Paper Technology Journal

think in paper – The future of paper
begins at Voith Paper.
News from the Divisions:
LEIPA-Schwedt PM 4 –LWC production line of the newgeneration.
Maxau PM 6 – A challenging projectand its implementation.
Bohui BM 1 – A benchmark in China
for the paper industry worldwide.

19

Innovative Trends in Automation.
Paper Culture:
Deep-frozen, dried – and saved.

Contents

EDITORIAL
Foreword
think in paper – The future of paper begins at Voith Paper
40 years of Voith in São Paulo – a reason to celebrate12
4NEWS FROM THE DIVISIONS
Thai Kraft Paper Industry, Wangsala – Significant cost savings
by upgrading the approach flow systemsof 4 paper machines to Voith C-bar technology
6
LEIPA-Schwedt PM 4 – LWC production line of the new generation
10
Four: the winning number! Successful start-upof the world’s most modern LWC paper machine with Voith Fabrics
15
Contribution by our partner BASF –Using paper chemicals intelligently yields top performance18
Maxau PM 6 – A challenging project and its implementation
20
Like Phoenix out of the ashes – UPM Shotton PM 2 was rebuilt
at the end of 2003 and now achieves ambitious goals
24
Velsen PM 2 with new drive concept –When gearwheels become superfluous
28
New frontiers – new paper mill at Yaslik in Turkmenistan
30
Reader opinion survey – twogether customer magazine:
helpful, useful, interesting, or…?
33
SAICA PM 10 – another complete production line
for the Spanish packaging paper manufacturer
34
Bohui BM 1 – A benchmark in China for the paper industry
worldwide
36
Amcor Cartonboard – Australasia Petrie Mill invests in the future
40
Voith Silent Technologies – SeaLencer
42
The two Offline Janus MK 2 at Chenming/Shouguang show their strength 44
Highest Coating Quality with Cast Coating Technology
46
Voith Process Solutions – Wet End Process Analysis
as the foundation of an optimization of paper quality
and process stability
48
Prozess analysis for stock and water loops –a well-proven process optimization and development tool
52
Innovative Trends in Automation
56
Development trends in non-contact eb drying systems
60
Field Service Specialist PikoTeknik Oy in Finland –one year with Voith Paper now
64
PAPER CULTURE
Deep-frozen, dried – and saved
Highlights

66
70

1

Dear Customer, Dear Reader,
The 19 th issue of the twogether magazine in front of you clearly depicts
the wide array of products and services Voith Paper Technology offers andsuccessfully supplies to its worldwide customer base.
On the one side of the spectrum is the world-class installation of the LEIPA
LWC production unit in Germany that performed from the very beginning to
its expectations. Using 100% recovered paper as raw material, it is a trendsetting novelty in its product segment. Voith Paper Technology supplied
the engineering as well as all the equipment starting from the recovered
paper handling to the roll wrapping and transportation system. It is the
success of the One Platform Concept in combination with the Process Line
Hans Müller

Package (PLP) that allowed seamless project management, start-up andcommissioning as well as process optimization.
On the other side of the spectrum is a small paper production line supplied
to Turkmenistan for the production of printing and writing paper based
mainly on cotton linters as raw material.
Voith Fabrics contributes its part to a demanding puzzle together with ourRolls and Roll Cover Division to make sure that throughout the production
process the web is in touch with optimally engineered surfaces be it rolls,
fabrics or felts.
Looking back at our business year 03/04 we owe thanks our customers
for the continued support and confidence in us. This past business year
has been one of our best. We will invest approx. 50 Mio Euro into a newPaper Technology Center to continue our support of an industry which weare convinced will play an important role in the advancement of mankind
and its standard of living.

Hans Müller
on behalf of the Voith Paper Technology team

2

think in paper –The future of paper begins at Voith Paper
On October 26, 2004, the foundation-stone for a uniqueproject for the future by Voith Paper was laid in Heidenheim: thePaper Technology Center (PTC). With the laying of the foundationstone the go-ahead was given for the world’s largest and mostmodern paper research center, which will commence operations ina year from now. With an investment totaling around 50 million
euros, the PTC marks the highest single investment made so far in
Anja Lehmann
Corporate Marketinganja.lehmann@voith.com

19/05

the field of research and development in Voith’s corporate history.

3

Approximately 60 guests from politics,
industry and the press were invitedto Heidenheim for this historic event.
Dr. Hermut Kormann, President and CEOof the Corporate Management Board ofVoith AG, and Dr. Hans-Peter Sollinger,
Member of the Corporate Management
Board of Voith Paper, together with themayor of Heidenheim, Bernhard Ilg, welcomed the guests and jointly embedded
an annual report, coins and a Heidenheim
daily newspaper in mortar in the preparedfoundation-stone.
The Paper Technology Center opens up
completely new dimensions in research &development at Voith Paper. “The PTC, asa milestone, marks a highlight in ourdevelopment from machine builder toprocess and service supplier”, Dr. HansPeter Sollinger explained to the audience.

At this research unit it will, for the firsttime, be possible to test and optimize thecomplete paper production process underreal conditions in advance – from the furnish to the machine configuration, theautomation system and machine clothingfrom Voith Fabrics up to the final product. With the Paper Technology Center,
it is intended to recognize customer
requirements and the challenges of thepaper industry at an even earlier stage
and to implement future-oriented solutions. The engineers and scientists will
be concerned with, among other things,

increasing the share of recovered paper,raising productivity and quality as well as
reducing energy requirements.
Other points of emphasis of the research
will be the reduction of the water requirements and closed water cycles in paper
production. All these subjects and many
more will make the paper production
process of the future more economical
and, at the same time, protect natural resources. With the Paper Technology Center, Voith Paper will further expand its role
as a leader in technology and innovation.

Laying the foundationstone:(from right to left):
Dr. Hermut Kormann,
Dr. Hans-Peter Sollinger,
mayor Bernhard Ilg.

19/05

4

40 years of Voith in São Paulo –a reason to celebrate

The celebration starts with a press
conference on September 16, 2004.

Mrs. Martina Mann (left), a daughter ofHans Voith, and her niece Ofelia Nick(right) visit the school Friedrich von Voith.

In September, Voith celebrated 40 years of the Brazilian
subsidiary company. Even before its establishment here, Voith
already took part in crucial projects for the Brazilian market throughits partnership with Bardella.

The prediction of Mr. Hugo Rupf, Voith

agement Board, Dr. Michael Rogowski,

AG president at the time could not be

Chairman of the Supervisory Board andmore correct. Today, Voith Brazil is the

Mr. Friedrich-Karl Finck, Corporate Com-

center of competence and manufacture

munications, as well as by the directors

for several products, exporting not onlyof the four Voith companies in Brazil.

capital assets but also technology and

They offered to the Brazilian and foreignknow-how. The events related to the cele-

journalists an optimistic and enriching

Guilherme Nogueira

bration of 40 years of Voith Brazil werescenario about the new plans and busi-

Voith São Pauloguilherme.nogueira@voith.com

attended by distinguished visitors, in-ness foreseen for the country. The jour-cluding customers, members of the Voith

nalists left the event very impressed, notfamily, Voith AG directors, Brazilian au-

only by the corporation history, but also

thorities and foreign authorities, stress-by the figures related to investments,

ing the importance of Voith Brazil and its

production and orders.

cooperators to the Brazilian society, as
well as to the Voith Group.

An unforgettable night

Press Conference

One of the events for the celebrities was
the gala dinner held at the Credicard Hall

19/05

The conference was attended by Voith AG

Theater on September 16th. The highlight

representatives Dr. Hermut Kormann,of the evening came from Mrs. Martina

President and CEO of the Corporate Man-

Mann, who, in a touching speech, told

5

the story of her involvement with Brazil,

Tropical sun and samba rhythm

and a lot of beer. Joy and excitement
contagiously involved all the participants.

including the occasion when she firstcame to the country on a trip with her

Besides the gala dinner, the guests wereparents in the 1950’s. Fifteen years later,

invited to visit the Voith São Paulo facili-

Affected by the samba school rhythm,

she became involved in meeting the chil-ties, where a special meeting place, in-the grand-daughter of Hans Voith, Ofelia

dren of the school named after her

cluding a presentation hall, was built, toNick, described Brazil and the Voith sub-grand-father, Friedrich von Voith, assist-

meet the tour guides and enjoy a special

sidiary: everything is very different, beau-

ed by the Labor Project, sponsored bylunch.

tiful, and everybody is happy and receptive, and she also would like to learn how

Voith.
The employees of the Brazilian subsidiary

to dance samba.

The governor of the São Paulo state,

had their celebration day too. On Septem-

Mr. Geraldo Alckmin, was also present at

ber 18th, Voith offered an Open Doors

In a speech to the employees, Mr. Jo-

Credicard Hall. He mentioned in his

party to the employees and their families.

hannes Hammacher, representing the

speech the importance of Voith to the de-Around 10,000 people attended the event.

Voith family, said in Portuguese: “Always

velopment of Brazil, creating employ-

There was music, raffles, live perfor-

remember that Voith cannot exist without

ment, income, wealth, and playing a greatmance of samba dancers, souvenirs,

you. Brazil will always have a specialsocial role.

playing activities for children, barbecue

place in the hearts of the Voith family.”

19/05

6

1

Thai Kraft Paper Industry, Wangsala –Significant cost savings by upgrading
the approach flow systems of 4 paper machines
to Voith C-bar technology
Gerhard Veh
Fiber Systems
gerhard.veh@voith.com

The Siam Pulp and Paper Public Company Ltd is Thailand’s
oldest and largest producer and converter of packaging and finepapers. Companies in the Group include the paper mills SKIC (Siam
Kraft Industry Co) Bangpong, TKIC (Thai Kraft Paper Industry Co)
Wangsala, TUPI (Thai Union Paper Industries) Wangsala and
Bangkok, as well as TPC (Thai Paper Co.) Bangpong. The paper mill
UPPC in Calumpit, Philippines also belongs to the Group.

Günter Held
Fiber Systems
guenter.held@voith.com

19/05

Voith Paper and Siam Pulp and Paper
have enjoyed a close and trustful partnership for decades. A number of Voith
stock preparation lines and paper machines are installed in the customer’s
mills.

Upgrading the stock
approach flows of PM 4, 5, 6
and 7 in Wangsala
To keep up with the constantly increasing
demands on paper quality and at the

7Fig. 1: Thai Kraft Paper Industry, Wangsala.
Fig. 2: Layout of the stock approach flow
systems for PM 4, 5, 6 and 7.

3
2

Fig. 3: Screen upgrade package for the backlinerof PM 6, consisting of C-bar basket, MultiFoil
rotor and belt pulley.

Approach flow system
Thai Kraft PM 4

Approach flow system
Thai Kraft PM 5

Approach flow system
Thai Kraft PM 6 and 7

Paper grade: CA 112 g/m2, EK 95 g/m2

Paper grade: KL 125/150/185/230

Paper grade: KA 150/230

From stock
storage chest

From stock
storage chest

From stock
storage chest

PS36
PS36
PS36

PS30

PS36

Headbox

Headbox
Topliner

Headbox
Topliner

PS30

PS36

PS36

To broke
chest

PS12
PS24

PS12

From stock
storage chest
PS36

Headbox

To broke chest
PS12

FillerFrom stock
storage
chest

PS30

Headbox
PS30

Filler
PS30

From stock
storage chest

To broke
chest

PS12

From stock
storage chest

PS12

To broke
chest

PS30

PS30

Headbox

Headbox
Backlinersame time reduce production costs, Thai
Kraft initiated an optimization programme
for the approach flow systems in Wangsala. This involved upgrading all the competitor pressure screens in the approachflow systems of PM 4, 5, 6 and 7 to Voith
C-bar technology.
Up till then the screens all operated withrotors with four continuous foils each,
together with milled baskets. Despitelarge slot widths of 0.45 mm, the millcould only achieve the required throughputs by running the screens with very

PS12

PS30

Backliner

PS30

high rotor speeds which meant a highspecific energy consumption.

Energy savings using C-bar
technology

This resulted in disturbing pulsations,while screening efficiency was not sufficient for the high paper qualities demanded by the market. In addition, therotors and screen baskets exhibited very
heavy wear.

Trial delivery for PM 6
backliner
The optimization phase began in February
2002 with a trial delivery of two optimization packages for the screens in thebackliner system of PM 6 approach flow
(Fig. 3).These were upgraded to Voith
MultiFoil rotors and 0.30 mm C-bar slotted baskets. At the same time the rotor
speed was reduced by 29 %. Motor load
dropped immediately by 47 % from 75 toFig. 2 shows the approach flow layoutsof PM 4, 5, 6 and 7 together with thepaper grades produced. PM 6 and 7 are
identical.

19/05

8
4 Location

Machines

Topliner

1st stage

2 x size 36

2 x 92

2nd stage

1 x size 12

1st stage

Power consumption [kW]beforeafter
P

kWh saved per year
(350 days)

2 x 572 x 35

588,000

PM 4

1,354,920 kWh/year

16

12

4

33,600PM 5

1,873,200 kWh/year

2 x size 30

2 x 742 x 402 x 34571,200

PM 6

1,797,600 kWh/year

2nd stage

1 x size 12

21

20

1

8,400

PM 7

1,797,600 kWh/year

3rd stage

1 x size 12

21

20

1

8,400

Total

6,823,320 kWh/year

Backliner 1st stage

2 x size 30

2 x 752 x 402 x 35

588,000
Overall cost savings

Euro 103,600 per year

Filler

Paper grade: KA 150/230

40 kW, representing energy savings of
588,000 kWh per year.
In view of this enormous reduction in energy and the technological improvements
described in the following, the mill completely converted the approach flow systems of PM 4, 5, 6 and 7 to C-bar technology.
Energy balance for PM 6 and 7
Fig. 4 shows the energy balance for theapproach flows of PM 6 and 7, – a totalsaving of 1,797,600 kWh per PM and year.
Overall energy balance for
PM 4, 5, 6 and 7
The energy balance shows overall energy
savings of 6,823,320 kWh per year for all
four approach flows (Fig. 5), representing energy cost savings of approximately
Euro 103,600 per year.
Overall energy balance in thelight of the Kyoto Protocol
At this point it is interesting to consider
the significant reduction in energy requirements in the light of the reduced
CO 2 emissions and the Kyoto Protocol.
The following observation is based on
100 % power supply from a coal-fired
power station.
Certain parameters such as the relationship between energy output in the formof electrical and thermal energy and primary energy input (overall power station
efficiency) and the relationship of electrical energy to thermal energy output(power coefficient), are based on values
taken from similar plants and therefore
may vary from those in Wangsala. The fol-

19/05

Total 1,797,600

Total energy savings

lowing estimate is therefore intended togive an idea of the additional potential
cost savings as a result of the savings inelectrical energy. The following figures
have been used as basis:

Based on the positive trial results with
PM 6 in Wangsala, PM 4 was the first paper machine to be completely upgraded,achieving an impressive increase in stickies removal efficiency.

● CO 2 emission from coal combustion
per kWh primary energy = 0.335 kg
CO 2● Overall power station efficiency = 75 %● Power coefficient = 0.5● Expected emission charges = between
Euro 5 and Euro 12.5 per ton CO 2.

For example, stickies removal efficienciesof 13 % and 34 % in the first screeningstage of PM 4 improved to 63 % and
75 % respectively. The residual stickies
content dropped to less than half theoriginal value (Fig. 6).

The previously mentioned energy savingof 6,823,320 kWh per year is equivalent
to a primary energy requirement of
27,293,280 kWh per year. The resultant
CO 2 emission amounts to 9,143 metrictons per year.
Assuming an emission charge of Euro 8
per ton CO 2 for the emission certificates,
an additional savings potential of Euro73,146 per year is possible.
Technological improvements
by upgrading to C-bar
The following describes the improvements in quality obtained in terms of
stickies removal efficiency. In the backliner trials for PM 6, the stickies removal
efficiency was improved from 25 % to
63 %. This can be attributed to the following:● MultiFoil rotor speed reduced by 29 %● Gentle operation of the MultiFoil rotors● High screening efficiency of the C-barbasket thanks to its flow-optimized
profile● Slot width reduction from 0.45 mm to0.30 mm.

The resultant reduction in deposits on thedrying cylinders and doctors significantly
reduced the number of paper breaks andconsiderably increased the overall production efficiency of PM 4. The same very
welcome improvements were also obtained on upgrading the approach flow
systems on the other PM’s 5, 6 and 7.
The optimization with C-bar technology
also reduced overall fibre losses. Taking
PM 4 as an example, overall fibre losses(Bauer McNett R 14 / R 30 / R 50) dropped
from 0.4 % to less than 0.1 % (Fig. 7).
There was not much change in CSF accepts freeness either compared with theinlet values, despite the significantly reduced slot width. This was a further welcome factor.
Overall fibre losses were much lower
than the forecast and guaranteed values,
providing a further appreciable cost savings advantage.
The reduction in overall fibre losses from
0.4 % to 0.1 % means a savings in raw
material of 1,507 b.d. metric tons per
year. Raw material costs in Thailand areabout Euro 85 per metric ton and pro-5

9

Fig. 8: From left to right:
Wiriyaumpaiwong Sangchai,
Production Department II Manager,
TKIC Wangsala.
Dheerakiatkumchorn Dumrongsak,
Engineering Division Director.
Günter Held, Voith Paper Fiber
Systems.
Kao-U-Thai Montri, TKIC WangsalaMill Director.
Manomayanggoon Nakorn,
Production Department I Manager,
8 TKIC Wangsala.
Before rebuild
0.45 mm milled basket + 4-foil rotor
5.9.2002
6.9.2002

After rebuild
0.30 mm C-bar basket and MultiFoil rotor
18.9.2002, 2 pm
18.9.2002, 6 pm

[g/m 2]

CA 112

CA 115

EK 95

EK 95

Stickies in inlet, 1st stage[mm 2/kg]

8,809

22,538

11,462

14,379Stickies in accepts, 1st stage[mm 2/kg]

8,147

15,663

4,501

3,923

[%]

13

34

63

75

Paper grade

Screening efficiency*
Stickies in inlet, 2nd stage[mm 2/kg]

37,591

58,147103,186

117,487

Stickies in accepts, 2nd stage[mm 2/kg]

28,424

33,771

24,68925,176

46

59

89

83

Screening efficiency*[%]

Stickies in inlet, 3rd stage[mm 2/kg]

824,027

833,463

1,226,880

819,463

Stickies in accepts, 3rd stage[mm 2/kg]

738,889

482,037

100,626

108,728

30

55

93

87

Screening efficiency*[%]

6*mass flow related

Before rebuild
0.45 mm milled basket + 4-foil rotor
5.9.2002
6.9.2002

After rebuild
0.30 mm C-bar basket and MultiFoil rotor
18.9.2002, 2 pm
18.9.2002, 6 pm

Paper grade[g/m 2]

CA 112

CA 115

EK 95

EK 95

Freeness in inlet, 1st stage

[CSF]

123

141

138

162

Freeness in accepts, 1st stage

[CSF]

105

113

131

147

[%]

< 0.4

< 0.4

< 0.1

< 0.1

Overall fibre losses

cessing costs are around Euro 82 per
metric ton. Overall savings attributable to
the reduction in fibre losses total aboutEuro 251,715 per year at Wangsala.
Fig. 4: Energy balance for the approach flowsof PM 6 and 7.
Fig. 5: Overall energy savings for the approachflows of PM 4, 5, 6 and 7.
Fig. 6: Improvement in stickies removal
efficiency for PM 4.
Fig. 7: CSF freeness and fibre losses in theapproach flow of PM 4.
Fig. 9: Total cost savings of Euro 428,315
per year.

