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Introduction to Paper and Board Machines

This course covers the equipment and processes needed in order to create a fully formed sheet of paper.

Paper Machine Refining

This course will describe low consistency refining as well as refining actions as they relate to double disc refiners.

Broke System Purpose and Operation

Because broke can amount to well over 5% of a machine's total production, broke is an important fiber source and the broke system is an essential part of the papermaking process, from both financial and operational perspectives.

Broke Cleaning and Screening

"Broke" refers to partly or fully manufactured paper or board that is discarded from paper or board making, converting, and finishing processes. It also refers to the stock made by repulping these materials. Broke is continuously being produced and it is the job of the "broke system" to collect this valuable resource and supply it back to the paper or board making process for reuse. Many broke systems include cleaning and screening stages just before the broke fiber is returned to the machine furnish. The purpose of broke cleaning and screening systems is to remove contaminants from the broke stream, break apart fiber flakes and bundles in the broke to improve sheet uniformity and minimize fiber losses, and return a clean, consistent flow of broke to the machine furnish.

Broke Repulpers

Broke is an important byproduct of the papermaking process that is reclaimed and recycled back into the furnish. Broke is generated at various points around a paper machine and so repulpers are positioned in both under-machine and off-machine locations to collect, repulp, and pump the broke back to the stock system for reuse in the paper or board making process. This course covers the safety hazards around broke repulpers, off-machine repulper designs, the broke repulping process, as well as repulper consistency control.

Broke System Inventory Management

There are two types of broke generated on a paper or board machine: continuous and event related. Broke is continuously generated as wet edge trim, winder trim, dressing from reels, and cull rolls. Event-related broke comes from sheet breaks and machine startups and shutdowns. Large quantities of broke can be generated during these events that end up going to under machine repulpers, such as the couch pit, press pit, and dry end repulper. It is important to recover and reuse as much of this valuable fiber resource as possible.

Broke System Purpose and Operation

"Broke" refers to partly or fully manufactured paper or board that is discarded from paper or board making, converting, and finishing processes. It also refers to the stock made by repulping these materials. Broke is continuously being produced, and it is the job of the "broke system" to collect this valuable resource, process it, and make it available for reuse. Because broke can amount to well over 5% of a machine's total production, broke is an important fiber source and the broke system is an essential part of the papermaking process, from both financial and operational perspectives.

Under-Machine Repulpers

Most paper and board machines are equipped with at least three under-machine repulpers. These repulpers collect and process wet and dry broke from the machine during normal operation and also during startups and sheet breaks. The three most common under-machine repulpers are located under the couch roll, press section, and reel. Some machines have another repulper located under the winder. This modules describes the purpose, locations, and components of under-machine repulpers.

Starch Cooking

Starch is a carbohydrate, a high molecular weight polymer of glucose, that is produced and used by all plants to store energy. It is widely used in the production of paper and board as a retention aid, dry strength additive, internal sizing agent, surface sizing agent, and as a binder in coating formulas. This course discusses how starch is used in the paper and board production process, the hazards it presents, as well the equipment and process variables of starch cooking.

Wet End Chemistry - Functional Papermaking Additives

Chemical additives are used in the papermaking process for many different reasons, and they are often divided into two groups. Functional chemicals directly improve properties of the sheet, while process chemicals affect operations on or near the paper machine. This module covers the first group – functional chemicals. It discusses the purpose of some of the more common functional additives used on paper and board machines, and describes how they work.

Wet End Chemistry - Papermaking Process Additives

Chemical additives are used in the papermaking process for many different reasons, and they are often divided into two groups. Functional chemicals directly improve properties of the sheet, while process chemicals affect operations on or near the paper machine. This module covers the second group – process chemicals. It discusses the purpose of some of the more common process additives used on paper and board machines, and describes how they work.

Wet End Chemistry Basics

Discusses the fundamentals of colloidal chemistry for paper machine stock and water systems. Describes the surface charge interactions that take place and the role of pH. Discusses how some commonly used chemicals affect wet end chemistry, machine operations, and sheet characteristics.

Calendering - Hard Nip

Hard nip calendering is used to smooth the surface and control the caliper or thickness of the sheet before it is wound onto a reel. Some sheet compaction or pressing also occurs. At the end of this module, you will be able to describe the purpose of hard nip calendering and describe the main components of a hard nip calender.

Calendering - Wet Stack

Calendering is a process used in the production of paper and board to smooth the surface and control the caliper or thickness of the sheet. Some sheet compaction or pressing also occurs. Wet stack calendering uses moisture to enhance calendering results. Wet calender stacks must be followed by dryers to remove the added moisture before they can be wound onto the reel.

Carrier Ropes - Design and Operation

Proper design and operation of carrier rope systems on paper and board machines. Discusses rope and sheave selection, sheave setup and alignment, rope tension.

Carrier Ropes - Procedures and Maintenance

Outlines several procedures and techniques, including routine inspections, rope cleaning techniques, rope replacement, and rope splicing. Stresses importance of approved procedures and techniques, and personal protective equipment.

Carrier Ropes - Safety

Discusses hazards associated with carrier rope systems on paper and board machines, including nips, burns, rope breakage.

Dry End QCS Scanner

The QCS scanner is a device located just before the reel that provides continuous measurement of key dry sheet properties. This module will describe safety guidelines for working around a dry end QCS scanner, how QCS scanners operate, and different types of sensors used.

