INTRODUCTION

• Nama : Yusup H • NIK : 1105111 • Pendidikan : S1 Teknik Mesin • Pengalaman : Consultan design (2009-2010), Warehouse Staff (2010),

GENERAL PAPERMAKING PROCESS

Paper Machine

Stock Preparation Plantation

Finishing

Raw Material

RAW MATERIAL

Long fiber : NBKP ( Needle Bleached Kraft Pulp )

NUKP ( Needle Unbleached Kraft Pulp )

• Short fiber : LBKP ( Leaves Bleached Kraft Pulp )

• BCTMP (Bleached Chemical Thermo Mechanical Pulp ) Short and long fiber

• Broke ( Recycled Process) Paper Machine , Finishing , return goods

•ONP ( Old newspaper )

Recycled paper, which has a content of 60-70% old newspaper, magazine max 30%, other paper & OCC includes 5% max

• OMG ( Old magazine ) Consisting of old magazine, catalog & similar materials, including other paper & OCC 2%.

• SWL ( Sorted White Ledger ) office paper

•OCC ( Old Corrugated Container ) wrapping paper (box) of food / goods ( brown color )

CACO3 PROCESS

CaCO3

Precipitated Calcium Carbonate

Ground Calcium

Carbonate

1. PCC (Precipitated Calcium Carbonate)

• CaCO3 CaO + CO2

• CaO + H2O Ca(OH)2

• Ca(OH)2 + Na2CO3 CaCO3 + side product

CO2

(NH4)2CO3

Pharmacy, food, milk,

mineral water, toothpaste etc

99.8 %

2. GCC (Ground Calcium Carbonate)

• Size reduction

Crushing Dry

grinding Wet

grinding Screening Storage

15-30 cm <4 cm <45 m <2 m 75% solid

Dispersant

CRUSHING

Type:

Jaw crusher 15-30 cm

<4 cm

DRY GRINDING

Rooller Mill

(VX Mill)

WET GRINDING

IKSC-95 4 stage

IKSC-65 2 stage

IKSF-60 2 stage

<45 m Dispersant

Water

Ceramic bead Slot screen

0,3 mm

Hardness

CaCO3 : 4 mohs

Ceramic bead : 6 mohs

Type:

Atrition Mill

SCREENING

Slurry 75% solid

325 mesh

350 mesh

Storage

Type :

Vibrating Screen (wire mesh)

PRODUCT & STORAGE

IKSC-95 (Indah Kiat Serang Coating -95)

particle <2 m = 95%

top side - top coat

IKSC-65 (Indah Kiat Serang Coating -65)

particle <2 m = 65%

top side - pre coat

IKSF-60 (Indah Kiat Serang Filler -60)

particle <2 m = 60% (actual : 65%)

added in wet end area

Duplex (DA) Filler (top layer)

Ivory Filler (top layer & back layer)

Capacity : 7,500 ton/month (dry)

10,000 ton/month (wet)

Duplex

Top – top coat (IKSC-95)

Top pre – coat (IKSC-95)

Top layer

Under layer

Filler layer

Back layer

PVA (Poly Vinyl Alcohol)

COLOUR KITCHEN

• Film press Surface sizing

Native starch

converter Jet cooker

enzyme

COATING

Function:

• Printability and print quality

• Paper appearance (gloss, brightness, colour, opacity)

Components of coating process :

• Base paper

• Coating colour

• Coater machine

COATING COLOUR

Pigment

The main component of coating color (70-80%), usually mineral particles (CaCO3, Clay 1 & clay 2)

Function : filling the pores of the paper surface (smooth)

Binder

Adhesive used to bond the pigment particles to the base paper( Latex )

Co-binder : Starch & modified starch, PVA & CMC

Additives

Dispersant, Lubricant, Defoamer, Biocide, Wet strength agent, OBA, Dyes, Caustic soda

