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Winding an Optimal Roll in a Paper Machine Reel

PURPOSE


Develop an improved nip loading (pli) curve for a Horizontal Rail Reel (Pope Reel) to wind parent rolls with improved bulk uniformity, and with a greater bulk.

AREAS OF APPLICATION


  • For reels equipped with PLC based nip control, compute and apply  improved psi curves.
  • For older reels, design and implement PLC based nip control.
METHOD OF SOLUTION

  • Analyze the current state by computing the nip pli and relating it to the current bulk profile.
  • Create a new nip pli curve using the above information, and past experience.
  • Convert this new pli curve to psi curve for the secondary arm loading cylinders, along with appropriate back pressure.
COMPUTER PROGRAMS
  • "REELAN": Analyses the current loading scheme to develop the line load  in the nip against the drum.
  • "REELSY": Computes the loading pressure in the loading cylinder to create the desired nip line load.
INPUT REQUIREMENT

  1. Scale drawing of the reel.
  2. Currently used nip control method, and loading curve.
  3. Corresponding bulk profile in the wound reel.
  4. Converting data: product variability from top to bottom, slab wastage.
MEASURE OF SUCCESS

  1. The bulk profile in the new reels would be fairly flat except near the core and the outside.
  2. The bulk in the new reels would be higher.
  3. Slab waste would be reduced, and there would be an increased utilization of the paper.
  4. The converting winders should pick up speed, and run steadily.
CASE HISTORIES

  • In through-dry (TD) process, the above method increased the throughput by as much as 5%.
  • In light-dry-crepe (LDC) process, the speed of the winders in converting increased by about 50 fpm.
  • In heavy-wet-crepe (HWC) process, perf breaks and wrap-ups were reduced.

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