Overview

The Plant was in production up to September 2012 and is currently configured for the manufacture of 100% recycled paper on two lines, line 1 having a top & bottom wire for the production of white top & liner papers. Speed Range 520-350M/min, 180-125GSM, deckle at slice 3200mm, deckle at reel 2850mm, producing 170-200 Tonnes/per day continuous, line 2 being single ply only. Speed Range 280-400M/min, 80-200GSM, deckle at reel 2200mm, producing 80-100 Tonnes/per day continuous.

Both paper machines have Valmet Dematic XDI systems which run motor stop/start functions including flows, pressure, temperature and level controls within the mill. The paper machines and stock preparation are well supported with documentation and spares. The plant has been maintained on a regular basis

PAPER LINE 1 - STOCK PREPARATION
De-Ink Stock Receiving Bay with two 1.5M x 24M inclined waste conveyors to pulpers.

White Line
LamortS/S pulper, 22.5M3 capacity with bottom rotor HC, 350kW gearbox drive, 18% consistency (1993), Lamort PoireModel 3 secondary pulper with 6mm holes, 5% consistency on discharge to two 40M3 (approx.) chests (T2 & [T3 with side entry agitator]), ComerDPA40 high density centrifugal cleaner with pneumatic timed rejects (1994), two LamortCH5 screens & LamortCHN5 screen each 45kW with 4mm holes, Lamort DiabloModel 1 screen (out of use) , two 40M3 (approx.) S/S pulp chests.

First Stage De-Ink
LamortVerticell Model 4 S/S de-inking cell, 560M3/hr, 7T/hr capacity at 1.2% consistency, with double & counter aeration pumps, low vacuum sludge removal fan, cell accept tank & white water silo.

Thin Stock De-Ink
LamortSPN12 S/S pressure screen with 0.15mm slots (1993), LamortCHA5 tailing screen 45kW, with 0.15mm slots, VoithC bar baskets. Greenson & Waitedrum thickener for de-ink pulp, 5.5M x 1.8M dia. with direct drive manifold & rubber couch roll, S/S tank (T12) 40M3 capacity with side entry agitator. ValmetEL consistency

Dispersion
Maulekneader dispersion system, 6T/hr with 6 inclined de-watering screws & de-watering screw into 1000 C unpressurised steam heated kneader. Dispersed stock chest with side entry agitator.

Post Dispersion De-inking
LamortVerticell Model 4 S/S de-inking cell, Voithdrum thickener with feed manifold, 4.5M x 1.5M dia. & rubber couch roll, 480M3/hr capacity at 1.2% consistency. S/S tank (T22) 40M3 capacity with side entry agitator. ValmetEL consistency Top Wire feed chest with top mounted agitator unit. Recirculation chest, two Beloit3000 series 26” dia. refiners, auto gear loading, VoithModel 20 0.35mm dia. top wire pressure screen, VoithKS160 three stage low density cleaners, KyjuanimcaiEL consistency with tertiary ‘rejectomatic’ cleaner. De-ink pulp brightness 88-90

Brown Line
Jylhavararoll splitter, 2500mm x 1250mm dia. FLT loaded roll.
Sicmawire baler for pulp bale wires. Floor level feed conveyor from FLT
BCIpulper, 16’ dia., D section mild steel tub with S/S liner. No. 3 gearbox drive.
Voith Trashex for pulper rejects, external trommel, dirty chest.
Voith ATS 21 turbo separator high density cleaner with 2.6mm holes – rejects to:
Voith 1000 4mm hole vibrating screen, S/S refiner chest with side entry agitator.
Valmet EL consistency
Voith SDM 30” disc refiner. S/S chest with top mounted agitator. Kyjuanimcai EL consistency
Two BCI36p S/S pressure screens with 0.2mm slots, primary rejects to:
BCIP24 selectifier, secondary rejects to Esher WyessRS2B reject sorter (1989) Six Bauer623 (5 x primary + 1 secondary) low density cleaners, 1217L/pm, 0.8% consistency. Palmac tertiary cleaner, 1000L/pm at 0.8% consistency.