● Reduced speed means reduced wear of
rotors, baskets and bearings● Cost savings due to reduced energy
consumption, reduced CO 2 emission
and higher fibre yield (Fig. 9).

Summary of the advantages
gained● The extremely low pulsation characteristics of MultiFoil rotors provide an
improved MD/CD profile of the finishedpaper● The higher screening efficiency of
C-bar baskets ensures better paper
machine runnability, and therefore
increased tonnage off the reel

Kyoto
ProtocolEuro 73,000
Savings due
to reduced fibre
lossesEuro 251,715

Energysavings
Euro 103,600

9

19/05

7

10

LEIPA-Schwedt PM 4 –LWC production line of the new generation
On July 30, 2004 the first LWC paper was wound on the
Sirius reel of PM 4 at LEIPA Georg Leinfelder GmbH in Schwedt an
der Oder, Germany. PM 4 produces 300,000 tons of high-quality
LWC paper per year on a wire width of 8.90 meters. Production canbe based on up to 100 % recovered paper. To produce the highest
product quality, Voith bases the entire production process on the
One Platform Concept.
Andreas Köhler
Paper Machines Graphic
andreas.koehler@voith.com

Everything from a single source– Process Line Package
With this order, LEIPA Georg Leinfelder
GmbH placed its trust in this projectmodel of the future and, with the ProcessLine Package, transferred overall responsibility for the new LWC production line
to Voith.

Falk Albrecht
Fiber Systems
falk.albrecht@voith.com

19/05

The scope of supply included, in addition
to the complete paper machine, also thestock preparation system, the approachflow with broke system as well as thewinder and roll transport and wrapping
system. A comprehensive automation
solution as well as the initial machine
clothing from Voith Fabrics completed
the order package.

11

Fig. 1: LEIPA-Schwedt PM 4.
Fig. 2: Schematic of PM 4.

1

Within the framework of the Process Line
Package, however, Voith not only took responsibility for its own scope of supply.
Rather the sub-suppliers were also incorporated into the overall planning and project processing performed by Voith.
The Process Line Package gave LEIPA
solid advantages: Voith was responsible
for the coordination of all sub-suppliers.
In this way, the interfaces with suppliers
that arose during planning, delivery,
installation, start-up and optimization of
the production line, were minimized. The
convincing result is a very fast and costeffective implementation of the project.
The smooth handling of the project with
the Process Line Package made a major
contribution to the fact that the production line was able to go into operation as
early as 4 weeks ahead of the contractually agreed start-up date.

Systematically to success –LWC from 100% recovered paper
LEIPA and Voith together faced a major
technological challenge with this project.
For the first time, it was intended to produce first-class LWC paper from up to
100% recovered fibres with a production
line of this dimension. To translate thisidea into reality, LEIPA and Voith enteredinto a system partnership.
Within the framework of this system partnership, comprehensive trials were conducted on the Voith pilot machines andwork was carried out on product development in intensive cooperation.
The system partnership forms the basis
for the further successful development of
the project and includes the following
core elements:● Joint planning and conduct of trials● Optimization of the machine even after
start-up to achieve a steep start-up
curve● Support by Voith for technologicalobjectives and further developments
beyond the agreement.
To achieve a good start-up curve, Voith
also carried out Performance Management for the new production line. For
this, the experience gained from thestart-up and operation of comparable machines was evaluated for the LEIPA project in order to determine the optimal
start-up parameters for PM 4 in advance.
Common expertise of LEIPA and Voith
paired with innovative Voith technology
ultimately led to the success: a state-ofthe-art LWC production line that sets new
standards in the LWC paper marketplace.
The LWC paper produced by LEIPA on
the basis of 100% recovered paper meetsthe same quality demands as LWC paper
based on virgin stock. Consequently,
PM 4 produces an economical and highquality, competitive product. Laboratory
analyses as well as the extremely satisfied customers of LEIPA today confirm
the excellent quality of the LWC paper
produced on PM 4.

2

19/05

12

3

4

The DIP went into trial operation (Fig. 4)
at the end of June 2004 – a few weeks
before start-up of the new PM 4. For thestart of PM 4, high-quality stock was,therefore, already available.
Engineering and scope of supply
In DIP 2, with a capacity of up to 850 t /24 h o.d. finished stock, intermediatechests have been largely dispensed with.
Intelligent placing of the individual components has considerably reduced thenecessary space. Short piping distancesin conjunction with the use of frequencycontrolled pumps lead to low specific energy costs. The overall engineering was
based on a 3D model (Fig. 3).

The technological concept
Based on the results of extensive trials, a2-loop deinking system with the following key components was designed jointlywith LEIPA (Fig. 5):

Refining

PM Loop
Bleaching II, reductive
Storage tower

Flotation II
Disc filter II

Disperger I

Bleaching I, oxidative

Screw press I

Loop II

Disc filter I

LC screening // 0.15

Flotation I

EcoMizer Cleaning

IC screening // 0.20

Hole screening 1.6/2.0 dia.

HC cleaning (HIPro)

TwinDrum pulping

Loop I

Screw press II
Disperger II

5

A chemical pulp line for slushing and refining of up to 150 t / 24 h was also supplied.

Paper machine

DIP 2 can supply both PM 4 and also theexisting PM 1. Although one chemical
pulp line exists, the joint objective, however, is to produce LWC paper from
100% recovered paper on PM 4 with aquality equivalent to that of customary
virgin stock-based LWC papers.

The individual machines have been combined in just a few group starts. An overall production control system ensures ahigh degree of operator convenience.
Close cooperation between process engineering and automation resulted in a very
short planning time. An important module – the system for dewiring and intermediate storage of the incoming recovered paper and feeding it to the DIP –was designed in close partnership with
LEIPA. The overall engineering and supply of the additive preparation system required for the preparation process was
also Voith’s responsibility. The rejects
are handled with a concept developedand implemented completely by Voith’s
partner Meri.

Approach flow

The new DIP 2

Fresh water
Conus
Trenner
DAF 3
Rejects
handling

19/05

Sludgehandling

Pre-thickening

Conus
Trenner

Chem.
pulp

DAF 2
DAF 1

Disc filter

PM shower water● The innovative TwinDrum slushingconcept combines gentle breaking
down of the paper into the individual
fibres with reduced additive requirement● The revolutionary EcoMizer cleaner
concept ahead of Flotation I● One of the largest EcoCell flotation
systems (throughput up to 1000 t / 24 h
in Loop I)● Thickening using Thune Bagless discfilters and a further development inThune screw presses● 2 dispersion systems with a newdisperger concept and SpeedHeater for
efficient stock heating and additive
blending● The proven C-bar screen baskets
in IC and LC slotted screening.
Brief outline of the process
After the bales of recovered paper havebeen dewired and mixed with loose paper, the mixture is stored in bays. A
wheel loader loads the furnish from thestorage bays onto a conveyor belt whichfeeds the TwinDrum. Here the recovered
paper is gently broken down into individual fibres at a consistency between 2528%. This high stock consistency as wellas good mixing of the stock thanks to theintegrated displacer achieves excellent
printing ink detachment.
Once coarse contaminants have been
removed from the stock using 2-stage
heavy particle separation and 2-stage
hole screening systems, it is then stored
in the dump chest. The subsequent stockcleaning at a consistency of 2 % using
EcoMizer cleaners provides efficient dirt
particle removal and protects the following IC slotted screening system. One of

13

Fig. 3: Part of the 3D model for DIP 2.
Fig. 4: Partial view of DIP 2.
Fig. 5: Block diagram of DIP 2.
Fig. 6: SpeedSizer.
6

the world’s largest EcoCell flotation systems then ensures efficient removal ofthe detached printing inks.
A 4-stage LC screening system provides
economic removal of stickies.
Ahead of the subsequent dispersion stage,
the stock is thickened to a stock consistency of 30% using both disc filters withwear-free Bagless segments and screwpresses. A SpeedHeater is used to heatup and homogenize the stock and to
blend in bleaching agents. In Disperger I,
any printing ink residues still on the fibres are now detached and optically disturbing particles are reduced in size to
below the visibility limit. At the sametime, peroxide is added directly in thedisperger for the oxidative bleachingstage.
The crumbly stock is then fed via a screw
system to a new type of high-consistency
bleaching tower with MC discharge. In
Flotation II the ink particles detached bydispersion are removed.
At the end of the process, thickening to aconsistency of >30% ensures strict water
separation between DIP and paper machine. Dispersion II is responsible for afurther homogenization of the DIP stock.
A final reductive bleaching stage ensures
a further increase in brightness.
Special attention has been given to watercleaning. Each loop has its own Deltapurge microflotation. The pick-up andmake-up water is also completely cleaned.
ConusTrenner machines in both loops reduce the ash content in the finished stock
when required.

Tightly-closed circuits can lead to extreme heating up of the loops. A consequent philosophy of process cooling using heat exchangers has therefore been
implemented.
LEIPA’s chosen concept ensures a stockwith optical properties close to that ofvirgin fibres. The strength characteristics
needed to meet the requirements of PM 4
are achieved by post-refining of the DIP
stock. The LWC paper produced is certainly a match for the qualities so far
available on the market.

Technology that convinces –One Platform Concept
The new PM 4 is based on the One Platform Concept. With the One Platform
Concept the economic efficiency of thesystem and the quality of the end productare of prime importance. The use ofproven and tested modules permits, precisely with this new, innovative production process, a maximum of planning certainty and reliability. With PM 4, an allonline concept is followed, i.e. precalendering, coating and calendering takeplace online.
The DuoFormer TQv with ModuleJet atthe headbox, which permits a uniformly
controlled CD basis weight profile, is followed by a TandemNipcoFlex Press. The
wire and press section are equipped with
DuoCleaners for the cleaning of all wires
and felts. The second press is equippedin the bottom position with a transfer
belt. The ModuleSteam ensures a uniform
moisture profile at the end of the TopDuoRun pre-dryer section. The first four

dryer fabrics have been equipped with
DuoCleaners for optimal cleaning.
ProRelease Stabilizers reduce the web
tension and in this way allow an increased speed potential. Immediately
after the pre-dryer section follows the
EcoSoft calender for precalendering,which was, for the first time, designed asa soft calender for LWC papers. The
EcoSoft calender has 45° inclined framing (Delta Design) for easier roll changing. The SpeedSizer coating unit isequipped with an automatic coat weight
CD profiling device.
The combination of coater, Profilmatic R
control software and the associated actuator system of the ModuleCoat ensurethat the high demands made on the quality of the paper are met. Between the two
hot-air dryer hoods is the Module IR infrared profiling unit. This selectively
eliminates moisture streaks in the CD
profiles after the coating operation.
BASF, one of the world’s leading manufacturers of paper chemicals, supplied atailor-made chemical package for the new
PM 4. It covers the entire process fromthe wet end up to the coating station. In
accordance with the basic concept of themachine, the system idea is in the forefront also in the case of the chemicals.
The online calender Janus MK 2,
equipped with 10 rolls, ensures maximum calendering quality. Following this,the Sirius reel winds parent rolls of up to
3.5 m in diameter.
Via an automatic rail transport system,
the parent rolls are forwarded to the two

19/05

14

7

8

9

VariTop winders. Afterwards, the slit rolls
are transported to an automatic weighing
device and labeling unit and finally to theTwister 2 Line roll wrapping system. The
finished wrapped rolls are then sent withthe help of chain conveyors over a connecting bridge from the PM building into
the finished goods warehouse.
As part of the Process Line Package,
LEIPA received a production line, that not
only included the complete automation
solution and the machine clothing but

Fig. 7: Reel section with Janus MK 2
and Sirius wind-up system.
Fig. 8: VariTop winder.
Fig. 9: Roll wrapping station Twister 2 Line.

19/05

also had these components optimally
matched to the paper machine in preliminary trials. For a trouble-free startup
curve, forming fabrics, press sleeves,press felts and dryer fabrics from Voith
Fabrics were used as initial machine
clothing.
The extensive Voith Automation solution
includes the process, quality control andinformation system and extends from the
preparation of the raw material to the finished end product. The web browser
makes all current and historical machine,
process and quality data mill-wide available in the information system. This facilitates easy access to data for the planning of optimization work and for trouble-shooting. The automation system was
subjected to extensive functional tests in„Factory Acceptance Tests“ at Voith sothat a tested and pre-optimized system
could be successfully installed.

Ahead of time
Project handling with the Process Line
Package, proven technology based on
the One Platform Concept as well as a
successful system partnership have
proven very successful at LEIPA. Since
production commenced as early as fourweeks ahead of the agreed date, the further optimization phase also went offvery successfully.
The intermediate trial 1 was brought forward by 7 weeks and intermediate trial 2even by 6.5 months: on October 13 thetwo trials were successfully completed
together.

15

1

Four: the winning number!
Successful start-up of the world’s most modern
LWC paper machine with Voith Fabrics
From beginning to end of this gigantic project, 4 was themagic number. On July 4, 2004 LEIPA’s PM 4 started up without ahitch, thanks to 4 decisive factors: the Leipa, Voith Paper andVoith Fabrics teams, plus a brilliant idea. The idea of building an
LWC paper machine using up to 100% recovered paper – a world
premiere.
Olaf Specht
Voith Fabrics
olaf.specht@voith.com

For Voith, the start-up actually began

From test machine to print shop

18 months earlier, with extensive re-Fig. 1: LEIPA-Schwedt PM 4 –the world’s most modern LWC paper machine.

search to check the feasibility of this ma-

The quality of the paper produced onchine concept. The Voith Paper VPM 4

VPM 4 was repeatedly checked using thetest machine in Heidenheim was convert-

latest analysis equipment. Towards the end

ed accordingly, and Voith Fabrics adaptedof the preliminary project phase, paper

the machine clothing in all three sections

samples were sent for printing and after-to the new requirements.

wards analyzed in the laboratory for print-

19/05

16

Fig. 2: PM 4 machine hall on the
LEIPA-Schwedt site.
Fig. 3: Happy teamwork between LEIPA andVoith Paper Technology.
From left to right: Josef Reinartz, Voith Paper,
Manfred Schäfer, LEIPA-Schwedt, andMartin Serr, Voith Fabrics.

That is why I am so glad we chose Voith

2

Fabrics, who took over everything for us
without problem”.
PrintForm H in the former
LEIPA’s PM 4 started up with structurally
integrated SSB wires in the TQv former.
Voith Fabrics PrintForm HC inner andouter wires more than satisfy all the main
ability. This extensive project sequence

A special challenge for fabricparameter requirements for a modern

ensured full satisfaction not only forsuppliers

forming wire. The combination of numerous sheet support points and minimal

LEIPA-Schwedt, but also for its customers – the print shops. “Voith’s effort

As shown in recent years, fabrics are de-wire thickness make excellent paper qual-

in this project, already before it began,

cisively important for the successful

ity at high production speeds possible,

was enormous”, said Manfred Schäfer,start-up of modern paper machines.

without interference by entrained water.

