Supercalender Performance Improvement
by Process Optimization
By:
D K Singhal

M S Gaur

Chandpur Enterprises Ltd.,
Sargam...
Conventional Supercalender
 Type: Typical 12 roll Supercalender
 Make: ECK Haubold
 Unwind: Single flat disc water cool...
Upgrades During Installation
 All chilled rolls were hard chrome plated and
superfinished.
 Hard chrome plating:




...
Upgrades During Installation
 Installation of hydraulic
accumulator.
 Hydraulic Accumulator:







Basically a pre...
Chilled Roll Superfinishing
 Done by Modinagar Rolls Ltd., by their
specially developed method (Mod-Finish) for
hard chro...
Initial Problems
 Low speed: 60-70mpm
 Low production capacity
 Frequent joints
 Unstable gloss
 Time consuming reel ...
Installation of Proximity Sensor
 A proximity sensor was mounted on to the
shaft of a paper roll near key
 The reset but...
Installation of Proximity Sensor
 A healthy competition started between
operators
 Within a few of weeks, production inc...
On-machine Gloss Indication
 Variation in gloss in machine direction.
 Inconsistent nip loading.
 Analog pressure gauge...
Lighting System Improvement
 Tubelights were fitted
 Operators can see the reflection
 Visual information about the
glo...
Unwind
 Original: Disk brake, water cooled.
 Larger brake area, low air pressure for
braking, poor control.
 Poor respo...
Unwind Modification
 Disk brake was replaced with a
locally fabricated drum brake.
 Optimized diameter pneumatic
cylinde...
Winder
 Original Winder





Center winder
Dyno-drive based tension control
Paper slippage between layers
Poor windi...
Winder Modification
 Modified Winder





Surface winder
Gear coupled DC Motor
DC motor was replaced by AC motor lat...
Winder Modification
 Results:





Excellent winding
No joints at winder
Uniform tension profile
Reduced side triming...
Removal of Paper Rolls
 Normal Operation Schematic



Paper rolls used for web cooling
Soft rolls life improvement

 P...
Removal of Paper Rolls
 Advantages:





Reduced reel changing time
Reduced tail feeding time
Reduced tail feeding lo...
Soft Roll Performance
 Problems:






Frequent failures immediately after a startup.
Roll slicing ►Roll became unus...
Improving in Soft Roll Performance
 Warming up before startup
 Installation of in-house grinder
 Uni-run operation
 Fr...
Roll Material
Feature

Paper Rolls

Glosvax (Cotton)
Rolls

Effect

Composition

Cotton / Wool / Linen

Cotton + Wool

Pro...
Installation of In-house Grinder
 Roll grinding done at a local
workshop.
 Grinding cost- not a big
issue.
 Transit in ...
Slicing
 Cotton rolls rotation in
clockwise or
anticlockwise possible.
 In case roll position
change, sometimes
directio...
Uni-run Operation
 To avoid slicing, rolls
were marked for Unirun operation.
 Slicing problem
eliminated.
Roll Cotton Behaviour
 Cotton:









Absorbs moisture in high humidity environment and vice
versa.
Around roll ar...
Frequent Sponge Humidification
 Frequent wetting the roll surface, particularly
in the dry weather (RH< 50%) helps a lot ...
Frequent Sponge Humidification
 Initial trials of sponge humidification used
water along with detergents e.g. Nirma,
Whee...
Frequent Sponge Humidification
 Advantages:





Grinding to grinding span improved.
CD caliper variation reduced sig...
Localized Roll Burn Out
 More roll failures
during dry weather
rather than during
summer.
 Often, such failures
required...
Climatic Improvements
 Sponge humidification is good technique,
but, it needs loss of production for 4-5
minutes after sa...
Climatic Improvements
 Use of air cooler was planned.
 Three coolers were installed at one side of
supercalendar.
 Obje...
Climatic Improvements
 Definite advantages were observed.
 Over a period of 4 months, there were at
least 6 incidences w...
Overall Results









