OCC Pulping System: Key Equipment for 400 TPD Kraft Liner Board | Leizhan
What Makes a High-Performance OCC Pulping Line?
Core Equipment for 400 TPD Kraft Liner Production
A complete OCC pulping system must handle high contamination loads while maintaining fiber strength. Here are the key components:
Drum Pulper — The First Line of Defense
The chain conveyor to drum pulper setup handles raw OCC bales with minimal fiber damage. Leizhan drum pulpers operate at 10-15% consistency with capacity of 400-600 TPD. The gentle tumbling preserves fiber length — critical for liner board strength.
- Capacity: 400-600 TPD
- Consistency: 12-15%
- Power: 15-18 kWh per ton
- Screen plate holes: 10-16 mm
High-Density Cleaner
After the drum pulper, an HD cleaner removes stones, metals, and glass before they damage downstream equipment. Leizhan HD cleaners achieve 98%+ removal efficiency at 3-4% consistency — saving mills $15,000-$25,000 annually in avoided screen basket replacement.
Coarse Screening with Pressure Screens
The pressure screen system is where many mills lose efficiency. For kraft liner board we recommend: primary screen 1.6-2.0 mm holes, secondary screen 1.4-1.6 mm holes. Motor power 55-90 kW primary, 37-55 kW secondary. Typical reject rate 12-18%.
Fractionation Screening
For multi-layer liner board, fractionation separates long fiber (surface layers) from short fiber (middle layer). Leizhan fractionation screens use 0.15-0.20 mm slots, 75-132 kW motor, handling 250-350 TPD at 1.5-2.0% consistency.
Energy Consumption: Where the Real Money Goes
A 400 TPD OCC pulping line typically consumes:
- Drum pulper: 15-18 kWh/t
- Pressure screens: 8-12 kWh/t
- Refining: 40-60 kWh/t (350-400 ml CSF target)
- Auxiliary: 5-8 kWh/t
- Total: 68-98 kWh per ton
At $0.08/kWh, that is $2,200-$3,100 per day. Optimized rotor design saves 8-12% — meaning $65,000-$130,000 annually over 330 operating days.
Maintenance Tips from the Field
- Screen basket inspection: Every 3-4 months. A worn basket drops efficiency by 15-30% before visible quality changes.
- Drum pulper tires: Check every 6 months. Worn tires cause slippage and 5-10% capacity loss.
- HD cleaner apex: Monthly check. A plugged apex sends contaminants downstream.
- Bearing monitoring: Install continuous temp monitoring. Bearings above 75 Celsius are heading toward failure.
Why Choose Leizhan
At Leizhan Technology, we design complete OCC pulping lines focused on fiber recovery, energy efficiency, and easy maintenance. Our systems achieve over 96% fiber recovery and over 92% availability in 24/7 operation. Every mill is different — we design for YOUR specific requirements.
Ready to optimize your kraft liner production? Contact leizhanequipment@gmail.com for a customized OCC pulping line proposal. Tell us your capacity target and raw material — we will send equipment layout and energy analysis within 48 hours.