Improving efficiency and runnability at JK Paper PM5 with targeted rebuild solutions
To boost efficiency and product quality, JK Paper teamed up with Valmet to implement a targeted rebuild at PM5. By introducing automated web handling, reliable tail threading, and precise caliper profiling, the mill achieved improved runnability, reduced downtime, and more consistent board quality—preparing for future production demands.
Background
JK Paper Ltd., one of India’s leading paper manufacturers, continuously strives to enhance operational efficiency, product quality, and machine runnability at its Fort Songadh mill. PM5 produces folding boxboard (FBB) and cupstock grades with basis weights ranging from 160 to 440 g/m² and operating speeds of up to 600 m/min.
To meet increasing production demands and improve machine performance, JK Paper partnered with Valmet to implement a focused rebuild targeting critical bottlenecks in the dryer and coating sections, as well as quality control at the calender.
The challenge
The PM5 line faced typical operational challenges associated with high-speed board production. Web break handling was inefficient, which led to longer downtime. In addition, tail threading in the coating section was manual and less reliable, creating challenges for consistent operation.
Variability in the cross-direction (CD) caliper profile also affected end-product quality. At the same time, there was a risk of web wrapping and operational disturbances in the dryer sections, further impacting stability.
JK Paper required a solution that would improve machine efficiency, safety, and product uniformity while also supporting future capacity upgrades.
Valmet solution: Advanced web cutting system in dryer section
Valmet installed two automatic web cutting devices in the pre-dryer section. These systems are triggered by break detectors and operate simultaneously, enabling fast and controlled handling of web breaks.
Web cutting deices activated in minimum possible time after the break and extra large opening of doctor beam help to clear paper pieces.
In addition, new knock-off doctors were introduced to prevent web wrapping around dryer cylinders and to guide the web safely to the basement. As a result, recovery from web breaks became faster, downtime was reduced, and safety improved. The solution also effectively prevents sheet wrapping issues.
Valmet solution: Tail threading system before curtain coater
Valmet’s tail threading system was installed to enable smooth tail threading from the dryer section to the coating section. The system utilizes advanced foil technology to create vacuum without external vacuum sources, ensuring stable and efficient tail transfer even at higher speeds.
With this solution, tail threading became reliable and automated, reducing the need for manual intervention. Operational safety and efficiency improved, and startups after breaks became faster and more consistent.
Tail transfer at higher speeds – Valmet threading system enhances safety, efficiency, and startup reliability before coating.
Valmet solution: Induction profiler on hard nip calender
An induction profiling system was implemented on the hard nip calender to provide precise control of the CD caliper profile. This enables improved product quality and uniformity, better control of caliper variations, and enhanced end-product performance for demanding applications.
Rebuild execution
The rebuild was executed in close collaboration between Valmet experts and JK Paper’s technical team. Engineering visits were conducted for both the dryer and coating sections to ensure optimal solution design.
Installation and startup were supported by Valmet specialists, and hands-on training was provided to operators to ensure smooth adoption of the new technologies.
The rebuild was designed to support future production speeds of up to 700 m/min, ensuring long-term scalability and performance.
Results and looking ahead
Following the rebuild, JK Paper PM5 achieved significant improvements. Machine runnability improved, with faster response to web breaks. Downtime was reduced due to more efficient web handling and tail threading.
Safety was enhanced through increased automation and reduced manual intervention. Product quality improved thanks to better control of the CD caliper profile, and operational reliability increased in critical sections of the machine.
This targeted rebuild demonstrates how selective technology upgrades can deliver substantial performance improvements without requiring a full-scale machine replacement. By combining automation, process optimization, and advanced profiling technology, Valmet helped JK Paper strengthen its production efficiency and product quality, supporting its position in the competitive packaging board market.
With this successful collaboration, JK Paper is well-positioned to meet future market demands with improved efficiency, quality consistency, and operational excellence.