Paper Coating Ingredients

Paper and board grades are sometimes coated to improve the printability, visual properties, or functionality of the sheet. Coating formulas typically contain three categories of ingredients: pigments, binders and additives. Pigments improve printing and optical properties of the sheet, binders adhere the pigment particles to each other and to the sheet, and additives either assist in the coating process or enhance sheet properties. This module describes common coating formulas and coating ingredients.

Paper Coating Operations

Paper coatings can be used to enhance the printability, visual properties or functionality of a sheet of paper board. Coating formulas vary widely because there are many different grades of coated paper and board with very different end uses. This module will identify the main purposes of paper and board coatings and describe the three most common coater designs.

Paper Machine Reel Systems

The purpose of the reel section (or simply the "reel") is to wind the continuous sheet produced on a paper or board machine onto a spool to produce jumbo rolls called "parent reels" that are ready for further processing. It basically completes the paper or board production process. This module describes the operation, functions, and main components of a pope reel system.

Tail Threading

Every time a paper or board machine is started up after a shutdown, and following wet end sheet breaks, it is necessary to rethread the sheet from the forming section to the reel. After dry end sheet breaks, the sheet must be threaded through some portion of the machine. This module will describe the sheet threading process on a paper or board machine and the main components of a carrier rope system, including rope sheaves, rope tensioners, and rope drives.

Web Guiding and Spreading

Web guiding and spreading are two elements of web control that are used in web-producing processes. On paper and board machines, several fabric loops require web control to keep them running correctly on the machine. Web control is also used on the sheet after it has been dried to ensure the success of dry end and winder operations. This module will discuss web guiding first, and then web spreading.

Paper Machine Winder Safety

Eliminating hazards is the best way to ensure the safe operation of paper and board machine winders and rewinders. Machine guarding and safety devices, interlocks, and controls are next. Safety can also be improved by automating activities and procedures, proper training, the use of standardized procedures, and regular monitoring and maintenance of equipment and controls. Additionally, operators should know the locations of E stops, first aid cabinets, eye wash fountains, emergency showers, and fire extinguishers, and know how to use them. [course outline] The Winding Process Winding Process Challenges Winder Safety Introduction Pinch Point Hazards 1 of 2 Pinch Point Hazards 2 of 2 Nip Point Hazards 1 of 4 Nip Point Hazards 2 of 4 Nip Point Hazards 3 of 4 Nip Point Hazards 4 of 4 Cutting Hazards 1 of 2 Cutt Regulations OSHA 1910.219 (C) (4) Guarding Projecting Shaft Ends NFPA 79 Emergency Stops

Paper Machine Winder Slitting

The purpose of a winder is to convert the large diameter, machine-width parent reels of paper or board produced on a paper or board machine into finished roll sets ready for converting or shipping. Winder slitters are used to cut parent reels into various roll widths and trim off the edges of the sheet in order to meet customer requirements. This module will describe common slitting methods and recognize safety guidelines applicable to winder slitters and slitter sections.

Paper Machine Winding Basics

Covers the winding process and winding equipment by section, including the unwind, slitting, windup and discharge sections. Discusses important winding variables (TNT) and how they are controlled during winding.

Pulp Drying and Baling

Some pulp mills are not integrated with papermaking operations, so they produce market pulp and sell it to papermaking facilities. Market pulp is dried and then cut into sheets that are stacked into bales so they can be transported. Most market pulp is dried to about 10% moisture, but pulp that will only travel a short distance might be dried to about 50% moisture. The higher moisture pulp is known as "wetlap." Pulp drying machines are similar to paper machines and typically include the following processes: forming, pressing, drying, cutting, and baling. This module describes each of these processes in detail.

Roll Handling and Wrapping

The main goal of roll handling and wrapping systems is to protect newly-produced paper or board rolls from physical damage, moisture and foreign debris during handling, transport and storage. This is necessary because paper and board rolls may be handled multiple times in multiple ways, and stored in several locations in different environments, prior to use by the customer. This module will describe the steps of a typical roll wrapping system and describe the equipment used in the roll wrapping process.

Forming Fabric Design

Discusses forming fabric design and construction. Discusses how the fabric characteristics, including mesh, count, yarn diameter, surface topography, and air permeability, affect final sheet quality.

Forming Fabric Tensioning and Guiding

The forming section can contain one or more fabric loops, and each loop has its own set of support rolls and cleaning showers. The purpose of a forming fabric is to dewater and support the sheet as it forms, and carry the formed sheet to the next section of the paper machine. The purpose of the tensioning and guiding systems is to keep the fabric running at the proper tension and centered on the machine. This module will discuss the purpose and operation of forming fabric tensioning and guiding systems.

Fourdrinier Design and Operation

A Fourdrinier is a type of forming section or former on a paper or board machine. It serves three main functions: to drain and recover white water from the stock suspension to form a sheet, to deliver the formed sheet to the press section at the highest possible consistency, and to optimize sheet formation to create a strong, uniform, high quality sheet of paper or board. Knowing the design and principles of the Fourdrinier is essential to proper sheet formation.

Multi-ply Forming

Multi-ply forming was first introduced in 1830 when two cylinder formers were combined to produce a two-ply sheet. Equipment designs have changed over the years, however, the multiple cylinder former design is still in use. Multi-ply sheets can contain a different stock mixture in each layer, which has several potential benefits, including those related to fiber costs, machine speeds, and sheet properties. Therefore, multi-ply forming has expanded from mostly paperboard grades to tissue and other paper grades.

