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A Presentation on Induction ProgramBrief History of ITC LimitedStarted in 1910 as Imperial Tobacco companyLater during 70s, It was changed into Indian Tobacco Company(I.T.C. Limited)In September 2001 periods in the name were removed and renamed as ITC Limited

Mainly concentrated in Tobacco based productsLater entered into Non-tobacco based streams likeFMCGHotelsPaperboards & PackagingAgri BusinessInformation TechnologyBrief History of Tribeni1949 Tribeni Tissues Ltd was founded by BAT1950 Two paper machines and a pulp mill erected for making Cigarette tissues, Plug wrap paper and Carbonizing tissues1961 Wiggins Teape, a specialty and fine papermaking company took over the operations

1969 & 1977 Installed PM 4 & PM 3 respectively1988 Management handed over to ITC by BAT1992 Merged with ITC2002 Integrated to become a part of PSPD

N SrivatsavaUnit HeadN K BhattacharyaPBU 3S MohantyHead (O)PBU 1&2P K PatraUnit Head HRBasab GhoshPBU 4Head EnggN SahaUnit HeadMaterialsBibuti SenUnit Head Quality, R&DYusuf CulcuttawalaUnit Head FinanceOrganogram of Unit TribeniTribeni An OverviewSpecialty papers ManufacturerCigarette Tissues & ComponentsLight Weight Communication GradesOther Specialty GradesDcor Grades

Steam & Power GenerationF-Grade Coal Fired boiler12MW Turbine

Competitors during 1980s

High Quality Cheaper priceEuropean MillsChinas MarketHow to Overcome these Threats?QualityLower priceOn-time delivery

To achieve a better quality at relatively lowerprice, we reduced the tolerance values tosustain in the market.

Various Departments in our UnitHRHuman asset of the UnitPermanent Employees 637Managers 152Budlies 148Contract workmen 331

Various other activities of HRManpower PlanningRecruitment, Selection and InductionTraining and DevelopmentIndustrial RelationStatutory complianceWelfare activitiesContract labour management

MarketingBridges the gap between company and the customersFinancePaymentTaxationFinancial accounting & AuditsCosting

EHSEnsures safety

MaterialsStores Engineering StocksThree types of stocks stored hereStock materialNon-stock materialInsurance materialHouse keeping

TPMWhat is TPM ?How do we follow TPM?Impacts of TPM?What is the role of Top Management?

Pillars of TPM

SAFETY PAUSE

EHS PolicyTo establish Sustainable developmentTo assess risks and mitigationTo provide appropriate trainingTo provide facilities and working conditionsTo ensure safe handling, storage, use and disposal of hazardous chemicalsTo reduce waste, conserve energy and promote recycling

Occupational Health &safetyWhat is SAFETY?SmartAttitude toFigure out and Eliminate risk inTime which involvesYouHeinrich studyHow to achieve safety?Fire Safety

Paper and PulpPaper is homogenous mixture of pulp, chemicals and water.

Tribeni manufactures specialty grade papers, the USP being cigarette tissue.

The grade of paper is described by its functional properties such as caliper, gsm , porosity, tensile strength etc. PulpPulp is fibrous material made out of cellulose and lignin majorly.Classification could be based on recycled pulp and virgin pulp.Recycled pulp are fibers extracted from the waste paper or broke.Virgin pulp the source of fiber being cotton, grass, leaf and majorly wood.

Another classification is made based on hardwood and softwood pulp.

HARDWOOD

DECIDOUS FORESTFASTER GROWTHCONVERSION DIFFICULTFIBRE LENGTH 0.5-2MMSHORT FIBER LENGTH AND ACT AS FILLER MATERIALIMPROVEDS FORMATION, SMOOTHNESS AND OPACITYSOFTWOOD

CONIFEROUS FORESTSLOWER GROWTHCONVERSION EASYFIBER LENGTH 2-5MMIMPROVES STRENGTH, BONDING AND TEAR STRENGTHPAPER-MAKING PROCESSHYDROPULPERREFINERPULPHEAD BOXPRESS SECTIONDRYERREWINDERREELINGBOBBIN SLITTINGPACKINGDespatchStock PreparationPulp Stock