COATING COLOUR

Coating colour

Additives

Binder & Co-

Binder

Pigment

mixture of pigment + binder + co-binder + additives + water

applied to base paper in the coating process

Raw material

Mixing Screening Storage

tank Working

tank

COATING APPLICATION

Working tank

• 131 – NBKP : 65 T/d

• 132 – LBKP : 360 T/d

• 135 – BCTMP : 350 T/d

• 136 – BCTMP : 360 T/d

• 140 – LBKP : 250 T/d

• 141 – BCTMP : 250 T/d

• 143 – LBKP T PULP: 60 T/d

VIRGIN PULP

• 134 – FILLER I : 360 T/d

• 137 – BACK LAYER : 230 T/d

• 138 – REJECT HANDLING : 60T/d

• 142 – OCC : 110 T/d

• 133 – UNDER LAYER : 260 T/d

WASTE PAPER

STOCK PREPARATION

HD

CLEANER

REFINER

BRUSH

REFINER

Long Fiber

HD

CLEANER

M/C CHEST

DUMP

CHEST STORAGE

TOWER

BLENDING

CHEST

Short Fiber

REPULPING CLEANER REFINING BLENDING

DUMP

CHEST

DEFLAKER REFINER STORAGE

TOWER

BLENDING

CHEST

VIRGIN PULP

PULPER

PULPER

REFINING PROCESS Refining : fibrillation process of fibers or fiber cutting to the degree of freeness (CSF) desired. fiber fibrillation : to improve the physical properties of paper (strength) Fiber cutting : paper formation

Under Layer

DUMP

TOWER

HD

CLEANER

THICKENER

CHEST

STORAGE

TOWER MIXING

CHEST

HOLE

SCREEN

SLOT

SCREEN FLOTATION THICKENER DISPERGER

CLEANER

PLANT

M/C CHEST

Filler Layer

STORAGE

TOWER

HD

CLEANER CLEANER

PLANT DUMP

TOWER

HOLE

SCREEN

FRACTIONATING

CHEST

M/C CHEST

THICKENER

SLOT

SCREEN

CHEST CHEST

DISPERGER

SECONDARY FIBER

PULPER

PULPER

CHEMICAL & ADDITIVE 1. SIZING

Function : To improve the properties of paper (cobb size, penetration, absorption etc)

a. Internal Sizing

Chemicals directly added to the stock which still form of suspension.

Example : ASA

b. Surface Sizing

Chemicals added to the sheet either still wet or it is dry.

Example : Natives Starch addition in the size press

2. DRY/Wet STRENGTH

Function : to enhance the properties of paper in a dry time (Ply Bonding, Tensile, Folding etc)

Example: Cationic Starch

3. DYES

Function : to generate a standard color paper production, measured using a test of L, a, b.

Chemical : Basic Dyes ( Blue & Violet)

4. DEINKING CHEMICAL

Function : to remove ink on waste paper (brightness will be higher)

Chemicals : H2 O2 (Hidrogen Peroxyde), NaOH (soda), Na2 SiO3 (Sodium Silicate), Soap (detergen)

5. COAGULANT & FLOCCULANT

Function : Drainage , water purification

6. BIOCIDE

Function : to prevent bacterial growth.

PM 3 PM 6

Manufacturer Voith Sulzer, Germany

Type Fourdrinier Multilayer (4 plies) Completed with 4 on line sensor

Design Speed 600 M/Min

M/C Width 4.2 M

Cylinder Dryer

87 dryer

2 cooling cylinder

Size Press Jagenberg, Germany

Coater 3 coating heads 4 coating heads

Rewinder

Jagenberg, Germany

2,000 M/Min

Product

Duplex (DA,) Ivory (IA, IF, IG, GV)

Triplex (T1) Art Board (IS,SV)

Ivory (IA,)

PM3/6 PROFILE

PAPERMAKING FLOW DIAGRAM

Wire part Press part Main dryer

Size press After dryer

Calender 1

Coater 1 Dryer Coater 2 Coater 3 Calender

2 Cooling cylinder

Pope reel

Stock preparation

Approach flow

system

Rewinder Roll

handling Finished

goods

CHEMICALS AND ADDITIVES

Chemical Function

CaCO3 Filler & brightness

ASA Starch Internal sizing (cobb size)