Better runnability
Better reel winding
Reduced trim losses
Reduced joints
Reduced gloss v...
Overall Results
 And of course-

 Happier Customers…..!
 Happier Operators……!!
 Happier Mill………….!!!
Thank You.
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Supercalender Performance Improvement for coating machine

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How to improve supercalendar performance, and get better cotton roll life

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Supercalender Performance Improvement for coating machine

  1. 1. Supercalender Performance Improvement by Process Optimization By: D K Singhal M S Gaur Chandpur Enterprises Ltd., Sargam Theatre, Chandpur-246725 Dist. Bijnor, (U.P.), INDIA deveshksinghal@gmail.com Techaids D-121-122, Industrial Area Phase VII, Mohali, Chandigarh-160055 m_s_gaur@yahoo.co.in
  2. 2. Conventional Supercalender  Type: Typical 12 roll Supercalender  Make: ECK Haubold  Unwind: Single flat disc water cooled  11 intermediate paper rolls  Dyno-drive center winder
  3. 3. Upgrades During Installation  All chilled rolls were hard chrome plated and superfinished.  Hard chrome plating:      No specific benefit in terms of roll hardness Chemical properties of surface greatly altered No development of a thin layer of corrosion products on roll surface No corrosion during a shut for a couple of days Better surface finish possible after hard chrome plating.
  4. 4. Upgrades During Installation  Installation of hydraulic accumulator.  Hydraulic Accumulator:      Basically a pressurized variable volume storage device Stores hydraulic oil at desired pressure Reduced electricity consumption Low hydraulic oil temperature Better hydraulic cylinder life
  5. 5. Chilled Roll Superfinishing  Done by Modinagar Rolls Ltd., by their specially developed method (Mod-Finish) for hard chrome rolls.  Surface smoothness achieved: approx. 0.25Ra.
  6. 6. Initial Problems  Low speed: 60-70mpm  Low production capacity  Frequent joints  Unstable gloss  Time consuming reel change  Time consuming tail feeding
  7. 7. Installation of Proximity Sensor  A proximity sensor was mounted on to the shaft of a paper roll near key  The reset button of the counter was deactivated.  The difference between shift readings indicated roll revolutions  More difference ≈ More paper length
  8. 8. Installation of Proximity Sensor  A healthy competition started between operators  Within a few of weeks, production increased by 2.5 times * This technique works well if the operators are too cautious to speedup the machine.
  9. 9. On-machine Gloss Indication  Variation in gloss in machine direction.  Inconsistent nip loading.  Analog pressure gauges difficult to read accurately  Due to manual control of loading.  It takes time to draw a sample and check for gloss.
  10. 10. Lighting System Improvement  Tubelights were fitted  Operators can see the reflection  Visual information about the gloss.
  11. 11. Unwind  Original: Disk brake, water cooled.  Larger brake area, low air pressure for braking, poor control.  Poor response at low speeds, particularly at startup.
  12. 12. Unwind Modification  Disk brake was replaced with a locally fabricated drum brake.  Optimized diameter pneumatic cylinder for better breaking control.
  13. 13. Winder  Original Winder     Center winder Dyno-drive based tension control Paper slippage between layers Poor winding Frequent breaks
  14. 14. Winder Modification  Modified Winder     Surface winder Gear coupled DC Motor DC motor was replaced by AC motor later on. Gear box was replaced by V-Belt drive Main calender drive and pope reel drive synchronized.
  15. 15. Winder Modification  Results:     Excellent winding No joints at winder Uniform tension profile Reduced side trimings
  16. 16. Removal of Paper Rolls  Normal Operation Schematic   Paper rolls used for web cooling Soft rolls life improvement  Problems Faced:    Time consuming reel change Time consuming tail feeding Increased tail feeding losses
  17. 17. Removal of Paper Rolls  Advantages:     Reduced reel changing time Reduced tail feeding time Reduced tail feeding losses Improved runnability