PM 4 production manager. “Comprehen-

Voith Fabrics has gained a lot of experi-“Voith Fabrics is first class not only withsively and in full detail, all interrelation-ence in this connection. For example, allregard to the former wires”, comments

ships between the machine concept, raw

significant new machines and rebuilds in

Schäfer, “but also in consistent produc-material and fabrics were investigated toGermany during the last two years alone

tion quality and adaptability to new chal-ensure optimal cleaning, optimal service

started up with Voith Fabrics as a suppli-

lenges. Voith is extremely reliable in mylife and optimally consistent paper qualityer – both for graphic grades and forexperience.”even before the actual installation work”.

board and packaging papers.
PrintFlex O in the press

Thanks to these efforts, PM 4 was started“Modern paper machines are a special

up four weeks earlier than planned, andchallenge for fabric suppliers”, confirms

The tandem-NipcoFlex press was started

produced saleable paper right from the

Schäfer, “the latest machine concepts areup with PrintFlex O double layer felts,

beginning.

not easily adaptable to suit the fabrics.

which are also well proven with Rhein

3

4

19/05

5

17

Papier in all positions. PrintFlex O felts

ning stability were continuously im-

have excellent start-up behaviour, withproved, so that operation today is charac-

stable drainage characteristics over theirterized by exceptionally long service life

entire service life. Their good condition-and outstanding reliability. “I have to rely

ing behaviour and constant permeability

totally on the dryer fabrics and related

havemoisture

service”, emphasizes Schäfer. “I gladly

cross-profile. Currently, felts from fourdelegate felt change scheduling to thedifferent suppliers are being tested in the

supplier – in whom I place my competepress section.

trust. It takes time to build up such con-ensuredaconsistent

ManfredSchäfer
Production
Manager PM 4
LEIPASchwedt

fidence, but after more than thirty years

Right though the PM 4 project, Manfred

Voith Fabrics has already received follow-

in this business, I know the quality and

Schäfer has repeatedly praised the goodup orders for both presses. “We are still

reliability of Quantum or PrintTech fab-

teamwork with Voith.

in the test phase”, says Schäfer, “and werics.”“Problems occur with every new project, but the way the supplier solves

shall certainly not keep all four suppliers.
Decisive in the end is the overall concept

them is decisive. And that is what really

A strong teamimpressed me about Voith. They always– forming, pressing and drying have to
be mutually complementary and harmo-

For Voith, the success of this project is atook our needs very seriously andnious.”

matter of prestige. “We are well aware

worked out solutions together with ourthat at the present time the eyes of theteam. Furthermore, it is an enormous

world are focused on LEIPA’s PM 4”,

advantage when the supplier brings

PrintTech Q in the dryer section

says Martin Serr, Voith Fabrics marketingalong his own felts for start-up. In

The first four dryer groups were started

manager Germany, Austria, Switzerland.

short, the service provided by Voith

up with Voith Fabrics PrintTech Q2 and“The experience and know-how we ac-

Paper and Voith Fabrics is exemplary –PrintTech QC. Once again, these high-quire working together with the Voith Pa-

both with regard to speed and quality.

speed fabrics proved themselves with

per teams will also help to boost produc-

Together, we have mastered all theoutstanding

dependable

tion for our other customers. At the nextchallenges of this project. And that ispress-to-drying transfer, and easy clean-start-up at the latest, we again can say:what I call teamwork!”

ing. Their abrasion resistance and run-four’s the winning number!”.

webcontrol,

Fig. 4: Voith Fabrics PrintForm H –structurally integrated SSB forming wire.
Fig. 5: Voith Fabrics PrintFlex O –double-layer press felt for demanding start-ups.
Fig. 6: Voith Fabrics PrintTech Q2 –dryer fabric for high-speed paper machines.
Fig. 7: Voith Fabrics PrintTech QC –dryer fabric with high resistance to dirt andabrasion.
6

7

19/05

18

Contribution by our partner BASF –Using paper chemicals intelligently yields
top performance
Most modern paper chemicals used in the production andfinishing of paper and board are functional polymers. Carefully finetuned to each individual paper machine, they control operational
performance and paper quality. Planning begins at the design stageof a new production plant. An example of this is Voith Paper’s joint
project with BASF for starting up LEIPA’s new PM 4 in Schwedt ineastern Germany.
Dr. Eckhard Parzich
BASF Aktiengesellschaft
eckhard.parzich@basf-ag.de

Dr. Hubert Meixner
BASF Aktiengesellschaft
hubert.meixner@basf-ag.de

Investing in big, state-of-the-art machinery has to pay off – and fast. What thismeans for machine suppliers is obvious.
The operating features of the machines
and the required paper qualities are both
crucially dependent on the materials
used. And these are first and foremost
raw materials. Without, however, a customized paper chemical system to control
it, even the most modern paper machine
cannot fully exploit its quality and performance potential. This is particularly true
when recycled paper is the only raw material used, as with the new LEIPA PM 4.
The paper, after all, has to satisfy the demands of the market. Printability, whiteness, tear resistance, surface feel andmany other properties are specified bycustomers in order to make the chancesof successfully marketing their products
calculable.

Cooperation generates added
value
Fig. 1: Pilot coater at Voith Paper, Heidenheim.
Fig. 2: Pilot coater at BASF AG, Ludwigshafen/
Rhein, Germany.
Fig. 3: The BASF AG site at Ludwigshafen/
Rhein, Germany.

19/05

The trend towards consolidation in thepaper industry and fierce competition between suppliers has intensified the pushtowards further increases in efficiency
across the entire process. Along with

Voith Paper, we see this as an enormous
opportunity – not least due to the positive experiences made during joint projects in the past. Bundling the resourcesof both partners within the framework ofefficient project management generates
added value for the paper industry. Thereis particularly strong potential in cooperating on the planning and launch of newpaper machines – for their mutual customers.
As a specialist for modern paper chemicals, BASF has developed a chemicals
system for LEIPA that spans the entire
process from paper production to paper
coating. What is crucial is ensuring thatthe various parts of this complex system– raw materials, process technology andpaper chemicals – are meticulously finetuned.
Even before the PM 4’s first trials, BASF
and Voith successfully met the paper
quality required by LEIPA. The tests werecarried out under realistic conditions inboth companies’ pilot plants. The subsequent printing trials confirmed that ourformulations delivered the desired results. These pre-trials made a vital contribution to preventing delays in the191

ambitious timetable and to ensuring astable operating performance from themachine’s very first start-up trials.
The example of the No. 4 machine at
LEIPA clearly shows that working together with the machine supplier, our strategic partner Voith Paper, means we canachieve ideal results more quickly andmore efficiently. Our timing was spot-on
and in fact we were even several weeks
ahead of schedule. Together with our2will benefit our customers in the future.
One of these is the curtain coater, a technology in which Voith is a leader andwhich was largely developed at its pilot
plant in Heidenheim, Germany. Here too,
we will be taking advantage of the synergies created by the research and development potential of our two companies andin this way improving considerably the
chances of introducing new technologies.
Our partnership with Voith Paper is both
successful and open.

customer, we now plan to identify further
room for improvement and to implement
the necessary measures swiftly.

New ideas for tomorrow’s
projects
Of course we do not persist in our current level of knowledge. Along with ourstrategic partner Voith Paper, we areworking on development projects that

3

19/05

20

Maxau PM 6 –A challenging project and its implementation
In March 2003, Stora Enso placed an order with Voith
Paper for the replacement of Voith PM No. 850 supplied in 1968
with a high-capacity paper machine for magazine papers.
The project

Ewald Budweiser
Paper Machines Graphic
ewald.budweiser@voith.com

To dismantle a complete paper machine
including the peripheral machine sectionsin an extremely short rebuild time andhand it back to the production process
requires an enormous effort in planning
as well as good organization in the dismantling/installation phase, as well as
during start-up.

Manfred Dreuse
Fiber Systems
manfred.dreuse@voith.com

2

19/05

Our customer set ambitious goals for thisproject:● Doubling annual production
to 260,000 t(plus further expansion reserves)● Increasing the trim widthby 300 mm to 7,200 mm● Fitting the new PM into the existingbuilding

21

Fig. 1: Maxau PM 6.
Fig. 2: Schematic of Maxau PM 6.
Fig. 3: Wire change.

NipcoFlex Press and Online Janus Calender, but also all auxiliaries, the approachflow system including broke pulper aswell as the complete production line engineering. As part of the Process Line
Package (PLP), the scope of supply also
covered the process pumps, tanks, piping
and air system equipment as well as theentire installation work, start-up and personnel training.

3

Project handling
Cramped space conditions and the linkage of the process piping and wiring withpaper machines 7 and 8 that have grownover the years rendered the implementation of the rebuild activities difficult.
1● Project duration max. 18 months● Shutdown time max. 65 days, incl. theextensive civil engineering work.
The project developed, based on thesetargets, from the first day on into a superlative for design, planning and logistics. Voith was able to convince the customer in the project phase that this could
only be achieved by minimizing the interfaces, i.e. by Voith Paper supplying all
the equipment and taking overall responsibility. The order covered not only
the paper machine based on the proven
One Platform Concept with DuoCentri-

During the planning phase further basic
knowledge of the extent of the construction work to be carried out in the peripheral system became transparent. This
necessary civil engineering work required
detailed progress and deadline schedules. Optimal implementation of theactivities between civil engineering andmechanical engineering was required tomeet the time frame.
When the old PM was shut down on
July 2, 2004, a meticulously planned
rebuild action began. The first machineparts in the wet end had hardly been dismantled when the civil engineering work
began with excavators lifted in throughthe roof to demolish almost the complete
machine framing.
The dismantling of the cabling, which has
grown over the decades, had to be prepared in tricky detailed work. Tracing ofcable routes, existing dead cables, identifying the cables and safety-conscious
dismantling of the cables called formonths of preparation work. The result
was extremely positive. Neither of thetwo paper machines still running was
stopped, and the safety requirements
were all met.
The reel section with Sirius reel andJanus calender were already installed
when the construction workers were stillworking on the wet-end foundations.
At times more than 1,300 erectors, civilengineering workers, electricians, pipe
layers, etc., were performing the impossible on a daily basis in cramped spaceconditions: punctually on August 31,
2004 the main part of the installation
work was finished and the start-up team
could begin with the check-outs.

19/05

22

4

Automation
On the basis of a uniform and constantoperating and engineering interface forthe machine controls, the process andquality control system, Voith Paper
Automation supplied the entire automation for the Maxau PM 6 production line.
The OnQ quality control technology ismatched to the production process insuch a way that short control loops andthus fast response times on changes in
the quality parameters are possible. Besides the OnQ quality measuring frames,
numerous CD and MD controls are usedin production. Thus an SC paper is produced on PM 6 that is perfectly suited
to further processing in the rotogravure
printing process.
The automation concept is completed by
the OnView Information System with machine and process status monitoring aswell as a sheet break analysis and sheet
inspection system. With this, all product,
process and machine data can be collected, analyzed and prepared. In addition,
the VariTop winder has been completely
Technical specifications of PM 6
Wire width

8,100 mm

Untrimmed web width

7,300 mmDrive speed

1,800 m/min

Design speed

2,000 m/min

Planned annual production
Phase 1

260,000 t

Planned annual production
Phase 2280,000 t

Basis weight45-56 g/m 2

Quality

SC-B (rotogravure)

Start of production

September 2004

19/05

renewed with the latest control and visualization technology meeting after therebuild the demands made on winders of
the new generation.

● Complete engineering and delivery of
the electrical control and power section● Increasing the capacity of the DIP
stock production, including disc filter
rebuild work.

The result
Stock preparation
On September 15, Voith Paper again proved
with the production of the first paper rollon the new PM 6 their professionalism inthe processing of such complex projects.
The first printing tests turned out to bepositive and allow us to expect an optimal conclusion to the project.
The production line of PM 6 includes thefollowing modules of the One Platform
Concept:● ModuleJet headbox● DuoFormer TQv● DuoCentri-NipcoFlex press with 4th press● TopDuoRun dryer section● Janus calender● Sirius reel
● VariTop winder (rebuild)● Complete engineering for PM andperipherals as well as almost completedelivery

As deinked recovered paper is also usedas the main furnish besides bleachedgroundwood and chemical pulp, thecapacity of the existing recovered paper
preparation system also had to be
expanded because of the significant increase in the paper machine capacity.
The production rates have been continually raised over the past few years and all
three DIP systems have been operating
significantly beyond their original layout
specifications. The additional capacity
increase by about 20%, spread over two
DIP lines, therefore presented a greatchallenge.
First, a detailed project study and balanceof the actual condition of the two selected DIP lines 1 and 3 were carried out.
5

23

Fig. 4: Reel section with Janus MK 2
and Sirius reel.

Carsten
Wenk

Fig. 5: TopDuoRun dryer section.

Production
Manager
Stora Enso
Maxau Mill

Fig. 6: The EcoCell primary cells forpost-flotation in DIP 3.

Based on this, the rebuild concept forthem was prepared.
For the capacity increase not only the existing machines but also all the peripherals had to be taken into consideration.
This was undertaken within the framework of the basic and detail engineering,
also carried out by Voith.
The major bottlenecks in DIP 1 were
pulping, MC slotted screening and thickening, in DIP 3 thick stock cleaning,pre- and post-flotation and likewise thickening.
By re-arranging the process layout andmodifications to existing machines, theextent of new investment has been
reduced to a minimum. Voith supplied a
Fiberizer for DIP 1 to assist pulper discharge operations as well as a vat thickener which was installed in parallel withthe existing thickener. The supply for
DIP 3 mainly consisted of an EcoCell
primary flotation stage for post-flotation,
consisting of five cells and the recently
developed EcoGaus foam killer, which
effectively destroys the foam directly in6

the foam collecting channel. The existingflotation cells that became free were split
up and installed in parallel with theprimary cells in the pre-flotation stage aswell as providing a new secondary stage
for post-flotation. This now allows themill to operate a separate loop layout.
As part of the expansion of the deinking
plants DIP 1 and DIP 3, Voith Paper
Automation provided the entire control
and instrumentation engineering, including the logic diagrams. The new components have been seamlessly integrated
into the existing process control systemand the group controls for new and old
conponents optimally combined. In DIP 1
the old process control system has been
completely exchanged for a new one.
Installation and start-up were also carriedout by Voith.
The results are convincing: both the contractually agreed production increases
and also the promised quality parameters
were reached shortly after start-up of DIP
1 and 3.

“With a great deal of commitment andcompetence on the part of all those
involved, the time pressure was successfully withstood. Even if the originally planned deadline for ,Paper on
Pope‘ was delayed by three days, thestart-up team brought forward by twodays the goal of producing salable
paper by September 24 at the latest.
From ,Stock on Wire‘ up to the firstsalable roll in eleven days – that is top
performance. A good quality approvedby our customers has been uninterruptedly produced since September 24,
2004.“By modifying the pulper helix and installing the additional Fiberizer in DIP 1,
pulping capacity significantly increased
and pulping quality as well as contaminants discharge were further improved.
Initial stickies tests showed a 50% reduction of the stickies content in the finishedstock, – a factor mainly attributable
to the modifications in the individual
screening stages.
Although the production of both DIP
plants was significantly increased, brightness of the finished stock has been maintained at a high level. In addition, by rearranging the pre- and post-flotation
stages in DIP 3, bleaching chemicals
have been significantly reduced. Achieving the required objectives in such ashort time was only possible thanks to asmooth and close cooperation between
supplier and customer.

19/05

24

Like Phoenix out of the ashes –UPM Shotton PM 2 was rebuilt at the end of 2003
and now achieves ambitious goals
The UPM Kymmene Shotton mill is located in North Wales.
About half an hour’s drive west of Manchester and a short distancesouth of Liverpool, a paper mill was set up here on a former steel
works site as part of Mrs Thatcher’s programme. In 1985, the millstarted with one paper machine, followed in 1989 by a second one.

Kerst Aengeneyndt
Paper Machines Graphic
kerst.aengeneyndt@voith.com

3

19/05

25

Fig. 1: Shotton Paper 2003.
Fig. 2: 1980 (Steel plant).
Fig. 3: Schematic of PM 2.
2

1

Within a short time, UPM Shotton developed into one of the largest and most important suppliers of newsprint based on
TMP and recovered fibre.
In 2002, UPM established the “100%Shotton” Project. This means that, in
future, Newsprint will be produced exclusively from domestic recovered fibre.
A new, third recovered fibre system has
been installed (see twogether issue
18/04).

Within the three-week November 2003
shutdown, the PM 2 was rebuilt:● the third press was converted into ashoe press(max. linear load 1,050 kN/m),● the fourth press was replaced by anadditional dryer group with two
ProRelease boxes,● the fifth dryer group was converted
from two-tier to single-tier,● a ropeless threading system wasinstalled,

Technical Data PM 2
Construction year
Manufacturer/RebuildPress
V reel (m/min) actual
targetPC (km 2 /m/d) actual
targetTons (t/d)
actualtargetBasis weights (g/m 2)
Paper grade

1989/2004
Valmet/Voith
Sympress + NipcoFlex
1,623
1,700
2.05
2.15
770
807
42.5-48.8
Newspaper

19/05

26

Fig. 4: PM 2 Wet end section.
Fig. 5: PM speed.
Fig. 6: Specific production.
Fig. 7: Number of breaks.

Pasi
Häyrynen

4

Project
Manager
UPM-Shotton
PM 2“Shotton PM 2 partnership with Voith
has been a very successful process.
In practical terms this partnership has
meant that we have had a Voith startup engineer on site since the start up.
This has allowed us to bring up any
issues with the new equipment immediately and problems have been solved
much faster. Also, issues left from the
project have been followed up in a very
professional way and feedback has
been quick and actions have been taken
to correct problems as soon as possible. We have been able to address any
additional training issues immediately
and this is still ongoing. Voith engineer
has become an important member of
our area team.”

1,600

1,500
Rebuild
1,400
Jan 03

19/05

PM 2 went into operation after a short,effective start-up. The first weeks after
start-up were convincing and promising.

Nov 03

Nov 04

Nov 05

ActualTarget
2.0

1.8

1.6
Rebuild
Jan 03In the meantime, the specific productionof PM 2 is stably above 2.00 km 2/m/d.

7

2.2
Specific production [km2/m/d]

PM speed [m/min]ActualTargetIn the subsequent optimisation phase in asystem partnership between UPM Shotton and Voith Paper, measures and improvements were worked out that helped
PM 2 toward stable running and high efficiency within a few months.

The particular challenge was that many
existing parts had to be reused and,
therefore, the time frame was very tight
due to extensive adaptation work.

6

1,700

The speed distinctly exceeded the self-set
target. The number of sheet breaks, theduration and number of unscheduled
shutdowns showed that there was further
need for optimisation.

Nov 03

8
Number of breaks [per day]5

● the gap due to the missing breakerstack was closed by dryers andDuoStabilizers,● four DuoCleaners were added for the
first dryer groups,● a water-jet tail cutter and● a HiVac were installed.