Flocculant & coagulant formation and retention

Defoamer to remove foam

Biocide to prevent bacterial growth

WIRE PART

Function :

1. Dewatering ( gravity & vacuum drainage)

2. Sheet Formation

3. Ply Bonding (Starch spray)

filler under top

back

FORMER & VACUUM SYSTEM Double side dewatering

Very gently and efficient dewatering

Highest capacities possible

Highest sheet strength, best formation

filler under top

back

Filler layer Under layer Top layer

Back layer

PRESS PART • Dewatering process by nip press (mechanical

drainage)

• Consist of tri-nip press.

Guide roll

PRESS PART

Stretcher roll

20 – 22 %

45 – 50 %

SHOWERING SYSTEM

• Use fresh water

• Oscillating ( HP Shower )

• Fix ( LP Shower )

Low Pressure Shower High Pressure Shower

DRYING Function : Drying & Evaporating

• Consist of 87 cylinder dryer (11 Group) and 2 cooling cylinder

• 6 group ( no 1-69) Main dryer

• 3 group ( no 70-81) After dryer

• 1 group ( no 82-83) After coater 1

• 1 group ( no 84-87) After coater 3

1 3

2 4

90 – 95 %

80 – 85 %

90 – 95 %

STEAM & CONDENSATE SYSTEM

Co-GEN

15 bar Coater

5.5 bar Cylinder

dryer

Separator

Condensate

SIZE PRESS ( FILM PRESS )

Function :

• Surface sizing (Starch addition)

CALENDER

Function :

1. Caliper Profiling

2. Sheet Gloss

3. Sheet Density

Consist of :

• Hard Nip Calender

• Soft Nip Calender

HNC

HNC

HNC

SNC

1st 2nd

Hot Oil

COATER

Function :

1. Printability & print quality

2. Paper appearance

Drying process :

• Hot air dryer ( steam 15 bar )

• Infra Red dryer

Top – top coat

Top pre - coat

Top layer

Under layer

Filler layer

Back layer

Back coat

COATING MACHINE CONFIGURATION

POPE REEL Production code

C 0 4 30 15

Paper machine identity

Year of production Month of production

Date of production

Roll Number

PM 3 : C

PM 6 : D January - September : 1 - 9

October - December : A, B, C

REWINDER Winding position

C043015

Number of winding

Roll position

Core diameter

FINISHING B DEPARTMENT

FINISHING B DEPARTMENT

• Tugas : membantu kelancaran proses pemotongan kertas maupun proses pengepakan kertas dari Winder PM B.

• Finishing B mencakup beberapa bagian :

▫ Finishing B Support Section

▫ Cutting Section

▫ Auto & Manual Packing Section

▫ Quality Control

STRUKTUR ORGANISASI FINISHING B DEPARTMENT

Kepala Department Finishing B

Kepala Seksi Finishing B Support

Kepala Seksi Cutting

Kepala Seksi AMPS QC Finishing Dept.

Wakil Kepala Seksi

Kepala Shift

Wakil Kepala Shift

Kepala Regu

Wakil Kepala Regu

Operator

Wakil Kepala Seksi

Kepala Shift

Wakil Kepala Shift

Kepala Regu

Wakil Kepala Regu

Operator

Wakil Kepala Seksi

Kepala Shift

Wakil Kepala Shift

Kepala Regu

Wakil Kepala Regu

Operator

Wakil Kepala Seksi

Kepala Shift

Wakil Kepala Shift

Kepala Regu

Wakil Kepala Regu

Operator

FINISHING B SUPPORT SECTION

• SMS : - Menerima Paper Roll dari PM#3 / 6 (Roll in)

- Mengatur Roll yang masuk BRSA dan area cutting (Roll out).

• CCR : Mengeluarkan Roll dari BRSA untuk dipotong di Sheeter atau Winder sesuai memo (PBCR dan PRCR).

