Retrofitting equipment in existing paper machines : a concept development case study

Abstract

This work addresses the engineering problem of retrofitting a coating applicator in paperboard machines. A technology review sets the foundation, offering an overview of the paper-making process; the headbox, forming section, drying section, surface treatments, and binder applicators are reviewed. The review also delves into the critical aspect of space allocation in the forming section and anticipates future developments in foam application. The research methodology is rooted in spatial analysis, which is leveraged to understand the area surrounding the forming section, maintenance routines, and the dynamics of changing processes during production. The study also outlines developing and comparing needs, establishing an analysis framework, and generating innovative ideas. The core of the thesis lies in the results section, where a spatial analysis of layouts for 2-ply and 3-ply is presented. The challenges encountered through spatial analysis are discussed, and a requirements analysis is conducted. The culmination of the study is the proposal of concepts for retrofitting an applicator in different layouts, with a chosen concept justified and detailed. The discussion section thoroughly examines the specific and generalized results, including proposed applicator and flush-up tray changes, and analyses the benefits and drawbacks of moving the applicator into the Tending Side (TS), Drive Side (DS), and on-web operations. Ending with suggestions for alternate approaches, speculation, and conclusions. As well as proposal for future development direction and efficacy of the work.