Nov 04

Nov 05

ActualTarget6

4

2
Rebuild
Jan 03

Nov 03

Nov 04

Nov 05

27“Perhaps you remember me.
I’ve been here before...”The project goals of 2.15 km 2/m/d and1,700 m/min at the reel are certainly realistic.
After just six months, the official acceptance test of the machine was carried out
and, almost simultaneously, in the presence of HRH Prince Charles and a large
number of British and international
guests from industry and politics, UPM
Shotton celebrated the inauguration of
the new recovered fibre preparation system. Prince Charles, who opened the newmill 25 years before, began his speechwith the amusing words “Perhaps you remember me. I’ve been here before...”The system partnership included the optimization of the two paper machines fromthe approach flow system to broke reduction. The success of PM 2 also “spilledover” to PM 1, which has not yet been rebuilt by Voith. The strict separation ofstock supply and also the water andbroke systems play here an importantpart. In addition to a consistent shutdown
management, the optimisation of thechemicals’ balance produced the major
breakthrough.
With these latest successes, UPM Shotton and Voith have demonstrated theirpotentials.

Like “Phoenix out of the ashes”, UPM
Shotton has moved with a powerful beatof its wings into the realms of Europe’s
most efficient paper mills and will in
future not have to comply with standards
but will set standards.

Voith Paper is proud to have participatedin the past and will participate in the
future history of success as a reliable
partner to UPM. On Voith’s side, UPM
will be continuously and competently
supported in all matters of paper production and technology.

19/05

28

Velsen PM 2 with new drive
concept –When gearwheels become superfluous

Papierfabrik Crown Van Gelder, Velsen, Netherlands, iswell known for its excellent woodfree papers, that are used forgraphics as well as industrial purposes: e.g. labels, endless laser
printers, boarding passes, writing and office papers. With themulti-year investment plan 2 the annual capacity will be increased
by 20,000 t/year. As the first step, Voith received an order for therebuild of PM 2 in September 2003.
Dr. Thomas Elenz
Paper Machines Graphic
thomas.elenz@voith.com

The following major objectives have beenachieved:● increase in production capacity,● distinct savings in steam through heatrecovery and new drying technology,● shortening of the threading times,● increased automation,● greater safety for the operators,● downtime reduction with new drive.

For the first time, Voith implemented thedrive of the entire dryer section withoutgear wheels, drive shafts and gear units,
but with the electric drives called“attached drive” (Fig. 3). The great advantage is that the motors are simply
slipped onto the journals of rolls anddryers both on the front side and on thedrive side.

The work was focused on the dryer section, but the press was also improved
with the use of the mill-proven G2000 rollcovers and expansion of the vacuum system. After an extremely tight delivery
time of seven months plus one month installation time, PM 2 went into successful
operation on June 5, 2004.

As gear wheels are not used with thisconcept, lubrication is no longer necessary and gear wheels as wear parts nolonger exist.
Finally, the noise levels have been so
enormously reduced that Klaas Flens,Senior Production Engineer at Crown Van
1

19/05

29

MiklasDronkers
Operations
Manager
Crown Van
Gelder N.V.
2

Gelder says: “Our PM 2 is now so quiet
that we can even hear if a sheet breakhappens on PM 1 behind it.”
Another important goal of the rebuild was
the new air and drying system, which has
been installed in a new, external “airhouse”. The esthetic design – similar to aroll of paper – has been arranged byVoith outside of the building above theoffices. The enormous heat recovery system and the new air system with stabilizers allowed us to easily achieve ourgoals.
With this order, Voith implemented forthe first time the PLP Concept (ProcessLine Package) in a major rebuild. Voith

was the overall supplier of all components and services inside the machinebuilding, inclusive of mechanical andelectrical drive, sectional electric drive,
DCS expansion, air system and heat recovery. The advantages for the customer,
such as the elimination of interfaces, one
contact partner and shortening of the
project time also show up in the excellent
start-up curve.

The new drive technology fulfils all expectations up to now and is classified asa trendsetter for future projects. Six
months after start-up all monthly results
are fully according to plan.

“The rebuild of PM 2 is the largest
project we have had for 15 years. As a
key element of our investment Master
Plan II, the rebuild will contribute toincrease our production by 20,000 t/year.
Just ten days after paper was wound
up on the reel, the targeted production
speed of 1,000 m/min was reached.
It was a great experience for all of us at
the paper mill to witness how smoothly
this success was achieved and how theimportant modernization of our PM 2,
in cooperation in a spirit of partnershipwith Voith, was implemented.”

3

Fig. 1: Miklas Dronkers in front of the new“air house”.
Fig. 2: Velsen PM 2 after-dryer section.
Fig. 3: From the left, in front of the “attacheddrive” at dryer 43: Axel von Noorden, head ofstart-up engineers at Voith Paper; Dr. Thomas
Elenz, Sales Benelux countries at Voith Paper;
Miklas Dronkers, operations manager
Crown Van Gelder; Andre Duiker, project
manager at Crown Van Gelder.

19/05

30

New frontiers –new paper mill at Yaslik in Turkmenistan
A small member of the Voith family made a contribution
to bring the name Voith to the new frontiers. At the end of August
Ulrich Flühler

2002, Voith Paper Schio in Italy signed a contract with Çalik

Voith Paper Schio, Italy
ulrich.fluehler@voith.com

Holding of Istanbul for the delivery of a complete paper production
line from headbox to winder in Turkmenistan, a country of theCommonwealth of Independent States of the ex-USSR.

William Nunes
Voith Paper Schio, Italy
william.nunes@voith.com

19/05Çalik Holding is a Turkish entrepreneur
who is investing in industrial plants inseveral Moslem and Arabian countries. In
Turkmenistan this company operates alarge textile plant for several years producing jeans for the United States. In addition they have fertilizers plants, buildings and power generation plants underconstruction.

The supplied paper production line was
integrated in a green field paper mill, thefirst paper mill in Turkmenistan. This wasin any case a success because in only
14 months Voith Paper, Schio, was able
to deliver and to erect with the customer
the whole machine. All equipment wasdelivered to Turkmenistan by about 100
trucks, a part coming from Heidenheim

31

Aral Sea
Kazakhstan

CaspianSea

Usbekistan

Kzyl-ArvataFig. 2: DuoFormer D.

Turkmenistan

ar yFig. 1: The paper machine in Yaslik
shortly before official handover.

Dzangaud

1

At present, the final product of writing
and printing papers is made from 35%
straw and 35% cotton. Already a basis toreach the project target: Paper production from 50% straw and 50% cotton. An
early start-up has been made possible by
the edition of long and short fibres,bought on the market, to the above men-TashauzAmknown by Voith. In crucial moments,
more than 230 people were on site inorder to complete erection in time. Voith
provided one erector supervisor, Mr. M.
Lago, responsible for the complete erection of the paper machine from the headbox to the winder. Mr. A. Antoniazzi,
responsible for the complete commissioning, instrumentation and check-out,
played a crucial role to start up the production line. Technological support camefrom some specialists from Europe.

Kazakhstan

Amu-Darya

Ashkabad
YaslikKarakum Canal

Iran
KushkaAfghanistan

Technical Data
Untrimmed width

3,550 mm

Operating speed

600 m/min

Design speed

900 m/minDaily production

180 t/dayBasis weight

60 g/m 2

and Krefeld (Germany) and Schio (Italy)
and the rest from São Paulo (Brazil) byship via Bandar Abbas (Iran). All 100
trucks arrived without major accidents.
This was the first positive point. Also theexcellent constructed building was finished in time.

2

The production line was designed to use
the two local raw materials straw pulp
and cotton linters.
The stock preparation plant for bleachedstraw pulp came from India and the line
for cotton linters came from Spanish andFrench suppliers. Fortunately the stock
preparation plant is also suitable to produce long and short fibre pulp. This
helped to start the production line in theforeseen time. Machine erection was
done by an Indian company, SFE, well

19/05

32

3

Fig. 3: Çalik Holding, plant Yaslik in Turkmenistan.
Fig. 4: DuoCentriNipcoFlex press.
Fig. 5: Winder.

Vahit
GokhanProject
Manager GAP
INSAAT,Çalik Holding“For our new paper machine we havedecided on the solution by Voith as
Voith’s was the one we trusted most.
They were in a position to meet all our
requirements by cooperating in a spiritof partnership with us. In retrospect I
must say that we made the rightdecision. The project was a complete
success.”4

tioned raw materials, the resulting paper
comes up to all expectations.
To everyone’s satisfaction, the production line was inaugurated on 21st May
2004 in an unforgettable ceremony, inthe presence of the Turkmenistan President Mr. Saparmyrat Türkmenbaşy and
Dr. Hermut Kormann, President and CEOof the Corporate Management Board ofVoith AG. The mill is now a good reference and can be visited by potential customers of the Middle East area.

For this PM Voith hasdelivered:● Masterjet FB Headbox with ModuleJetdilution water technology for bestbasis weight distribution and fiber

orientation, lamellas to improve paper
structure and a Profilmatic control
concept.
● Fourdrinier and Duoformer D for agood formation and symmetric dewatering.
● DuoCentriNipcoFlex press to ensure
highest dry content, since straw pulp
has a high content of fines.
● Double tier pre- and after dryer
section, SpeedSizer, rope tail-transfer
system.
● DuoSoftNip Calender with thermo rolls
heated with warm oil in order tominimize two-sidedness.
● Reel wind-up diameters up to2,600 mm, jumbo rolls magazine,
Unwind and Variflex S Winder.
The order included also lubrication system and basic process engineering.
5

19/05

33

1st prize:
Wellness weekend for two.

Reader opinion survey

twogether customer magazine:
helpful, useful, interesting, or…?
Dear Readers,This year, twogether magazine celebrates
its tenth birthday – how time flies! Since
the first issue in 1995, readership worldwide has almost tripled. The editorial
team is of course very proud of thisgrowing interest, but we shall certainly
not rest on our laurels. In order to ensureongoing improvement, we would like to
ask you two questions: Does twogether
magazine in its present form meet yourinformation needs in full? Which aspects
could or should be expanded in youropinion to meet your own needs andthose of readers in general?
In order to find out as much as possible
about your needs and wishes, we havelaunched a reader opinion survey on our
homepage at
www.twogether.voithpaper.com

We depend on our readers to help us
make twogether magazine even better. So
please spend a few minutes of your valuable time answering the straightforward
questions we have prepared for you.
As a small tribute of thanks, we will raffle
off a wellness weekend for two andseveral other attractive prizes among
those responding to this call. Maybe you
will be one of the lucky winners!
We shall carefully evaluate all replies received. The results will be reflected in our
editorial planning for twogether magazine
as well as its content and graphical layout. Many thanks for your valuable assistance!
Last deadline June 30, 2005

2nd prize:
Sony DSC-T3 Cyber-shot digital
camera in silver-finish housing only
17 mm thick.

3rd prize:
iPod mini (blue),
4 GB, for Mac
and PC.

4th to 10th prizes:
1 USB 128 MB memory stick.

19/05

34

SAICA PM 10 –another complete production line for the
Spanish packaging paper manufacturer
Never change a winning team! True to this motto, theSpanish paper manufacturer SAICA (Sociedad Anónima Industrias
Celulosa Aragonesa) again decided with its new production line infavour of the reliable Voith technology and trusted cooperation
when it placed the order for the supply of the new PM 10 line with
Voith in May 2004.
HelmutRiesenberger
Paper Machines
Board and Packaging
helmut.riesenberger@voith.com

Benito Rodriguez
Fiber Systems
benito.rodriguez@voith.com

Fig. 1: Schematic of PM 10.
Fig. 2: Only positive experience with the PM 9that went into operation in 2000.

1

19/05

After the throughout positive experience
with the PM 9 that went into operation in
2000, there was a wide range of reasonsfor continuing the successful cooperation. On the one hand, the One Platform
Concept has been more than proven at
SAICA, reflected in the fact that the existing PM 9 has been running at the highest
level of productivity since its start-up andis actually the world’s most productive
line for the production of corrugating
medium. Furthermore, SAICA is again relying on the exceptionally good cooperation with Voith that was demonstrated inparticular during the optimisation of thisworld-class line.
For the new PM 10, that will go into production in May 2006, Voith will supply
the stock preparation system and the paper machine, including an automation
package, and hence practically the wholeprocess technology. The paper machineis laid out for a wire width of 8,550 mm

and a design speed of 1,800 m/min. The
operating speed is 1,500 m/min. With basis weights between 75 and 145 g/m 2, up
to 400,000 tonnes of high-quality corrugating medium and testliner can be produced per year from 100% recovered paper.

Stock preparation
The new stock preparation system has acapacity of 1,440 t/24 h. Its design is essentially based on the successful conceptof the line supplied for PM 9, whererecord efficiencies are being achieved today. Voith’s scope of supply for the newline includes:● Virtually all the process machines for– recovered paper preparation– the Advanced Wet End Process(WEP) including suspension deaeration– broke pulping and preparation● Basic engineering

35

2● Erection and erection supervision● Start-up support.
The process modules for the recovered
paper preparation technology orderedfrom Voith are:● Pulping in two continuous LC pulpers,
each with a TwinPulp III discharge
system for removing the majority ofcontaminants from the process at theearliest possible stage, minimizing at
the same time fibre losses● 2-stage HC cleaning with the Protector
system● Hole screening with deflaking-action
disc screens. Combisorters are installed in the final stage for removing
the high concentration of contaminants
at a high dry content● Double fractionation using 0.15 mm
slotted C-bar screen baskets for an
extremely clean short fibre fraction
and a high long fibre concentration in
the long fibre fraction● LC heavy-particle cleaning of long andshort fibres with EcoMizer cleaners forhigh separation efficiencies at higher
than usual stock consistencies● LC slotted fine screening in the long
fibre line using C-bar screen baskets.
This provides gentle screening,
especially for the efficient removal of

stickies that have built up here, thus
contributing to a high paper machine
runnability● Long fibre refining with two TwinFlo
double disc refiners for increasing
strength characteristics● Long and short fibre thickening,each with Thune Bagless disc filter
technology.

Paper Machine
In the former section, a MasterJet M2
two-layer headbox with ModuleJet dilution-water control system and the provengapformer DuoFormer Base ensure optimum CD profiles and strength values
and economical use of raw materials.
High dryness while simultaneously saving
bulk of the paper web are achieved with
the DuoCentri-NipcoFlex press. A closed
web run ensures high operational reliability.
The TopDuoRun dryer section uses the
single-tier concept in both the pre-dryer
and the after-dryer section. This configuration together with ProRelease boxes,
DuoStabilizers and the ropeless threading
system ensures optimum runnability.
A Speed-Sizer will be used for uniform
starch application on both sides. The
scope of supply also includes a ModulePro P for moisture profile control in theafter-dryer section.
In addition to the basic engineering forthe control system Voith Paper Automation will deliver the hydraulic and pneumatic control systems for the paper machine and the CD profile control system:

Francisco
CarillaProject
Manager
SAICA 4“We chose Voith as the main supplierof the PM 10 production line, because
we think its technology is more adaptedand proven for our grades and furnish.
The PM 10 configuration comes very
close to our existing PM 9, which was
also delivered by Voith four years ago.
Besides, since the PM 9 project, wehave established a very high cooperation level between Saica and Voith,
with a high and open commitment of
the two technical teams. This makes
us trust that for the next steps taken
both on PM 9 and PM 10, we will havea solid basis to achieve our goals.”● Profilmatic M on the ModuleJet M2
headbox● Profilmatic S for the ModuleSteamblow box in the press section● Profilmatic MP for the ModulePro P-50
nozzle humidifier in the after-dryer
section.
At the end of the paper production line,
the paper web is wound up on a Sirius
reel, which allows maximum roll diameters of 4,000 mm with optimum winding
quality. A Rollmaster will be used at the
Sirius reel for optimisation and analysisof the wind-up process.

19/05

36

1

Bohui BM 1 –A benchmark in China for the paper industry
worldwide
This new board machine for the Bohui Paper Group in
China was smoothly commissioned on July 18, 2003, some weeks
earlier than planned. With a capacity of 300,000 t.p.a. it is one of
the world’s biggest production lines for white coated carton. Thiswas of course the focus of great expectations in the paper industry– which after more than one and a half years of outstandingly
successful operation have been fully justified.
HelmutRiesenberger
Paper Machines
Board and Packaging
helmut.riesenberger@voith.com

19/05

Bohui Paper Group
Bohui is about one hour’s flight south of
Beijing, right in the center of Shandong
Province with its rapidly expanding industries. The Bohui Paper Group production portfolio includes linerboard, folding
boxboard and graphic grades as main
products. Apart from paper and board,
Bohui also makes various chemical products such as PVC and common salt

(NaCl, sodium chloride). The group’s
very considerable energy requirements
are covered by its own thermal power
plant, soon to be joined by a second one
to keep pace with demand.
With about 4000 employees and an output of around 450,000 t.p.a. of board and120,000 t.p.a. of graphic paper grades,
the Bohui Paper Group is already one ofChina’s ten largest paper producers. And37

2

it plans to expand overall paper andboard production to about 1 million t.p.a.
by the year 2008.
At the end of March 2002 the Bohui Paper Group entrusted Voith Paper with thedelivery, erection and commissioning of acomplete new board machine.
One of the most decisive reasons forbooking this order was our excellent references in this area – over the last few
years Voith Paper has successfully delivered and commissioned no fewer thaneleven board production lines in China.

State-of-the-art technology
The new machine produces high-grade
carton, coated on both sides, from 100%

chemical pulp, and folding boxboard withwhite coated cover layer from recovered
paper furnish. Voith Paper delivered theentire process technology on a singlesource basis.
In the stock preparation system, apartfrom cleaning, hole and slot screening aswell as fractionation, the mill has also
installed EcoCell deinking and two complete disperger systems, each with preceding disc filter. A further disc filter isused to recover fibers.
The new paper machine comprises thefollowing components:● 4 fourdriniers and a DuoFormer D● 4 MasterJet F/B headboxes, with theliner headbox being equipped with a
ModuleJet dilution water control
systemTechnical data of the new board machine
Product

Folding boxboard(coated white board
grey/white back)Cardboard (coatedwhite cardboard)

Basis weight150-450 g/m 2

Wire width

6,230 mm

Untrimmed width at reel 5,630 mm
Operating speed

233-500 m/min

Design speed

600 m/min

Production capacity

932 t/24 hFig. 1: Bohui board machine 1.
Fig. 2: Bohui Paper Group in Bohui,
Shandong Province, China.