• PCS : Mengontrol order yang belum, sedang atau sudah diproses.

CUTTING SECTION

Tugas :

Memotong Roll yang diproduksi PM #3 dan PM #6 menjadi produk kertas berbentuk sheet / lembaran.

Memotong dan menggulung roll-roll dari PM #3 dan #6 untuk menjadi roll yg lebih kecil ukurannya sesuai order dari konsumen.

AUTO & MANUAL PACKING SECTION Tugas :

Membungkus sheet hasil potongan sheeter dan mengemas sesuai packaging yang diminta costumer

Mentransfer Finish Good ke auto warehouse melalui elevator

Memotong kertas ke ukuran standar atau sesuai permintaan costumer dengan M/C Polar

Memproses Request HB / HF sesuai nota permintaan

Suporting: Melakukan reservasi pallet dan material packaging (roll laminating, plastik shrink, strapping PET, lakban, lem, layer)

Paper Roll dari PM #3/6

BRSA

Salvage Winder

Sheeter

Roll Wrapping

Ream Wrapping

Manual Wrapping

Strapping Auto

Warehouse

FLOWCHART ACTIVITY FINISHING B DEPARTMENT

Sortir

Un Sortir

Semi Auto Wrapping

Shringkage

Dari Rewinder PM B

ROLL RECHEIVING

• Roll diterima dari PM3/6 untuk diproses lebih lanjut di Finishing.

ROLL HANDLING

• Roll dari PM B distrapping untuk kemudian disimpan di base roll

• Untuk urgent order, roll di bypass langsung ke cutting area

• Roll yang order PRCR lewat bypass untuk menyingkat waktu

ROLL HANDLING Roll yang masuk dalam

PBCR, dari slat conveyor dipindahkan ke area cutting dengan travelling kicker oleh operator

BASE ROLL STORAGE AREA Roll yang tidak masuk dalam PBCR atau PRCR

disimpan di Base Roll Storage Area untuk keperluan stock

Base Roll Spesification Capacity Total (A+B) : 15,000 Ton Roll Diameter : 1.2 – 2.1 m Roll Width : 0.6 – 2.20 m Roll Weight : 1,000 – 6,000 Kg Roll High/Pile : 0.6 – 12 m

CUTTING SECTION

SALVAGE WINDER PROCESS

Profil Mesin Salvage Winder

Pasaban

Jumlah : 2 unit

Kapasitas : 50 Ton/Mc/Shift

Yue Li

Jumlah : 1 unit

Kapasitas : 50 Ton/Mc/Shift

GREAT WALL (Barrier Coating)

Jumlah : 1 Unit

Kapasitas : 30 Ton/Mc/Shift (winding)

: 20 Ton/Mc/Shift (barrier coating)

SALVAGE WINDER PASABAN

Pasaban Spesification Maximum winding width 2100 mm Minimum winding width 600 mm Maximum mother roll diameter 2100 mm Maximum finished roll diameter 1500 mm Finished roll core diameter 6” , 10”,12” Number of slitters 6 Minimum sliting width 200 mm Maximum speed 1500 m/min Balancing speed 1700 m/min Material to be wound Paperboard

Grammage 250-500 g/m2

SKEMA SALVAGE WINDER PASABAN

Roll Unwind

Guide Roll

Banana Roll

Slitter Drum Roll

Web

Rider Roll

Roll Winding

Core Chuck

Yue lie Spesification Machine Supplier You lie Machinery Paper width 2200 mm Design speed 1500 m/min Basis weight 210-500 g/m2

Finished roll core diameter 6”,10”, 12” Paper quality Board

SALVAGE WINDER YUE LI

SKEMA SALVAGE WINDER YUE LI

Roll Unwind

Guide Roll

Slitter Drum Roll Web

Rider Roll

Roll Winding

Core Chuck

SALVAGE WINDER GREAT WALL (BARRIER COATING)