Paper Machine Twin-Wire Formers

A twin-wire former captures the stock jet in the converging nip formed between two fabric-covered rolls. These are also sometimes referred to as "gap" formers. There are four types of twin-wire formers - blade, roll, hybrid and roll/blade. Each has its own challenges and strengths. With twin-wire formers, it is especially important to define the desired sheet properties, and then work with equipment and fabric suppliers to configure, control and operate the design that is selected.

Sheet Formation

Formation is a property of the sheet that is based on the overall uniformity of the fiber distribution in the sheet. Sheet formation is important because it affects both the appearance and the performance of paper and board products. At the end of this module, you will be able to identify three mechanisms available to minimize flocculation and describe the differences between mechanical and chemical fibers related to fiber length, refining response and sheet strength.

Wet Edge Control

Deckles run along the wire edges adjacent to the headbox to keep the stock on the wire until it has dewatered sufficiently. Curling boards and water jet deckles can help minimize the formation of deckle wakes. Edge showers are used to keep the deckles, curling boards and wire edges clean and lubricated. Trim squirts are used to trim off the edges at the end of the former and establish the sheet width into the press section. They must all be installed and positioned properly to minimize wear and prevent edge profile and edge transfer issues. This module will describe the function and operation of each of these device.

Wet End Edge Trimming

At the beginning of the forming section of a paper or board machine, deckles and curling boards keep the stock on the wire until it has sufficiently dewatered and solidified. At the other end of the former, the trim squirts trim off the edges of the sheet before it transfers to the press section. This establishes the sheet width all the way to the reel. The deckles and trim squirts must be set up correctly, and the trim squirt nozzles and water supply system must be regularly monitored to ensure the cleanliness of the edge cuts and trouble-free sheet transfer into the press section.

Containerboard Customers' Needs

It’s easy to understand why people who work in sales or marketing need to pay attention to the customer, but why should someone who works at a manufacturing facility, far removed from the sales process, worry about them? The answer is this: your job depends on them. If the product you’re helping to produce doesn’t have enough customers, you won’t have a job for very much longer. This course is geared towards workers at sites that produce containerboard. It discusses how each operation, from the powerhouse to the pulp mill to the board machine, affects the final product and why all employees should care about customer satisfaction.

Instrumentation Calibration

Have you ever chased down an alarm only to find out the problem was with a probe, meter, or sensor? Have you ever reacted to a faulty reading and introduced a problem, and then had to deal with the consequences? False alarms, faulty readings, and misguided reactions (and their consequences) can often be avoided if instruments are calibrated properly at the needed intervals. You should always consider calibration when troubleshooting a high, low, or otherwise unusual process value. This course discusses the importance and benefits of regular instrument calibrations, including the risks and costs of not doing them.

Introduction to Paper and Board Machines

Paper can be defined as a flat, nonwoven network of cellulose fibers that are bonded together to form a sheet. In the papermaking process, the sheet is formed on a fine-mesh screen from a dilute suspension of fibers in water. This course covers the equipment and processes needed in order to create a fully formed sheet of paper. This includes the forming and press sections, together known as the "wet end" to the "dry end" of the machine where the paper is dried, calendered, and wound onto large rolls of paper called reels. This course also discusses the purpose of the white water and broke collection systems as well as different types of forming and dryer sections that are used in the papermaking process.

Paper Machine Doctor Blade Components and Troubleshooting

Doctors are used on paper and board machines to remove excess water and contaminants from roll and cylinder surfaces, and to remove the sheet from these surfaces during sheet breaks and threading. Doctors must be properly installed and maintained to ensure their continued safe and efficient operation. It is important to examine worn blades and document wear patterns, and work with doctor and blade manufacturers to identify problems and improve doctoring operations. This course lists the potential causes and possible remedies for some well-known blade wear patterns. It also lists the steps necessary to properly install a doctor. [Discussion Points] Do you record doctor wear on your machine? Do you have a documented procedure for doctor installation for your machine?

Paper Machine Doctors

Doctors are used in all sections of paper and board machines to remove excess water and contaminants from roll surfaces. In some applications, they are also used to remove the sheet from roll surfaces on sheet breaks or during sheet threading. Doctors must be checked and inspected on a regular basis to ensure their continued, safe, efficient operation.

Paper Machine General Safety

There are many hazards associated with paper making and converting facilities. Equipment and process hazards can be minimized by using safety guarding, personal protective equipment (PPE), safety training, and standardized procedures. Personal behavior also plays a major role in safety. This course details common hazards and hazardous situations in pulp and paper mills and describes methods for minimizing or avoiding these hazards to ensure safety in papermaking and converting facilities.

Paper Machine Vibration Monitoring

As paper and board machine speeds are continuously increased, vibration becomes more and more important. Vibration analysis is used to prevent unscheduled downtime and reduce production costs by detecting problems long before complete failure occurs. Vibration can be measured periodically or continuously with sensors. Spectrum analysis provides a method to isolate the impact of specific defects, which is important on paper and board machines, where there are a lot of interconnected parts. This course will discuss common causes of vibration and vibration monitoring methods for paper machines.

Pulping and Papermaking Overview

Brief history of papermaking and discussion on types of fibers used in the production of paper products. Discusses mechanical, chemical, and semichemical pulping. Also describes several pulp processing operations, including bleaching, and ends with a description of the various sections of a paper machine, including the forming section, press section, dryer section, and reel.

