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Broke & Trimming Reprocessing Optimisation


The term 'broke' refers to any formed paper from the beginning of the paper making process to the finished product. Broke will exist in many forms and varying quantities and it will always be generated by the paper making process. Depending on the particular case, machine broke will be generated at different locations.

The main goal of a broke system is to return the paper fibre back to the process with no disruption in the uniformity and quality of the stock flowing to the paper machine.  The amount of broke produced during papermaking is normally 5 – 20% of the machine capacity.

This case study describes, how in the pilot industry, the paper machine broke and trimmings generated were collected and fed back into the pulper for reprocessing, 

Implementing Industry

Daman Ganga Paper Mills is a medium sized company engaged in recycled packaging products. Company produce a range of recycled products such as Paper, Core-Board, Cores & Tubes, Fibre-Drums, Partition Boards, Insulation Boards, Acoustic Boards, etc. The company started its operation in the year 1982, with present production capacity of Kraft Board 60 Tons per day, with annual turnover of 50 Crores.


Implemented technology / technique


  • During the paper reel production, prior to final packaging of the rolls, the paper is required to pass through the Pop Real & Re-winder process, in which paper broke & trimmings of about 5% (3 Ton/Day) are generated as process waste.
  • This waste was collected and recycled by directly feeding into the Hydro Pulper for reprocessing and thereby again undergoing the entire cycle of process steps.
  • This reprocessing accounted for additional costs in terms of energy, man power and chemicals consumed, eventually increasing the overall production cost.

  • Continuous reprocessing of fibre also degrades the fibre strength and thus affects paper quality.


  • With small operational change in the process, the broke & trimmings are now directly fed to the Machine Chest through fan pump in place of Hydro Pulper.
  • This change in process circumvents additional reprocessing of material by again undergoing 8 to 9 process steps, and therefore helps in optimising the costs of power, chemicals, man power etc. 

  • It directly results in net saving of energy (electrical power used in reprocessing) to the tune of approx. 50 kWh/ton of paper.

  • By avoiding reprocessing, the strength of fibres is also found to be improved giving an improved paper quality. 


Economic benefits

  • The company implemented change in March 2014 by investing an amount of Rs. 10,000.
  • The observed savings in the electric cost was Rs. 30,000 per month, giving simple payback of 10 days.
  • The total savings of Rs. 3,60,000 per annum (only electricity cost) is thus estimated.

Contact details 

Mr. Banjul Shah, Director;