Spesification Paper width 2200 mm Operational speed 800 m/min Basis weight 210-500 g/m2 Finished roll core diameter 6”,10”, 12” Paper quality Board Chemical kit Kit 6, kit 8 dan kit 10

SKEMA SALVAGE WINDER GREAT WALL (BARRIER COATING)

Coater

Guide Roll

Slitter Drum Roll

Rider Roll

Roll Winding Core

Chuck

Roll Unwind

Dryer

Web

1. Pasang paper core. 2. Setting Slitter. 3. Pasang paper roll.

SALVAGE WINDER (SW) PROCESS

1

2

3

SALVAGE WINDER PROCESS

QUALITY CHECK

Check kualitas winding

Check Size order

Roll disusun sesuai order dan label

SALVAGE WINDER PRODUCT AREA

• Roll disusun sesuai order,label diletakkan di dalam paper core

• Pemasangan core plug

• Pemasangan carton sheet

MESIN ROLL

WRAPPING 2

ROLL WRAPPING PROCESS

MESIN ROLL

WRAPPING 1

Winder Conveyor Kicker Auto

Wrapping Labeling Strapping Kicker

Elevator to AW

AUTO ROLL WRAPPING PROCESS FLOW

Winder Conveyor Kicker Semi Auto Wrapping

Conveyor Labeling Strapping Kicker Elevator to AW

SEMI AUTO ROLL WRAPPING PROCESS FLOW

Sheeter Machine Profile

Old Pasaban New Pasaban Tai Yong

Quantity : 6 units Quantity : 2 units Quantity : 2 units

Capacity : 42 Ton/Mc/Shift Capacity : 50 Ton/Mc/Shift Capacity : 10 Ton/Mc/Shift

Will Pemco Saito

Quantity : 4 units Quantity : 1 unit

Capacity : 32 Ton/Mc/Shift Capacity : 5 Ton/Mc/Shift

SHEETER PROCESS

SKEMA M/C SHEETER

Roll Unwin

d

Guide Roll Decurler

Banana Roll

Slitter

Drum Roll

Nip Roll

Cross Cutter

Fast Belt

Slow Belt

Web Overlap

Outlet

Jogger

Sheet Stack

Pallet

Stacker/ Lay Boy

M/C SHEETER

UNWIND GUIDE ROLL

NIPP ROLL

DECURLER

TRIM VACUUM SLITTER BANANA ROLL

FAST BELT SLOW BELT OUTLET JOGGER

SHEETER OLD PASABAN (2,3,8,9,10 & 11)

Machine Specification :

Machine Width : 2300 mm

Maximum Web Width : 2200 mm

Mother roll dimensions :

Maximum roll width : 2300 mm

Minimum roll width : 430 mm

Maximum roll diameter : 2100 mm

Minimum roll diameter : 600 mm

Mother roll core diameter : 10” & 12”

Maximum mechanical speed : 300 m/ menit

Cut sizes:

Minimum slitting width : 300 mm

Maximum sheet length : 1600 mm

Minimum sheet length : 400 mm

Maximum pile height : 1600 mm

Maximum knife load at the crosscut : 600 GSM

Material to be processed : Card board

Material grammage : 250-500 GSM

SHEETER NEW PASABAN (15 & 16)

• Machine Specification : • Machine width : 2300 mm • Maximum speed : 320 mm / menit • Material to be cut : 175-500 GSM • Reel maximum diameter : 2100 mm • Reel minimum diameter : 500 mm • Reel maximum width : 2200 mm • Reel minimum width : 450 mm • Core diameter : 10 “ dan 12” • Maximum length : 1600 mm • Minimum length : 350 mm • Maximum width : 2200 mm • Stack height : 1800 mm

(dengan pallet)

SHEETER WILL PEMCO (4,5,6 DAN 7)

Machine Specification

Machine width 2300 mm

Maximum speed 350 m/min

Material to be cut Board 190-400 gr/m2

Reel maximum diameter 2100 mm

Reel minimum diameter 400 mm

Reel maximum width 1800 mm

Reel minimum width 580 mm

Core diameter 6", 10" & 12"

