scissors.
*When roll sizes change, how are the slitters repositioned?

Ans: Slitters can be repositioned manually or automatically. Manual positioning exposes workers to
hazards and takes longer, so is more appropriate when slit widths don't change very often.
 Paper Machine Winder Safety::::
Description:
Eliminating hazards is the best way to ensure the safe operation of paper and board machine
winders and rewinders. Machine guarding and safety devices, interlocks, and controls are next. Safety
can also be improved by automating activities and procedures, proper training, the use of
standardized procedures, and regular monitoring and maintenance of equipment and controls.
Additionally, operators should know the locations of E stops, first aid cabinets, eye wash fountains,
emergency showers, and fire extinguishers, and know how to use them.
-Compare the operation and speed of a paper or board machine to a winder.
-List devices and strategies that can be used to prevent accidents and injuries on winders.
-Define the terms "pinch point," "nip point," "ingoing nip," and "outgoing nip".
-Describe how machine guarding types and locations are determined for a winder.
-Identify the locations of pinch point hazards, nip hazards, cutting hazards, fall hazards, thermal
burn hazards, and slipping and tripping hazards on a winder.
-List important safety guidelines for overhead cranes.
-List ways to improve safety for winder operator procedures.
-List safe behaviors to use around winders.
Key Questions:
*Why must winders run so much faster than paper and board machines?
Ans: Because they must stop occasionally to load new reels, eject finished roll sets, reposition slitters,
and change blades, winders must run much faster in order to keep up with the machine's
production.
*How can workers be protected from the fall hazard presented by broke holes (openings in the
floor)?
Ans: Guards and/or covers on broke holes should be interlocked with light curtains or safety gates,
and current fall protection guidelines must be followed when working around unguarded broke
holes.
*What kinds of hazards are presented by the hydraulic systems used by many winders and
rewinders?
Ans: Hydraulic fluid is pressurized and is heated during operation. If a fitting or coupling were to
come loose, the fluid would present burn, fluid injection, and fire hazards, as well as the hazards
presented by any flailing lines or hoses.
*What is recommended or required for platforms and catwalks around winders?

Ans: All walking surfaces should be slip-resistant, and elevated surfaces should be equipped with top
rails, mid-rails, and toe boards.
*Do winders and rewinders have any cutting hazards?

Ans: The slitters and set change device (a cut off knife or guillotine) both present nip point and
cutting hazards to operators.
 Roll Handling and Wrapping::::
Description:
The main goal of roll handling and wrapping systems is to protect newly-produced paper or board
rolls from physical damage, moisture and foreign debris during handling, transport and storage. This
is necessary because paper and board rolls may be handled multiple times in multiple ways, and
stored in several locations in different environments, prior to use by the customer. This module will
describe the steps of a typical roll wrapping system and describe the equipment used in the roll
wrapping process.
-Identify the main goal of roll handling and wrapping systems.
-Identify safety guidelines for roll handling and wrapping areas.
-List common roll wrapping materials.
-Describe the basic steps of a typical roll wrapping system.
-Identify and describe the equipment used in the roll wrapping process.
-List the typical information included on roll labels.
Key Questions:
*Why are rolls wrapped?

Ans: Rolls are wrapped to protect them from physical damage, moisture, and foreign debris during
handling transport and storage.
*What materials are used to wrap rolls?

Ans: Paper rolls are usually wrapped with unbleached kraft paper. The kraft paper can be coated and
sometimes a clear film is applied in conjunction with kraft paper.
*What are headers?

Ans: Headers are pa per or board discs that are placed on the ends of the rolls for protection.
*What is an upender?
Ans: An upender takes a roll from its side and stands it on end so a clamp truck can pick it up.
*How are rolls secured to prevent damage during transport?

Ans: Roll damage during transport can be prevented by following the correct loading pattern and
securing the rolls with air-filled bags, honeycomb and contoured void fillers, risers, and non-metallic
strapping.
 Pulp Drying and Baling::::
Description:
Some pulp mills are not integrated with papermaking operations, so they produce market pulp and
sell it to papermaking facilities. Market pulp is dried and then cut into sheets that are stacked into
bales so they can be transported. Most market pulp is dried to about 10% moisture, but pulp that
will only travel a short distance might be dried to about 50% moisture. The higher moisture pulp is
known as "wetlap." Pulp drying machines are similar to paper machines and typically include the
following processes: forming, pressing, drying, cutting, and baling. This module describes each of
these processes in detail.
-List the processes that produce market pulp bales.
-Describe the impact each pulp drying process has on fiber properties/characteristics.
-Describe the purpose or goal of the forming section of a pulp dryer.
-Explain why pulp is pressed.
-Identify the goal of pulp drying.
-Describe airborne pulp drying process and equipment.
-Identify and describe the key processes or steps for forming pulp bales.
-Identify and describe pulp baling equipment.
-Identify and describe typical pulp bale labeling and dimensions.
-Identify and describe pulp drying and baling safety hazards and guidelines.
Key Questions:
*How is market pulp made?

Ans: A thick pulp web is formed and pressed using equipment similar to a paper machine. Usually,
the pulp sheet is dried in an airborne dryer. After the pulp is dried, it is cut in to sheets. The sheets
are collected into bales which are compressed, wrapped, and strapped.
*What is an airborne dryer?

Ans: An airborne dryer is a large enclosed structure. The pulp web enters the top of the enclosure
and makes several horizontal passes around unheated rolls. Fans force air through blow boxes and
onto the pulp web. The air removes water and carries it away from the pulp web.
*What are blow boxes?

Ans: Blow boxes are air headers that direct air onto the pulp sheet. The pulp web travels between
upper and lower blow boxes. The lower boxes blow air to help hold the sheet above the box.
*How is the pulp web cut into sheets?

Ans: The pulp web is cut lengthwise by slitters. Then a rotary cutter cuts the sheet width-wise.
*How are the bales wrapped?

