INDUSTRIAL TRAINING REPORT

NAME:
COLLEGE: Rajiv Gandhi College Of Engineering Research And Technology.
TRAINING ORGANIZATION: Ballarpur Graphic Paper Production
LIMITED (BGPPL)

DEPARTMENT: Mechanical
FIELD OF TRAINING: Mechanical Workshop And Paper Machine 1 TO 6
PERIOD

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 ACKNOWLEDGEMENT

I 2nd year student of RAJIV GANDHI COLLEGE OF ENGINEERING

RESEARCH AND TECHONOLOGY, considering training to be a challenging
job and the completion of my practical training, I would like to thank all the
personalities at BGPPL who have help me in completing the work.

For their valuable explanation and their contribution. They not only delivered
me the practical knowledge but also provided parental attitude towards me
during practical work. Thanks are due to all Engineers and working Technical
without the help of which I would not be reach at this point.

I am equally obliged to all the Engineers Technical personnel and operators at

BGPPL who gave me their valuable time and rendered practical knowledge in
my training period. And at last I want to thank my colleagues. Without their
help guidance and suggestions it was not possible to produce this training
report.

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 TABLE OF CONTENTS

TRANING INFORMATION 1

ACKNOWLEDGEMENT 2

TABLE OF CONTENT 3

WORKSHOP 4

FLOW CHART 5

CHIPPER HOUSE 6

DIGESTER/PULP MILL 8

MACHINE HOUSE 10

PAPER MACHINE DETAIL 11

FLOW CHART PROCESS 12

STOCK PREPARATION 14

VARIOUS PAPER MACHINE PARTS 15

REWINDER 23

DRIVE SYSTEM 24

MSD 25

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 MECHANICAL WORKSHOP

MACHINES AT THE MECHANICAL WORKSHOP:

1. Lathe Machine
2. Shaper Machine
3. Universal Milling Machine
4. Planner Machine
5. Roller Grinder Machine
6. Slotter Machine
7. Drilling Machine
8. Knife grinding Machine
9. Roller Knife Grinding Machine

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FLOW CHART FROM CHIPPER HOUSE TO MSD

Chipper house

Digester house

Pulp mill

Stock preparation

Machine house

Rewinders

Cutters

Finishing dept.

MSD

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 Chipper house

In chipper house chipping of raw material is done. At first the wood

(bamboo,eucalyptus , and from any other tree is brought by trucks . Then these
woods undergoes primary washing so that the soil particles, dust and other
impurities should be wash off from the wood logs. After primary washing these
wood logs get unloaded with the help of a typical type of crane called Grabber.
The Grabber have a capacity to hold 8-10 wood logs at a time. While unloading
the wood log get on conveyors and through that conveyor wood logs get cut into
chips .The chips are of specific size its dimension is 25×35mm width and 8-9
mm in thickness.

The speed of the blades cutting the log is so high that it produces 60 tons
chips in one hour. It means 60 tons chips /hour . Due to its high speed and use it
needs to be change in every 8 hours in 24 hours. This blade then sent to the
mechanical workshop for making its edges sharp again. While passing from
conveyor a shower of water is there which wet the chips so that the moisture
content of the chips should increase as it will be beneficial for further processes if
its moisture level is high.

Size determination of the chips i.e. if the chips cut are not in proper dimension i.e.
25×35mm in width and 8-9mm in thickness then the chips get separated end
improper chips are again chipping. And if the chips are in proper size, this can be
conform from screening of chips then these chips are store in silos after
distribution. This distribution of chips in silo are done through conveyor belts.

Extraction of chips from silo bottom and convey to chip bin and then according to
the demand from the pulp mill they sent the chips where further processes may
carry out.

Here is flow chart showing the passage of the wood logs to its formation to chips.