Maximum sheet length 1650 mm

Minimum sheet length 550 mm

Maximum sheet width 1800 mm

Minimum sheet width 410 mm

Stack height 1350 mm (with pallet)

SHEETER TAI YONG (13 DAN 14)

• Machine Specification :

• Merk : Tai Yong

• Sheeter Cutting Width : 1600 mm

• Minimum Sheet Width : 400 mm

• Maximum Sheet Length : 1350 mm

• Minimum Sheet Length : 480 mm

• Unwind Core Diameter : 3”, 6”, 10” dan 12”

• Maximum Speed : 200m/menit

QUALITY CHECK

Quality check oleh QC team (Visual,Order, Size)

Macam-macam abnormal sheet: Botak Garis Gelombang Wrinkles Marking Melipat / terjepit GSM campur Kertas basah Calendar mark Coating jelek Bintik hitam Lubang Sobek pinggir

QUALITY CHECK

BUFFER AREA (AFTER CUT AREA)

• Tempat paper sheet setelah turun dari sheeter dan menunggu proses selanjutnya di AMPS

SORTIR

Sortir dilakukan dengan tujuan untuk mengindari produk (kertas) yang tidak memenuhi spesifikasi (abnormal) terkirim ke costumer

AUTO & MANUAL PACKING SECTION (AMPS)

SHEET WRAPPING PROCESS FLOW

Buffer Wrapping Labelling QC Shrinking

/ Stretching

Strapping QC AW

PROSES 1. AUTO , SEMI AUTO & MANUAL WRAPPING

Proses pembungkusan Paper Sheet menggunakan Sheet Laminating

2. LABELING Penempelan label pack dan label pallet 3. AUTO & MANUAL SHRINKAGE FILM Proses pengemasan Packing Sheet menggunakan Plastic Shrink 4. AUTO & MANUAL STRAPPING

Proses pengikatan Packing Sheet pada pallet menggunakan Strapping Band

5. HANDED TO AW

Proses transfer produk ke bagian Auto Warehouse

AUTO REAM WRAPPING (WRAPMATIC)

• Total : 5 unit

• Max Speed : 15 ream/min

• Ream Paper Substance : 60 – 400 gr/m²

• Max Ream Weight : 40 Kg

• Wrapping Material : Kraft Poly Coated

• Substance : 80 – 120 gr/m²

• Glue Type : Hot Melt

• Pallet Size

– Wide : 440 – 1000 mm

– Length : 550 – 1400 mm

– Height : 100 mm

• Production Target :

4500 pack/MC/shif

80 ton/MC/shift

• Operator : 3/shift (2 karyawan + 1 outsourching)

PROCESS FLOW WRAPMATIC

SHEET REAM FEED

GUN BELT

CONVEYOR LAMINATING

PAPER GLUING

(hot melt) WRAPPING

WOOD PALLET

STACKING (slat bar)

CONVEYOR (after

wrapping)

SEMI AUTO WRAPPING (AC ROOM)

• Khusus costumer dari negara beriklim dingin (Amerika, Jepang)

• Dikerjakan dalam ruangan tertutup ber-AC

• Tujuan :

– Untuk menyesuaikan suhu saat membungkus kertas dengan suhu di negara tersebut (+ 22oC)

– Untuk mengurangi kontaminasi debu dan kotoran

• Proses :

– Secara umum identik dengan auto wrapping

– Pembungkusannya dilakukan secara manual menggunakan lakban

PROCESS FLOW SEMI AUTO WRAPPING

SHEET REAM FEED

GUN BELT

CONVEYOR LAMINATING

PAPER

WRAPPING (lakban – manual)

WOOD PALLET STACKING (slat

bar)

LABELING SHRINGKAGE STRAPPING HANDED TO

AW

SHEET REAM FEED

GUN BELT

CONVEYOR LAMINATING

PAPER

WRAPPING (lakban – manual)

WOOD PALLET

STACKING (slat bar)

