1. MALAYSIAN NEWSPRINT
INDUSTRIES
PULP MILL

2. MALAYSIAN NEWSPRINT
INDUSTRIES
• World Class in all aspects:
– Scale
– Productivity
– Quality
– Inputs
• Labour
• Power
• Water
MNI Mentakab Mill

3. MALAYSIAN NEWSPRINT
INDUSTRIES
Pulp Mill
• Objective
– Convert the Recovered Paper to
clean, bright, high quality pulp
• Recovered Paper
– 75% Old Newspapers
– 25% Old Magazines
• Typical Composition
– Fibre & Fillers 85%
– Water 13%
– Contaminants 2%
– Ink >1%

4. MALAYSIAN NEWSPRINT
INDUSTRIES
Pulping
• Objective:
– Break down the paper into individual fibres.
– Detach ink
from the fibres.
– Conveyor adds
15 mt of paper
to pulper
– Helical Agitator
slushes up the
paper at 15%
solids
– Water+chemicals
added

5. MALAYSIAN NEWSPRINT
INDUSTRIES
Pulping Chemicals
• Sodium Hydroxide (16 kg/t)
– Swells the fibres, loosen Ink
• Hydrogen Peroxide (20 kg/t)
– Prevents brightness loss due to
Caustic
– Bleaching
• Sodium Silicate (15 kg/t)
– Peroxide Stabilizer
– pH Buffer,
– Dispersing Agent,
• Soap/Surfactants
– Ink separation and collection

6. MALAYSIAN NEWSPRINT
INDUSTRIES
• Separate contaminates based
on physical size:
– 1st stage: 8mm holes
– 2nd stage: 1.2 mm holes
– 3rd stage: 0.25 mm slots
– 4th stage:0.15 mm slots
Screening
– Stock is feed to inside
of Screen
– Good Fibre passes
through screen plate
– Contaminates that
cannot pass through
are rejected

7. MALAYSIAN NEWSPRINT
INDUSTRIES
Cleaning
• Separates contaminates
based on density:
– 1st Stage:
• High Density Cleaners
• Remove large, dense
materials (e.g. staples)
– 2nd stage:
• Heavy Weight Cleaners
Removes fine heavy
contaminants (e.g.sand)
– 3rd stage:
• Light Weight Cleaners
• Removes material with
density >1e.g plastics)

8. MALAYSIAN NEWSPRINT
INDUSTRIES
Flotation
• Separates ink from
the fibre:
– Stock is pumped into cell
(1)
– Air is added. (2)
– Air bubbles are created.
– Ink attaches to
outside of the air bubble.
– Air bubbles rise to the
surface
to create a foam layer.
– The foam/ink overflows
into rejects trough
– De-inked stock exist at
bottom
– Flotation is repeated 6
times to maximize ink
removal

9. MALAYSIAN NEWSPRINT
INDUSTRIES
Disperging
• Mechanical Energy is
applied to:
– Remove residual ink from the fibres
– Breaks up large ink particles in
smaller particles (<50 m)
Pulp Feed
– Pulp brightness is reduced
by 2-3 points
– Recovered in Post Flotation

10. MALAYSIAN NEWSPRINT
INDUSTRIES
Pulp Mill Summary
• Reached nameplate capacity:
• Able to supply enough pulp for
280,000 tpa with minor de-
bottlenecking work.
• Able to produce higher quality pulp
due to high levels of equipment
• Able to produce high quality pulp from
lower grade ONP/OMG
• Good Yield performance.

11. MALAYSIAN NEWSPRINT
INDUSTRIES
Paper Machine
• Objective:
– Convert Fibre Pulp in Finished Newsprint
Rolls.
• Four distinct Sections:
– Former
– Press
– Dryer
– Calander
– Winder

12. MALAYSIAN NEWSPRINT
INDUSTRIES
Former
• Forms the paper web and starts the
water removal process.
• Headbox:
– Creates a Jet of stock
• 8 mm thick X 9000 mm
wide.
• Jet velocity is precisely
controlled.
• Very uniform.
• Control of basis weight

13. MALAYSIAN NEWSPRINT
INDUSTRIES
Former
– Top Wire
– Bottom
Wire
– Headbox
– Jet is captured
between
converging wires

14. MALAYSIAN NEWSPRINT
INDUSTRIES
Press Section
• Increase web dryness by pressing out
the water out
– The Web enters the press at 17 % solids
and leaves at 43% solids
– The sheet is press 4 times with increasing
pressure
• 1st Nip 70 kN/m
• 2nd Nip 90 kN/m
• 3rd Nip 130 kN/m
• 4th Nip 150 kN/m.

15. MALAYSIAN NEWSPRINT
INDUSTRIES
Press Section
First
Press
Nip
Second
Press
Nip
Third
Press
Nip Fourth
Press Nip

16. MALAYSIAN NEWSPRINT
INDUSTRIES
Dryer Section
Sheet enters Dryer
Section at 55% water
and leave at 8 %
36 Steam Heated
Cylinders in 6
sections

17. MALAYSIAN NEWSPRINT
INDUSTRIES
•The top roll is covered with hard
rubber
Calander Section
•The sheet from the dryers
is too rough and needs
smoothing in a process
called Soft Nip Calandering
•The paper is compressed between
two rolls under high pressure.
•The bottom roll is Steel
•CD caliper control by heating
different zones

18. MALAYSIAN NEWSPRINT
INDUSTRIES
Winder Section
• The Winder converts a parent reel to
individual customer sized rolls.
• Parent Reel is
unwound from
Backstand.
• The sheet is slit in
customer width by
slitter blades
• The individual
customer rolls are
wound on paper
cores on alternative
sides of the center
drum

19. MALAYSIAN NEWSPRINT
INDUSTRIES
Efficiency Aids
• Break Camera System
– Automatically records last 20 seconds before a
break.
– Used to determine where and why the break
occurred.
• Online Vibration Monitoring
– Continuously monitors the conditions of bearing,
clothing etc.
– Allows maintenance to be planned before failure.
• Hole Scanner
– Scans every square inch for defects like holes
light spots etc.

20. MALAYSIAN NEWSPRINT
INDUSTRIES
Quality Testing
• Paper Testing
– Valmet
PaperLab.
– Test Every
Parent Reel.
– Wide range of
tests including:
• Tear
• Tensile .
• Fibre
Orientation
• Brightness

21. MALAYSIAN NEWSPRINT
INDUSTRIES
PM Summary
• Reached nameplate capacity of 250,00
tpa:
• Target is to increase to 280,000 tpa
– Increase Speed
– Increase Efficiency
• Sheet Quality is world class
– Dilution Head box
– Winder.