Steam Theory Fundamentals

Steam is generated by adding enough heat energy to water to change it from a liquid to a gas phase. Latent heat is the heat energy required to accomplish this phase change. The latent heat in the steam can then be used to transfer heat to lower temperature surfaces. When saturated steam gives up its heat, it changes into liquid water called condensate that is at the same temperature as the steam. This module lists safety guidelines for steam generation and distribution systems, describes how steam can be used to transfer heat, and describes the relationship between steam pressure and saturated steam temperature.

Air-Padded Headboxes

An air-padded headbox is a piece of equipment that is designed to deliver a constant, uniform flow of stock to the Fourdrinier wire at the desired speed and location. The headbox has several design elements, including a perforated plate or tube bank and rotating rectifier rolls, that are designed to create and maintain turbulence to keep the fibers dispersed up to the slice opening. This is important because the design and operation of the headbox are critical to the quality of the sheet produced on the paper machine.

Hydraulic Headboxes - Multi-Layer Headboxes

Describes the advantages of a multi-layer hydraulic headbox. Describes major components, and how they all work together to fulfill the headbox objectives. Includes stock inlet headers, dilution profiling systems, recirculation lines and valves, turbulence-inducing elements, slice opening, and various stock jet adjustment mechanisms. Also includes some protection and care guidelines for the headbox and forming fabrics.

Hydraulic Headboxes - Stock Jet Geometry for Fourdriniers

A hydraulic headbox is designed to deliver a uniform, low consistency stock stream to the Fourdrinier wire. It is important to monitor the geometry of the stock jet because it greatly impacts the appearance and performance of the sheet. Only by understanding the variables that affect the stock jet, and how the jet geometry affects sheet properties, can one begin to make adjustments to the headbox to optimize sheet quality.

Hydraulic Headboxes - Stock Jet Geometry for Roll Type Gap Formers

Describes the critical features of the stock jet geometry for a hydraulic headbox installed on a twin-wire paper machine. Discusses the importance of sheet formation and describes the stock jet geometries that affect formation and other sheet properties. Covers some common headbox adjustments and other settings that can affect the stock jet geometry.

Palletizing

"Palletizing" is the process of arranging and stacking products onto pallets in preparation for bulk shipping. While palletizing can be done manually, this task is often performed by a machine called a "palletizer." This module describes the basic steps in the palletizing process and the functions of common palletizing and wrapping equipment.

Paper Ream Packing

Paper is a major commodity used all across the world for many different products. One important use for paper is the creation of copy paper and digital printing paper. These paper products are created from large parent rolls of paper that are slitted, cut, stacked, and wrapped. The wrapped bundles of sheets of paper are called "reams." This module will provide an overview of the process for grouping wrapped reams and preparing them for shipping.

Sheeting of Paper

Paper is a major commodity used all across the world for many different products. Two important types of paper products are copy paper and digital printing paper. These paper products are created from large parent rolls of paper that are slitted, cut, stacked, and wrapped. This module will provide an overview of the process for sheeting and forming reams of paper.

Medium Consistency (MC) Pumps

Medium consistency (MC) pumps are commonly used in pulp mills, bleach plants, and secondary fiber operations. They can also be found in sugar beet processing plants and other industrial operations that deal with wet pulp suspensions and viscous (thick) liquids.\nThis course covers MC pumping challenges, common MC pump designs and applications, and best practices for maintaining and troubleshooting MC pumps.

Paper Machine Adjustable Drives

Sectional drive technology has evolved over the years and advancements in drive and motor designs are continuously being made. Innovations have allowed for increasingly higher machine speeds and production rates. Yet, for all of the advancements in technology, the purpose of sectional drive systems remains the same. That is to give the papermaker a means of controlling the speed and tension of the paper web as it is transferred from one section to another. AC sectional drives are most common on newer machines because of the durability, energy efficiency and affordability of AC motors. This module covers the purpose, types, and operation of paper machine adjustable drives.

Paper Machine Hydraulic Systems

The main reason why hydraulic systems are used in industrial settings is that they can deliver a great deal of force to multiple locations in a simple and controllable manner. On a paper or board machine, one or more hydraulic systems are typically used to provide a continuous source of clean pressurized oil to hydraulically-actuated equipment. This module describes the components and functions of a typical paper or board machine hydraulic system.

Paper Machine Line Shaft Drives

Line shaft technology dates back to the 18th century and was literally the driving force behind the Industrial Revolution of the 19th century. Line shafts are still in use on many older paper and board machines. This course discusses the design and function of common line shafts used in the papermaking industry along with maintenance and safety guidelines.

Paper Machine Liquid-Ring Vacuum Pump Troubleshooting

Liquid-ring vacuum pumps can perform several different functions in the papermaking process, including: dewater the stock as the sheet forms in the forming section, dewater and clean the press felts in the press section, and transfer all or part of the sheet in multiple locations. Vacuum systems that use liquid-ring vacuum pumps are reliable, but problems can occur. Routine maintenance, regular observations, and system checks can help prevent these problems from impacting production. The vacuum provided by liquid-ring vacuum pumps is vital to paper machine operations, which is why it is so important to take action to get vacuum systems back to their desired state when an issue develops. This course describes some of the more common issues and their causes, and describes some best practices for troubleshooting vacuum pump systems.