LABELING STRAPPING HANDED TO

AW

SEMI AUTO WRAPPING • Maximum Speed : 5 pack/min • Ream Pape Substance : 60 – 400 gr/m² • Production Target : 2000 pack/MC/shif • Maximum Ream Weight : 40 kg • Total : 2 unit • Glue Type : Lakban ( ADH Tape) • Operator : 3/MC/shift • Wrapping Material : Kraft Poly Coated • Substance : 80 – 120 gr/m²

– Jenis : Cokelat Putih Savicoat

MANUAL WRAPPING • Khusus produk Ream Wrapping

– Menggunakan pallet plastik (after sheeter)

• Pembungkus = kertas laminating

– Sudah dipotong sesuai ukuran bungkusan sheet

100 cm x 120 cm

120 cm x 150 cm

130 cm x 160 cm

150 cm x 160 cm

75 cm x 140 cm (tambahan / sambungan)

– Jenis :

Cokelat

Putih

Savicoat

• Perekat = Lakban plastik (ADH Tape)

• 100% tenaga manusia (ibu-ibu)

PROCESS FLOW MANUAL WRAPPING

SHEET (AfterCut)

LAMINATING PAPER

WRAPPING (lakban)

WOOD PALLET

STACKING (manual)

LABELING STRAPPING HANDED TO

AW

SHEET (AfterCut)

LAMINATING PAPER

WRAPPING (lakban)

WOOD PALLET STACKING

(manual) LABELING SHRINGKAGE STRAPPING

HANDED TO AW

MANUAL WRAPPING

• Tenaga :

Karyawan : 2 orang/pasang x 3/shift

Outsourching : 2 orang/pasang x 3/shift

• Target Produksi :

Karyawan : 850 pack/shift

Outsourching : 800 pack/shift

• Dilakukan setelah proses wrapping • Operator menempelkan label Pack & label

pallet pada bagian lebar dari pallet • Susunan Pack Label harus lurus dari pack

atas sampai bawah.

LABELING

• Untuk kertas yang belum downgrade, pallet label berukuran kertas A3 & berwarna sesuai dg jenis kertas & jenis packing, diletakkan pada bag.lebar pallet.

• Pack label di sebelah pinggir kiri sedangkan Pallet label berada di sebelah kanan.

Pack Label

Pallet Label

Ukuran A3

LABELING

Pack Label

Pallet Label Ukuran A4

• Untuk kertas downgrade, pallet berwarna putih dan berukuran A4, peletakannnya berada di bagian tengah pada bag.lebar dari pallet

LABELING

AUTO SHRINKAGE FILM

• Mesin : 1. Robopack Senior

2. Octopus Hailola (nonactive)

3. OMS

• Bekerja secara otomatis

• Dilengkapi dengan line konveyor yang terhubung dengan Wrapmatic, Strapping, dan Elevator AW

ROBOPACK SENIOR

• Membungkus sheet menggunakan plastik dengan cara dililitkan secara melingkar

• Material : LDPE 60 µm

• Jumlah lilitan : 3 atas + 2 tengah + 3 bawah

• Type : Helix system

• Length : 3810 mm

• Height : 4235 mm

• Net Weight : 1700 kg

• Color : Ral 7030

• Arm Rotation Speed : Max 30 rpm

• Max Capacity : 60 pallet / jam

PROCESS FLOW ROBOPACK SENIOR

CONVEYOR (After

Wrapping) LABELING

CARTON SHEET

ROBOPACK SENIOR

(Stretching Fim)

STRAPPING HANDED TO

AW

OCTOPUS HALOILA

Membungkus sheet menggunakan plastik dengan cara dililitkan secara melingkar

Memerlukan pemanasan setelah dibungkus

Material : LDPE 60 – 80 µm

Karena kapasitas terlalu kecil maka mesin tidak digunakan

OMS

Menggantikan fungsi mesin Octopus Haloila

Membungkus sheet menggunakan plastik

Memerlukan pemanasan setelah dibungkus

Material : LDPE 100 µm

Produksi : 40 pallet/jam

Temperatur : 160 – 210° Celcius

Lebar Pallet : 500 – 1200 mm

Panjang Pallet : 580 – 1400 mm

Tinggi Pallet : 1600 mm

Stack Weight : 1500 kg

PROCESS FLOW OMS

CONVEYOR (After

Wrapping) LABELING

SHRINGKAGE PROCESS

OVEN STRAPPING HANDED TO

AW

MANUAL SHRINGKAGE (ROBOPACK JUNIOR)