Paper Machine Line 1 (PM1)
Top wired for the production of white top & liner papers. Cylinders rated 100 psi, 520-320 M/min, 180-125 gsm. Deckle at slice 3200mm, Deckle at reel 2850mm, right hand sectional DC drive. Basement designed machine producing 170-200T/day

Top Wire Approach Flow
Twelve VoithKS160 cleaners in 3 stages (7 in stage 1, 4 in stage 2, 1 in stage 3+ fibre saver) VoithSize 20 pressure screen with 0.35mm slots. De Zurickbasis weight control.

Top wire (1981)
VoithJetmaster commander flowbox. Pressure equilizing tank, slice 3150mm, manual slice adjustment, 25 micro adjusters. The wire section is cantilevered.

Breast roll 514mm dia., rubber covered, forming board stainless with ceramic cover, low vacuum suction foils, rubber covered forward drive roll 514mm dia., stainless steel trim handling system, couch tail cutter, wire cleaning high pressure: Permajet system. Thuneauto wire guide. The top wire runs in opposite machine direction.

Bottom wire
Stainless wire frame cantilever type. VoithDuo shake motion (2003). KMWpressurized flowbox with ABBauto slice control, two driven evenor rolls, breast roll with Voithlubrication system (2003), forming board stainless with polyethylene top, Johnnson gravity foils in stainless with polyethylene tops. Low vacuum foils in stainless steel with 3 ceramic foils each, complete with vacuum fans and CH Johnnsonauto vac with two control systems. High vacuum boxes in stainless with two ceramic foils each. Vacu foil box with six ceramic foils. Suction box with PTFE cover. NordiscDandy roll 1200mm dia., NEF wire dandy frame including shower and drive, Schwarkauto wire guide. Suction couch roll 762mm dia.. Forward drive roll 500mm dia.. All wire rolls covered with Glatexcovers. Electric wire stretcher. Wire centres from breast roll to suction couch: 16 m. High and low pressure showers.

Press section
Suction pick up with suction roll in first press and plain press pneumatic loaded in the second press. Under machine pulper

Drying sections
Dryers are on A/F bearings with auto lube system. Dryers with some on gear drives and other felt driven. Central lubrication systems. 28 dryers before the size press. 1500mm dia. with bolted ends, Thune felt guides, Judd felt stretchers. Sheehan rope feed. Valmet Cross machine scanner measuring moisture and profile.

Size press
Warburtoninclined size press with pneumatic loading of rolls, Sheehanrope feed.

After Drying section
After dryer section on A/F bearings, Thunefelt guide, eleven cylinders, Sheehanrope feed. Under machine dry end pulper. Vib damper unit

Calender
Voithtwo roll calender stack with Kusterroll and hydraulic loading.

Cross machine scanner
ValmetIQ scanner measuring moisture, caliper, gsm, ash and profile. (1992).
IBStail transfer tape turnover system.

Reel up
Black Clawsondrum reel up for finished rolls of 2.4m dia..

Rewinder
Masson ScottUIA rewinder with unwind on fixed stand, water cooled drum brake with pneumatic operated brakes, tension control, taking a reel 2.4m dia., shaftless rewind dia. 1500mm. Rewinder has been rebuilt with twin motor drive and converted to hydraulic operation. Drive on left side. Reel ejector and lowering table.

PAPER LINE 2 - STOCK PREPARATION
Flat bed conveyor for waste paper feed from fork truck
BCI Pulper medium consistency 14ft, Volkes type rotor, batch operation, gearbox drive.
Perforated plate below rotor, Reject to a BCI Trashex unit and rejects are dumped to waste container, Trommel, Stainless chest for dirty stock
Two Voith S3HD cleaners with auto reject chambers.
Two 24P thick stock pressure screens running 4.5% with 1.8 /1.6mm holes. Rejects from the BCI 24P screens go to a Voith vibrating screen.
Accepts go to a tank returning to the pulper.
JCO-1 refiner with 355kw motor.
Palmac LD cleaners in three stages.
BCI 24 P machine screen unit with 1.8mm holes.
Refiner stock/feed chests: stainless with side entry agitators and Scann pumps.Waste water silo. Machine chests and re circulation system. Backwater feed chest. Eurocontrol Basis weight system

Paper Machine Line 2 (PM2)
This machine has a left hand drive and a sectional electric drive, speed 450m/min, dryers rated 30 psi, deckle at the reel 2200mm, DC. Speed is 415 to 200m/min, gsm 80 to 200. Production: 80 to 100t/day. Open gear drive with C.I and Polypemco gears.