Paper Machine Lubrication Systems

The main function of lubricants is to keep moving metal surfaces separate in order to reduce friction. On paper and board machines, lubricants are used to reduce friction, wear, and heat in bearings, gears, and drive couplings. Common lubrication points include roll bearings, dryer gears, drive gearboxes and couplings, pump bearings, fan and blower bearings, and agitator bearings. This course describes the main functions of lubricants, safety hazards and safety guidelines for lubrication systems, advantages of grease lubricants, components of and flows in circulating lube oil systems, and the importance of lube oil conditioning and monitoring.

Paper Machine Sheet Threading Troubleshooting

Each time a paper or board machine is started up after a shutdown, and following wet end sheet breaks, it is necessary to rethread the sheet from the forming section to the reel. After dry end sheet breaks, the sheet must be re-threaded to the reel. Sheet threading is typically accomplished by threading a “tail” (a narrow section of the sheet) along the front or tending side, and then widening the tail out to the full sheet. In many cases, this is done twice – the “wet end tail” is used to thread the machine to the end of the dryers, and a second “dry end tail” is used to thread the sheet to the reel. The goal of all threading systems is the same, to thread the machine quickly with minimal operator involvement. Quick and efficient sheet threading helps maximize production and minimizes the creation of broke, which is why it is so important to take action to keep threading equipment functioning well at all times. This course describes some of the more common sheet threading issues and their causes, and provides some practical solutions and troubleshooting best practices.

Paper Machine Vacuum Systems

Vacuum systems on paper and board machines dewater the stock as the sheet forms, dewater and clean the press felts, which, in turn, remove water from the sheet, and helps transfer the sheet between sections of the machine. This module describes the main functions of vacuum systems on paper and board machines, the safety hazards and safety guidelines associated with vacuum systems, and the equipment that can be used to produce vacuum.

Steam Theory for Paper Machines

How steam is created, how heat energy is transferred from the steam to the sheet on a paper machine, and the relationship between steam pressure and steam temperature. Discusses latent heat, condensate, and superheat.

Vacuum Pumps, Blowers, and Ejectors

Liquid-ring vacuum pumps, centrifugal blowers, and steam ejectors are three devices that are commonly used to produce vacuum. This module explains how liquid-ring vacuum pumps create vacuum, explains why vacuum pump seal water should be cool, and describes the operation of liquid-ring vacuum pumps, single-stage and multi-stage centrifugal blowers, and steam ejectors.

Wet End Showers

Various types of showers are installed around the wet ends of paper and board machines to keep the fabrics and other surfaces clean and lubricated. Wet end shower systems should be monitored and maintained on a regular basis to ensure their optimal performance. This module will give you a better understanding of wet end showers and how they function in paper machines.

Dryer Felt Design

On conventional paper and board machines, the energy required to dry the sheet to the desired moisture target at the reel is supplied by a series of rotating steam-heated dryer cylinders or cans that are grouped together into drive sections. Each drive section is equipped with one or two dryer felts to hold the sheet tightly against the heated dryer cans. This improves heat transfer to maximize drying, and also helps control cross-machine direction shrinkage and other sheet distortions. On many machines, dryer felts also drive some of the cans. This course covers the design and construction of dryer felts.

Dryer Felt System Operations

On conventional paper and board machines, the energy required to dry the sheet to the desired moisture target at the reel is supplied by a series of rotating steam-heated dryer cylinders or cans that are grouped together into drive sections. Each drive section is equipped with one or two dryer felts to hold the sheet tightly against the heated dryer cans. This improves heat transfer to maximize drying, and also helps control cross-machine direction shrinkage and other sheet distortions. This course discusses the importance of dryer felts, how they operate, typical installation steps, felt guiding components, and the safety hazards that are present around dryer felt systems.

Paper Machine Alternative Drying Systems

On most conventional paper and board machines, the energy required to dry the sheet to the desired moisture target at the reel is supplied by a series of rotating steam-heated dryer cylinders or cans. This module briefly covers the principles behind this system of drying. It will discusses applications where this system is not the best choice, and where alternative drying techniques can be used. These alternatives include: Yankee drying, through-air drying, infrared drying, impulse drying, and air impingement drying.

Paper Machine Cascade Steam Systems

Paper and board machines use steam-heated dryer cylinders to dry the sheet to its final moisture target. In a cascade steam system, fresh steam is typically introduced to the main steam group and then it is cascaded upstream to the intermediate and wet end steam groups. This arrangement automatically stair steps steam pressures (and steam temperatures) upwards as the sheet travels through the dryer section and moisture becomes harder to remove. This module describes the steam and condensate flows and controls for cascade steam systems. It also discusses their advantages, limitations, and safety hazards and guidelines.

Paper Machine Dryer Hood Air Systems

Paper and board machine dryer hood air systems have two main goals: remove the water vapor evaporated from the sheet in the dryer section and control the temperatures, humidities, and air flows in the dryer pockets across the full machine width. A properly designed and operated hood air system will increase the drying capacity of the machine, improve the reel moisture profile, reduce steam requirements, and improve the runnability of the dryer section. This module will cover the components and operation of paper machine dryer hood air systems.

Paper Machine Drying

On conventional paper and board machines, the energy required to dry the sheet to the desired moisture target at the reel is supplied by a series of rotating, steam-heated, dryer cylinders. These cylinders, or "cans," are grouped into multiple drive sections, which go progressively faster in order to adjust for machine direction stretch and to maintain sheet tension. This module will provide a general overview of the drying section of a paper machine.