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 Raw material accepted through truck

Primary washing of the woods

Truck unloaded on chipper belt

Washing of raw material

Chipping initiate action

Is ok

Screening of chips/accept chips

Dust for disposal

Distribution of chips in silo

Extraction of chips from silo bottom and convey to chip bin

Chip bin for process

DIGESTER HOUSE/ PULP MILL

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 PULP MILL

Pulp is a fibrous material prepared by chemically separating cellulose

fiber from the wood A pulp mill is a mill in which the wood chips are convert into
pulp by undergoing number of processes. The pulp is mainly prepared from the
cellulose fiber and the lignin a type of bond which hold together the molecules of
the cellulose. Our main aim of the pulp making is to break the bonds structure
into a fibres.

Process flow chart at the digester / pulp mill:

Chip silo

Chip metering screw

LP feeder (low pressure feeder)

Screening screw

HP feeder (high pressure feeder)

IV

Digester

Blow fan

Store in silo

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 MACHINE HOUSE

Total number of paper machines available at BGPPL is 7.

But I ‘m going to discuss about only 6 i.e. from 1 to 6.

Total production per day according to the each machine is given as follows:

1. PM-1 50 -60 MT per day

2. PM-2 30 MT per day
3. PM-3 160-170 MT per day
4. PM-4 45-47 MT per day
5. PM-5 50 MT per day
6. PM-6 72-75 MT per day

Paper machine 3 is the highest production machine as it is a high speed

machine and also it is called as MF machine meaning Machine Finish. The paper
producing from PM-3 is having glaze from both side.

While Paper machine 2& 5 are MF machine meaning Mono Glaze

machine. The paper is having glaze from one side only.

Mainly PM-1,3,4.6 are same in basic designing and parts are also same and
there function is also same as they are MF machines but PM2&5 are MG machines
and therefore these two machines have same designing and parts.

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 ● PAPER MACHINE -1

Make : John Inglis, Canada

Vintage : 1950

Speed, mpm :280

Deckle width, m 3.2

Production MT/day :50-60

GSM :44-85

● PAPER MACHINE – 2

MAKE : VOITH, Germany

Vintage : 1962

Speed, mpm : 145

Production, MT/ day : 30

GSM : 26-60

● PAPER MACHINE -3

MAKE : VOITH, Germany

Vintage : 1962

Renovated in : 1990

Speed , mpm : 480

Deckle width, m : 3.5

Production per day ,MT : 160-170

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GSM : 68-120

● PAPER MACHINE -4

Make : Alimand, France

Vintage : 1965

Speed, mpm : 220

Deckle width, m : 2.84

Production MT/day : 45-47

GSM : 58-100

● PAPER MACHINE – 5

MAKE : VOITH, Germany

Vintage : 1962

Speed, mpm : 145

Production, MT/ day : 30

GSM : 26-60

● PAPER MACHINE -6

Make : Bertram Scinnes UK

Vintage : 1962

Speed, mpm : 250

Deckle width, m : 2.9

Production MT/day : 72-75

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GSM : 68-140

PROCESS FOR PAPER MAKING ON PAPER MACHINE

Pulp mill

Collecting chest

TDR Refiner

Mixing chest

Machine chest

Machine stock regulation box

Fan pump

Machine head box

Machine wire part

Machine press part

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 Dryer part

Clupak unit ESKP Paper

Post dryer

Calender part

Pope reel

Rewinder

Cutting

Packing

Market

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STOCK PRIPERATION

COLLECTING CHEST :

In collecting chest the pulp coming from pulp mill is collected it is made
rotating so that the pulp should not set at down or else separation of pulp and
water would be occur due to which pulp will not move forward so it is always keep
in motion.

MIXING CHEST:

In the mixing chest various additives are added in it like color of the
paper is determined by the additives which we are adding. Also ph value of the
pulp is maintained . starch, NTPD, various enzymes are also mix in mixing chest
into the pulp.

TDR REFINER:

The main purpose of the refiners is to refine the pulp coming from the
collecting chest . In TDR Refiner 8 blades are present having two set of 4 blades
each. These blades blend the pulp properly so that no lump should which will
cause fault in paper making process.

Blades of the disc refiner

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VARIOUS PARTS OF PAPER MACHINE:

● HEADBOX:

Headbox serves the important function in paper making process. It is in

vertical cross section as shown in fig. the main function of the headbox is to
convert low consistency fiber suspension flow i.e. stock in a round pipe into a
uniform jet of some length wide that will fall on the wire for the further process .