Ans: Two larger sheets of pulp are folded around the stack of cut pulp sheets and secured with
either wires or straps.
 Paper Machine Auxiliary Systems:::::::
 Wet End Showers::::
Description:
Various types of showers are installed around the wet ends of paper and board machines to keep
the fabrics and other surfaces clean and lubricated. Wet end shower systems should be monitored
and maintained on a regular basis to ensure their optimal performance. This module will give you a
better understanding of wet end showers and how they function in paper machines.
-Describe the main functions of wet end showers on a paper or board machine.
-Identify and describe the four basic types of wet end showers - flooding, lubrication, high pressure
and chemical.
-Identify and describe additional shower types, including trim squirts, wet end tail cutter and roll
flushing showers.
-Describe the purpose of shower oscillators, filters and strainers, shower brushes and purgeable
nozzles.
-Identify important shower system inspections and monitoring points.
-Identify hazards and safety guidelines associated with wet end showers.
Key Questions:
*What is the purpose of the showers at the wet end of a paper machine?
Ans: Showers keep the wet end fabrics clean and open, provide lubrication between moving and
stationary elements, and prevent stock buildup and deposits on surfaces.
*How much water should be used in a flooding shower?

Ans: For optimal results, the shower flow should exceed the void volume of the fabric, which can be
provided to you by the fabric supplier.
*Where are high pressure showers used on the wet end?
Ans: High pressure showers are typically installed on the wire run and on the sheet-contacting
surface of each wet felt, and often on grooved and drilled roll covers.
*Why are high pressure showers oscillated in the cross-machine direction?

Ans: To provide uniform coverage and prevent damage to the fabrics and roll covers.
*When are flushing showers in suction rolls used?

Ans: High volume flushing showers are used to flush out the openings in suction roll shells when
the sheet is off.
 Paper Machine Line Shaft Drives::::
Description:
Line shaft technology dates back to the 18th century and was literally the driving force behind the
Industrial Revolution of the 19th century. Line shafts are still in use on many older paper and board
machines. This course discusses the design and function of common line shafts used in the paper
making industry along with maintenance and safety guidelines.
-List the two most common power sources for line shaft drives on paper and board machines.
-List the drive sections of a typical paper or board machine.
-Define the term "draw".
-Explain the difference between cone pulley and non-pulley line shaft drive systems.
-Explain t he purpose of helper drives.
-List the elements of a typical line shaft drive system maintenance program.
-Identify and describe safety hazards and safety guidelines for paper and boa rd machine line shaft
drives.
Key Questions:
*What is a line shaft drive system?

Ans: A line shaft system uses one prime mover to power the whole machine instead of a different
one for each section.
*What is draw?
Ans: Draw is the speed difference between two adjacent sections of the paper machine.
*What are the types of line shaft drives?

Ans: There are two main types of line shaft drives: cone pulley drives and non-pulley direct drives.
In both types, power is transmitted the length of the machine by a line shaft running parallel to the
machine.
*What is a helper drive?
Ans: Helper drives are electric motors installed on some parts of the machine to supply auxiliary
driving energy.
*How are line shaft drives started up?

Ans: First, the line shaft drive is accelerated with all the machine sections unclutched or
disconnected. Then, one by one, each section is accelerated up to speed by engaging or closing the
section clutch.
 Paper Machine Adjustable Drives::::
Description:
Sectional drive technology has evolved over the years and advancements in drive and motor designs
are continuously being made. Innovations have allowed for increasingly higher machine speeds and
production rates. Yet, for all of the advancements in technology, the purpose of sectional drive
systems remains the same. That is to give the paper maker a means of controlling the speed and
tension of the paper web as it is transferred from one section to another. AC sectional drives are
most common on newer machines because of the durability, energy efficiency and affordability of
AC motors. This module covers the purpose, types, and operation of paper machine adjustable
drives.
-State the purpose of adjustable speed drives.
-Identify and describe the different types of adjustable speed drives.
-Describe the importance of draw.
-Identify and describe different section control modes.
-Identify and describe safety hazards and guidelines associated with paper machine drives.
Key Questions:
*What is draw?
Ans: Draw is the speed difference between the sections of a paper machine and is usually expressed
as a percentage.
*How do DC drives work?

Ans: DC drives control the speed of the motor by varying the voltage. A DC motor's speed varies
proportionally with the applied voltage.
*How do AC drives work?
Ans: AC drives control the speed of the motor by changing the frequency supplied to the motor.
The motor speed is directly proportional frequency.
*What are common sectional controls?

Ans: Each section of the machine usually has run, stop, jog, crawl or slow, slack take-up, and draw
controls.
*What is a regenerative drive?

Ans: Under braking conditions, regenerative drives convert mechanical energy of the motor and
connected load into electrical energy.
 Paper Machine Hydraulic Systems::::
Description:
The main reason why hydraulic systems are used in industrial settings is that they can deliver a great
deal of force to multiple locations in a simple and controllable manner. On a paper or board
machine, one or more hydraulic systems are typically used to provide a continuous source of clean
pressurized oil to hydraulically-actuated equipment. This module describes the components and
functions of a typical paper or board machine hydraulic system.
-Explain the purpose of hydraulic systems.
-Identify the safety hazards and safety guidelines associated with hydraulic systems.
-Identify and describe the common components of a typical paper or board machine hydraulic
system.
-List the functions of common hydraulic system components.
-Describe the types of valves that are commonly used in hydraulic systems.
-Identify and describe the typical process flows of a hydraulic system.
Key Questions:
*What are some hazards of hydraulic systems?

Ans: Hydraulic fluid is highly pressurized and becomes very hot during operation, which can cause
burns or start fires. Hydraulic systems should be de-pressurized and isolated prior to any work. Also,
pinhole leaks can inject hydraulic fluid under the skin, which can be very serious.
*What are the components of a hydraulic system?

