The stock preparation is partitioned into two independent furnish feeding lines plus an approach flow system:
Configured for sorted office waste (SOW), ledger, and local recycled paper. Includes High-Consistency Hydrapulper (12%-15%), High-Density Cleaners, Multi-Stage Coarse & Fine Pressure Screens, Flotation Deinking Cells (multi-stage counter-current), Disc Thickener, Heating Screw Conveyor, and High-Speed Disc Hot Disperser (热分散机, operating at 95°C–105°C) to thoroughly melt and disperse residual stickies, hot-melts, and microscopic ink specks below 40 μm.
Equipped with high-efficiency D-Type Hydrapulper (for bleached hardwood/softwood kraft pulp boards), HD cleaner, and Double Disc Refiner (Φ550mm) with precision automated plate gap positioning for optimal fiber fibrillation and softness enhancement.
Automated ratio stock blending chest, machine chest, low-pulsation variable-frequency fan pump, multi-cone centrifugal cleaner battery, and multi-stage inflow pressure screen directly feeding the hydraulic headbox.
| Section | Engineering Specification & Construction Highlights |
|---|---|
| Hydraulic Headbox | Fully enclosed hydraulic micro-turbulence headbox in solid SS316L (electropolished Ra < 0.2 μm). Multi-tube step-diffuser header with balanced recirculation. Precision micro-metric slice lip adjustment providing CD basis weight profile variation strictly within ±1.5%. |
| Crescent Forming Section | Crescent former configuration: Forming roll Φ1200 mm with corrosion-resistant SS sleeve. Vacuum suction breast roll and foil box. Cantilever wire/felt framing allowing seamless 1.5-hour fabric exchange without dismantling bearing housings. |
| Press Section | Single suction press roll Φ900 mm (blind-drilled polyurethane elastomer cover) hydraulically loaded against the Yankee dryer with linear pressure up to 90–110 kN/m. Maximizes sheet dryness exiting press to 42%–44% before thermal drying. |
| Steel Yankee Dryer | Steel Yankee Cylinder Φ3,660 mm × 3,200 mm Face. High-tensile forged steel alloy construction offering 30% higher thermal conductivity than cast iron. Design operating steam pressure: 0.8–1.0 MPa. High-precision oscillation creping, cleaning, and cutoff doctors. |
| High-Velocity Air Hood | High-efficiency canopy impingement hood. Nozzle velocity: 110–130 m/s. Supply air temperature up to 160°C–200°C (steam-heated or optional gas-fired). Multi-stage heat recovery system capturing exhaust enthalpy to preheat boiler feedwater and hood make-up air. |
| Pope Reel Section | Horizontal surface reeling machine with pneumatic primary and secondary loading arms. Reeling cylinder Φ1,100 mm water-cooled. Maximum parent jumbo roll diameter: 2,500 mm. Automated full-width turn-up device. |
| High-Speed Slitter Rewinder | Two-Drum High-Speed Tissue Rewinder (Operating speed: 1,300 – 1,600 m/min). Shaftless unwinding stand for 2,500 mm jumbo rolls with mechanical disc braking and closed-loop load-cell tension control. Pneumatic shear slitters, rider roll nip control, and automated finished roll ejection. |
| Electric Sectional Drive | Fully digital AC sectional drive powered by Siemens S7-1500 master PLC with Profinet communication. High-efficiency ABB ACS880 inverters with multi-motor torque sharing. Fully compliant with Indian industrial grid: 415 V ± 10%, 50 Hz, 3-Phase. |
| Package / Subsystem | Scope of Supply & Components | Budgetary Price (FOB/CIF Nhava Sheva / Mundra) |
|---|---|---|
| Package I: Stock Preparation Line | Virgin pulp line + Waste paper Deinking line (high-cons. pulper, float cells, disc thickener) + Hot Disperser System (with preheater screw) + Approach flow fan pump & screen. | USD 520,000 |
| Package II: Crescent Former Tissue Machine | Hydraulic headbox, Crescent forming unit, Suction press roll, Φ3660mm Steel Yankee Cylinder, High-velocity steam hood with heat recovery, and Pope reel (Φ2500mm roll). | USD 1,080,000 |
| Package III: High-Speed Slitter Rewinder | 1,300–1,600 mpm tissue rewinder, shaftless unwinder for 2500mm jumbo rolls, shear slitting section, tension control, finished roll discharge. | USD 185,000 |
| Package IV: Automation & Electrical Drive | Siemens S7-1500 PLC control cabinets, ABB ACS880 inverters, operating desks, cables inside machine boundary, QCS basis weight & moisture scanner frame. | USD 145,000 |
| Package V: Engineering, Commissioning & Spares | Complete civil foundation loading drawings, piping schematics, installation supervision by SEN senior engineers, 1-year essential spare parts pack. | USD 60,000 |
| TOTAL ESTIMATED TURNKEY PACKAGE (CIF Mundra / Nhava Sheva) | USD 1,990,000 | |