The pulp on the headbox come from the manifold to the number of tubs
present on the upper of the headbox.

The uniformity of the flow will determine the quality of paper. Therefore at
the headbox part there are several tubes from which pulp is falling on the wire part
these tubes are controlled by the valve present at the upper on that.

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 ● WIRE PART:

The wire part of the paper machine is also one of the most important
part as it carries the pulp to the press part. The wire is consist of the nylon. The
wire is set up on the hydrofoils. The function of the hydrofoil is to remove excess
water from the pulp. The pulp present on wire part contains near about 99.9%
water and only 0.85 pulp so it become necessary to remove excess water. If the
amount of water present in the pulp does not remove it will effect the quality of the
paper. The wire is embraced at the headbox side by the breast roll and on the other
side by the suction roll also called as couch roll.

The wire part length depends upon the PM performance and on the
type of paper produce. The PM wire is carried and stretch by the number of rolls in
the lower part of the wire. In case of wire return the wire is wash by the water
shower. These remove mainly the fiber that has stuck on the wire part. The paper
width is determine by the nozzles of water coming from them at very high force
and with very less diameter 0.002 cut the paper in appropriate size as we need.

Hydrofoils -it is fixed to beams with stand which enables its height
adjustment . The design of foil can be stationary or to some angle 1 to 25.

HYDROFOILS BOX: it is made of stainless steel and fixed to beam and

having options for height adjustment. The foils are made up of ceramics . all the
foils are fixed to box.

HYDRO FOILS

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 ● DOCTOR BLADE:
The doctor blade are fixed at various places on the rolls to remove
the excess pulp from the rolls . the pulp which get stick to the rolls may
create problems in the processes of paper making so it is necessary to
continuously remove the pulp from there.

● BREAST ROLL:
The breast roll supports the wire at the headbox starting of paper
machine . Both the breast roll and machine wire are oscillating so that the
mixture of pulp and water flowing through wire part should not sweep out.

● DANDY ROLL:
dandy roll is also consist in a wire part. The main purpose of the
dandy roll is to watermark the paper. A watermark is made by
impressing a water-coated metal stamp on dandy roll on the paper
during the manufacture. The Dandy rolls are light rolls . The faint
lines on the Dandy rolls are parallel to the axis of the dandy roll
and the bold lines are run around circumference. Watermark is an
identifying image or pattern in paper that appears at various shades
of lightness. Watermark is very useful in the examination of the
paper because it can be use for identifying sizes, locations and
determining the quality of the paper.

Dandy rolls are also use to break the bubbles form during paper making
process. Due to the presence of the bubbles quality of the paper may effected.

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 DANDY ROLLS

● COUCH ROLL:

The purpose of the couch roll is to strengthen the sheet as much

possible before it enters the press section . to that end water is removed from the
sheet as it passes over vacuum area of suction box.

Couches boxes have one or two vacuum boxes the suction box set up is basically
on the wire return roll. Couch roll can increase the overall efficiency of the paper
machine press section. The couch roll can improve sheet dryness by 3% as there is
a long felt is present . The couch roll will do its function properly only when the
suction box works properly. To increase the performance of the couch roll it is
necessary to clean the roll. Cleaning is done through high pressure nozzle shower.

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Suction boxes are given to absorb the excess water from the paper. The end
deckles must be positioned correctly to gain proper amount of vacuum. Pressure
must be maintained in this section because too much pressure in this section will
wear the seal.

● PRESS PART:

Press part consist of the four rolls namely:

1st press top roll 1st press bottom roll

2nd press top roll 2nd press bottom roll

The main mechanism behind the press part is to squeeze the paper
to remove the water particles from it. In press part ,mainly two important points-
The felt: whose function is to carry the wet paper through press nip which is
contacting zone between to rolls where the water is transferred from wet paper to
the felt. In the press section the average life of the felt depends on its type.

