A Presentation on

Induction Program

Brief History of ITC Limited

Started in 1910 as Imperial
Tobacco company
Later 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

products
Later entered into Non-tobacco based
streams like
FMCG
Hotels
Paperboards & Packaging
Agri Business
Information Technology

Brief History of Tribeni

1949 Tribeni Tissues Ltd was
founded by BAT
1950 Two paper machines and a
pulp mill erected for making
Cigarette tissues, Plug wrap paper
and Carbonizing tissues
1961 Wiggins Teape, a specialty
and fine papermaking company took
over the operations

 1969 & 1977 Installed PM 4 & PM 3

respectively
1988 Management handed over to
ITC by BAT
1992 Merged with ITC
2002 Integrated to become a part
of PSPD

N
Srivatsava
Unit Head

S Mohanty
Head (O)
PBU 1&2

NK
Bhattachar
ya
PBU 3

P K Patra
Unit
Head HR

Basab
Ghosh
PBU 4
Head Engg

N Saha
Unit
Head
Material
s

Bibuti
Sen
Unit
Head
Quality,
R&D

Organogram of Unit Tribeni

Yusuf
Culcuttaw
ala
Unit Head
Finance

Tribeni An Overview
Specialty papers Manufacturer
Cigarette Tissues & Components
Light Weight Communication Grades
Other Specialty Grades
Dcor Grades

Steam & Power Generation

F-Grade Coal Fired boiler
12MW Turbine

Competitors during 1980s

European Mills

High Quality

Chinas Market

Cheaper price

How to Overcome these

Threats?
Quality
Lower price
On-time delivery
To achieve a better quality at
relatively lower
price, we reduced the tolerance values
to
sustain in the market.

Various Departments in our

Unit
HR
Human asset of the Unit
o Permanent Employees 637
o Managers 152
o Budlies 148
o Contract workmen 331

Various other activities of HR

o Manpower Planning
o Recruitment, Selection and Induction
o Training and Development
o Industrial Relation
o Statutory compliance
o Welfare activities
o Contract labour management

 Marketing
Bridges the gap between company and
the customers

Finance
Payment
Taxation
Financial accounting & Audits
Costing

 EHS
Ensures safety

Materials
Stores Engineering Stocks
Three types of stocks stored here
o Stock material
o Non-stock material
o Insurance material

House keeping

TPM

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

Pillars of TPM

SAFETY PAUSE

EHS Policy

To establish Sustainable development

To assess risks and mitigation
To provide appropriate training
To provide facilities and working
conditions
To ensure safe handling, storage, use
and disposal of hazardous chemicals
To reduce waste, conserve energy
and promote recycling

Occupational Health &safety

What is SAFETY?
Smart
Attitude to
Figure out and
Eliminate risk in
Time which involves
You
Heinrich study
How to achieve safety?
Fire Safety

Paper and Pulp

Paper 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.

Pulp
Pulp 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 FOREST
FASTER GROWTH
CONVERSION DIFFICULT
FIBRE LENGTH 0.5-2MM
SHORT FIBER LENGTH AND
ACT AS FILLER MATERIAL
IMPROVEDS FORMATION,
SMOOTHNESS AND OPACITY

SOFTWOOD
CONIFEROUS FOREST
SLOWER GROWTH
CONVERSION EASY
FIBER LENGTH 2-5MM
IMPROVES STRENGTH,
BONDING AND TEAR
STRENGTH

PAPER-MAKING PROCESS
PULP

DRYE
R

HYDR
OPUL
PER

PRESS
SECTIO
N

REFINE
R

HEAD
BOX

REWIND
ER

REELING

BOBBI
N
SLITTIN
G
PACKIN
G

Despatc
h

Stock Preparation
1. Pulp Stock
2.
.
.
.
.
.
.
.

Chemicals
Filler: Clay, Chalk, Talc, Titanium Dioxide
Retention Aids
Biocides: Oxiclean, Busan
Acids and Bases
Sizing Agents: Rosin , Waxes
Dry strength additives: starch
Wet strength additives: crosslinking polymers

3. Hydra pulper, Hi-Lo pulper/ Repulper

4. Sw/Hw unrefined chest
5. Refiners
6. Refined chest

Paper Making
Machine
Chest

1. Machine Chest
2. Centri-cleaner cascading
3. Pressure screen

Head Box

4. Head box
5. Wire

Centri-cleaners

Pressure screen

6. Press section
Wire

7. Dryer
Press Section

Dryer

Finishing 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 Screen

Cylindrical 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.

Wire
Stock 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.

Press section
Paper 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.

Packaging
1. Reeling
2. Rewinding
3. Bobbing slitting
4. Packaging
5. Despatch

Dryer

Drying: Heat and Mass Transfer

operation
Main function is to dry the paper
sheet from press part properly so
that moisture profile is uniform
throughout
thePost
paper
Paper
Pre Dryer
Dryer
Total
Machine
Sections
of
Dryer:
1
1-8
9-12
12
Pre-Dryer
3
1-13
4
1-10
Post
Dryer

14-19

19

11-14

14

Biggest part of the paper machine

Entering 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 vapour
Pocket Ventilation

Important things of dryer

section

Drying cylinder is made of cast iron

Even drying
Even moisture profile
Temperature should be increased slowly to prevent
OVER DRYING
Steam consumption should be min.
consumption of 1.6T of steam per ton of paper is
acceptable
Steam should be dry saturated and not super saturated
More the speed of the machine more is the steam
pressure reqrd

Doctor blade
Main functions are
Sheet removal
Removal of roll surface
contamination

 Size Press :

Between pre and post Dryer Section.