19/05

38

Fig. 3: SpeedFlow.
Fig. 4: Overall layout of the paper machineand coating line.
Fig. 5: Bohui coating machine.
Fig. 6: Reel.
3● NipcoFlex shoe press● Suction press● Offset press● 2-tier dryer section with a predryer
section, afterdryer section and acorrection group● On-line coating machine with 4 GL
coaters for double coating on bothsides
● Krieger InfraElectric infrared dryer,
with integral InfraMatic moisturecross-profiling for the coat
● SpeedFlow coating unit
● 1 hardnip calender and2 softnip calenders● TR 125 reel
● VariFlex two-drum winder.
The entire machine control, operation andvisualization systems were installed by

4

19/05

Voith Paper Automation. The automation
system also includes Profilmatic M
cross-profile control, Aquapac moisturizing spray nozzle system and IR coating
dryer. Voith also took responsibility forthe erection and commissioning of thisboard machine. All machine clothing was
supplied and installed by Voith Fabrics.
Major components such as the dryer section and coating machine frames, thedryer cylinders and rolls were made in
China by Voith Paper Liaoyang Ltd.

The special features of this coating machine include modular arrangement of thecoater stations, and the Airturn dryers.
These innovative dryers ensure contactless turning of the board web during thesimultaneous drying process.

The new coating line

The coaters are suitable both for rod andblade operation modes.

The on-line coating machine with four GL
coaters was built according to the Voith“One Platform Concept” and fitted with a
Krieger IR-drying system.

This modern coating line is particularly
distinguished by its short and uniform
web runs before and after the coaters,
each with its own web tensioning group,
as well as fast web transfer and the low
overall machine height.

Extremely operator-friendly, this coating
line with its compact dimensions ensures
the highest coating quality and excellent
runnability.

39

5Erection, commissioning
and optimization
The notably short erection and commissioning time of only six months in total
was only possible thanks to first classcoordination and cooperation between
the Bohui Paper Group and Voith Paper.
One month after commissioning, the newboard machine was already producing
saleable board at full production capacity. A decisive reason for the uncommonly
short completion time of only 16 months
for a project of this size – from contract
signing to commissioning – was that
Voith effectively took over responsibility
for the entire machine and thus reduced
interfaces to a minimum.

quirements for folding boxboard as well
as for cardboard production were complied with at full production capacity.
The highly successful commissioning took
place in July 2003.
6

Hardly a year after commissioning thisnew board machine, all the specified re-

19/05

40

Amcor Cartonboard –Australasia Petrie Mill invests in the future
Amcor Cartonboard Australasia invested US$ 40 million
to replace the Wet End of their board machine at Petrie Mill witha state-of-the-art Multifourdrinier forming section. The objective of
this upgrade was to improve quality and to offer their customers
the best board they can possibly make.

Marcelo K. Santos
Voith São Paulomarcelo.santos@voith.com

Rebuilding for the Future

Improving quality and keeping pace withmarket demands and progress haveAmcor Cartonboard’s Petrie Mill is aalways been major motivating factors inmember of a major international packag-

the Amcor Cartonboard philosophy. The

ing company and is the only coatedfirm go-ahead for the wet end project

cartonboard producer in Australia. Its

was given by the Amcor Board in Octoberprimary market is Australasia and Asia.

2002 and Voith Paper São Paulo was

Although Amcor is the major supplier tochosen as the major supplier.

the Australasian greyback market, theintention of the upgrade is to increase the

Marcos Blumer
Voith São Paulomarcos.blumer@voith.com

Paper grades

4-ply white lined chipboard

Basis weight240-467 g/m 2

Wire width

4,060 mm

Untrimmed width

3,550 mmMax. operating speed 500 m/min
600 m/minFig. 1: Wet End components.
Fig. 2: Petrie Mill: Wet end of the BM.

19/05

The Wet End Components

open new avenues for the premium endof the market such as pharmaceuticals,

The Multifourdrinier forming section sup-cosmetics, confectionery and high quality

plied by Voith Paper is the concept used

printing.

by majority of the leading Cartonboard

1

Technical Data

Design speed

market share of the whiteback market and41

2

manufactures around the world. It com-

Voith Paper provided an extensive train-prises a fourdrinier for each of the fouring program to the Petrie Mill. The train-

plies resulting in a top product quality.

ing included an interactive 3D module,

Each fourdrinier has a headbox typeclass room and on site training sections.

MasterJet F/B. The Middle Ply headbox
features the dilution control through a

The perfect interaction between Amcor,

ModuleJet system that permits excellent

Voith Paper and the contractor during thebasis weight control. The Middle Ply anderection and commissioning led to a very

Under Top Ply forming section each havesmooth and safe start-up on April 12,

a DuoFormer DC installed enabling opti-

2004 and the results were nothing but

mum formation with a higher basis

outstanding.

weight split. With a length of more than
40 meters, it is one of the longest wet

Due to the common goal of all parties in-ends ever manufactured by Voith Paper.

volved, excellent results were achieved

Bob Scard

Dick Lock

Project
Manager
Amcor
Cartonboard

Production
Manager
Amcor
Cartonboard

very shortly after start-up and the prelim-“Dealing with Voith Brazil has been noth-

Because of the upgrade, the approachinary machine acceptance document was

ing but a positive experience. Their ex-flow system was also slight modified toissued less than 4 weeks later, on May 07,

pertise and professionalism is second to

be compatible with the new Wet End. It

2004.

none”, Bob Scard, Petrie Project Manag-

was necessary to rebuild the screening

er, stated. According to the Petrie team,systems. The upgrade mainly involved

In order to achieve the project’s premium

the Voith engineers listened to Petrie’s

the installation of MultiScreen pressure

Cartonboard quality goal, machine sec-

problems and suggestions. “Voith has ascreens, fine slotted screens on all fourtions like press, dryer, calender, coater

flexible and open-minded team of experts

plies that remove impurities, a Mini-

etc were analyzed. A team of specialists

and they tailor each machine to theSorter for handling the rejects from thefrom Voith Paper and Voith Fabrics visit-

specific requirements of their customers.

middle ply and twin impeller fan pumps.

ed Petrie to check the machine and makeAlso, being an international company,

suggestions for improvements.

most of the Voith people speak fluent
English and the language posed no prob-

The Project
Project results on each individual project

A consultant for coater chemistry joinedlems”, Dick Lock explained.

the team for the optimization of the exit-

Every stage, from design to construction,

ing coater.

pre-assembly, packing for shipment andphase really exceeded expectations. The

start-up of the wet end has gone smooth-perfect planning and interaction between

ly so far and there are no obvious reasons

Amcor and Voith started during the sales

Voith Paper would like to thank all per-why this project should not conclude

phase and contract phase with the dis-sons that contributed to the outstanding

without any major problems. Amcor

cussion of an optimization plan that also

results of this project and looks forward

Cartonboard has nothing but praise forincluded machine sections beyond Voith

to a long and strong partnership with

Voith Brazil. “It was a pleasure dealing

Paper’s scope of supply.

Amcor group.

with them”, Bob Scard added.

19/05

42

Voith Silent Technologies – SeaLencer

The increasing industrialization makes noise a key issue.
The industry, in particular the paper industry, often faces the
problem that the operation of technical equipment is not, or only toa limited extent, possible if the legal limit values are exceeded.
The pioneering solution of the SeaLencer sealing strip systemdeveloped by Voith for suction rolls fully satisfies today’s demands
on noise abatement.
Dr. Harald
Graf-Müller
Silent Technologies
harald.graf-mueller@voith.com

than 90 dB, A-weighted, to be achieved at
operator level on a long-term basis is tosignificantly improve the workplace quality in the vicinity of paper machines. The
suction rolls in the wire and press sections are the crucial noise sources of apaper machine. Due to their “noise dominance”, the acoustic design process
presently focuses on suction rolls.

Harald Freytag
Silent Technologies
harald.freytag@voith.com

The starting position
The sound pressure level usual in thevicinity of paper machines confronts thedesign engineers with the task of taking
noise abatement measures. In particular,
the legal provisions for employee protection and neighborhood protection requirenoise reduction measures. The targets
set by Voith Silent Technologies are topave the way for systematic noise reduction in paper machines: By the end of
2005, the suction roll noise is to be reduced by 5 dB, A-weighted, which corresponds to a sound energy reduction of
68%. The noise level reduction to less

19/05

Voith’s acoustic test standAn acoustic test stand is used to systematically analyze and optimize the acoustic
characteristics of suction rolls understandardized conditions. It allows to altervarious physical parameters (such as felt
speed, vacuum, amount of water, etc.)
within wide limits.
In addition to acoustic analyses, innovative technologies are developed in the research fields of “wear-optimized designof seals”, “reduced energy consumption”
and “reduced vacuum losses”. Extensive
studies and tests result in innovative
sealing materials and new seal geometries. The Voith SeaLencer described below is the result of systematic researchand development for low-noise design on
the acoustic test stand.

Voith SeaLencer –Seals of Silence
A suction roll comprises, among otherthings, a perforated roll shell and an
evacuated suction box. Sealing strips areused to seal the vacuum against the air in
the rotating suction roll and are pressedagainst the inside of the suction rollshell. When conventional sealing strips
are used, the vacuum suddenly collapses
after the sealing strip is passed. Impulsesof high-frequency sound are emitted dueto the abrupt flow of air back into theholes of the suction roll after leaving thesuction area and produce the annoying
effect of suction roll whistling.
The function of the SeaLencer – patentapplied for – (Fig. 1) is determined by its
special geometry for optimizing the pressure gradient in the gap above the sealing
strip. The gradual, non-abrupt flow of air
into the suction holes at the bevelledsurfaces results in controlled and uniform pressure reduction in the holes(Fig. 2), which is clearly audible: A “softer" sound with a lower sound pressurelevel is created.
A run-up test from 1,000 m/min to 2,200m/min on the acoustic test stand demon-

43Fig. 1: Optimized geometry of SeaLencer.
Fig. 2: Continuous pressure reduction due touniform flow of air into the suction-roll holes.
Fig. 3: Fingerprint: Standard sealing strip.
Fig. 4: Fingerprint: Voith SeaLencer.
1

Perforated roll shell

2

SeaLencer

Underpressure

strates the acoustic effect of the SeaLencer by using acoustic fingerprints(Figs. 3 and 4): The horizontal axis correlates with the frequency, the verticalaxis is the speed. The colour denotes thesound pressure level in the relevant frequency band (yellow = very high level,
red = high level, blue = medium and low
level). The comparison of a conventional
sealing strip and the SeaLencer shows a
distinct reduction of the emitted soundpressure level and a strong reduction of
the disturbing high frequency portions(yellow lines, red areas).
After installation of the SeaLencer, theemitted sound pressure level is usually
reduced by up to 5 dB, A-weighted. In
individual, psychoacoustically disturbing
frequency bands, reductions of up to
15 dB, A-weighted, were often measured.

of the sealing strip material are substantially diminished. Extensive trial runs arepresently made on the acoustic test standand on running paper machines to analyze the additional advantages of longer
service lives and lower drive powers.

mation on the SeaLencer and sound examples can also be found on the Internet
at http://www.voithpaper.com

The silent future
The development of silent technologies isa key topic of Voith Paper’s research activities. High acoustic workplace quality
and increased neighborhood protection interms of noise are core areas of our R&D
activities. Noise is a topic of the future inmany sectors – the consistent development of innovative noise reduction technologies helps Voith Paper to further
strengthen its position as a pioneer innoise abatement.

The acoustic successof the SeaLencer
The noise reduction effect of the SeaLencer has meanwhile been confirmed on
30 paper machines in operation. Since
January 2002, 91 SeaLencer units havebeen installed in suction rolls. Machine
operators describe the noise of rebuilt
suction couch rolls to be “softer”, “quieter” and “more pleasant”. Further infor-

3

4

Increased lifetime andless friction energy
Additional advantages of the SeaLencer
are less friction energy and reduced wearof the sealing strip material (increased
lifetime). As the sealing surface is reduced, both the friction between sealing
strip and roll shell and the thermal stress

19/05

44

Johannes Linzen

1Finishingjohannes.linzen@voith.com

The two Offline Janus MK 2 at
Chenming/Shouguang show their strength
The two 10-roll Janus MK 2 from Voith Paper, started up in
2002, are performing to the customer’s greatest satisfaction. Both,Winshin Hu
Finishing
winshin.hu@voith.com

19/05

productivity and the obtained surface properties are excellent.

45

Fig. 1: Mr. Geng Guang Lin, Vice President ofChenming Paper Shouguang together with
Mr. Thomas Koller, Executive Vice President ofVoith Paper, Finishing Division.
Figs. 2 and 3: Shandong Chenming Paper
Holdings Ltd. in Shouguang, China.
2

3“No doubt that our expectations in thisrespect were high from the very beginning. Yet, the actual results are even better than anticipated”, says Mr. Geng
Guang Lin, Vice President. And he adds:“The calenders equipped with automatic
un- and rewind are in fact doing so wellthat we are able to additionally run paper
from another line over these calenders.”
To better understand this statement one
should know that the Janus MK 2 offline
calenders, installed together with Voith’s

During the past months, however, theform Concept. However, the achieved

offline-coater producing woodfree-coatedspeed has been increased to 1,500 m/min

performancefine papers and coated label printing pa-

and the basis weight was simultaneously

without the effective assistance of Chen-

pers with a max. web width of 4,635 mm,raised to 250 g/m 2.

ming’s engineers. Voith Paper is proud of

would

be

inconceivable

the optimum result obtained by the com-were designed to run at an operating
speed of max. 1,000 m/min, to finish

This success is certainly a token of thebined efforts and wishes his Chinese

papers with a basis weight of up tounique Janus MK 2 calendering technolo-

partners all the best with the new equip-

210 g/m 2.

gy firmly embedded in Voith’s One Plat-

ment.

19/05

46

Highest Coating Quality with
Cast Coating Technology

12Cast coating is applied for board and graphical paper
grades which require extremely high brightness, gloss, durability
and appeal of the printed colors.

Ozawa Hiroaki
Voith IHI, Tokyo, Japanozawa.hiroaki@voith.ihi.co.jp

These are products such as:active development and continuously im-

Paper: High-grade printing paper (calen-

proves the cast coating process suitable

dars, posters, catalogs)

to produce the required highest quality at

Information-related

products(labels,max. possible speeds.

badges, ink jet/laser printed products)
Cardboard: Gift boxes, shipping boxes.

Historycally, about 30 years ago the maininvestment into cast coating was in

The demand for such high quality grades

America and Europe, but afterwards,

will grow, i.e. with the rapid spread ofJapan and other Asian countries became

digital cameras and household printers invery active in this field and the techno-

recent years, the demand for high quality

logical progress went ahead rapidly.

coated paper has attracted attention andVoith IHI is market leader for cast coaters

Tachikawa Yasushi

is a promising field for the paper industry(new lines and rebuilds) and has more

Voith IHI, Tokyo, Japantachikawa.yasushi@voith.ihi.co.jp

in the long run.

than 30 years experience in this technology. The total number of lines is close to

19/05

Cast-coated paper for label paper applica-

40 units. Especially in the recent years,

tions has already shown steady growth

the technology has been improved con-within the last ten years. Voith IHI does

siderably.

47

Fig. 1: Examples for cast coated paper products.
Method3

Operating Speed [m/min]Appeal on Consumers

Direct Method

20 - 40

Good

Gel Method

30 - 90

Superior

Rewet I

50 - 200

Good

Rewet II

30 - 100

Superior

4

Fig. 2: Voith IHI pilot coater machines in Japan.
Fig. 3: Cast coater cylinder from outside.
Fig. 4: Cast coater drying section.
Fig. 5: Moisturizing and reel section.

important to allow the paper to transfer

5

the moisture/vapor during the drying on
the cast dryer drum. In addition, the basepaper’s smoothness has a significant influence on the smoothness of the coatedlayer.

Required coating color
properties
The properties of the coating color differ
slightly according to the production
There are three representative production

cause if water vapor is discharged fromprocess. However, the main common

methods, which can be characterized andthe coating surface, pin holes can occur,

point is that the size of the pigment parti-

evaluated as shown in the table above.

influencing the printability and appear-cles, the pigment mixing ratio, and theance of the surface. A further key point isbinder type and mixing ratio are impor-to control moisture (omit excessive dry-tant elements.

Key features of theing) and curling after the coated paper

cast coating technology

left the cast coater cylinder.

Key of the cast coating process is to ap-

There are various adjustment measures,

more important in the near future. Within

ply the coating color onto paper tosuch as application of a curling preven-

the Voith Paper Group, Voith IHI willachieve a hard, mirror-like surface whiletion agent onto the backside, application

assume the role to continue the develop-

the coating color is still wet. After the ap-of steam to both sides or passing the pa-

ment of the cast coating technology

plication on the base paper the coating

per through a hood with moisturized air.

together with the industry.

color is pressed against the cast coater

Voith IHI’s longterm experience andcylinder in moist condition, which results

accumulated know is a solid foundationin such extreme surface quality. Since

for serving the industry with whatever isgloss of cast coated grades tends to de-required to improve the cast coatingcrease with increased production speed

process.

Considering the market trends, this special coating technology will become even

We trust that even with the improvement

and pin hole defects of the coat appear, itof other coating technologies, the chal-is extremely important to achieve higher

lenge of cast coating remains important

speeds without such quality defects.

Required base paper properties

to the industry and we would like toinvite interested customer to develop

It is essential to mainly discharge water

For the base paper there are two main re-together with us business chances in thisvapor from the uncoated paper side, be-quirements: Porosity of the base paper is

specific coating field.

