Apprenticeship training course

Papermaker (level 3)

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Information about Papermaker (level 3)

Working as a machine operator or an assistant in the overall papermaking process converting raw materials into paper products.

• Knowledge, skills and behaviours:
  View knowledge, skills and behaviours

  Knowledge

  • Systems and processes associated with exchange/recording of information required for the role.
  • Site and process safety, environment and risk management systems.
  • Compliance with statutory, industry and company health, safety and environmental regulations.
  • Quality processes and procedures to meet the requirements of quality standards relevant to the organization.
  • Quality compliance requirements.
  • Mechanical pulpers, chemical pulpers, refiners, de-inkers and other such equipment are used to produce optimal flow and required specifications.
  • How fibres react with chemicals.
  • Calculate optimal flow rates using chemicals.
  • Flow in pipes.
  • Vessels including holding and mixing.
  • Chemical additives including process aids and functional aids.
  • Fourdrinier, twin wire systems, multi ply, mould machines and other machines to produce paper for a specific sector.
  • Control sheet forming and drainage through use of control settings of material flow and drainage components.
  • Primary objectives of pressing.
  • Types of presses.
  • Press rolls.
  • Press felts & dry wires.
  • Drying Systems.
  • Steam and Condensate Systems.
  • Calandering systems to gain customer paper specifications.
  • Reel up systems for optimum reel.
  • Slitting systems.
  • Lubrication systems.
  • Basic Air systems.
  • Pump systems.
  • Basic Hydraulics
  • Structures problem solving.
  • Route cause analysis.
  • Fault finding techniques.
  • Basic electrical supply.
  • Health and Safety.
  • 8 Wastes.
  • Key Performance Indicators (KPIs)
  • Process Flow Analysis.
  • Problems Solving Techniques, 5s – Workplace Organization, Visual Management Systems.
  • Standard Operating Procedures.
  • Single Minute Exchange of Die.

  Skills

  • Communicate effectively using a full range of techniques: speaking; listening; writing; body language and presentation.
  • Work safely on a paper machine and other specific areas of the mill, maintaining excellent housekeeping.
  • Be aware of environmental controls and impact.
  • Test the paper to site and customer specifications using a variety of testing equipment and methods.
  • Take responsibility for decisions on quality.
  • Prepare fresh water and primary and secondary fibres and test the properties of material.
  • Operate machines such as mechanical pulpers, chemical pulpers, refiners, de-inkers and other such equipment to produce the specifications required for the paper machine for a specific sector.
  • Produce machine stock through mixing of fibres, additives and colours.
  • Control consistency, dilution, screening and cleaning of stock.
  • Control the use of chemical additives to enhance and improve paper properties utilizing sizing, starch, bleaching and brightening agents.
  • Control the use of chemicals to improve runnability such as de-foamers, fixatives and biocides.
  • Carry out in-depth cleaning of chests, vats, silos, pits etc to an acceptable standard.
  • Operate a paper machine for a specific sector.
  • Carry out forming wire changes to the relevant paper machine.
  • Mechanically drain paper by use of presses and by use of heat by drying and rolling of these.
  • Test and evaluate the quality properties measured on the running paper and control any changes required.
  • Carry out fabric and dry wire changes appropriate to the relevant paper machine.
  • Prepare coatings according to formulae and utilize these according to customer paper specifications.
  • Operate reel up systems for optimum reel.
  • Operate slitting systems.
  • Measure temperatures, pressures, speeds, and flows; carry out adjustments for any measurement out of specification.
  • Carry out basic operator engineering maintenance such as lubrication, fitting of parts and changing filters etc.
  • Carry out deep cleaning on a variety of equipment.
  • Use the lean tools and techniques to identify waste in stock preparation, paper machines and finishing.
  • Able to identify areas for business improvement
  • Carry out a continuous improvement project in a specific area to improve a process.
  • Use KPIs as a tool for measuring performance.

  Behaviours

  • The required attitudes, behaviours and interpersonal skills associated with the professional workplace.
  • Active promotion of positive safety behaviours at all times
  • The ability to work effectively as an individual and as part of a team.
  • Proactivity in finding solutions to problems.
  • A commitment to quality and continuous improvement.
  • A recognition and appreciation of equality and diversity in the workplace.
  • The ability to handle change and respond to change management processes.
• Apprenticeship category (sector): Engineering and manufacturing
• Qualification level: 3; Equal to A level
• Course duration: 36 months
• Maximum funding: £6,000 ; Maximum government funding for ; apprenticeship training and assessment costs.
• Job titles include:
  • papermaker
  • paper maker
  • paper making

View more information about Papermaker (level 3) from the Institute for Apprenticeships and Technical Education.