Ans: Each system consists of a hydraulic power unit (tank with one or more pumps), filtration
equipment, heat exchanger, distribution and return piping, various valves, actuators, and instruments
and controls.
*What type of pump is used to pump hydraulic fluid?
Ans: Positive displacement pumps are typically used because they move the same volume of fluid
with each revolution and the flow volume is relatively unaffected by the discharge pressure.
*What analysis can be performed to determine if the hydraulic fluid is suitable for use?
Ans: Fluids can be analyzed for dirt content, water content, oxidation, and particulate levels.
*What is the purpose of an accumulator?

Ans: Accumulators can be used to maintain hydraulic pressures for short periods of time, dampen
pressure pulses in fluid flow, and to allow equipment to slowly return to a lower energy state if
hydraulic pressure is lost.
 Paper Machine Vacuum Systems::::
Description:
Vacuum systems on paper and board machines dewater the stock as the sheet forms, dewater and
clean the press felts, which, in turn, remove water from the sheet, and helps transfer the sheet
between sections of the machine. This module describes the main functions of vacuum systems on
paper and board machines, the safety hazards and safety guidelines associated with vacuum systems,
and the equipment that can be used to produce vacuum.
-Describe the main functions of vacuum systems on paper and board machines.
-Identify and describe the safety hazards and safety guidelines associated with vacuum systems.
-Describe the equipment that can be used to produce vacuum.
-Describe the vacuum devices used on paper and board machines.
-Explain why vacuum pump seal water must be cool.
-Describe how vacuum levels are controlled in paper and board machine vacuum systems.
Key Questions:
*How is vacuum used in the forming section of a paper or board machine?

Ans: In the forming section, vacuum is used at vacuum foil boxes and flat boxes to remove water
from the stock.
*Why are vacuum levels usually stair-stepped (gradually increased) in the forming section?
Ans: Vacuum is increased because the water becomes harder and harder to remove as the sheet
forms, and also to prevent the sheet from sealing early on, which makes it harder to remove the
remaining water.
*Where is vacuum used in the press section of a paper or board machine?

Ans: In uhle boxes to remove water and debris from the press felts, and in suction rolls for multiple
reasons, including sheet transfer, pulling in steam, and preventing sheet flutter.
*What devices are used to produce vacuum on paper and board machines?
Ans: Liquid-ring vacuum pumps, centrifugal blowers, and steam ejectors.
*How do bleed valves work in vacuum systems?

Ans: Bleed valves work by letting in air to reduce the vacuum level (or increase the pressure). They
are opened to lower vacuum levels and closed to increase vacuum levels.
 Steam Theory for Paper Machines::::
Description:
Steam is commonly used in industrial environments for power generation and in heating and drying
applications. On a paper or board machine, steam is used to dry the sheet of paper or board to a
target moisture content before it is wound up on large rolls that can be transported, stored, or
shipped. Before one can understand how steam is used in heating and drying applications, like paper
machine drying systems, it is important to understand how steam is created, how heat energy is
transferred from the steam to the sheet, and the relationship between steam pressure and steam
temperature.
-Describe the three phases of water.
-Define the boiling point of water.
-Define "latent heat".
-Define "condensation".
-Define "superheated steam".
-Describe problems with using superheated steam on a paper machine.
-Describe the relationship between steam pressure, temperature, and latent heat.
-Describe how steam is used in a paper machine drying system.
-Identify the flow of steam and condensate through the paper machine.
Key Questions:
*Why does water boil at lower temperatures at higher elevations?

Ans: The phase of water (solid, liquid, or gas) is determined by its temperature and pressure.
Atmospheric pressures are lower at higher elevations, and liquid water boils at lower temperatures at
lower pressures.
*What is condensate?
Ans: When water molecules in steam contact a cool surface, they lose energy to that surface and
change into a liquid. The resulting liquid water is called "condensate."
*What is superheated steam?

Ans: Superheated steam is steam that has been heated above its boiling point for the current
pressure.
*How can superheated steam cause problems with the rotary joints on dryer cans?
Ans: The moisture in saturated steam lubricates the carbon rings in the rotary joints. Without this
lubrication, the rings will wear more rapidly and could even crack if they get too hot.
*Why is it important to collect and reuse the condensate from a paper or board machine?
Ans: The condensate still contains heat, which is valuable because it lowers the amount of heat
needed to produce additional steam.
 Vacuum Pumps, Blowers, and Ejectors::::
Description:
Liquid-ring vacuum pumps, centrifugal blowers, and steam ejectors are three devices that are
commonly used to produce vacuum. This module explains how liquid-ring vacuum pumps create
vacuum, explains why vacuum pump seal water should be cool, and describes the operation of
liquid-ring vacuum pumps, single-stage and multi-stage centrifugal blowers, and steam ejectors.
-List safety hazards and safety guidelines associated with vacuum pumps, vacuum blowers, and
steam ejectors.
-Explain how liquid ring vacuum pumps create vacuum.
-Explain why vacuum pump seal water should be cool.
-Identify and describe the main components of liquid ring vacuum pumps, centrifugal blowers, and
steam ejectors.
-Identify and describe key process flows for a liquid ring vacuum pump.
-Describe the operation of liquid-ring vacuum pumps, centrifugal blowers, and steam ejectors.
Key Questions:
*How is the seal water used in liquid-ring vacuum pumps?

Ans: It seals in the pumping chambers and it also cools the incoming air.
*Why is it important for vacuum pump seal water to be cool?

Ans: It helps cool the incoming air, which increases its density and the vacuum level produced. It
also helps avoid vaporization inside the pumps, which would reduce capacity and efficiency.
*How is vacuum used on a paper machine?

