Many of you familiar with Lean Manufacturing will recognise the Japanese term 'Muda' which means waste, and in lean philosophy is a bad thing, something to be eliminated. But for Muda Paper Mills expansion in Malaysia, waste is a vital raw material.
Muda Paper Mills own and operate two paper mills that have a combined capacity of 300,000 metric tons per year. Manufacturing is designed to produce industrial paper from either 100% wastepaper or from a mixture of wastepaper with virgin pulp. In response to the prevailing market conditions Muda are producing industrial paper from 100% waste paper.
The rising demand for industrial paper from waste paper has necessitated the expansion of production capacity and so the engineers were set the challenge to build additional capacity. Part of the challenge was to replicate existing drying processes and so the engineers returned to Turnbull & Scott many years after we supplied the original heat exchanger. Jamie McGee, Technical Support at Turnbull & Scott recalls the intial enquiry, "The engineer didn't have any drawings or specifications, just our contacts from the nameplate on the previous product. He was not even sure if we still existed, and certainly didn't know where Hawick was!"
Fortunately for Muda, Turnbull & Scott give every heat exchanger a unique identification number and retain all production drawings. "Today these are all stored electronically" explains Jamie, "but we still have thousands of hand drawings in our archive goings back over forty years. Muda were delighted to learn that not only could we supply an exact replica heat exchanger, but all he needed to give us was the unique number contained on the name plate."
In October last year, Muda took delivery of a 2000mm x 2000mm Steel/Aluminium heat exchanger and have now increased their capacity to convert waste into industrial paper, so they can continue to realise their vision.
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