Paper Machine Thermocompressor Steam Systems

Paper and board machines use steam-heated dryer cylinders and multiple steam groups to dry the sheet to its final moisture target. In a thermocompressor steam system, each steam group has a thermocompressor that uses high pressure motive steam to pull flash and blow-through steam from the section condensate tank and boost it to a more useful pressure. This steam is supplied to the section steam header where makeup steam is added to control the steam pressure going to the cans. This module will cover the components and operation of a thermocompressor steam system.

Size Presses

Surface sizing is commonly used on grades of paper and board that will be coated and/or printed. The traditional purposes of surface sizing have been to improve the sheet’s resistance to the penetration of fluids and to improve certain sheet properties. Traditionally, a starch-based sizing solution is applied to both sides of a fully dried sheet in a two-roll nip at a "size press" that is located between drying sections. This course discusses the design and functions of a size press.

CD Profile Control

QCS scanners are used to monitor key sheet properties at one or more locations on modern paper and board machines, and report average values, standard deviations, and MD and CD profiles. The CD profile data can be used to make automatic or manual adjustments at one or more profiling systems. Because sheet properties can be affected by more than one profiling system, profiling actuator adjustments can affect multiple sheet properties, and sheet shrinkage and sheet wander occur, it can be challenging to coordinate CD profiling efforts. [course outline] QCS Reel Scanners Scanner Sensors Benefits of CD Profile Control 1 of 2 Benefits of CD Profile Control 2 of 2 MD vs CD Variation Safety Guidelines 1 of 2 Safety Guidelines 2 of 2 QCS Scanner Locations Fabric Profiles Profiling Actuator Locations Headbox S

Common Physical Tests for Paper and Board

Depending on the grade and end use, different tests are performed to assess the quality of the paper or board being produced on a machine. Physical tests assess physical properties of the sheet, such as density, thickness, and different kinds of strength. Common physical tests include basis weight or grammage, moisture content, caliper, density, bulk, smoothness, porosity, stiffness, tensile strength, burst strength, tear strength, and folding endurance. This module will introduce some common physical tests, followed by a discussion on the importance of sample collection and conditioning, sheet formation, and moisture content.

Paper and Board Optical Tests

Paper and board products are widely used in our daily lives. Sheet characteristics can fall into one or more of the following categories: physical, optical, electrical, thermal, structural, and surface. Different tests have been developed by various organizations to quantify and help predict how a sheet of paper or board will perform during converting and finishing processes, and in its end use. This module will discuss the tests that are commonly used to assess the optical properties of paper and board sheets.

Paper and Board Strength Tests

Paper and board products are widely used in our daily lives. Sheet strength is critical to the performance of most grades, not only in their end uses, but also in converting and finishing operations. Because different paper and board grades are subjected to different stresses and strains, several different strength tests have been developed. The most common are tensile, burst, stiffness, tear, internal bond, and ring crush. This module will discuss common strength tests for paper and board grades, as well as sheet parameters that affect strength properties.

Papermaking Process Testing

Several characteristics of stock and water flows to and around a paper or board machine are often monitored and/or controlled. This module will cover pH, consistency, temperature, fiber size distribution, freeness, and charge demand testing.

Centrifugal Cleaner Troubleshooting

Centrifugal cleaners are widely used in the pulp and paper industry to remove contaminants from pulp fiber suspensions based on density differences. They can remove everything from nails, staples, and pieces of glass, to sand and grit, to lightweight plastics and adhesives . Besides improving the appearance and strength of the final product, cleaners protect downstream equipment from damage and wear. The setup and design of each cleaning system are based on the nature and concentration of the contaminants targeted for removal, characteristics of the pulp fiber suspension, and end product requirements. In some cases, a single large cleaner or set of cleaners can perform the job. In others, multiple banks of cleaners arranged in three or more stages are required. Centrifugal cleaner operations affect downstream equipment reliability, machine runnability, and product quality, which is why it is so important to take action to get cleaner systems back into their desired state when an issue develops. This course covers the key operating variables for centrifugal cleaners, common issues, possible causes and corrections for those issues, and best practices for troubleshooting centrifugal cleaners.

Centrifugal Cleaners

Purpose, design, and operation of centrifugal cleaners installed in paper machine thin stock systems. Effect of pressure drop, feed consistency, and reject rate on cleaner efficiency is covered, followed by a discussion of cascade cleaner systems.

Pressure Screen Troubleshooting

Pressure screens are used in pulping, recycling, and papermaking operations to remove oversized contaminants from pulp stock and whitewater flows. They can remove everything from knots and shives, to glass and plastic bits, to clumps of adhesive, often called “stickies.” Pressure screens can also help “defloc” or break up clumps of fibers, straighten and comb them out, and keep them dispersed as separate, individual fibers. The flow rate and consistency of the incoming stock, characteristics and concentration of the contaminants targeted for removal, and end product requirements all affect the design of a screening system. In some cases, a single screen can perform the job. In others, multiple screens set up in two or more stages are required. Pressure screen operations affect downstream equipment reliability, machine runnability, and product quality, which is why it is so important to take action to get screens back into their desired state when an issue develops. This course covers the key operating variables for pressure screens, common issues, possible causes and corrections for those issues, and best practices for troubleshooting pressure screens.