Batteries : 12 volt 8 A

Jumlah lilitan : 3 atas + 2 tengah + 3 bawah

Wheel size : 260 x 70 mm

Ukuran stretch film : 50 cm x 30µm

Kapasitas Maximum : 1 pallet / menit

PROCESS FLOW ROBOPACK JUNIOR

MANUAL WRAPPING

LABELING SHRINGKAGE

PROCESS STRAPPING

HANDED TO AW

AUTO STRAPPING BAND

Strapping 2 kali : untuk pallet eropa order lokal dan export

Strapping 3 kali : untuk pallet asia order lokal, export dan big size

Strapping 4 kali : untuk order special packing

Equipment Data:

Merk : Messersi Packaging

Berat : 81 kg

Selling time : 2 sec

Strapp feed : 4 Ms/sec

Tension : 200 – 2400 N

Strapp width : 10 – 15 mm

Strapp thickness : 0.4 – 0.9 mm

POLLAR PROCESS Alasan utama mengapa produk harus melalui proses polar adalah:

• HB : Status produk yang sampai di AW tetapi mengalami kerusakan karena penyimpanan/handling, salah transaksi atau salah proses sehingga harus diperbaiki di Finishing.

• HF : Status produk dimana permintaan Rework berasal dari marketing . Biasanya adalah produk idle stock.

• Abnormal dari Sheeter

SORTIR RESIZE WITH

POLLAR MACHINE

SORTIR MANUAL

WRAPPING LABELING SHRINGKAGE STRAPPING

HANDED TO AW

POLLAR PROCESS FLOW

SORTIR RESIZE WITH

POLLAR MACHINE

SORTIR LABELING SHRINGKAGE STRAPPING HANDED TO

AW

TOP

Bottom Heigth = 13.8 cm - 15 cm

Top Heigth =

0.6 cm

PACKING SHEET DESIGN

ASIAN NONSTOP PALLET

B

O

T

T

O

M

TOP

Top Heigth =

0.6 cm

Bottom Heigth = 13.8 cm - 15 cm

PACKING SHEET DESIGN

EUROPEAN NONSTOP PALLET

LOCAL

REAM WRAPP PACKING “A”

EXPORT

REAM WRAPP PACKING “N” DAN “M”

REAM WRAPP PACKING “M” BRAZIL

REAM WRAPP PACKING “M” JEPANG

NON REAM PACKING “Q” SPECIAL

NON REAM PACKING “Q” JEPANG

NON REAM PACKING “Q” BRAZIL

NON REAM PACKING “J,K,P”

NON REAM PRINTING PACKING “R”

Slip sheet

REAM WRAPP PACKING “U” UNPALLET

NON REAM PACKING “K”

Bottom Heigth= 15 cm

ROLL PALLET DESIGN

PACKING “0”

ROLL UN PALLET PACKING “1,2,7,8”

ROLL PALLET PACKING “3,4,5,6,9”

• Less Pack (Pack Kurang)

Solusi : adanya pengecekan jumlah pack oleh QC Packaging sebelum produk ditransfer ke AW

PROBLEM SOLVING

Solusi : Pengecekan packing oleh QC Packaging hendaknya lebih teliti

sebelum produk ditransfer ke AW Mechanic/ Electric segera memperbaiki mesin strapping jika hasil

strapping tidak sempurna.

Strapping miring

PROBLEM SOLVING

TERIMA KASIH

Acknowledge by

Tsai Cheng Chi

Checked by

Rul Ngaini

Presented by

Yusup H