19/05

48

Bernd Stibi
Process Solutions
bernd.stibi@voith.com

Voith Process Solutions –Wet End Process Analysis as the foundationof an optimization of paper quality and process
stability

Where is paper actually made? That question is often
asked rhetorically to emphasize the complexity of the papermaking
process. Fact is that the “wet end”, between the machine chestand the first dryer cylinder, forms the basis for good paper profiles.
Stefan Natterer
Process Solutions
stefan.natterer@voith.com

19/05

Disturbances and errors made here could hardly be changed further
downstream. They often cause extensive quality and efficiency
limitations of the whole line.

49

Voith
Process
Solutions
Wet End Process
AnalysisFig. 1: Procedure for a WEP Analysis.

Procedure for solving product quality problems,e.g. basis weight and ash content fluctuations

Fig. 1 shows the basic procedure for a
Wet End Process Analysis evaluation.
Starting with the paper characteristics,

Periodic fluctuations

Stochastic variations

such as basis weight or ash content stability, potential periodic or stochastic
variation parameters are identified andPressure pulsation

Pressure pulsation

Mechanicalvibrations
Speeds andspeed variations

Analysisin frequency
range(Fourier
spectra)Time signal
analysis(statistics
anddistribution)

Stock/ash samples andstock consistency variations

between pulsation and rotational frequencies, gas content and defoamers andsheet breaks are investigated thereby us-

Process control system(raw signal registration)
Gas content, temperature,
pH-value, conductivity

Paper transmission andquality control systemevaluated. Interrelationships for example

ing all available information from theprocess.
Typical aspects related to thepapermaking process

Paper laboratory tests
e.g. Tapio analyzer (Fig. 3)● Hydraulic stability (freedom frompulsation) of the stock and water loops● Inflow and outflow conditions as wellas headbox pressure stability

The approach and evaluation method ofThis tool can also be used as a condition● Stock mixing efficiency among thethe Wet End Process Analysis explained

analysis prior to rebuilds or for assessing

various flows in the approach flow

here shows that it is a largely standard-

optimization potential and investment,

ized service product developed by Voith ine.g. to increase runnability or operatingclose partnership with the paper industry.

speed or better profile quality.

section● Efficiency-optimized operating rangesof the cleaner and screen sections● Optimized positioning of pipe elbows

The results from a Wet End Process

and fittings● Necessity and efficiency of mechanical

Goals of Wet End Process

Analysis by Voith Process Solutions are

Analysis

the basis for answers to various questions.

degassing systems in relation to

Since the Wet End Process Analysis is

The analysis in the paper mill consists of● Additive quality in relation to gas

largely standardized, it serves as a toolon-site measurements of all parameters

for various purposes:

affecting the papermaking process, pro-● Stability of the jet impingement line

chemical defoamers
content and retention of fiber and ash

duction output and quality. Thanks to so-

after the headbox; web pick-up

It can be used for troubleshooting prob-

phisticated evaluation techniques, con-deviations on the central press rolllems such as bad sheet profile or wrin-

clusions can then be drawn on widely● Drainage element and vacuum settingskles.

varying aspects.

for optimal quality and water removal

19/05

50

Fig. 2: Wet end data collection:
Pressure pulsation sensors
Gas content sensors
Stock consistency variation sensors
Stock consistency measurement
IDM
Additives dosing point

VoithVacNash
SC 6/7

Nash
904L2

2

MSA
08/08
LC header

Sulzer
APP 41-300

CycloneAir
Bottom wire Top wireDS
Sulzer
APP 44-200

HC header

TS

MSA
15/15

Whitewater tray
Sulzer
ZPP 42-500
Whitewater
to cleaner stages 2./ 3./ 4.

1st stage cleaner(EcoMizer)

MSS
08/08

to 2nd stage
cleaner

SulzerAPP 61-500● Web profile control loop stability in

2nd stage cleaner accepts

BTG
stock consistency
Sulzer
APP 41-200

on process control loops

Scope of Wet End Processmachine and cross-machine directions.

– short-wave fluctuations

Analysis

Typical product-related aspects● Formation improvement

The complexity of a Wet End Process● Basis weight and ash distribution● Stabilization of fiber orientation andAnalysis covering all aspects is basically(e.g. visible striping)stability in the machine and cross-tear factor

irrespective of the end product, paper

machine directions and residual● Pinhole troubleshooting

quality or operating speed. This is con-profiles as a function of:● Production limitation by shrinkage

firmed by experience with the procedure– long-wave fluctuation with periodsof several minutes and their effect19/05

wrinkles● High sheet break rates.

on more than 120 lines so far.

51

Fig. 3: Tapio analyzer.
Fig. 4: Measuring location.
3

Wet End Process Analysis

4evaluation and assessment
methods
An intensive Wet End Process Analysis,
generally completed in 2 to 3 days by aexperienced Voith team of experts, delivers an enormous amount of data andreadings. Generally, the analysis covers
settings for more than one grade or production rate.
A well-structured analysis and evaluation
Our reference list includes high and low
speed lines for graphical grades such as
newsprint, SC and LWC as well as numerous machines for specialty grades
like decorative papers, photographic papers and also board and packaging paper
machines.
As shown in Fig. 2, various process con-

● Speeds and speed variations of mixers,
pumps, screens and fans

methodology is imperative for efficient
goal attainment.

● Free and dissolved gas content instock suspension● pH and conductivity values for all
stock and water loops

The paper quality characteristics on-site
are determined by direct transmission
sensors and complemented with data

● Mixing conditions based on stockfrom the other measurement parameters.

consistency and ash content

This procedure enables targeted measures

measurements in each flow stream.

to be taken already at the measurement
stage, particularly for troubleshooting, so

ditions are analyzed at the same time, using a common procedure with compara-

Apart from data delivered by the Voith

that the causes of paper defects or mark-ble instrumentation:measuring systems specially developed

ings can be pinpointed and eliminated.

for Wet End Process Analysis, settings● Hydraulic stability from machine chestand readings are also taken over from theAnother benefit is that it reveals the curi-

to headbox; simultaneous recording

process control system and directly fromous effect that the negative influence onof up to 32 pressure signals in thethe wet end machines. These include op-

paper quality can be caused by vacuum

0-1000 Hz range

erating speed, chest levels, flow rates,

pumps, refiners, chemical dosing equip-

valve and headbox settings, vacuum set-ment, shakers or fans well away from thesimultaneous recording of up to 3 flowtings, etc. Also included in the documen-

stock and water loops.

streams in the 0-10 Hz range

tation and evaluation are process-rele-● Stock consistency variations;● Vibration measurements in all relevantvant data such as furnish characteristics

A Wet End Process Analysis is therefore

points to establish interference

and additives, as well as production-a universal tool in the decision making

potential; simultaneous recording on

related data like shift reports and sheet

process for optimization measures in theup to 48 channels

break records.

Wet End.

19/05

52

Process analysis
for stock and water loops –a well-proven process optimization anddevelopment tool
The experienced specialist teams at Voith Process
Solutions cover the entire spectrum of technical, technological andengineering services for the paper industry.

Ralf Mönnigmann
Fiber Systems
ralf.moennigmann@voith.com

Paper production problems often arise at

To work out a detailed problem-solving

many levels. The only way to solve themstrategy for process analysis, various

satisfactorily is by thorough process

tools are required:analysis in order to diagnose and elimi-● Operating data records

nate the causes. The following objectives● Stock sample data

can be involved:● Laboratory examination of stock andpaper samples● Product quality enhancement● Higher production● Better runnability● Reduced operating consumables.

Bernd Stibi● Inspection of all key machines andcomponents● Balancing and process modelling(simulation)● Checking of machine sizes

Servicebernd.stibi@voith.com

Cost saving goals can also be met by● Trials in Voith’s Technical Centre.

process analysis and optimization to reduce the expensive emission of for exam-

Voith process analysis incorporates allple effluent, residues, polluted air, heat

the latest know-how from our R&D pro-and additives.

grammes together with new multi-platform machine and process developments

As with analyses of the wet end, process

as well as control and automation exper-

analysis for stock and water loops istise.

largely standardized and independent of

Voith
Process
Solutions
Wet End Process
Analysis

19/05

the end product and system configura-

The WEP analysis described in the previ-tion. Experience from more than fifty

ous article should provide back-up inter-

process analyses clearly shows that thisest when analyzing the approach flow

systematic procedure can also handle

system and paper machine loops andproblem areas not originally identified

their effects on paper quality.

as such. The amount of analysis work
Process analysis
for stock
and water loops

involved on site and in the laboratory

The following practical examples fromdepends on the specific problems andmill operation illustrate the systematic

objectives involved.

procedure used for process analysis.

53

Fig. 1: System configuration of a newsprint
production plant.

COD
Chemical oxygen demand[mg/l]

Saveall

RejectHandling

SludgeHandling
DAF

Case study2
After optimization(balancing)

Samplepoint forclear
filtrate

PM 1/PM 2

Storage Tower

Disc Filter II

Flotation II

Disperger

Screw Press

Disc Filter I

Approach Flow

PM Loop

Loop IILC Screening // 0.15

HW Cleaner

Flotation I

MC Screening Ø 1.4

HD Cleaner

Drum Pulper

Loop I

Before optimization(measurement)

1

Before optimization(balancing)Fig. 2: COD values as an indication of how far
the counterflow principle is followed.

1st waterloop> 40004682

1678

2nd water
loop

941

1104

231

PM water
loop

235

288

60

hole and fine slot screening and in theas dust and flocks on the drying cylin-cleaning system.

ders.

After seven years of production and growing competition on the Asian market, aTheresults

Since intermittently operating final stages

newsprint mill using 100% recovered

showed an extremely high stickies con-demand exceptionally sensitive adjust-paper needed to take fundamental steps

tent in the final stages of these subsys-

ment of the operating and wash cycles,

to strengthen its market position. The

tems. Due to badly adjusted intermittent

simple rebuild measures were recom-

entire paper production process was ana-

operation of each final stage, large quan-mended in both cases. The result waslyzed to show the best ways of enhancing

tities of stickies were washed into the ac-user-friendly continuously operating final

product quality and increasing produc-

cepts and re-entered the previous stage.

stages with a high removal efficiency.

tivity.

This led to stickies concentration in eachstock

sampleanalysisof these final stages. A large proportion

During the WEP analysis a higher thanof these stickies was broken down by thisnormal gas content was detected in the

Results from analyzing the stock

recirculation and they then found their

headbox, causing unstable operation of

preparation and approach flow

way into the downstream subsystems.

the paper machine. To reduce this gas

The stock preparation line is a classicalSome of them reached the paper machinecontent,

system with two water loops (Fig. 1) andas microstickies, clearly causing prob-

amounts of defoamer despite the ade-intermittently operating final stages inlems such as deposits on the felts as wellquately dimensioned deaeration system.

the

mill

added

increasing

19/05

54

COD input 2nd loop

DF Thickening

Flotation II

Disperger

0.4
0.015
2885.8
1104
3.19
1.281
0.10
1281
3697
4.73

Production [kg/min]Consistency [%]Volume flow [l/min]
COD concentration [mg/l]
COD load [kg/min]

89.2
50.00
178
3697
0.33

93.1
2.26
4128
3697
14.91

Reject and
Sludge Handling

3.95
0.10
3949
3697
14.58
2.67
0.10
2669
3697
9.85

to PM

0.6
0.01
5718
288
1.65

Fresh water

PM Loop

Approach Flow

533.7
15.00
3558
1104
3.34

Loop II
Peroxide Bleaching

HC Thickening

LC Slot Screening

HW Cleaner

Flotation I

MC Screening

625.0091.00
687
192111
11.9

0.00 kg/min

558.6
30.00
1862
4682
6.10

Loop I

Furnish:Newspapers
Magazines

0.0
0.00
8558
0.0
0

533.2
50.00
1066
288
0.15

PM

Input
900 t/24 hSpec. effluent DIP 5.00 l/kg
Spec. effluent PM 10.00 l/kg

Drum Pulper

3

0.5
0.01
5332
288
1.54

COD concentration in comparison:
Calculation
1st Loop
COD = 4682 mg/l
2nd Loop COD = 1104 mg/l
PM Loop
COD = 288 mg/l

Measurement
1st Loop
COD > 4000 mg/l
2nd Loop COD = 941 mg/l
PM Loop
COD = 235 mg/l

● The aluminium sulphate dosing

Inspection of the vacuum system re-Apart from optimizing the spray nozzles

vealed a defect in the vacuum pump

to break down the foam more efficiently,

method was inadequate, resulting inplant, which restricted the deaeration ca-

a combination of tensides and soap wasexcessive local dosages and formation

pacity. This was then repaired.

recommended to aid flotation.

of deposits just after the dosing point.

Analysis of chemical inter-

By using less tensides, foam formation

actions in the stock and water

has been reduced and the use of soap

silicate) dual retention system wasloops

has improved the removal efficiency ofcorrectly operated. Interaction with

While inspecting all the main machines

the cells.

the relatively high concentration of● The Composil (PAC and anionicaluminium sulphate led however toand components, excessive foaming in
the flotation cells with extremely stable

Heavy deposits were found ahead of thedeposits in the headbox and thesefoam and poor removal efficiency wasmachine chest and in the headbox. Chem-

were very difficult to remove.

found. Due to the low content of maga-

ical-physical analysis in the laboratoryzine papers in the furnish and the resul-

revealed aluminium sulphate as the main

Balancing results and processtant low ash content, only tensides werecomponent of deposits at the machinemodel analysis with the focus

used to aid flotation.

chest as well as a silicate mixture in theon water management

headbox. Analysis of the additives andWhile the analysis work was being under-

quantities identified the following situation:

taken, about twice as much process wa-

19/05

55

4

Stock buffer

Dump chest

1000 m 3

Total stock buffer DIP 1000 m 3

Water buffer

Beforeoptimization

After
optimization

Buffer DIP–

1000 m 3 (new)Total water buffer DIP–

1000 m 3

Fig. 3: Simulated COD balance
for conditions before optimization.
The simulated balance indicatedsignificant COD and disturbing
substance improvements following implementation of the counterflow principle (see also Fig. 2).
Fig. 4: Lack of dynamic water
buffer capacities leads to uncontrolled overflows.

Storage tower 1 DIP

800 m 3

Clear filtrate buffer 1

1500 m 3

1500 m 3

Storage tower 2 DIP

1000 m 3

Clear filtrate buffer 2–2000 m 3 (existing)

Dry broke

800 m 3Wet broke

800 m 3

Total water buffer PM

1500 m 3

3500 m 3

Total stock buffer PM 3600 m 3

ter was flowing from the paper machine

The COD value (chemical oxygen de-flow principle. The relationship of dynam-

loop into the biological effluent treatmentmand) serves as a measure of colloidal

ic stock and water buffer levels was also

plant compared with process water fromand dissolved solids content (disturbing

checked out and optimized (Fig. 4).

the first stock preparation water loop.

substances) in the various process waterThis indicated that the counterflow prin-flows. In this mill case the COD test

ciple had not been properly implemented

results clearly confirmed the balancing

in the mill’s water management pro-results (Fig. 3).

Process analysis conclusions

gramme.
In particular, the first water loop in the

About one year after presenting theWith the counterflow principle, process

stock preparation line showed an unnec-

process analysis results, the success ofwater flows in the opposite direction toessarily high level of colloidal and dis-

all optimization measures taken so far

the stock flow. In other words, overflow

solved solids due to the restricted oper-

has been confirmed. Some smaller, lessfrom the paper machine water loop with aating mode (Fig. 2).

spectacular measures still have to be taken. The process analysis has led to close

relatively low dissolved solids content is
re-utilized in the stock preparation water

Using a simulation model of the entire

teamwork between the mill and Voith

loops before passing with a high dis-

papermaking process, a proposal was

Process Solutions, so that all objectives

solved solids content to effluent treat-

worked out for a systematically optimized

are being reached in an economicallyment.

water management based on the counter-sensible way.

19/05

56

Innovative Trends in Automation
Quality control systems of the future will put significantly
higher emphasis on analytical tools. This will improve processcontrol and disturbance analysis can be carried out sooner. The
papermaker can use the analysis results to identify complex techDr. Wolfgang
Bamberger

nological interrelations. Nowadays, – analytical tools are alreadyVoith Paper Automation
wolfgang.bamberger@voith.com

essential, given the complexity of a paper production plant. The
high quality targets cannot be economically achieved any longer
in any other manner.

Powerful quality control systems play

This trend in automation technology is

an increasingly important part in thisprimarily based on:process, although important process data
are also gathered from other systems andAntje Nicolas
Voith Paper Automation
antje.nicolas@voith.com

of no significance for the machine operator. It is only important that these data
flows

are

channeled,archived

19/05● information systems for data
integration,

andprocessed in a uniform manner. These
Co authors:
Rainer Schmachtel, Paper Machines Graphic
Rudolf Münch, Voith Paper Automation● machine-integrated sensors,

measuring devices. The origin of data is● quality and process controls whichanalytical tools will determine the great

are increasingly linked and realized bydevelopment steps of the near future.

DCS tools.

57

Fig. 1: EnviroScan installation location.
Fig. 2: Felt condition measurement.

Machine-integrated Sensors

erator can recognize the influence of the1

wet end and the press on the moisture
Conventional quality control systems re-

profile.

quire places with open draw, where thepaper web is accessible from top and

The felt condition measurement can bebottom, for installation in the paper ma-

used to assess the felt or, in conjunctionchine. In modern paper machines with

with an automatic felt cleaning device, forlargely closed web runs, such places are

specific felt cleaning action at the same

becoming increasingly hard to find.

time. The latter guarantees longer felt life
and with it fewer machine downtimes for

New measuring methods focus on single-

felt change.

sided quality measurement, increasingly
even in places hard to access to date. The

Future quality control technology will be

attempt becomes even harder, because

more concerned with the process itself

this is often a great challenge due to thenot only with the final product. With

ambient conditions. And then there aresmooth processes, quality is speaking up

the sensors of similar design, which dofor itself.

not monitor the paper, but the production
process.