Pressure Screens

Pressure screens are used primarily to separate unwanted debris or contaminants from the desirable fibers in papermaking pulp. This is accomplished by flowing a pulp slurry over a surface that has many small holes or slots in it. Most of the small flexible fibers pass through the openings, and are accepted, and the larger particles which cannot pass through the openings are held back, or rejected. A typical pressure screen consists of a vertical cylindrical housing that contains a perforated cylindrical screen basket. Within the basket is a spinning rotor which supports foils or protrusions that run close to the surface of screen. Screen performance is quantified by looking at such factors as the reject rate, debris removal efficiency, and long fiber reject rate. [course outline] Pressure Screen Internal Construction Pressure Screen Baskets Pressure Screen Rotors Screening Theory 1 of 2 Screening Theory 2 of 2 Screen Performance 1 of 2 Screen Performance 2 of 2 Multiple Stage Screening Systems Pressure Screen Control Pressure Scre

Stock Approach - Deaeration

Entrained air in the dilute stock supplied to the headbox of a paper or board machine can cause problems with drainage, foam, sheet formation, and overall process stability. Therefore, mechanical deaeration is sometimes required. This module will identify four ways to keep entrained air out of paper and board making processes and describe the three ways mechanical deaerators remove air from stock.

Thin Stock Screening

The purpose of thin stock screening is to remove debris from the dilute stock going to the headbox. Screening also deflocculates the stock and protects downstream equipment. Screening systems often use two or three "cascaded" stages in order to reduce fiber losses and improve overall debris removal efficiency. The design and operation of a screening system must take into account the requirements of the paper or board machine, desired sheet quality and properties, and characteristics of the particles to be removed.

Thin Stock System Design

The thin stock system is responsible for supplying clean, dilute stock to the headbox of a paper or board machine. The thin stock system uses white water to dilute the stock to the proper consistency for cleaning, screening, and delivery to the headbox. This module will list the objectives of a thin stock system and identify how each objective is satisfied.

High Consistency Refining

Refining is the mechanical treatment of pulp fibers to develop paper and board sheet properties. The two main types of refining are low consistency refining and high consistency refining. This module will examine the design and operation of high consistency refining systems.

High Density Cleaners

High density (or HD) cleaners are large diameter forward cleaners capable of processing several hundred tons of fiber per day. The main purpose of high density cleaners is to separate heavy contaminants from fibers in suspensions of fibers in water (often referred to as "stock"). This protects downstream equipment from excessive wear and damage. They may also be used for fiber recovery. This module will describe the operation of high density cleaners and identify typical applications of high density cleaners in secondary fiber, pulp mill, stock preparation, and broke systems.

Paper Machine Refining

Refining is one of the critical process steps in engineering the structure of paper and board as it has a major influence on fiber quality. Refining mechanically alters the fibers by brushing, hydrating, and cutting them. This course will describe low consistency refining as well as refining actions as they relate to double disc refiners. It also discusses the different refiner types, key components of a double disc refiner, typical control strategies, and the effects of refining on sheet properties.

pH and Consistency Control for Paper Machine Stock

The main goal of a paper or board machine stock system is to consistently supply the desired mixture of fibers, fillers, chemicals, and water to the paper or board making process. As part of this goal, it is important to control two stock variables - pH and consistency. If either of these variables is outside its desired range, the sheet produced will not meet product specifications. Having good control of stock pH and consistency helps to produce the same quality sheet, day in and day out.

Thick Stock System Design

The thick stock system is where the papermaking process begins. In this system, pulp fibers are blended together, refined, diluted, metered, and some additives may be added. This course discusses the principles of the thick stock system as well as the key equipment used, how stock blending is achieved, as well as how high density chests and stock thickeners work.

Clamp Trucks - Preventing Paper Roll Damage

A roll clamp truck is similar to a forklift, but instead of forks, it has a special hydraulic clamp attachment for handling rolls of paper. Clamp trucks are essential for moving large paper rolls throughout the supply chain. From the time a roll of paper comes off the winder to when it is delivered to the converting equipment, which is often in a separate facility, a single roll can be handled as many as 15 times. Each time the roll is touched, there is an opportunity for damage to occur, so it is important to use the right clamp truck and follow proper handling procedures to prevent damage.

Product Storage and Tracking

Storing and tracking products are critical steps in the order fulfillment process. Finished products are typically stored in warehouses or distribution centers before being shipped in large volumes for commercial customer orders or individually for end user orders. Products that move through the warehouse should be handled carefully to avoid injuries and maintain product quality.

Railcar Loading - Corrugated Paper Rolls

Every day, thousands of paper rolls are shipped around the country by commercial trucks or railcars from paper facilities to be used in a variety of paper-related products. This course will cover the standard procedures, techniques and safety practices associated with loading paper rolls into railcars.

Roll Storage and Tracking

Rolls of paper or board are typically produced to meet order specifications for shipment to commercial customers. Storing and tracking rolls are critical steps in the process of fulfilling these production orders. At the end of this module, you will be able to describe the basic steps of receiving, storing, and loading a roll for shipment.

Truck Trailer Loading - Corrugated Paper Rolls

Every day, thousands of paper rolls are shipped around the country from paper facilities to be used in a variety of paper-related products. These rolls are commonly delivered by commercial trucks or railcars. This course will cover the standard procedures associated with loading paper rolls into truck trailers in order to become familiar with day-to-day operations as well as to comply with common regulations.

Cooling and Chilled Water Systems

When equipment runs, it generates heat. Overheating can lead to equipment malfunctions and possible downtime. In order to prevent this, cooling and chilled water systems are set up to continually remove heat from the components to keep them within a desired temperature range. This course describes the design of cooling and chilled water systems as well as the principles of operation for both chilled and cooling water systems.

