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
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