Process Analysis

As examples, we mention the traversing

Traditional

moisture measurement after the press

based on the assessment of process data

section by the EnviroScan (Fig. 1) andin graphic representation (trends). Thisthe traversing felt condition measurement

can be refined further if a screen pageby a permeability sensor and a moisture

can display both quality and process vari-sensor (Fig. 2), all done under difficult

ables in the same diagram at the sameambient conditions in the wet end of thetime.

analyticaltechnology

was2
Press felt
Permeability sensor

paper machine. There, potential trouble isdetected early, which allows faster con-

The present example (Fig. 3) shows thetrol, as the disturbance is detected closedevelopment of a felt over a period ofto the place of origin.

more than 3 weeks. Specific cleaning al-

Moisture sensor

lows one to extend the life of the felt. The
The EnviroScan can detect characteristic

data, however, show that the impact offeatures in the moisture profile of thecleaning does not have lasting effects.

web after the press very quickly. This al-

Twelve hours after washing, the felt

lows an assessment of the mechanicalreaches the same condition as before thedewatering behavior of the press. The op-cleaning process.

19/05

58

Fig. 3: Development of felt condition over
several weeks – permeability of the press felt.
Fig. 4: : Integrated information displayof quality data and paper defects.
Fig. 5: OnQ traversing quality scannerat LEIPA-Schwedt.

Although cleaning initially increases the3permeability streak = felt damaged

uniformity over the entire web width andthe permeability is briefly increased at
the same time, it quickly and continuously decreases again. In the last phase, permeability streaks increasingly appear,
which requires the felt to be replacedsoon. The picture in particular shows two
streaks of higher permeability after a
shut-down. The increased permeability of
the felt in these places was the result of
damage to the felt during startup of thepaper machine. The nap of the felt was
partly rubbed off in two places.

13 March,
new felt

Washing the felt:
influence on permeability only approx. 0.5 days

4 April

The example shows: Sequential analysisof the moisture profiles in different
places of the process and carefully excluding influences allow successful per-4

Display of defect probabilities,
dependent on quality (e.g. basis weight)

formance of problem analysis.

Integrated Information Systems
Process information is obtained in a variety of places in the paper production
process. It is important, however, that all
Color map
(e.g. basis weightprofiles)superimposedby informationfrom a web
inspection system

CD scaling
left: data boxes
right: mm

MD scaling
top: parent roll number and web lengthbottom: time axis

this information should be seen in context. This is particularly true for the assessment of paper defects, for which aconnection to other quality parameters
can be assumed.
When such connections are found, measures to eliminate them can be found in
most cases. But even without correcting
actions, problem areas like that can be

19/05

59

5

taken into account later during finishing

These techniques allow both model-

complex physical relationships and facili-

or optimized cutting.

based forecasts and a deeper insight into

tates the understanding of the process.

the process interrelationships.

This allows forecasts of process behavior, for example. However, the methods

An integrated representation of quality
deviations and paper defects in connec-

In the case of “Self-Organizing Maps

require good data quality from a large

tion with cutting optimization is, there-(SOMs)”, the system starts with a contin-amount of data available, and they cannot

fore, desirable. A so-called color map canuous data set, which may comprise hun-be mastered without basic technologicalshow color-coded quality data and paper

dreds of data for one parent roll and re-knowledge.

defects together (Fig. 4).

produces the data on a two-dimensional
display. Each data set is assigned to one

System-integrated Process

spot on the display.

AnalysisPaperMiner
The SOM method can be used for fore-

Due to networking via Ethernet and theIn the above example of a color map, acasts with good success. Once a SOM

communication standard OPC, it is today

relatively small amount of specific infor-

has been generated, the place of a modi-

possible to exchange and link data, re-mation is sufficient to allow a meaningful

fied machine setting can be determined

gardless of the place of their acquisition

analysis. In paper production, however, –on the two-dimensional map, and it can

within a system’s network. This now pro-this is rather the exception. As a rule, thebe used to determine the expected values

vides a uniform user interface that allows

interrelations are complex and difficult tofor the desired target parameters (porosi-

functional data integration between QCS,

identify, although or because a hugety, formation etc.). Of course, the quality

DCS and other systems.

amount of data is available. For example,of such forecasts is greatly dependent on

This is particularly important for all sys-

the question under which process condi-

the number of data sets used to generatetems that provide process information.

tions good printability is achieved cannot

the map, and whether or not all major in-

These include:

be answered by simple means.

fluences were included.

● Reporting of the quality control system,● Web inspection,

These and similar questions are typical

Decision Trees are another method of● Web break analysis,tasks for the PaperMiner. But first, theanalysis. In order to use Decision Trees,● The bearing monitoring system,

data must be collected and prepared fora target value to be analyzed is first se-● The technology monitoring system,

the PaperMiner. The PaperMiner can picklected. The decision tree can then be● The traditional distributed control

up its information from this data pool.

used to find out which process adjust-system and more.

ments must be made.

All data acquired by means of these sys-

The PaperMiner provides a number ofGenerally, it can be said that the Paper-tems will be available in a central data-

methods for analysis. The most impor-

Miner is a very efficient tool for database in the future and can be linked totant ones of these are the so-called Self-

analysis. It is capable of handling large

each other. This makes physical relation-

Organizing Maps and Decision Trees,

volumes of numerical and non-numericalships visible and allows them to bewhich originate from the area of “ma-data (such as grades, felt type, ...). It

processed in a total plant visualization forchine learning methods”.

provides a high quality of results even forthe operator.

19/05

60

1

Development trends in non-contact
web drying systems
Due to rising production speeds and quality requirements,
drying systems and concepts for non-contact drying of paper andcoating color are increasingly being customized depending on theirapplication. At the same time, high energy efficiency, trouble-free
web guiding and low life-cycle costs must be ensured.

Jan Eberhard
Krieger GmbH & Co. KG,
Mönchengladbach, Germany
j.eberhard@krieger-mg.de

For many years, Krieger has been thetion of new materials and the simplifica-

only system supplier worldwide to pro-tion of maintenance work, Krieger’s activ-

vide a complete range of products forities in convection drying are focused on

non-contact drying. Thanks to our own

increasing the performance and efficiency

intensive development work and constantof the systems – as well as optimizing

exchange of ideas and experience within

the web run (Fig. 1).

the Voith Divisions, optimally matchedsystem configurations are guaranteed. In

With the modular system designed byan effort to increase energy efficiency,

Krieger, the following features can easily

Krieger’s range of products includes gas-be adapted to individual applications:

fired and electric infrared systems, aswell as different types and combinations● Fuel (gas, steam)of hot-air dryers for both drying methods.

● Maximum operating temperature(up to 450 °C)

While the development of gas-fired infrared dryers is geared toward the utiliza-

19/05● Nozzle supply air velocity(up to 70 m/sec)

61

Fig. 1: One-sided CB-Dryer, HCB-Turn anddouble-sided CB-Dryer.
Fig. 2: Comparison of heat transfer coefficientsin hole-type and slotted nozzles.

stallation, because they allow for com-

● Nozzle spacing / nozzle widthparatively high drying rates at lower web● One-sided dryer or double-sided

temperatures.

floating dryer● Non-contact drying with simultaneous
web turning (HCB-Turn).

Next, the drying cylinders finish the remainder of the drying with the simultaneous possibility of correcting the curl ofConsequently, any quality requirements

the paper or board web.

relevant to the user can easily be incorporated during the project engineeringWith our different types of CB-Dryers,

phase. In this regard, the following as-

Krieger offers a modern air-drying sys-

pects should be given special attention:

tem which, in addition to a uniform, non-2

350
Heat transfer coefficient [W/m2/K]● Number of nozzles

50 °C

300

200 °C
250

Hole-type nozzles

200

50 °C
200 °C
300 °C

150
100

300 °C

Slotted nozzles

50
10 20 30 40 50 60 70
Nozzle outlet velocity [m/s]

80

contact web run, features highly efficient● Level of heat transfer and drying rate

heat and mass transfer and maximum

drying air. This causes an increased heat

● Avoidance of web overheating

thermal stability. One of the main fea-

exchange between core flow and paper● Stability of the web runtures of the Krieger CB-Dryers is the CB2

surface. A measure of the number and in-● Minimization of the open draws

hole-type nozzle, which permits the high-tensity of these vortices, and thus also of● Energy efficiency.

est possible heat transfer rates. The de-the intensity of the heat transfer, is thevelopment of this highly effective nozzle

so-called degree of turbulence. In addi-

type is based both on fundamental in-tion to the air velocity and the direction

Krieger CB-Dryers as compo-

sights into flow mechanics and on manyof the approaching air flow, the nozzle

nents in coating color drying

years of experience in dealing withshape is of major importance for the level

the special requirements of the paperof the degree of turbulence. Scientificindustry.

studies have shown that hole-type noz-

In many cases, a combination of infrared
dryers, air dryers and drying cylinders iszles have a distinct advantage over thesuitable for coating drying. The function

The development of the CB2 nozzle,

simple, slotted nozzles. With the sameof IR dryers is to heat the web to a hightherefore, aims not only at ensuring max-

air-flow rate (and the same required heat-temperature as quickly as possible andimum heat transfer to the web, but also

ing and fan capacity!), hole-type nozzles

simultaneously cause the evaporation ofat obtaining optimized load capacity. In

achieve up to 50 % higher heat transfer

as much of the water contained in the

addition, it achieves the highest possible

rates than slotted nozzles (Fig. 2).

coating as possible. Depending on theinsensitivity to thermal deformation andcoating formulation, by incorporating acontamination by coating color during

Furthermore, the CB2 nozzle ensures ho-large percentage of IR drying, web tem-sheet breaks.

mogeneous heat transfer since, unlike

peratures can reach over 100 °C in theslotted nozzles, a thermal change in thecourse of coating drying. For this reason,

If air is blown onto the paper surface at a

nozzle geometry is impossible. ThroughKrieger prefers to use air dryers from oursuitable angle at high velocity, vortices

the use of materials with relatively low

series of CB-Dryers at this point in the in-form in the air, thoroughly blending thethermal expansion coefficients, a high

19/05

62

Fig. 3: Schematic of air flow of the CB2 nozzles.
Fig. 4: Web run concepts for drying the bottomside of the web.
Left without HCB-Turn– long web run– motor driven rolls– risk of contamination.
Right with HCB-Turn– short web run and simplified tail threading– fewer rolls– low risk of contamination.
3

4

thermal stability of all CB-Dryers used isthe energy that is present in the combus-

carrying capacity (turning of a paper orguaranteed.

tion exhaust gases of the gas-fired IRboard web by 180° with high web draws)

emitters.

and high drying rates with simultaneous
space-saving web guidance (Fig. 4).

Another feature of the CB2 nozzle is the
special geometry of the air nozzle. The
nozzle outlet openings, placed opposite

The Krieger HCB-Turn for

In extensive trials, the ratio of the width

to each other, generate an extremely

simultaneous turningof the supply-air nozzle beam to thestable cushion pressure and, due to theand drying of a paper web

width of the exhaust gap in particular,
was optimized and a patent is pending forrecessed arrangement of the holes, contamination is nearly impossible. As a re-

The Krieger HCB-Turn has been devel-

this design. This feature ensures a highsult, downtime is greatly reduced (Fig. 3).

oped in response to persistent market de-exhaust capacity even at high web draws,

mand concerning space requirements andas is frequently the case in board produc-

In the CB-Dryer, the largest portion of the

web run, – both in the case of rebuilds

tion. It also results in uniform drying

drying air is recirculated, whereby theand new installations, and recently wentacross the entire web width (Figs. 5 - 7).

drying air repeatedly makes contact with

into operation.
In non-contact web-turning systems, a

the web. This results in the transfer ofmore energy (energy efficiency). A cer-

The construction of the HCB-Turn iscertain amount of the air invariably es-

tain portion of the air must, however, bebased on our experience with the above-

capes from the area of the cushion pres-continuously withdrawn from circulation

mentioned excellent characteristics of thesure into the atmosphere. In order toin order to remove the steam that is

CB2 nozzle – which, for many years, hasachieve the required high drying output,

being created. In the combination ofbeen used successfully in the Krieger CB-

the air has to have a high temperature.

CB-Dryers and infrared systems, the en-

Dryer – and the optimized load-carrying

Krieger has developed a suction systemergy balance of the entire system can becapacity of the Krieger CB-Turn. Ourthat recaptures a portion of this heated

optimized through the partial recovery ofchallenge was to combine the high load-

air on both drive and tending sides and

19/05

63

5

recirculates it back into the circulation-air

below the HCB-Turn in order to provide

Summarysystem. A patent for this system is pend-

room for additional drying components

When it comes to the optimization of ap-

ing. The operation of gas-fired systems(e.g. infrared dryers). For this reason,

plication-related performance in coating

generates temperatures of approximately

Krieger developed an additional model

drying, Krieger CB-Dryers and HCB-Turns

350 °C. In order to avoid overheating ofthat splits the HCB-Turn with a wrap an-

are important components, especially inthe rope-pulley bearings, an additionalgle of 180° into two separate parts eachcombination with other non-contact dry-cool-air duct has been integrated into thehaving a wrap angle of 90°. In order toing systems (infrared). As a rule, only thetending-side exhaust system.

stabilize the straight section of the web

suitable combination of systems leads tobetween the two 90° HCB-Turns, it isthe desired level of performance andIn web widths greater than 6 meters, it isequipped with heated CB2-nozzles as

quality. Each application, therefore, re-often necessary to plan for more space

well.

quires an individual solution.

6

7

Fig. 5: Online coating systemwith two CB-Dryers and HCB-Turn.
Fig. 6: Additional tending-side
air return.
Fig. 7: Support-nozzle geometry
and air-cooled rope pulleys.

19/05

64

Field Service Specialist
PikoTeknik Oy in Finland –one year with Voith Paper now
Happy Birthday – PikoTeknik! The Finnish Field Service
Company PikoTeknik Oy is a member of the Voith Paper for one
year now!
Ingmar Vesterlund
PikoTeknik Oy
ingmar.vesterlund@pikoteknik.com

By acquiring PikoTeknik with its wide

PikoTeknik Oy was founded in 1989 bycompetence in field service mainly for the

Ingmar Vesterlund and Göran Antila inpaper industry, Voith Paper Service has

Pyhäjoki near Oulu in central Finland andstrengthened its position for Mill Ser-has meanwhile become the biggest com-vices in the Nordic Countries and espe-pany in Finland specialising in on-site

cially in Finland. Being closer to the cus-maintenance and coating of pulp andtomers in this important market area waspaper machine rolls and cylinders.

the driving force for Voith Paper. ExpandGöran Antila

ing with such activities on a more global

After being an established player for more

PikoTeknik Oy
goran.antila@pikoteknik.com

basis is the next target.

than 15 years mainly on the Finnish andScandinavian markets, PikoTeknik now“Joining Voith Paper was a natural con-intends, together with Voith Paper, to fo-

tinuation of our deep co-operation withcus on other markets in the world, too.

Voith”, says Ingmar Vesterlund, the Man-

Andreas Arnhold
Serviceandreas.arnhold@voith.com
19/05

aging Director of PikoTeknik. “Thanks to

PikoTeknik has know-how, wide experi-

Voith we have access to new valuable

ence, flexibility and innovative productknow-how for our product development

development concerning work that has toand power to continue our rapid growth

be performed at the customer’s facilities

in the paper industry.”

during short downtimes.

1

65

2

3

4

The main expertise of PikoTeknik Oy lies in:

PikoTeknik has developed a comprehen-August 2003, to raise the production ca-● coatings: wear-resistant, frictional,

sive selection of coatings. For example

pacity from 800 m/min to 1,400 m/min,non-sticky and repair coating

PikoClean, which is a non-stick compo-

PikoTeknik was responsible for on-site

sition coating with high ability for doctor-

balancing of 65 rolls, 53 drying cylinders● on-site machining: grinding, grooving,ing. It combines the unique qualities bothand one suction roll and, besides that,● repair of machine partsof hard carbides and repellent PTFE

the drilling of several drying cylinders.

● inspecting rolls and drying cylinders(Teflon). This prevents effectively stickies

The work was completed within 11 days.

drilling of drying cylinders

at the customer’s facilities● balancing rolls and drying cylinders

and fibers from picking, linting and dusting even at high temperatures. Applica-

In October-November 2003 a major re-at the customer’s facilities and even intions on-site have successfully been madebuild project was carried out at Stora-

the machine.

on drying cylinders after presses, size

Enso in Kemi, Finland, together withpresses or coating stations.

Voith Paper. PikoTeknik’s part included
the changing of drives and bearings of“In the production process of a modern
paper mill it is of essential importanceAlso PikoFric, which is a roughening

56 drying cylinders, as well as grindingthat all potential bottlenecks are foreseen

and frictional coating, has been devel-and balancing of the 56 drying cylinders

in time. On-site solutions help to de-oped for on-site applications on drums infor a speed of 1,400 m/min, drilling ofcrease machine downtime and improvereels and winders. Using the HVOF (High

6 drying cylinders and coating of 5 cylin-

runability. Working directly in the mill

Velocity Oxygen Fuelled) spraying methodders with PikoClean, that improves sheet

takes less than half the time required for

ensures more effective adhesion with up

release on dryers.

traditional off-machine cylinder mainte-

to 50 % improvement in comparison tonance, grinding or coating in combina-

plasma spraying methods.

placements”, says Ingmar Vesterlund.

Together with Voith Paper Service teams,
PikoTeknik was involved in several majortion with time consuming cylinder reA complete on-site machining to speci-

projects in Germany, Austria and even in

fied dimensional and surface tolerances

India, Indonesia and New Zealand.

ensures optimum roll/cylinder perforOptimal cylinder performance

mance for several years, that offers theThis first birthday can be considered asfor years

possibility to increase speed and to pro-an important milestone towards a longduce a higher-quality end product.

lasting relationship – all the best for further development!