  18. 18. Soft Roll Performance  Problems:      Frequent failures immediately after a startup. Roll slicing ►Roll became unusable Often a deep cut desirable. Roll life was very low. Uneven nip profile.
  19. 19. Improving in Soft Roll Performance  Warming up before startup  Installation of in-house grinder  Uni-run operation  Frequent sponge humidification  Climatic improvements
  20. 20. Roll Material Feature Paper Rolls Glosvax (Cotton) Rolls Effect Composition Cotton / Wool / Linen Cotton + Wool Process Die Cutting / Pressing Carding / Caking Better interlocking and hence low possibility of slicing. Assembly Fast Pressing Slow Pressing Better interlocking and hence low possibility of slicing. Finishing Turning / Grinding Turning / Polishing Better surface of roll and hence better gloss. Hardness 80-92 Shore D 72-82 Shore D Increased nip width resulting in better results even at high speed operation. Flexibility Low High Better resistance to score marks Mark Resistance Moderate / Low Excellent / Moderate Frequent grinding is avoided. Cut Depth Low Depth Deep Cut Grinding time is reduced significantly. Grinding Frequency Very High Moderate / Low Lesser downtime for fewer roll changes. Costing Moderate Economical
  21. 21. Installation of In-house Grinder  Roll grinding done at a local workshop.  Grinding cost- not a big issue.  Transit in tractor trolley, prone to roll damage.  A new grinder (double chuck type) was purchased & installed.  Quality of grinding was also improved significantly.
  22. 22. Slicing  Cotton rolls rotation in clockwise or anticlockwise possible.  In case roll position change, sometimes direction of rotation reverses.  Reverse rotation ►Slicing.
  23. 23. Uni-run Operation  To avoid slicing, rolls were marked for Unirun operation.  Slicing problem eliminated.
  24. 24. Roll Cotton Behaviour  Cotton:      Absorbs moisture in high humidity environment and vice versa. Around roll area, temperature is higher, and so relative humidity is lower. So, cotton rolls tend to release moisture during operation. Deterioration of cotton rolls speeds up if the moisture is lower than a critical level. This results in roll failure (burn out).
  25. 25. Frequent Sponge Humidification  Frequent wetting the roll surface, particularly in the dry weather (RH< 50%) helps a lot by     Maintaining desired moisture in the roll cotton. Lowering down the temperature of roll. Improving the flexibility of roll, thus better nip. Reduced CD caliper variation. Increase roll life between grindings.
  26. 26. Frequent Sponge Humidification  Initial trials of sponge humidification used water along with detergents e.g. Nirma, Wheel, Ezee and shampoos like sunsilk etc.  Use of Techzyme was found very useful.
  27. 27. Frequent Sponge Humidification  Advantages:     Grinding to grinding span improved. CD caliper variation reduced significantly. Much better reel winding. Improvement in roll life.
  28. 28. Localized Roll Burn Out  More roll failures during dry weather rather than during summer.  Often, such failures required deep cuts.
  29. 29. Climatic Improvements  Sponge humidification is good technique, but, it needs loss of production for 4-5 minutes after say every reel.  Sometimes, operators may tend to skip it a couple of times.  So, we needed to have a better solution.
  30. 30. Climatic Improvements  Use of air cooler was planned.  Three coolers were installed at one side of supercalendar.  Objects were   To increase the humidity. To reduce the climatic temperature. To reduce the dependency on sponge humidification.
  31. 31. Climatic Improvements  Definite advantages were observed.  Over a period of 4 months, there were at least 6 incidences when no roll had been changed during 7 consecutive days.  Reel winding improved further.  Physical work (sponge humidification) by operators was reduced.
  32. 32. Overall Results         Better runnability Better reel winding Reduced trim losses Reduced joints Reduced gloss variation Reduced caliper variation Reduced grindings per ton of paper Improved roll life
  33. 33. Overall Results  And of course-  Happier Customers…..!  Happier Operators……!!  Happier Mill………….!!!
  34. 34. Thank You.
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