Wire section
Knock down wire section with a Voith K1000 flowbox. Pressure operation, two driven evenor rolls.
Bertrams wire shake motion. Wire centres from the breast roll to the suction couch roll: 15m. Forming board in stainless with polyethylene blades, nine Johnsson foil units in stainless with polyethylene foils, two are vacuum foils, Steam shower over the stainless suction boxes, Thune automatic guide. Lump breaker roll prior to suction couch. Baggley blow off box for tail transfer.
Millspaugh Cantilever suction couch.

Press sections
First press: suction press with a Millspaugh suction roll and a plain top roll pneumatic loaded with a Sheehan rope feed.
Second press: plain press with pneumatic loading. Wet end pulper (located below presses)

Dryers
Four sections with sectional electric drives. Dryers 1500mm dia. with bolted ends, first two cylinders with oscillating doctors. A/F bearings with central lubrication.
Twenty nine drying cylinders with bolted cylinder ends. Tail feeding by rope feed

Calender
Tandem twin soft nip with hydraulic loading. Alternative top and bottom kuster rolls.

Cross machine scanner
ValmetPaper IQ scanner measuring moisture, gsm and ash. (1992)

Reel up
Black Clawsonhorizontal 1500mm dia. reel up.

Rewinder
Masson ScottUIA rewinder with unwind on fixed unwind stands taking a reel dia. of 1.5m dia., water cooled drum brakes, pneumatic operation, tension control, rewind dia. 1500mm and shaftless rewind. Variable tension to the drums with a manual adjustment. Five slitters. RH Drive. Reel ejector and lowering table.
Vacuum system- Four NashCL 2001 series pumps

Surplus Equipment
Press roll R/C for PM 1, Three VoithS3 or S4 HD cleaner bodies with reject chamber, VoithATS 30/31 turbo separator length 1830mm, reject outlet 175mm dia. Two suction couch roll shells in bronze: width 2898 mm face and 2860mm drilled face and dia. 609mm. Couch roll shell, overall face width 3275mm, drilled face width 3135mm, overall dia. approximately 758mm, wall thickness approximately 36mm.Suction couch roll new, 3270mm face and drilled face 2950mm, dia. 762mm. Suction press roll r/c with bearings and housings for above roll position Drum thickeners: stainless steel drum and vat

Two BCIPulper Model 3 gearboxes, VoithAP 20S/S pulper, Two MauleS/S screw presses, Reject press for final rejects, Esher Wyess100 t/day dispersion system, Pre thickening by Reiss and Krimascrew inclined presses. Krimahorizontal press, feed press, heating screw and Esher Wyessdispersion unit. Heating unit and dispersion unit rated at 4/t/hr. System has a BCIdrum thickener with couch roll, LamortVerticell model 4 S/S De Ink cell, Two JCO-1 refiners ( one without fillings and b/housing) JylhavaaraRoll spitter: maximum roll dia. 1200mm, maximum reel handling length 1500mm. LamortDiablo model 1 in stainless steel complete with motor. Esher WyessRS1 reject sorter. Black Clawson14 ft batch pulper operating at low consistency. Gearbox drive with a perforated plate. Two KroftaSPC22 units.

Effluent Plant
Primary treatment KufferathScrew press, consisting of AKSEdisc thickener ( primary dewatering ) into the screw press . Dryness of sludge approx 55-60% throughput of 2.5 tph bone dry

Simon-Hartley Klamp press. Dryness of sludge approximately 40%.thruput of 2.tph bone dry

Starch tower
External starch silo 55 ton capacity.