Ans: To help dewater the stock in the forming section, to dewater and clean the felts in the press
section, and to help transfer the sheet between sections.
*What is the difference between a centrifugal fan and a centrifugal blower?
Ans: The American Society of Mechanical Engineers uses the "specific ratio" - the ratio of discharge
pressure over suction pressure. Fans have a specific ratio up to 1.11, while blowers have
specifications of 1.11 to 1.20.
*Is a thermo-compressor a type of steam ejector?

Ans: Yes. A thermo-compressor is a steam ejector whose purpose is to recover the latent heat
content of low pressure steam.
 Paper Machine Lubrication Systems::::
Description:
The main function of lubricants is to keep moving metal surfaces separate in order to reduce
friction. On paper and board machines, lubricants are used to reduce friction, wear, and heat in
bearings, gears, and drive couplings. Common lubrication points include roll bearings, dryer gears,
drive gearboxes and couplings, pump bearings, fan and blower bearings, and agitator bearings. This
course describes the main functions of lubricants, safety hazards and safety guidelines for lubrication
systems, advantages of grease lubricants, components of and flows in circulating lube oil systems,
and the importance of lube oil conditioning and monitoring.
-Describe the functions of lubricants on paper and board machines.
-List the safety hazards and safety guidelines associated with lubrication systems.
-Describe sliding, rolling, and fluid friction.
-List the advantages of grease lubricants.
-Identify and describe the main components and flows of a circulating lube oil system, like those
used on paper and board machines.
Key Questions:
*What advantages do grease lubricants have over lubricating oils?

Ans: Grease lubricants offer some advantages over oils: they adhere better to metal surfaces, do not
easily leak out, protect against corrosion, and provide some sealing action
*Are there any disadvantages to using a grease lubricant instead of a lubricating oil?
Ans: Greases do not remove heat or debris away from equipment, like the lube oil in a circulating
lube oil system can.
*What kinds of chemical additives are used in lubricating oils?
Ans: Lube oils can contain preservatives and performance-enhancing additives, such as viscosity
modifiers, corrosion inhibitors, detergents, and extreme pressure additives, to name a few.
*What can be determined by the lab analysis of lube oil?

Ans: A typical analysis will determine the dirt content, wa ter content, wear metals present, and level
of oxidation of lube oil.
*How can the lube oil flows to a paper or board machine be monitored?
Ans: Optical devices like sight glasses and rotameters require regular observation by operations to
confirm flows, while digital flow meters can send the flow information to computer control systems.
 Chemical Additives::::::
 Wet End Chemistry Basics::::
Description:
This course discusses the fundamentals of colloidal chemistry for paper machine stock and water
systems. It describes the surface charge interactions that take place and the role of pH. It also
discusses how some commonly used chemicals affect wet end chemistry, machine operations, and
characteristics of the sheet produced on the paper machine.
-Identify the three major classes of furnish components.
-Define and describe a "colloid".
-Describe two ways to measure charge
-Describe the effect of furnish surface area on additive uptake
-Describe coagulation and flocculation
-Identify the sources of anionic trash and describe its effect on the system.
-Explain why water plays a large role in paper making.
-Describe the pH Scale.
-Describe the two classes of paper making additives.
-Identify common chemical additives and their purpose.
-State the importance of wet end chemistry control.
Key Questions:
*What is "wet end chemistry"?

Ans: "Wet end chemistry" involves the chemistry of and chemical interactions between the
components of a papermaking furnish. The furnish contains whole fibers, fiber fines, and chemical
additives in a large amount of water.
*What are "colloids"?
Ans: "Colloids" are particles that do not easily settle out of a solution under the influence of gravity.
They have very small particle sizes and very large surface areas, and tend to carry electrical charge on
their surfaces from the presence of anionic (negatively charged) and cationic (positively charged)
groups.
*What are "anionic trash" and "cationic demand"?

Ans: The furnish coming to a paper machine typically contains some negatively-charged materials
that are collectively called "anionic trash" or "cationic demand." These colloidal and dissolved
materials can build up in the recirculating water loops and preferentially adhere to cationically-
charged additives, reducing the effectiveness of the additives. They can also play a role in deposit
formation, spots and defects in the sheet, and reduced sheet strength properties.
*Where does "anionic trash" come from?

Ans: Anionic trash can include wood components that are dissolved or dispersed during the pulping
and bleaching processes, plus defoamer, talc, and other residual chemicals from these processes. It
can also be generated from pulp fibers during refining and storage, or enter with the fresh water,
chemical additives, broke fiber, or recycled fiber inputs.
*Why is pH important?
Ans: Consistent pH is c rucial to steady paper machine operation because pH indicates the level of
ions, and ions can interfere with colloidal surface charge interactions. Among other things, pH
affects chemical additive efficiencies, pulp refining, water removal on the former, and dryer coating
characteristics.
 Wet End Chemistry - Paper making Process
Additives::::
Description:
Chemical additives are used in the paper making process for many different reasons, and they are
often divided into two groups. Functional chemicals directly improve properties of the sheet, while
process chemicals affect operations on or near the paper machine. This module covers the second
group - process chemicals. It discusses the purpose of some of the more common process additives
used on paper and board machines, and describes how they work.
-Describe the composition of paper making furnishes.
-Differentiate between the two classes of paper making additives.
-Describe the composition of "anionic trash".
-Describe the purpose and function of common paper and board machine process additives,
including pH control chemicals, charge neutralizers, retention and drainage aids, pitch control
additives, biocides, and foam control additives.
Key Questions:
*How do paper making process additives differ from functional paper making additives?
Ans: Process additives affect process operations on or near the machine, while functional additives
directly improve properties of the sheet.
*Where does "anionic trash" come from?

Ans: Anionic trash can enter the paper making process in several ways. It can enter with the
incoming fresh water, broke pulp, or purchased pulp, or with virgin slush pulp as residuals from
pulping or bleaching operations.
*Why is good retention important?
Ans: Improved retention decreases the fines concentration in the white water, improves drainage,
decreases press felt filling, reduces sheet two-sidedness, improves additive efficiencies, and improves
overall machine cleanliness.
*What is the best pitch control additive for my machine?

