⚡ Low Capex • Fast 15-Day Shutdown Retrofit • Up to 35% Speed Increase
Turnkey Rebuild Package: Air-Cushioned Headbox & High-Load Press Modernization
Designed specifically for Indian Kraft Paper & Duplex Board Mills to increase operating speed, eliminate CD profile variations, and slash boiler steam consumption by up to 25%.
1. Executive Summary & Value Proposition for Indian Mill Owners
Many operating packaging mills across Uttar Pradesh and Gujarat face high coal/biomass steam costs and cannot ramp up production speed because of outdated open headboxes and weak roll presses. Building a new paper machine requires substantial civil foundation investment and 12+ months lead time.
❌ Before Rebuild (Existing Aging Line)
- Open / gravity headbox, speed capped at 160–200 m/min
- Cross-direction (CD) weight variation ±4% to ±6%
- Press exit sheet dryness: Only 37% - 39%
- Excessive boiler steam: 1.8 – 2.2 Ton steam / Ton paper
- Frequent paper breaks at wet end
✅ After SEN Rebuild Package
- Air-cushioned headbox ramps speed to 280 – 350 m/min (+35%)
- Micrometer slice lip holds CD profile within ±1.5%
- High-load press boosts sheet dryness to 46% - 48%
- Steam consumption reduced to 1.35 – 1.45 Ton/Ton (-25%)
- Direct drop-in replacement on existing foundations in 15 days
2. Module 1: Air-Cushioned Pressurized Headbox Retrofit
| Item |
Engineering Specification |
| Wire Width Compatibility |
Custom-fabricated from 2200mm to 4200mm wire width |
| Material of Construction |
Full SS304 or SS316L for all stock-contact parts, mirror inner polished |
| Distributor System |
Tapered inlet manifold with multi-tube step diffusor matrix for balanced stock cross-flow |
| Micro-Adjust Slice Lip |
Precision manual micrometer spindles (spaced at 100mm intervals) or motorized auto-slice option |
| Liquid Level & Air Control |
Automated air-cushion pressure transmitter and bypass valve linked to PLC |
| Direct Mounting |
Equipped with adaptable base plates matching existing Fourdrinier rails without civil modification |
3. Module 2: High-Load Dewatering Press Section Upgrade
Replacing conventional small nip roll presses with a modern large-diameter high-load press section drastically mechanically removes water before the dryers, which is 5 times cheaper than thermal drying.
| Component |
Technical Details |
Benefit |
| Top Roll Assembly |
Ф800–Ф900mm Natural granite roll or composite ceramic cover roll |
Superior sheet release without picking |
| Bottom Press Roll |
Ф850–Ф1000mm Blind hole rubber/polyurethane cover roll with SS shafts |
Nip linear pressure up to 120–150 kN/m |
| Hydraulic Loading Unit |
Independent left/right hydraulic cylinders with proportional control |
Uniform nip pressure across the web |
| Felt Conditioning |
SS304 high-pressure oscillating needle showers + ceramic vacuum suction pipes |
Prolongs felt service life by 40% |
4. Module 3: High-Speed Double-Drum Slitter Rewinder Modernization
| Specification |
Technical Parameter |
| Operating Speed |
1200 – 1500 m/min (Eliminates finishing room bottlenecks) |
| Drum Roll Face |
Ф400–Ф600mm hard-chrome grooved front and rear winding drums |
| Slitting System |
Pneumatic circular shear knives with digital positioning display |
| Tension Control |
Closed-loop pneumatic disc brake tension control with load cell feedback |
| Ejection & Unloading |
Hydraulic roll ejector and lowering table |
5. Rebuild Investment & Payback Analysis (Indian Mill Case Study)
Real-World Economic Return (Based on a 100 TPD Indian Kraft Mill):
• Coal/Biomass Steam Savings: Increasing press dryness from 38% to 47% reduces steam use by ~0.45 Ton steam per ton of paper. At ₹ 2,500/Ton steam, savings = ₹ 112,500 / day (~USD $1,350/day).
• Additional Production Output: Ramping up speed by 25% produces an additional 25 Tons/day of saleable Kraft paper. At ₹ 3,000 gross margin per ton, extra profit = ₹ 75,000 / day (~USD $900/day).
• Combined Daily Gain: ~USD $2,250 / Day.
👉 Total Rebuild Investment (~USD $280,000) is 100% RECOVERED in just 4 TO 5 MONTHS of operation!
6. Turnkey Budgetary Scope (CIF Mundra / Nhava Sheva Port)
| Modernization Package Option |
Scope Included |
Price Range (USD) |
| Package A: Headbox Retrofit Only |
Air-cushioned SS304 headbox + Tapered header + Level control |
$ 85,000 – $ 115,000 |
| Package B: Wet-End + Press Section |
Air-cushioned headbox + Ф900mm high-load press + Hydraulic station |
$ 180,000 – $ 240,000 |
| Package C: Full Mill Speed-Up Package |
Headbox + High-load press + 1500 m/min Rewinder + Drive sync |
$ 260,000 – $ 340,000 |
Modernization Engineering Dept:
SEN INTERNATIONAL MACHINERY CO., LIMITED
Email: sales@senintlpapermachinery.com
Application Engineering Specialist:
Rebuild & Wet-End Retrofit Team
WhatsApp: +86-18678887729
Web: https://senintlpapermachinery.com