Complete OCC Pulping Line Design: Key Parameters for 400 TPD Kraft Liner Production

OCC Pulping System: The Foundation of Kraft Liner Quality

The OCC (Old Corrugated Container) pulping system is the first and most critical processing stage in kraft liner board production. A well-designed pulping system directly determines fiber quality, energy consumption, and overall line efficiency. For a 400 TPD production line, proper equipment selection and parameter optimization can reduce total pulping energy by 18-22% compared to conventional designs.

Key Equipment Specifications for 400 TPD OCC Line

Drum Pulper or Hydraulic Pulper

• Capacity: 400-500 TPD at 4-6% consistency
• Motor power: 315-400 kW
• Pulping time: 15-20 minutes per batch
• Deflaking efficiency: >90% in single pass

High-Density Cleaner

• Throughput: 400-600 TPD
• Operating consistency: 3.5-4.5%
• Reject rate: 8-12%
• Heavy contaminant removal: >98% for particles >1mm

Pressure Screen (Primary)

• Screen basket: 0.20-0.30mm slots or 1.2-1.6mm holes
• Capacity: 400-550 TPD
• Operating consistency: 1.5-2.5%
• Reject rate: 12-18%
• Motor power: 75-110 kW

Double Disc Refiner

• Disc diameter: 910-1100mm
• Motor power: 500-710 kW
• Specific energy: 80-120 kWh/ton
• Freeness reduction: 150-200 ml CSF per pass

Energy Optimization Strategies

A 400 TPD OCC line with optimized equipment selection typically consumes 18-22 kWh per ton of pulp in the pulping and screening stages. Key energy-saving measures include:

• VFD (Variable Frequency Drive) on all major motors — reduces no-load power by 25-30%
• Cascade screening configuration — secondary screen accepts return to primary, reducing total pumping energy by 12%
• Refiner plate pattern optimization — bar width and groove depth matched to fiber type for 15% energy savings

Maintenance Schedule for Critical Components

• Pulper rotor and extraction plate: Inspect every 500 operating hours, replace at 3,000-4,000 hours
• Pressure screen basket: Check slot width monthly, replace when wear exceeds 0.03mm
• Refiner plates: Monitor motor load daily, replace when specific energy increases by 15% from baseline
• Cleaner cones: Inspect for wear every 1,000 hours, especially lower cone sections

Benefits of Integrated OCC Line Design

An integrated OCC pulping line from a single manufacturer ensures compatibility between all components — from pulper to refiner discharge. This eliminates interface problems common with multi-vendor installations and typically achieves fiber recovery rates above 95% with stickies removal efficiency exceeding 90%.

For detailed technical consultation on OCC pulping line design parameters and equipment selection for your specific production requirements, contact the Leizhan engineering team.

Contact Leizhan Technology
Email: leizhanzhang@gmail.com
Web: www.pulprefining.com