The Light Green Machine Institute
Check out Nip Impressions weekly
Nip Impressions´┐Ż is Paperitalo Publications' flagship publication.  Published every Thursday afternoon (US Eastern Time), Nip Impressions´┐Ż is eagerly read by pulp and paper professionals around the world.

22 Apr 15: Applications 16: Chop Broke?
Forever and a day, or at least since the Fourdrinier Brothers came on the scene, conventional wisdom has been that we need broke pulpers under the machine at various locations, to collect the sheet when we are threading up or experiencing less than stellar conditions (read: sheet not getting to the reel).  


If you think about it, this requires a tremendous amount of equipment, water and pumping energy.


What if we could develop a new dry-broke chopper that could chop up the whole sheet and blow it to the wet end for reintroduction to the system?


Yes, I know you think I am crazy, and the next question out of your mouth will be, "Have you never experienced the maintenance on winder trim choppers, Jim?" And you would not be alone in your doubt.


However, the savings that could come from developing and implementing a great, full-sheet chopper/blower are huge. 


Let me suggest just a few:


1. No under-the-machine pulpers with their agitators, pumps and water requirements

2. No consistency problems from said pulpers

3. No problems with fiber churned into mush by over pulping under poor startup conditions

4. Lower energy costs (I don't have to pump all that water or run all those agitators)

5. One may be able to lower the height of the basement by as much as five feet


Yes, the challenges to designing such an installation are great, but the payoff would be even greater.


Or maybe the design is not so difficult.  Perhaps in your office you have a paper shredder. Here in the United States, these are at least 8 inches wide.  Are they 1/4 horsepower?  Perhaps that is a good estimate.  Extrapolating this machine to 240 inches wide, it would require 7.5 horsepower. Assume this is underestimated by a factor of 10, so it is 75 horsepower.  Add a blower and you are done.


What do you think?

We would like to hear from you. Please send an email to [email protected] 

with "LGMI Frontiers" in the subject line. 


Comments from last week:

Your idea to truly distribute these equipment systems is a good one that could save $$'s, lots of $$'s, but will be hard to sell. Since most DCS trouble-shooting is via laptops/Ipad, having an external hook-up from the field-mounted DCS boxes could prevent many needs to open these hardened boxes. Further, there are lots of ways to purge these boxes and maintain a good atmosphere inside IF the mechanics maintain the boxes' hardened condition as they open/close them.

Significant savings could be realized over today's MCC/DCS room approach if only mills would accept the idea of a smaller, self-contained, environmentally isolated FRP room that could be located close to concentrations of motors and/or field devices. These rooms could be pre-wired and tested before delivery, set in place, and be ready to attach to field devices and the central controllers when delivered. This intermediate approach might help mills begin the transition to your LGMI approach.

Ed Turner

Camden, North Carolina





LGMI Design Practices
As always, your comments will be appreciated.
Think light!


Brian Brogdon, Ph.D.
Executive Director




Jim Thompson

Send us your comments by emailing Brian Brogdon
or Jim Thompson!




LGMI Weekly Ideas are presented for your consideration and inspiration only.  It is solely your responsibility to check for engineering correctness, applicability, standards, insurance policy and local, national or any other legal compliance required before implementing.  Neither The Light Green Machine (TM) Institute, Paperitalo Publications, Talo Analytic International, Inc., nor any individual associated with these entities accepts any responsibility for your application or compliance issues.


The Light Green Machine Institute is a stand-alone non-profit Delaware Corporation.  

Copyright 2015 LGMI All Rights Reserved