ChemicalsFiller: Clay, Chalk, Talc, Titanium DioxideRetention AidsBiocides: Oxiclean, BusanAcids and BasesSizing Agents: Rosin , WaxesDry strength additives: starchWet strength additives: crosslinking polymers

Hydra pulper, Hi-Lo pulper/ Repulper

Sw/Hw unrefined chest

Refiners

Refined chest

Paper MakingMachine Chest

Centri-cleaner cascading

Pressure screen

Head box

Wire

Press section

Dryer

Machine ChestHead BoxWireDryerPress SectionCentri-cleanersPressure screenFinishing house.Centri-Cleaners Equipments used to remove air, dirt, shives and specks from the pulp stock.

Inlet consistency is around 1%.

Generally connsist of 3-4 stages and reject of each stage flows through the nozzle to a common tank.

Inlet and outlet valve of each bottle is controlled to maintain a required pressure drop.Pressure ScreenCylindrical body with tangential inlet and outlet along with a reject outlet.

Metallic screen drum having required slots(0.15-0.8mm) is fitted in drum co-centrally.

Rotor placed at centre provides centrifugal force .

Stock which passes through holes flows through outlet pipe and reject goes for further treatment.Press sectionPaper coming from wire part have 13-14% consistency.

Paper exiting from press section have 30-40% consistency.

Combination of suction pickup cum press: combination of suction roll, granite roll, rubber roll and then second press felt.WireStock enters from head box with 0.5% consistency and exits with 13-20% consistency.

Wire shakers with optimum frequency for proper orientation of fibres.

Wire tray and suction boxes for water removal.

Suction couch roll from where the paper exits to press section.

PackagingReeling

Rewinding

Bobbing slitting

Packaging

Despatch

DryerDrying: Heat and Mass Transfer operationMain function is to dry the paper sheet from press part properly so that moisture profile is uniform throughout the paperSections of Dryer:Pre-DryerPost Dryer

Paper MachinePre DryerPost DryerTotal11-89-121231-1314-191941-1011-1414Biggest part of the paper machineEntering Moisture Content: 40-50%Leaving Moisture Content:3-5%Energy Intensive Section:Hood System-insulated enclosure covering the dryer part many exhaust fans to drive out moisture laden vapourPocket Ventilation

Important things of dryer sectionDrying cylinder is made of cast ironEven dryingEven moisture profileTemperature should be increased slowly to prevent OVER DRYINGSteam consumption should be min. consumption of 1.6T of steam per ton of paper is acceptableSteam should be dry saturated and not super saturatedMore the speed of the machine more is the steam pressure reqrd Doctor blade Main functions areSheet removalRemoval of roll surface contaminationSize Press :Between pre and post Dryer Section.Used for adding Sizing ChemicalsCalendria: Similar to IroningHard RollSoft RollIn Paper Machine 4 Oil is used in Calendria which is heated upto 300CMain function is toMake the caliper of the paper sheet uniformImparts desired smoothness and glossiness which improves printabilityIt reduces average thicknessPAPER MACHINE-1 Installed in 1950 Thirty & CIE, BelgiumDeckle : 2.7 metresSpeed : 300 mpmGrades : Cigarette tissues & plug wrap tissueDaily capacity : 25 T

PAPER MACHINE-3Installed in 1978 Bertrams Sciennes, UKDeckle : 3.35 metresSpeed : 400 mpmGrades : Thin printing : 28 to 48 gsmWax match tissue : 44 gsmAnti rust : 27 to 35 gsmInsulating grades : 40 to 90 micronMedical insert : 40 gsmWhite tipping : 36 gsm Daily capacity : 55 T

PAPER MACHINE-4Installed in 1969 Thirty & CIE, BelgiumDeckle : 2.7 metresSpeed : 145 mpmGrades : Decor 40 to 100 gsmInsulating 40 to 190 micronMedical grade 60 gsmDaily capacity : 25 T

FINISHING HOUSEREWINDERREELINGBOBBIN SLITTINGPACKINGTechnical DepartmentFunctions :Input material inspection & testing Process controlOutput monitoring final product and controlProcess developmentETP and E&U lab activities.

