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LIQUID PACKAGING BOARD LIQUID PACKAGING BOARD “”TETRAPAK””” “”TETRAPAK””” PROCESSINGPROCESSING - Recovering Fiber out of Waste- Recovering Fiber out of Waste

ByByVENKATRAMAN GOKULAKRISHNANVENKATRAMAN GOKULAKRISHNAN

Date: 06Date: 06thth August, 2015 August, 2015Venue: IPPTA ZONAL SEMINAR, AHMEDABAD, INDIAIPPTA ZONAL SEMINAR, AHMEDABAD, INDIA

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There is no CIRCLE without RADIUS

There is no LITERACY without PAPER

• UBC product grade, composition, different layers• Informative Pictures and Tables• Different new products out of UBC• Impact of Waste on Environment• UBC Technology, Flow Diagrams• Stock Preparation Line- Process• Stage Wise Operational Description:

– Pulping– High Density Cleaning & Coarse Screening– Fine Screening and – Reject Thickening

• Informative Pictures of UBC Line, 3D Model and different by-products• Conclusion

CONTENTS

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INTRODUCTION

• Used Beverage Cartons (UBC) also called “Tetrapak”. On one hand,

Tetrapak poses a serious threat to the environment as waste, on the other

hand, a preferred source of economic recovery as a secondary raw

material. Tetrapak is composed of 60 - 70 % cellulose fibers and 30 - 40 %

polyethylene foils and aluminum (not always). All these components are

valuable raw materials for further industrial use. However, there is one

condition is that the components must be separated from each other

perfectly.

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INTRODUCTION

What is UBC?

UBC means Used Beverage Cartons also called “Tetrapak”.

Threat: Serious threat to the environment as waste

Raw material: A preferred source of economic recovery as a secondary raw

material.

Tetrapak is composed:

60 - 70 % cellulose fibers

30 - 40 % polyethylene foils and aluminum (not always).

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GradeAseptic packaging

Germfree packagingShelf-stable carton

Non-aseptic packagingRefrigerated carton

Cardboard Grammage 210 – 325 GSM 250 – 330 GSM

Cardboard 74% 80%

LDPE 22% | 50 μm/layer 20% | 50 μm/laye

Aluminium 4% | 6 μm/layer -

Color Brown, white 70 – 88% White 78 – 85%

Layers 6 3 or 4

Use Long-life beverages80% of production

Fresh milk, juices20% of production

FeedSource•Factory outlet, or•Municipal wasteColor•White, or•GraySize•Large, or•Optimal 10 – 25 cm

ProductFibers•40% dry mat, or•4% stock – tissue or notebooksFoils•Mixture of PE & AL, size over 12 mm, and•Mixture of AL & PE, size 1.8 – 12 mmRejects•Heavy rejects (sand, stones, etc.), and•Light rejects (polystyren, etc.)

Table 1- Composition

Table 2 - In & Out

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Different new products out of UBC

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Impact of Waste on Environment

“Collection” is not the same as

“Recycling”

Recycling includes processing and making new products!

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UBC Technology, Process Flow Diagrams

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UBC Technology, Operation Flow Diagrams

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Stage Wise Operational Description- Pulping

• During periodical pulping at high consistency (being more suitable for

hard pulpable materials) fibres are separated from foils.

• The products in this stage are a washed foil mixture containing less than

1.5% b. d. fibres and fibre stock collected in a chest before a coarse

screening stage.

• In this step more than 80% of foils are separated.

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Stage Wise Operational Description- High Density Cleaning & Coarse Screening

• In the high density cleaning stage, on a high-density cleaner, stock is made

free from sand and specifically heavy particles.

• In coarse screening, most of the remaining foils are removed. The foils are

intermittently drained to a reject thickening unit.

• Accept is collected in a chest before a fine screening stage.

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Stage Wise Operational Description- Fine Screening • Pressure screen (slotted screen) removes fine foils and non-pulped

fractions. This reject is intermittently drained to a reject dewatering unit.

• Reject volume usually is not high, beverage cartonboards do not contain

kind of impurities usually in other sorts of processed raw materials.

• Fine screening accept is thickened up to 35 – 40 % b.d. on a belt press

with a palleting device.

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Fig. 12 – Feed Material Tetrapak

Fig. 13 – Rejects from washing

separator

Fig. 14 – Foils from dewatering

drum

Fig. 15 – Final output material from Belt Press

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Informative Pictures of UBC Line, 3D Model and different by-products

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• Recycling Used Beverage Cartons has following benefits:

– Enabling the efficient use of raw materials by extending

their life into new products.

– Reducing greenhouse gas emissions.

– Diverting valuable materials from landfill.

CONCLUSION

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Thank you for your attention.

If you have any questions, I will be pleased to answer them now OR

You may contact use-mail: vegokul@papcel.cz Tel.: +9140 6544 1888; Mob: +91 97010 66100

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