The press section of the paper machine is an important part of the machine giving
it properties of the paper. Low efficiency in this section causes difficulties in the
reduction of the strength, increase steam consumption in the dryer section of the
paper machine. So it is necessary to squeeze water from the paper in the press
section than to evaporate water in the drying section. The purpose of the press
part is to obtain the best of production of reels at the time of replacement of the
felts, increasing the water removal in the press section.

More advanced press rolls are suction rolls. These are rolls with shells and cover .
The shell made of metal material such as bronze is covered with rubber or
synthetic material. The rubber made material is basically ebonite material. End
face mechanical seals are use for the interface between the inside surface of the
shell and the suction box. For smooth rolls they are made of granite rolls. The low
vacuum zones pick up the sheets and transfer, while the high vacuum zone given to
remove moisture. There are hydraulic in the press rolls that ensure the roll does not
go out of work.

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 ● DRYER PART:

When the paper sheet enters the paper machine Dryer section, it is
near about 50% water. This must be dried to less than 10% water for finish
product. Most commonly dryers sections is steam dryer. It is steam heated
cylinders that evaporates the moisture. For this very high steam pressure is
required. Steam enters the end of the dryer head through a steam joint and
condensate exits through a siphon that goes from internal shell to a center pipe.
The sheet of paper is held against the dryer by long felt loops on the top and
bottom of each dryer section . The felts greatly improve the heat transfer. Dryers
felts are made of coarse thread .

Paper dryers are arrange in a groups called sections so that they ca n be run at a
slower speed to maintain the sheet shrinkage as the paper dries. In the heating
phase the sheet enters and some amount of temperature is increase there. Generally
the first set of the dryers are the pre heating zones or the heating zones. Then in
constant heat zone heat is added at about the same rate that evaporation is
removing the heat. The final zone is most difficult as it must remove at last 10%
of moisture without causing problem of over drying.

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H

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 ● CALENDER PART OF PAPER MACHINE

A calendar is a hard pressure rollers used to form or smooth a sheet of paper.

The calendar section of a paper machine consists of a calendar and other
equipment. The paper reel is run in between to smooth it out which also gives it
more uniform thickness. The pressure applied by the reel to the roller determine
the finish of the paper. After calendaring the reel has moisture of about 6% .

The purpose of calender is to make paper smooth and glossy for writing and
printing.

● POOP REEL:

The poop reel is a last part of the paper machine from here the paper reel
will start wounding on the on it. The function of the pope reel is to support the
paper coming from the dryer parts.

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 Head box

Wire part Breast roll

Dandy roll

Couch roll

Lump break roll

Wire return roll

Press part 1st press top roll

1st press bottom roll

2nd press top roll

2nd press bottom roll

Dryer parts

Calender

Pope reel

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 ● REWINDERS:

In rewinders the reel of paper coming from the paper machine is unwound
and trim according to the orders or trim in small reels to further cutting it down on
the cutters.

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 ● LINE SHAFT DRIVE :

Line shaft drive is a power driven rotating shaft for power transmission to the
respective rolls. In this a line shaft would be suspended from the area and would
run the length of that area. One pulley on the shaft receive power from the main
line shaft. The other will supply power to pulleys on individual rolls. Shafts are
usually made up of rigid steel the shafts are suspended by hangers with bearing at
certain interval of length. The distance depend on the weight of the shafts and the
pulleys. The shaft must be in a line or the it may be break due to the weight of the
bearings. The bearings are for decreasing friction and must be lubricated. Shafts
are in horizontal direction rotating.

● RORATRY UNION:

It is a part that allows the rotation the united part. A rotatry union will
lock an input valve while rotating to meet at outlet. Rotatry union comes in many

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shapes and combined of a shaft, bearing, and a seal. These are constructed from
stainless steel to resist corrosion and rust.

● PASABAN CUTTERS:

This machine is cutting , counting of paper for the final processing of paper.
Basic mechanism of this machine is the web of the paper is loaded on to unwind it
from reel. The web is guided and side to entering the crisscross knife. After the
knife cut the sheets are sent to delivery system.

● MSD :

MSD is a market sale department. According to the order from the customers
delivery of packed paper of reel is loaded in the truck through the hydraulic
vehicle. MSD is the last department of paper machine area.

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