DEFECTS of PAPERTechnical defects: porosityPhysical defects:loose papercreaseagglomerationthin spotsburstWATER TREATMENT PLANTMGFACFUFRODEGASSERSCESBAMIXED BEDDM STORAGE CONDENSATE FROM PM 1,3,4CONDENSATE ACFMBHEThermal Power PlantOperating Cycle: Rankine CycleEssential parts Boiler TurbineCondenserPump

BoilerThe place where Heat is added to water and it is converted into steamCapacity: 72 Tonnes/HourTurbinePrime mover which converts the heat energy of steam into mechanical energy.Capacity: 12 MWSpeed :8440 RPMCondenserThe place where heat is rejected from the system with the help of cooling tower.PumpA device that raises, transfers or compresses the fluids .

ContdWaste heat recovery systems:EconomizerSuper HeaterAir Pre-HeaterFiltering systemESPBoiler EfficiencyCycle Efficiency

RefiningIt is a mechanical process which makes the paper suitable for paper makingFibrillation + cutting of fibers happens in refiningPulp with water is allowed to pass through the narrow gap between a revolving rotor and stationary rotor both of them having barTackles are 24 or 21 in diameter having bars. The angle between bars in stators and rotors are normally 10 to 15 degree.If the angle between bars increases, fibrillation will also increase at the rate of increase in pumping cost.Types of refinersJylha or conical refinerDisk refinerDouble disk (DDR)Triple disk (TDR)Types of refining:Mixed refiningHard wood and soft wood are mixed in ratio as per requirement and refined. Uniformity of stock is less, power consumption is high

Separate refiningHard wood and soft wood are separately refined. Uniformity of stock is high, power consumption is lessSingle passThe stock from unrefined chest will enter into a set of refiners and reach the refined chestCirculationThe stock from the refined chest is made to pass through a same set of refiners again and again until required properties are obtained.Single streetPulp suspension is passed through a set of refiners consisting of no of refiners in line and discharged to refined chest

Double streetPulp suspension is passed through one set of refiners consisting of no of refiners in line and discharged to a unrefined chest from which stock is again passed through a second set of refiners

Refiners are filled with waterRegulating valves at inlet and outlet are fully openedShut off valve which is between refiner and pump is initially opened to 25 to 30%Then the shut off valve is fully opened and loading is given using pilot motor which adjusts the gap between stator and rotorFlow control valve is made to maintain 1200 LPM2 way valve is used for circulation of stock4 way valve is used for bypass a refiner30% of stock must be maintained in unrefined chest

Factors affecting refiningConsistency in the range of 4 to 5 %Uniform flow of stock is to be maintained by using flow control valveFeeding pressure may be kept in the range of 1.4 to 1.7 kg/cm2Temperature of stock should be maintained. Else vaporization of water takes place leads to decrease in fibrillationIncrease in fibrillation will lead to increased bonding. Hence opacity decreasesLubricationOil and Grease are used as lubricantsCentralized Oil Lubrication Tank (COL Tank)PumpFlow meterCondition MonitoringIt is the process of monitoring vibration, temperature etc. in order to identify a significant change which is indicative of developing a faultBreakdown maintenanceIf a part in a machine is replaced after its failure is called breakdown maintenance

Periodic or preventive maintenance:Changing or replacing a part after a certain period of timePredictive maintenancePredicting when maintenance is to be performedIdentifying which machines are more prone to failureIt is done by Vibration Analysis Lubricant AnalysisInfrared ThermographyMotor current analysis

Pumps:Positive displacement pumpIt works by trapping a fixed amount and forcing that trapped volume into the discharge pipe.It produces a uniform flow at a given speed no matter what the discharge pressure, thus they are constant flow machinesPressure relief value should be used at discharge endEX: Reciprocating, gear type, vane type, screw type, lobe typeFan pump:Uniform flow, double suction pump

Centrifugal pump:It transports fluid by conversion of rotational kinetic energy to hydrodynamic energy of fluid Open type (7 to 10%)Semi open (3 to 7%)Closed (