Ans: In acid systems, alum can be used to attach pitch to fibers. In alkaline systems, dispersants can
be used to prevent pitch from precipitating, or fillers can precipitate the pitch onto the furnish.
Lowering calcium and magnesium levels, or adding chelating agents, can also help. The best
approach must often be determined by trial and error.
*What is the difference between a defoamer and an anti-foamer?

Ans: A defoamer works by breaking down the foam, while an anti -foamer prevents the foam from
forming.
 Wet End Chemistry - Functional Paper making
Additives::::
Description:
Chemical additives are used in the paper making process for many different reasons, and they are
often divided into two groups. Functional chemicals directly improve properties of the sheet, while
process chemicals affect operations on or near the paper machine. This module covers the first
group - functional chemicals. It discusses the purpose of some of the more common functional
additives used on paper and board machines, and describes how they work.
-Describe the purpose and composition of paper making furnishes.
-Differentiate between the two classes of paper making additives.
-Identify strength properties of paper.
-Identify the variables that affect the dry strength characteristics of paper.
-Describe the purpose and function of common functional additives, including: dry strength
additives, wet strength additives, internal sizing agents, fillers and dyes.
Key Questions:
*Most chemical additives are delivered as ""aqueous"" solutions. What does that mean?
Ans: The chemical is dissolved or dispersed in water, and delivered as a liquid in a tote or tanker
truck.
*What is the difference between the two main types of additives - functional and process?
Ans: Functional additives are added to impart or enhance a property of the sheet, while process
additives are added to improve operations or the runability of the paper machine.
*What are the different ways that the dry strength of a sheet can be improved?
Ans: In general, dry strength can be increased by using longer fibers, less filler, more wet pressing
(higher nip pressures or longer dwell times), or more refining. It can also be improved by the
addition of dry strength additives.
*How do wet strength additives work?

Ans: When paper gets wet, the fiber-to -fiber bonds are replaced by water-fiber bonds and the sheet
falls apart. Wet strength additives work by creating additional water-resistant bonds between the
fibers.
*What kinds of additives are used to change the color of a sheet?

Ans: Acid dyes, direct dyes, basic dyes, and colored pigments can all be used to change the color of a
sheet of paper or board.
 Starch Cooking:::::
Description:
Starch is a carbohydrate, a high molecular weight polymer of glucose, that is produced and used by
all plants to store energy. It is widely used in the production of paper and board as a retention aid,
dry strength additive, internal sizing agent, surface sizing agent, and as a binder in coating formulas.
This course discusses how starch is used in the paper and board production process, the hazards it
presents, as well the equipment and process variables of starch cooking.
-Identify the hazards present around starch cooking and make-down systems.
-Define "starch," "internal sizing," "surface sizing," "amylose," and "amylopectin".
-Identify and describe the uses of starch in paper and board production processes.
-Describe cationic, anionic and amphoteric starches.
-List the ways starch can be delivered to a site.
-List the four things necessary to cook starch.
-Identify the equipment used in batch and continuous starch cooking processes.
-Identify key process variables for cooking starch.
-Identify and describe the primary process flows.
Key Questions:
*How is starch used in the production of paper and board?
Ans: Starch can be used as an internal sizing, dry strength, or surface sizing additive, as a binder in
coating formulas, or as an adhesive in corrugated board.
*What four things are required to cook starch and prepare it for use at a mill?
Ans: Water, time, temperature and agitation.
*Describe how starch can be cooked using a batch process.

Ans: Steam is used to heat a starch-water slurry in an agitate d tank for at least 20 minutes at 200 to
210 degrees F.
*Describe how the continuous jet cooking process can be used to cook starch.
Ans: Steam is injected into a starch-water slurry as it travels through a mixing device and the
temperature is usually around 250 degrees F.
*How can the cooking method affect the viscosity (or flow resistance) of the starch solution?
Ans: When more thermal or mechanical energy is put into the starch cooking, the starch molecules
will be less entangled and so the viscosity will be lower (it will flow more easily).
 Paper Properties and Testing::::::::
 Paper making Process Testing::::
Description:
Several characteristics of stock and water flows to and around a paper or board machine are often
monitored and/or controlled. This module will cover pH, consistency, temperature, fiber size
distribution, freeness, and charge demand testing.
-Explain the purpose of monitoring the pH, consistency, temperature, fiber size distribution,
freeness, and charge demand of stock and white water flows to and around paper and board
machines.
-Describe common paper making process tests including what they measure.
-Define "first pass retention" and identify problems that can result from low retention values.
-Explain how the results of these tests can be used to optimize or ensure machine runnability or
sheet quality.
-List safety hazards and safety guidelines associated with sampling and testing stock and white water
systems.
Key Questions:
*What is consistency?
Ans: Consistency is the weight percentage of dry fiber in a mixture of fiber and water.
*What is first pass retention?

Ans: First pass retention represents the percentage of the solids delivered to the former that are
retained in the sheet and is an indication of how well fines are retained.
*What is freeness?
Ans: Freeness mea sure the drainage rate of water from a dilute pulp suspension. The faster the
water drains, the higher the freeness.
*Why is charge demand important?

Ans: Anionic trash or cationic demand is important to measure because undesirable dissolved
materials in the paper machine white water reduce the effectiveness of additives and can cause
runability problems.
*Why is pH control important?