Fresh Water Systems

Water is used in virtually every step of the pulping and papermaking process. It is used for cooking, bleaching, washing and fiber transport. It is used for steam creation and cooling. This module covers the major sources of mill raw water, the contaminants commonly found in raw water, as well as raw water testing and treatment.

Paper Machine Seal Water Systems

Seal water systems used on paper and board machines are used to cool and lubricate key equipment, create seals, and increase the efficiency and operation of key equipment. This course discusses the typical equipment used in seal water systems, as well as safety guidelines and hazards around seal water systems.

Felt Cleaning and Conditioning

Felt cleaning and conditioning systems use mechanical and chemical means to keep press felts clean and open during press operation. Showers and uhle boxes are positioned in the felt runs to remove contaminants from and dewater the felts. This helps maintain the dewatering capacity of the felts, and improves the overall cleanliness and runnability of the press section. This module will discuss the cleaning and conditioning equipment used on a paper or board machine.

Felt Tensioning and Guiding

The felt guiding system is responsible for keeping the press felt centered on the rolls in its felt run. The felt tensioning system is responsible for maintaining a constant, uniform tension in the felt. This module will provide you with a better understanding of how felt tensioning and guiding systems are operated and their value to an effective wet pressing operation.

Paper Machine Suction Rolls and Roll Covers

Though their design and construction are very similar, suction rolls perform several different functions on paper machines, depending on their position. They can be used to remove water from the sheet, transfer the sheet, improve dewatering in a press nip, dewater a felt, stabilize the sheet, or pull steam into the sheet. Roll cover selection should take into account the functions of the roll and the operating conditions.

Roll Presses

Roll presses are often used on paper and board machines to mechanically remove water from the sheet. They also consolidate and flatten the sheet, increase wet sheet strength, and improve final sheet strength characteristics. This module will give you a better understanding of roll presses and how they function in press sections of paper machines.

Shoe Presses

Shoe presses are used in the production of many different grades of paper and board. They differ from conventional roll presses in that they offer a significantly longer nip width and dwell time. Shoe presses offer many different benefits, including higher dryness to the dryer section, improved bonding and sheet strength properties, and increased bulk. Understanding the design and operation of shoe presses will help with day-to-day operations and troubleshooting.

Wet End Steam Boxes

On a paper machine, the sheet dryness after pressing is important because it is more economical to remove water by mechanical means at the wet end than by evaporation in the dryer section. One way to increase after-press dryness is to increase the temperature of the sheet when it is pressed. Increasing the sheet temperature reduces the viscosity and surface tension of the water contained in the sheet. This reduced viscosity makes it easier for the water to travel out of the sheet, which increases the dewatering capacity of the press. A common way to raise the sheet temperature is to apply steam with a steam box on the wet end of the paper machine.

Wet Pressing Theory

This module begins with a description of the objectives of the wet pressing process on a paper machine. Then, it discusses how water is removed from the sheet in press roll nips. It explains the purpose of a wet felt in wet pressing and how wet felts are designed. This module will give you a better understanding of how water is removed from the sheet during the wet pressing process.

DAF System Chemicals and Chemistry

Dissolved air flotation (DAF) is a water treatment process that removes suspended solids from fresh water, process water, or wastewater. Coagulant and flocculant chemicals can be added to the feed water to aggregate and join together the small solid particles to form larger flocs or bundles and improve solids removal. This training module describes how these chemicals work in the DAF process.

Dissolved Air Flotation (DAF) Systems

Dissolved air flotation (DAF) is a water treatment process that removes suspended solids from water using air. This separation is achieved by dissolving air into water under pressure, and then releasing the air at atmospheric pressure in a flotation tank. This module will describe common applications of the dissolved air flotation (DAF) process and the main steps of the DAF process.

Strainers and Filters

Strainers and filters are devices that mechanically remove solids from flowing fluids. Strainers are often employed in pipelines to protect downstream equipment, such as heat exchangers, pumps, compressors, flowmeters, spray nozzles, turbines, and steam traps, from the detrimental effects of sediment, rust, pipe scale, and other extraneous debris. This module will list the functions of strainers and filters and describe Y strainers and duplex, twin, back-flushing, automatic self-cleaning, and scraper basket strainers as well as surface and depth type filters.

White Water Circulation Loops

The collection and reuse of white water in paper and board making processes reduces fresh water usage, sewer losses and loads, and energy usage. The primary white water circulation loop, or short circulation loop, quickly returns white water removed from the stock on the former to the thin stock system and headbox. The secondary white water loop, or long circulation loop, collects the excess white water, clarifies it, and supplies dilution, shower, and make-down water back to the process. This module will identify and describe the components and main functions of the primary and secondary white water circulation loops.

White Water Clarification

White water clarification refers to the removal of fiber fines and other solids from paper or board machine white water. The clarified white water can then be reused for showers, stock dilution, and make down of certain chemicals. This module will list the purposes of white water clarification and describe the operation of disc filters, rotary drum filters, and DAF systems.

White Water System Design

The purpose of a white water system is to collect and reuse as much white water as possible, in order to minimize fresh water usage and effluent losses. At the end of this module, you will be able to identify the three main objectives of a white water system, identify major components of the short and long white water circulation loops, and identify the purpose or function of each major white water system component.

Full Library Course List

Chemical Additives

Dry End Equipment

General Papermaking

Paper Converting

Paper Machine Auxiliary Systems

Paper Machine Dryers

Paper Properties and Testing

Stock Preparation

Storage and Shipping

White Water and Filtrate Systems

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