Used for adding Sizing Chemicals

Calendria: Similar to Ironing

Hard Roll
Soft Roll
In Paper Machine 4 Oil is used in Calendria which is
heated upto 300C
Main function is to
Make the caliper of the paper sheet uniform
Imparts desired smoothness and glossiness which
improves printability
It reduces average thickness

PAPER MACHINE-1

Installed in 1950 Thirty & CIE, Belgium

Deckle : 2.7 metres
Speed : 300 mpm
Grades :
Cigarette tissues & plug wrap tissue
Daily capacity : 25 T

PAPER MACHINE-3

Installed in 1978 Bertrams Sciennes, UK

Deckle : 3.35 metres
Speed : 400 mpm
Grades :
Thin printing : 28 to 48 gsm
Wax match tissue : 44 gsm
Anti rust : 27 to 35 gsm
Insulating grades : 40 to 90 micron
Medical insert : 40 gsm
White tipping : 36 gsm
Daily capacity : 55 T

PAPER MACHINE-4
Installed in 1969 Thirty & CIE,
Belgium
Deckle : 2.7 metres
Speed : 145 mpm
Grades :
Decor 40 to 100 gsm
Insulating 40 to 190 micron
Medical grade 60 gsm
Daily capacity : 25 T

FINISHING HOUSE
REWIND
ER

REELING

BOBBI
N
SLITTIN
G
PACKIN
G

Technical Department
Functions :
1. Input material inspection & testing
2. Process control
3. Output monitoring final product and
control
4. Process development
5. ETP and E&U lab activities.

DEFECTS of PAPER
Technical defects: porosity
Physical defects:
loose paper

crease
agglomeration
thin spots
burst

WATER TREATMENT PLANT

MGF

ACF

CONDENSA
TE FROM
PM 1,3,4

HE

CONDENSA
TE

UF

RO

DEGASS
ER

MIXE
D BED

SBA

SCE

ACF

MB

DM
STORA
GE

Thermal Power Plant

Operating Cycle: Rankine Cycle
Essential parts
1. Boiler
2. Turbine
3. Condenser
4. Pump

 Boiler
The place where Heat is added to water and it is converted into steam
Capacity: 72 Tonnes/Hour

Turbine
Prime mover which converts the heat energy of steam into mechanical energy.
Capacity: 12 MW
Speed :8440 RPM

Condenser
The place where heat is rejected from the system with the help of cooling tower.

Pump
A device that raises, transfers or compresses the fluids .

Contd
Waste heat recovery systems:
1. Economizer
2. Super Heater
3. Air Pre-Heater
. Filtering system
1. ESP
. Boiler Efficiency
. Cycle Efficiency

Refining
It is a mechanical process which makes the paper
suitable for paper making
Fibrillation + cutting of fibers happens in refining
Pulp with water is allowed to pass through the narrow
gap between a revolving rotor and stationary rotor both
of them having bar
Tackles 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 refiners
Jylha or conical refiner
Disk refiner
Double disk (DDR)
Triple disk (TDR)

Types of refining:
Mixed refining
Hard wood and soft wood are mixed in ratio as
per requirement and refined. Uniformity of stock
is less, power consumption is high

 Separate refining
Hard wood and soft wood are separately refined. Uniformity of
stock is high, power consumption is less

Single pass
The stock from unrefined chest will enter into a set of refiners and
reach the refined chest

Circulation
The stock from the refined chest is made to pass through a same set
of refiners again and again until required properties are obtained.

Single street
Pulp suspension is passed through a set of refiners consisting of no
of refiners in line and discharged to refined chest

 Double street
Pulp 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 water

Regulating valves at inlet and outlet are fully opened
Shut 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 rotor
Flow control valve is made to maintain 1200 LPM
2 way valve is used for circulation of stock
4 way valve is used for bypass a refiner
30% of stock must be maintained in unrefined chest

Factors affecting refining

Consistency in the range of 4 to 5 %
Uniform flow of stock is to be maintained by using flow
control valve
Feeding pressure may be kept in the range of 1.4 to 1.7
kg/cm2
Temperature of stock should be maintained. Else
vaporization of water takes place leads to decrease in
fibrillation
Increase in fibrillation will lead to increased bonding.
Hence opacity decreases

Lubrication
Oil and Grease are used as lubricants
Centralized Oil Lubrication Tank (COL Tank)
Pump
Flow meter
Condition Monitoring
It is the process of monitoring vibration, temperature etc. in
order to identify a significant change which is indicative of
developing a fault
Breakdown maintenance
If 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
time

Predictive maintenance
Predicting when maintenance is to be performed
Identifying which machines are more prone to failure
It is done by

Vibration Analysis
Lubricant Analysis
Infrared Thermography
Motor current analysis

 Pumps:
Positive displacement pump
It 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 machines
Pressure relief value should be used at discharge end

EX: Reciprocating, gear type, vane type, screw

type, lobe type
Fan 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 (<3%)

Gear box:
Mainly used for speed reduction
Spur gear, helical gear, worm wheel and bevel
gears are used

Rolls:
Couch roll
Pick up roll

ETP
BOD 100 to 273 mg/l
COD is very high(472-826 mg/l)
Types of pollutants
1.Natural Pollutants
2.Synthetic Pollutants
The impurities are mainly two types.
1.Dissolved impurities
2. Suspended impurities

 Adverse effects on aquatic life

Lowering of the dissolved oxygen
content
Suspended impurities decreases
photosynthesis
Acceptable limits as per standards
BOD level - 100 ppm
Suspended solids upto 110 mg/l
COD -350 mg/l

THANK YOU