Ans: pH affects chemical additive efficiency and retention, refining, retention, drainage, and
formation.
 Common Physical Tests for Paper and Board::::
Description:
Depending on the grade and end use, different tests are performed to assess the quality of the paper
or board being produced on a machine. Physical tests assess physical properties of the sheet, such as
density, thickness, and different kinds of strength. Common physical tests include basis weight or
grammage, moisture content, caliper, density, bulk, smoothness, porosity, stiffness, tensile strength,
burst strength, tear strength, and folding endurance. This module will introduce some common
physical tests, followed by a discussion on the importance of sample collection and conditioning,
sheet formation, and moisture content.
Learning Objectives::
-List common criteria used to differentiate between paper and board grades.
-List some common paper and board grades.
-Describe basis weight testing, including principles and units.
-Describe moisture testing, including principles and units.
-Describe caliper, density and bulk testing, including principles and units.
-Describe smoothness testing, including principles and units.
-Describe porosity testing, including principles and units.
-Identify the organizations which have established standard testing, sampling, and conditioning
procedures.
-Explain how sheet formation and moisture content can affect test results.
-Describe the importance of standardized sampling techniques and sample conditioning.
Key Questions:
*Which standardized test methods are most commonly used in the U.S.?
Ans: The standards managed by the Technical Association of the Pulp and Paper Industry (TAPPI)
are most common.
*What is basis weight?
Ans: Basis weight refers to the weight in pounds of a ream of paper, where a ream is defined as 500
base size sheets. Different grades have different base sizes so basis weight cannot be directly
compared across grades. Grammage (grams per square meter) is another way to express the weight
per area, and values can be directly compared.
*What is caliper?
Ans: Caliper is the thickness measurement of paper or board.
*How is smoothness measured?

Ans: There are many different ways to measure smoothness (optical, friction, profile measurements,
ink contact area) but air flow measurements are must commonly used.
*Why is porosity measured?

Ans: Porosity determines the ability of a sheet to absorb ink or water, protect certain products, or
act as a filter.
 CD Profile Control::::
Description:
QCS scanners are used to monitor key sheet properties at one or more locations on modern paper
and board machines, and report average values, standard deviations, and MD and CD profiles. The
CD profile data can be used to make automatic or manual adjustments at one or more profiling
systems. Because sheet properties can be affected by more than one profiling system, profiling
actuator adjustments can affect multiple sheet properties, and sheet shrinkage and sheet wander
occur, it can be challenging to coordinate CD profiling efforts.
-Identify the main components of a QCS scanner.
-List the potential benefits of CD profile control.
-List safety guidelines for QCS scanners and CD profiling systems.
-Identify common locations for QCS scanners.
-Identify and describe the types and locations of profiling systems commonly used on paper and
board machines.
-Describe when manual profile adjustments might be used instead of automatic profile adjustments.
-Identify the challenges of CD profile control on modern paper and board machines.
Key Questions:
*What are the main benefits of improving the uniformity of CD profiles?

Ans: The two potential benefits of improved CD profiles are reduced cost and improved runnability.
*Why are QCS scanners often installed ahead of size presses?

Ans: Sheet moisture is often monitored before a size press because moisture greatly affects the
sheet's ability to absorb the sizing solution.
*Are QCS scanners installed around coating operations?
Ans: Sheet weight is often measured before and after coating operations in order to monitor the
applied coat weight and coating uniformity.
*Are profiling systems ever installed in dryer sections?

Ans: Rewet showers are sometimes installed in dryer sections to flatten the CD moisture profile at
the reel.
*Why are some profiling adjustments made manually?

Ans: Manual profiling adjustments might be made if a system has a limited number of cross-machine
zones or if automatic actuators are not available.
Paper and Board Optical Tests::::
Description:
Paper and board products are widely used in our daily lives. Sheet characteristics can fall into one or
more of the following categories: physical, optical, electrical, thermal, structural, and surface.
Different tests have been developed by various organizations to quantify and help predict how a
sheet of paper or board will perform during converting and finishing processes, and in its end use.
This module will discuss the tests that are commonly used to assess the optical properties of paper
and board sheets.
-Identify the organization whose standardized paper and board test methods are most commonly
used in the U.S.
-Describe the four mechanisms of interaction between light and the surface of a sheet of paper or
board.
-Describe brightness testing, including principles and units.
-Describe opacity testing, including principles and units.
-Describe formation testing, including principles and units.
-Describe color testing, including principles and units.
-Describe gloss testing, including principles and units.
Key Questions:
*How does light interact with a paper surface?

Ans: The incident light can be reflected, transmitted, scattered, or absorbed.
*What are common optical tests for paper?

Ans: Common optical tests include brightness, opacity, gloss, and color and formation.
*What is brightness and how is it tested?
Ans: Brightness is the visual impression of scattered light from the sheet surface. It is tested using
blue light with a wavelength of 457 nanometers.
*What is gloss?
Ans: Gloss measures the amount of light reflected from the sheet surface at an angle equal to the
incident light.
*What is formation?
Ans: Formation is an optical test that measures the uniformity of the sheet structure and orientation
of fibers. Poor basis weight uniformity, thick and thin spots, equals poor formation.
 Paper and Board Strength Tests::::
Description:
Paper and board products are widely used in our daily lives. Sheet strength is critical to the
performance of most grades, not only in their end uses, but also in converting and finishing
operations. Because different paper and board grades are subjected to different stresses and strains,
several different strength tests have been developed. The most common are tensile, burst, stiffness,
tear, internal bond, and ring crush. This module will discuss common strength tests for paper and
board grades, as well as sheet parameters that affect strength properties.
-Identify the organization whose standardized testing procedures are followed most often in the U.S.
-Identify important factors to consider during sample collection and sample conditioning.
-Explain why paper and board sheet strength properties are important.
-Explain why it is important to keep track of the machine direction during sampling and testing.
-Describe tensile, TEA, stretch, burst, stiffness, tear, internal bond, ring crush, and SCT testing,
including principles and units.
Key Questions:
*Why is sample conditioning important?

Ans: Water interferes with fiber bonding so the moisture content of the sheet affects many paper
properties, especially strength properties. Temperature also affects results because air can hold
different amounts of water vapor at different temperatures.
*What factors can impact strength properties?

