SMURFIT KAPPA SSK BIRMINGHAM

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SMURFIT KAPPA SSK BIRMINGHAM

• WELCOME!!!
• PAUL FREEMAN
• MONIKA MACIEJEWSKA
• DEBORAH PORTER-WALKER

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Smurfit Kappa SSK
Please enjoy your visit

• All visitors to site are required to
• Report to Reception wear visitors pass at all
  times
• Follow the Smurfit Kappa 12 Must Haves for HS
• Stay with your guide / supervisor
• Follow all marked foot paths
• Wear High Visibility Vests
• Wear stout footwear or preferably safety shoes
• Use hearing protection in all production areas as
  designated
• Follow our Hygiene rules
• This is a No Smoking site
• Know the Fire Evacuation Procedure.

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SK SSK Fire Evacuation Assembly Points
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THE MILL
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THE MILL

• Founded by 3 Victorian Gents (Smith, Stone and
  Knight) in 1862
• 22 Acre site
• 110 employees
• Single machine (PM4) Output 200,000 t.p.a.
• Saleable width (deckle) 4.7m
• Machine Speed 850m/min max.
• Products manufactured T2, T3 Recycled Fluting
• Grammage range 100 220 gsm
• 2 Bore holes providing process water requirements
• 2 CHPs generating 8MW of electricity 40t/hr of
  steam at 12bar
• 3 Package boilers generating 60t/hr of steam at
  12bar
• An Anaerobic Waste Water Treatment Plant

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STORAGE YARD (The Front End)

• 14.9Kt stock capacity (up to 3 weeks supply) /
  4Kt per week input
• 14.5Kt baled
• 400tonnes loose

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THE PAPER MAKING PROCESS

• Pulping add water (96) to recovered fibre (4)
  thickstock
• Cleaning the thickstock by sieving, screening
  and centrifuge
• Spraying Spray a jet of thinstock (99 water)
  onto a wire (a woven synthetic fabric the
  forming sheet - moving at 720 mtrs/min).
• Drying remove water from the forming sheet
• Sizing add chemicals (starch etc) to achieve
  physical strength properties by squeezing into
  the paper.
• Reeling up, slit, and wind to required customer
  width and diameter.
• Finishing/Transporting - to finished reel
  warehouse.

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PULPING and CLEANING

• Stock preparation on twin stream pulping lines
• 17.5 Kt rejects p.a. (80 landfilled, 20 land
  spread)

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PM4
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SPRAYING (The Wet End)
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DRYING

• This is achieved in 4 stages
• Draining by gravity 1 fibre99 water
• Drawing by vacuum 20 fibre80 water
• Squeezing by rollers 54 fibre 46 water
• Heating by hot air 93 fibre 7 water

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SQUEEZING (PRESS SECTION)

• Two presses working at 5 bar reduce water content
  to about 60
• A third, extended nip press (ENP) reduces water
  content further to about 47
• The ENP operates at 68 bar using hydraulic
  pressure.

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HEATING and SIZING (The Dry End)

• Steam heated cylinders in the Pre-Dryer section
  are now used to bring moisture content down to
  about 12.
• Starched / sized products have to be rewetted
  in a size press as the chemical additives are
  absorbed.
• More steam heated cylinders in the After-Dryer
  section are now used to bring moisture content
  down to the finished product specification of
  7-8.

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WINDING

• Jumbo reels
• c.18 Tonnes

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FINISHING

• The Valmet slitter is fully automatic and
  capable of being run by 1 man
• Jumbo reels are slit to customers orders
• 6 to 15 finished reels per jumbo are produced
• Each weighs between 0.78 and 3.2 tonnes

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WAREHOUSING The Rear End

• Fully automated unmanned forklifts
• (self guided vehicles SGVs)

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ENERGY FROM WASTE PLANT

• Energy
• 2 Gas fired CHPs
• CHP1 Centrax KB5 built in 1985, generating 3.5 MW
  20 tonnes/hour of Steam
• CHP2 Centrax KB7 built in 1997 installed at SSK
  in 2000, generating 4.5 MW 20 tonnes/hour Steam
• 3 dual-fuel, package boilers
• installed 1989, generating 20 tonnes/hour each of
  Steam
• Import and Export electricity dependant on
  product mix
• Typical specific electricity usage 315 KWh/gross
  tonne

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WATER TREATMENT PLANT
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THE LOCAL ENVIRONMENT

• Water is drawn from the aquafer under the city
• Input from 2 boreholes at 3.5 m3/tonne
• Input from citys water main at 1.1 m3/tonne
• Output 3.1 m3/tonne to Severn Trent Minworth
  sewage works
• Used water is treated on site before returning to
  Severn-Trent

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THE TOUR

• Health and Safety
• Do
• Stay with your guide / supervisor
• Follow all marked foot paths
• Be alert
• PPE
• Wear High Visibility Vests
• Use hearing protection in all production area as
  designated
• Clothing
• Wear stout footwear preferably safety shoes
• Its loud, its hot, its humid, its wet do
  you still want to see it?