Ans: Paper strength depends on the strength and arrangement of individual fibers, the number and
distribution of fiber-to-fiber bonds, and additives. Fiber strength can be affected by pulping,
bleaching, and refining and bonding can be impacted by refining and we pressing.
*Why is it important to keep track of the machine direction for a sample?
Ans: MD and CD strength properties can be significantly different. Many grades have specific
requirements. For example a high MD strength might be required for converting.
*What are the major strength tests?

Ans: The most common tests are tensile, burst, stiffness, tear, internal bond, and ring crush.
*What is zero-span tensile?

Ans: Zero-span tensile is a modification of the tensile test that eliminates the gap between clamps.
Zero-span tries to measure the fiber strength instead of the sheet strength and is considered the
maximum tensile strength of the sheet.
 Storage and Shipping:::::
 Product Storage and Tracking::::
Description:
Storing and tracking products are critical steps in the order fulfillment process. Finished products
are typically stored in warehouses or distribution centers before being shipped in large volumes for
commercial customer orders or individually for end user orders. Products that move through the
warehouse should be handled carefully to avoid injuries and maintain product quality.
-Describe the fundamental steps of receiving, storing, and loading a product for shipment.
-Identify basic personal protective equipment (PPE) that may be required in a warehouse
environment.
-Identify and describe common safety hazards in a warehouse environment.
-List and describe information that may be found on bulk product labels.
-Describe the principle of "First In First Out".
-Describe the purpose for and contents of a bill of lading.
-Describe how automated storage systems function
Key Questions:
*What is the purpose of warehousing product?

Ans: Warehouses provide space to sort and store product prior to it being shipped to a customer.
*When in the storage and shipping process are labels applied?

Ans: Labels are applied to product as it is received in a warehouse so that it can be tracked during
storage and shipping.
*What does FIFO stand for and how does it apply to warehousing?
Ans: FIFO stands for First In First Out and refers to a common method for storing and retrieving
products in the order that they were received.
*What should be listed on a bill of lading?

Ans: The bill of lading applies to a truck or railcar and should include the date and location of
loading, the products loaded, the carrier name and the destination of the load.
*What type of label is commonly used to automate tracking of a product?

Ans: Tracking labels applied to products often include a printed barcode with a universal product
code number that can be read by a laser scanner.
 Roll Storage and Tracking::::
Description:
Rolls of paper or board are typically produced to meet order specifications for shipment to
commercial customers. Storing and tracking rolls are critical steps in the process of fulfilling these
production orders. At the end of this module, you will be able to describe the basic steps of
receiving, storing, and loading a roll for shipment.
-Describe the basic steps of receiving, storing, and loading a roll for shipment.
-Identify basic personal protective equipment (PPE) that may be required in a warehouse
environment.
-Identify and describe common safety hazards in a warehouse environment.
-List and describe information that may be found on roll labels.
-Describe the principle of "First In First Out".
-Describe the purpose for and contents of a bill of lading.
-Describe how automated storage systems function.
Key Questions:
*What are hot loaded rolls?

Ans: "Hot loaded" refers to rolls which are not stored, but shipped immediately after production.
*At what point in the storage and shipping process are labels applied?
Ans: Labels are applied to rolls as they are received in a warehouse so that they can be tracked
during storage and shipping.
*What does FIFO stand for and how does it apply to warehousing?
Ans: FIFO stands for First In First Out and refers to a common method for storing and retrieving
rolls in the order that they were produced.
*What should be listed on a bill of lading?
Ans: The bill of lading applies to a truck or railcar and should include the date and location of
loading, the rolls loaded, the carrier name and the destination of the load.
*What type of label is commonly used to automate tracking of rolls?

Ans: Tracking labels applied to rolls usually include a printed barcode with a universal product code
number that can be read by a laser scanner and perhaps an RFID tag.
 Clamp Trucks - Preventing Paper Roll Damage::::
Description:
A roll clamp truck is similar to a forklift, but instead of forks, it has a special hydraulic clamp
attachment for handling rolls of paper. Clamp trucks are essential for moving large paper rolls
throughout the supply chain. From the time a roll of paper comes off the winder to when it is
delivered to the converting equipment, which is often in a separate facility, a single roll can be
handled as many as 15 times. Each time the roll is touched, there is an opportunity for damage to
occur, so it is important to use the right clamp truck and follow proper handling procedures to
prevent damage.
-Describe the importance of preventing roll damage.
-List the key guidelines for roll protection from damage.
-List the factors for selecting a proper clamp truck and c lamp.
-Identify and describe the roll clamp and its components.
-Identify the variables that determine the required clamping force.
-Identify and describe the typical causes of structural, end, edge, and belly damage on paper rolls.
-Identify and describe roll handling practices for preventing roll damage.
-Identify safety hazards associated with clamp trucks.
Key Questions:
*How is roll damage prevented when handling paper rolls?

Ans: Damage can be minimized by wrapping the roll with a protective outer layer, selecting and
maintaining the right equipment, following standard handling procedures, and by avoiding any
unnecessary handling of rolls.
*How is the proper roll clamp truck selected?

Ans: The proper equipment depends on the roll weight, width, and diameter, the paper type, and
handling and storage requirements.
*What is the clamp force factor?
Ans: The clamp force factor (CFF ) is used to determine how much force can be applied to a roll
without causing damage. It is the ratio of the clamping force to the weight of the roll. The CFF
varies by paper grade.
*What are common roll damage categories?

Ans: Most damage falls into the following 4 categories: structural (e.g. out of round), end, edge, and
belly damage.
*How can out of round rolls be prevented?

Ans: From an equipment standpoint you should ensure the clamps pads are in good condition and
the appropriate clamping force is applied.
 Truck Trailer Loading - Corrugated Paper Rolls::::
Description:
Every day, thousands of paper rolls are shipped around the country from paper facilities to be used
in a variety of paper-related products. These rolls are commonly delivered by commercial trucks or
railcars. This course will cover the standard procedures associated with loading paper rolls into truck
trailers in order to become familiar with day-to-day operations as well as to comply with common
regulations.
-Describe proper truck trailer loading setup.
-Identify and describe typical safety hazards associated with truck loading.
-Define the major equipment used when loading truck trailers.
-State the purpose of loading ramps.
-Explain the importance of truck inspections.
-Identify and describe key truck inspection points.
-Explain the importance of roll inspection.
-State the primary goals for truck trailer loading.
-List proper trailer loading techniques.
-Identify proper truck trailer loading patterns for different roll sizes.
Key Questions:
*What are two important safety procedures to complete before starting to load a commercial truck
trailer?
Ans: Before loading, truck and trailer wheels should be chocked and the ICC bar of the trailer
should be secured to the dock.
*In terms of weight, what is the goal when loading a commercial truck trailer?
Ans: The goal is to maximize the loaded weight in the trailer without exceeding the safe and legal
limits for the individual axle loads and the overall truck and trailer weight.
*What are some of the items used to secure rolls in trailer and keep them from moving?
Ans: Some of the equipment used to secure rolls in trailer include blocking, bracing, friction mats
and strapping.
*What method of securement is mandatory for a split load?

Ans: When groups of rolls are separated, they must be held together by strapping.
*What happens if a truck trailer is overweight?

Ans: A loaded trailer which is overweight must be unloaded and reloaded in such a manner that is
under the legal and safe weight limit.
 Railcar Loading - Corrugated Paper Rolls::::
Description:
Every day, thousands of paper rolls are shipped around the country by commercial trucks or railcars
from paper facilities to be used in a variety of paper-related products. This course will cover the
standard procedures, techniques and safety practices associated with loading paper rolls into railcars.
-Describe proper railcar inspection practices.
-Explain the importance of railcar inspections.
-Match dunnage types with their descriptions.
-Explain the importance of roll inspections.
-Explain proper roll inspections techniques.
-Identify and describe typical safety hazards associated with railcar loading.
-Describe proper railcar safe loading practices.
-Identify and describe common railcar loading equipment.
-Identify railcar loading patterns.
-Define "T-loading"
Key Questions:
*What should you be looking for when inspecting a railcar before loading it?
Ans: Railcars should be checked for sturdy, clean, dry, hole-free flooring. The floors and walls
should also not have any nails, bolts or protrusions which might damage loaded rolls.
*What are common types of dunnage?

Ans: Dunnage includes corrugated fillers, risers, rubber mats, tapered roll wedges and inflatable air
bags.
*What are common railcar sizes?
Ans: The railcars typically used by paper mills are either 50 or 60 foot long, high cube or standard
box.
*What is T-loading?
Ans: T-loading is the term used for placing a roll on its side, or "bilge position", on top of the rolls
set on the floor of the railcar.
*What is a dock plate?

Ans: Dock plates are reinforced steel plates used to span the gap between the dock and railcar to
support loading clamp trucks.

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Paper Manufacturing Training

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 General Paper Making

 Introduction to Paper and Board Machines:::::

* What is typically contained in a paper making ""furnish""?

*What dangers are present in papermaking and paper converting facilities?

*What behaviors can contribute to injuries?

*What are the leading causes of fall injuries?

*What precautions can be taken to avoid paper machine hazards?

*What is "latent heat"?

*Why is it important that steam contains latent heat?

*Why is superheat sometimes added to steam, and then removed?

*Where are air doctors used on paper and board machines?

*Why is it important to change doctor blades on a regular basis?

*What could cause a blade edge to become feathered?

*Why is it important to control stock consistency in the thick stock system?

*Where is consistency typically controlled in a thick stock system?

*What is the purpose of savealls in thick stock systems?

*Why is it important to control consistency in a paper or board machine stock system?

*How is consistency controlled in a paper or board machine stock system?

*Why is it important to control pH in paper and board machine stock systems?

*How is pH controlled on a paper or board machine?

*What is the purpose of high density cleaners?

*Where are high density cleaners typically used?

*What is the purpose of the elutriation water in a high density cleaner?

*What is the purpose of paper and board machine refining?

*What happens to the fibers during refining?

*On what paper or board grades is high consistency refining used?

*At what consistency is high consistency refining performed?

*What is the difference between cleaners and screens?

*What is the purpose of the attenuator in a thin stock system?

*What is the purpose of cleaners?

*What are forward cleaners?

*What is a cascade cleaner system?

*Why is pressure drop important for cleaning efficiency?

*Are there multiple forms of entrained air?

*How do deaerators remove entrained air from the stock suspension?

*Can a deaerator cause pulsations in the stock flow to a headbox?

*What is the purpose of thin stock screening?

*What are disadvantages of vibratory flat screens?

*How are pressure screen basket openings created?

*What debris properties affect removal efficiency?

*What is the primary purpose of a pressure screen?

*What is the purpose of the spinning rotor in a pressure screen?

*What is a good strategy for unplugging a pressure screen?

*What could be some causes of poor accepts quality?

*What are the four basic functions of a headbox?

*What is the purpose of the headbox?

*What are rectifier rolls and what do they do?

*How is the air pad maintained?

*Why is sheet formation so important?

*What is the "stock jet geometry"?

*Why is it important to have a short free jet length?

*What is the jet impingement angle?

*Why is the stock jet geometry so important?

*What is the "jet-to-wire ratio"?

*What is the "L/b ratio" and why is it important?

*Why are multi-layer headboxes increasingly popular?

*What happens when the slice opening is widened slightly?

*Does the addition of starch affect sheet formation?

*How can the forming section influence sheet formation?

*What are the two main jobs of a forming fabric?

*How can you tell if a forming fabric is misaligned?

*What is the purpose of seam straightening?

*What is the basic principle of fabric guiding?