PikoTeknik has developed its methods, awide assortment of equipment and special tools in co-operation with Finnish

Fast execution, where needed
Fig. 1: Main building of PikoTeknik Oy
in Finland.

paper mills and the Technical ResearchCenter of Finland.

There are many examples of fast on-site
work:

As an important solution to the sticking,

When Neusiedler SCP a.s. in Ruzomberok,

dust and corrosion problems which might

Slovakia, carried out a major machine re-even lead to frequent paper breaks,build project together with Voith Paper in

Fig. 2: On-site grinding of a drying cylinder.
Fig. 3: On-site coating of a drying cylinder
with PikoClean.
Fig. 4: Application of the Teflon layer.

19/05

66

Deep-frozen, dried – and saved
In the night of September 2nd, 2004, a major fire destroyedlarge sections of the historic building housing the Duchess Anna
Amalia Library in the German town of Weimar. Local residents, library
employees and several hundred volunteers formed a human chain andrescued more than half of the irreplaceable original manuscripts andincunabula from the burning building, which is on the UNESCO World
Cultural Heritage list. Some 30,000 of the library’s volumes werepassed from hand to hand in this way, and a further 30,000 also
escaped the flames, though damaged to a greater or lesser degree.

Most of the books that were rescued,
were already singed or soaked in water
as a result of the fire-fighting operations.
They were taken temporarily to the Book
Preservation Center (ZFB) in Leipzig, aninstitute possessing expertise unparalleled anywhere in the world in the savingof old books, periodicals and musicalscores for posterity, and the restorationof old maps and plans, certificates andofficial records.
Months after the catastrophe in Weimar,
visitors to the ZFB can still detect a slightsmell of smoke and burning in the air. It
emanates from the ‘patients’ brought
there from the Anna Amalia Library.
These are stacked everywhere in theworkrooms and corridors. Some have already been given initial treatment, which
involves sorting and classifying them into
groups according to the degree of damage they have suffered. Group One consists of largely undamaged items, whereas Group Six contains those that havebeen almost completely destroyed.
The first treatment stage for the books is
to be stored temporarily in large cold
storage chambers at 20 degrees Celsius

19/05

below freezing point. Wrapped individually in muslin or fleece, each soaking wetbook is transformed within a very shorttime into a frozen-through block of ice.
This technique avoids further loss ofshape or disintegration, but more importantly prevents the spread of mold spores
and is a means of gaining valuable time.
Although the Institute is working roundthe clock in three shifts, its skilled methods of limiting damage are unavoidably
time-consuming. Nobody expected to be
confronted with tens of thousands ofbooks, all needing urgent attention toprotect them against irrevocable damage.
The second stage in the treatment
process is freeze drying – using a methodthat the ZFB itself developed to extract
moisture from the books. If they were to
be allowed to dry in a normal atmosphere, the inks, color pigments and glues
would run, the pages would tend to stick
together and the paper would become
wavy and brittle. In other words, evenworse damage would be caused. Freeze
drying, on the other hand, prevents the
moisture in the book, once it has been
turned into ice, from thawing again in theconventional sense of the term. It trans-

67

1

forms the ice into vapor that can then escape and leave the book dry.

ment process may be over within a few
hours, but can also take two to threedays. Afterwards, the books are absolutely dry.

A load of books weighing up to a ton issealed into a pressure chamber, the temperature inside lowered to 192 degrees
Celsius below zero and the air pressure,which is normally in the region of 1,000
millibars, reduced to below 7 millibars.
Instead of melting, the ice begins to ‘vaporize’ in these conditions, and in thisstate can easily be extracted from thechamber. The normal atmospheric pressure is then restored and the temperatureallowed to rise gradually to 20 degrees
Celsius.

The last stage in their treatment involves
the removal of residual dirt by hand.
Rows of work booths have been installed
beneath an air extraction system, andZFB staff armed with fine brushes turnthe pages of each book with great careand remove the mixture of ash and limewash dust that the fire extinguishing water removed from the shelves, ceilings
and walls.
This treatment of the books completes
the task that the ZFB has been commissioned to carry out.

Depending on the number of books being
processed and their formats, the treat2

Many of the ‘patients’ have already beenreturned to Weimar, and now confront
the experts and restoration staff of theAnna Amalia Library with some difficult
decisions: what further restoration measures should be applied to them, and inwhat order of priority. One thing is certain: many years will elapse and extensive
financial support will be needed before
this unique historic heritage can re-open
for academic study or for the generalpublic. It is doubtful whether the final
traces of the fire will ever be eliminated.
Following this spectacular rescue operation, the ZFB will return to its normal
day-to-day book preservation activities,
and we can indeed be grateful if rectifying fire damage remains one of its more
exceptional activities.

3

Fig. 1: Damaged books from the DuchessAnna Amalia Library in Weimar, Germany.
Fig. 2: Freeze drying damaged documents.
Fig. 3: Removing ash and lime.

19/05

68

ZFB document restoration techniques:Fig. 8: Bulk deacidification, in which the books
are soaked in a non-aqueous solution. A treatment
capacity of more than 100 tons a year.

Fig. 11: Mechanical paper splitting if the document is less severely fragmented. In this case, athin but highly tear-resistant core sheet is inserted
between the two halves.

Fig. 9: Aqueous fungicide treatment to eliminate
mold spores.

Fig. 12: Closing holes and gaps by mechanicalfiber reconstruction. As in papermaking, a fiber
suspension is applied to a screen in such a waythat the fibers take up the desired position and arelinked together.

Fig. 4: Paper destroyed by acids.
Fig. 10: Manual paper splitting.
Gelatin is used to hold the damaged document
between two supporting sheets of paper; it is thensplit apart so that it can be stabilized by inserting
an interleaved core sheet between the two halvesof the original document.

Fig. 5: Mold damage.
Fig. 6: Damage caused by aggressive inks.
Fig. 7: An extensively damaged map.
4

Acid damage to paper – thebiggest problem and challenge

5

The ZFB, had its origin in the restoration
departments of two German libraries, the‘Deutsche Bücherei’ and the ‘Deutsche
Bibliothek’, which were combined in
Leipzig following the German reunification. For some time now it has confronted this specific acid-damage problem anddeveloped equipment suitable for thebulk deacidification of books. Such large-

The acids that cause this damage often
enter the paper in the fillers or as a result8

6

scale methods are clearly essential if theloss of possibly millions of importantbooks is to be avoided. In 1998 the ZFB
ceased to be part of the Deutsche Bibliothek and became an autonomous institute. With its know-how, its experienceand the methods at its disposal, it is today in a position to assist all international
state-run and private bodies that have thetask of maintaining important collectionsof books.

of incorrect dosage of strengthening
agents during the papermaking process,but environmental influences both pastand present are also to blame. The acids
break down the cellulose that provides
the paper with its mechanical strength,
whereupon it becomes brittle and breaks
up easily. This is an auto-catalytic ageing
process, in other words one that speeds
up automatically and can only be countered by effective deacidification.

Books are part of our cultural heritage,
but are exposed to many different dangers. The worst of these are not bookworms, bark beetles or other destructive
insects, nor even mold or similar problems caused by incorrect handling ofvaluable volumes. If asked about themain priorities in the preservation of oldbooks, Dr. Manfred Anders, the ZFB’s
General Manager, is sure that the main
challenge for the future will be to stopacid decay, which according to current
knowledge threatens at least two-thirdsof the world’s most significant libraries,
archives and document collections.

19/05

Fig. 13: Restoring damaged book covers andspines.

The ZFB’s ‘Papersave’ process
The books are pre-dried to reduce theirnatural moisture content temporarily
from the usual 5 - 7% to below 1%. Thisis followed by the actual deacidification
process, in which the books are soaked
in an alkaline, non-aqueous solution. For
9

10

69
Zentrum für Bucherhaltung GmbH
Gewerbegebiet Heiterblick
Mommsenstraße 7D-04329 Leipzig
Telephone +49 (03 41) 2 59 89-0
Telefax+49 (03 41) 2 59 89-99
eMail
info@zfb.com
Internet http://www.zfb.com

hands and seeing the work of scribes andprinters dating from many centuries ago,and representing the basis for our own
history and culture. The passage of timeand various unwelcome events have already destroyed so many of these artifacts. What still remains must never be
regarded as a burden imposed by our ancestors, but as a legacy that – for ourown sake – it is our duty to preserve.
Manfred Schindler

The ‘Papersave’ process and bulk deacidification are capable of stopping damage,but clearly can not reverse any deterioration that has already taken place. The
ZFB, therefore, concerns itself with allforms of restoration work as well: repairs
to paper eaten away by inks, paper stabilization, prevention of mold and all related forms of damage reduction, from identification to remedial treatment, subject
to the limitations imposed by research,know-how and the available techniques.
Astonishing results have been achievedin many cases, for instance a scarcely
decipherable Beethoven music manuscript, the almost completely decayed
first printed edition of a Luther Bible andplans drawn out by the great Germanarchitect Schinkel have all been restored
to (almost) their original condition.

7

this purpose, the treatment chamber containing the books is completely flooded.
The solution is then pumped out and thebooks removed after subsequent drying.
Next comes a reconditioning phase inwhich they recover their normal moisture
content from the surrounding air. The fulldeacidification process takes three tofour weeks to complete.

What the ZFB offers:● Bulk deacidification● Paper stabilization with wet treatment,
fiber reconstruction and paper splitting● All forms of wet treatment (aqueousdeacidification, bleaching, re-gluing● Book cover restoration● Treatment of specific forms of damage
such as mold or aggressive inks
● Recovery work after water damage –freeze drying including protective
action, cleaning and logistics, posttreatment● Decontamination and chemical cleaning● Processing of plans and maps
● Production of protective patterns● Microfilming, reprinting and digitizing● Elimination of complex forms ofdamage● Consultation and advanced training

One could ask why such efforts should bemade in view of the fact that all such material could be recorded on microfilm or
digitized, and indeed these tasks are normally carried out in parallel with therestoration work.

Following neutralization of the paper, it
retains about 0.5 - 2% magnesium carbonate as a kind of ‘alkaline reserve’, toprotect it against acids that develop lateror reach it from external sources. Experimental work and the results so far obtained confirm that the life of paper
deacidified in this way is extended by afactor of 4 to 5. The earlier the deacidification process is undertaken, the longer
the paper’s potential life.

There’s a fundamental difference, however, between studying text, illustrations
and drawings on the screen and actually
holding a valuable document in one’s
11

12

13

19/05

70

Startup highlights in 2003/2004

Fiber Systems
Stock preparation systems
and sub-systems for graphic
papersStora Enso North America,
Port Hawkesbury, Canada.
Daishowa Paper,Port Angeles, USA.
Abitibi-Consolidated, Alma,
Canada.
International Paper, Augusta,
USA.
Bowater Newsprint, Calhoun,
USA.
International Paper, Norway, USA.
Atlantic Newsprint, Whitby, USA.
UPM-Kymmene, Miramichi,
Canada.
Great Lakes Pulp, Menominee,(pulp), USA.
LEIPA Georg Leinfelder, Schwedt,
Germany.
Stora Enso Magazine Paper,
Maxau, Germany.
Stock preparation systems
and sub-systems for board andpackaging papers
PCA, Tomahawk, USA.
Longview Fibre, Longview, USA.
Inland Paperboard, Orange, USA.
United States Gypsum,South Gate, USA.
Weyerhaeuser, Valliant, USA.
APP, Ningbo, China.
SCA Packaging Containerboard,
Aschaffenburg, Germany.

19/05

Shanghai Chung Loong,
Shanghai, China.
Stock preparation systems andsub-systems for tissue papers
SCA Tissue North America,
Barton, USA.
Georgia-Pacific, Green Bay, USA.
Georgia-Pacific, Clatsklanie, USA.
J.D. Irving, Saint John, Canada.

Paper machines
Graphic papers
Stora Enso Magazine Paper,
Maxau, Germany.
LEIPA Georg Leinfelder, Schwedt,
Germany.
Calik Group, Yaslik,
Turkmenistan.
Khanna Paper Mills Private,
Khanna, India.
Board and packaging papers
Papierfabrik Adolf Jass, Rudolstadt/Schwarza, Germany.
Shanghai Cheng Loong,
Shanghai, China.
Installation and rebuilds
UPM, Shotton, Great Britain.
Stora Enso Veitsiluoto,
Veitsiluoto, Finland.
Suzano Papel e Celulose, Suzano,
Brazil.
Abitibi Consolidated, Alma,
Canada.

Stora Enso, Kotka, Finland.
Papresa, Renteria, Spain.
Papelera del Besaya, Besaya,
Spain.
International Paper, Quinnesec,
USA.
Ledesma, Ledesma, Argentina.
Krkonosske Papirny, Hostinne,
Czech Republic.
Holmen Paper, Braviken,
Sweden.
August Koehler, Oberkirch,
Germany.
Crown van Gelder, Velsen,
Netherlands.
Ahlstrom, Osnabrück,
Germany.
OP papirna, Olsany, Tschechien.
PCE – Papel, Caixas e Embalagens, Manaus, Brazil.
Klabin Fabricadora de Papel e
Celulose, Telêmaco Borba,
Brazil.
Visy Pulp and Paper, Tumut,
Australia.
CMPC Celulosa– Planta Laja,
Laja, Chile.
Orsa Celulose, Papel e Embalagens, Paulínia, Brazil.
Amcor Cartonboard, Petrie,
Australia.
Inpa – Indústria de Embalagens
Santana, Pirapetinga,
Brazil.
Cocelpa Cia de Celulose e Papel
do Paraná, Araucaria, Brazil.
Shin Daeyang Paper,
Shiwa, Korea.

Hwa Seung Paper, Korea.
Oji Paper, Matsumoto,Japan.
Oji Paper, Saga, Japan.
Oji Paper, Sofue, Japan.
Oji Paper, Oita, Japan.
Mead Westvaco Corporation,
Chillicothe, USA.
Cartitalia, Mesola/Ferrara,
Italy.
Tolentino, Tolentino/Macerata,
Italy.
Coating technology
LEIPA Georg Leinfelder, Schwedt,
Germany.
August Koehler, Oberkirch,
Germany.
Krkonosske Papirny, Hostinne,
Czech Republic.
Winding technology
LEIPA Georg Leinfelder, Schwedt,
Germany.
Stora Enso Magazine Paper,
Maxau, Germany.
M-real Zanders,Germany.
Norske Skog Follum, Follum,
Norway.
W. Hamburger, Pitten,
Austria.
Stora Enso Veitsiluoto,
Veitsiluoto, Finland.
Mondi Business Paper SCP,
Ruzomberok, Slovakia.
Stora Enso Baienfurt, Baienfurt,
Germany.

71

FinishingJanus Concept
LEIPA Georg Leinfelder, Schwedt,
Germany.
Stora Enso Magazine Paper,
Maxau, Germany.
Midwest, USA.
Ecosoft calender
LEIPA Georg Leinfelder, Schwedt,
Germany.
Feinpapierfabrik Dr. Franz
Feurstein, Traun, Austria.
Papresa, Renteria, Spain.
Zhejiang Tianting Yalun Paper
Group, Longyou, Zhejiang, China.
Minfeng Special Paper, China.
Shenzhen Wander Color Printing& Packaging, China.
NipcoFlex calender
Stora Enso Baienfurt, Baienfurt,
Germany.
Calenders
Minfeng Special Paper, China.
Zhejiang Yongtai Paper, Fuyang,
Zhejiang, China.
Shanghai Chung Loong Paper,
Shanghai, China.
Twister / Roll Handling
LEIPA Georg Leinfelder, Schwedt,
Germany.
Papresa, Renteria, Spain.
Dresden Papier, Heidenau,
Germany.

Roll cutting machines
LEIPA Georg Leinfelder, Schwedt,
Germany (3).
Stora Enso Magazine Paper,
Maxau, Germany.
Stora Enso Baienfurt, Baienfurt,
Germany.
Feinpapierfabrik Dr. Franz
Feurstein, Traun, Austria.
AO Kondopoga, Kondopoga,
Karelien, Russia.
Ningbo Zhonghua Paper, Ningbo,
China (2).
International Paper, Jay, USA.
SCA Tissue North America,
Barton, USA.
Calik Group, Yaslik,
Turkmenistan.
Shanghai Chung Loong Paper,
Shanghai, China.
Parent reel cart
LEIPA Georg Leinfelder, Schwedt,
Germany.
Papresa, Renteria, Spain.

Automation
Norske Skog Albury, Albury,
Australia.
Holmen Paper, Braviken,
Sweden.
Gold East Paper, Dagang, China.
Fabrica Nacional de Papel,
Fanapel, Uruguay.
Changde Heng An Paper
Products, Hengan, China.
CNTIC Trading, Huatai, China.

Shandong Huatai Paper Group,
Huatai, China.
Stora Enso Kabel, Kabel,
Germany.
Norske Skog Tasman,
Kawerau, New Zealand.
Oji Paper, Matsumoto, Japan.
Mondi Paper, Merebank,
South Africa.
Oji Paper, Nakajima, Japan.
Papeteries Emin-Leydier,
Nogent-sur-Seine, France.
Holmen Paper Papelera Peninsular, Peninsular, Spain.
MD Papier, Plattling, Germany.
Oji Paper, Saga, Japan.
Papierfabrik Adolf Jass, Rudolstadt/Schwarza, Germany.
W. Hamburger Pitten,
Spremberg, Germany.
Appleton Papers, Spring,USA.
Papier- und Kartonfabrik Varel,
Varel, Germany.
Veracel Celulose, Veracel,
Brazil.
Nippon Paper Industries,
Yatsushiro, Japan.
Pan Asia Stonebridge,
Stonebridge, China.
Steinbeis Temming Papier,Glückstadt, Germany.
Thai Kraft Paper Industry,
Thailand.
Weyerhaeuser Pulp & Paperboard
Division, Longview, USA.
Kaysersberg Packaging,
Kaysersberg, France.

Korsnäs, Korsnäs,
Sweden.

Voith Fabrics
Graphic papers
LEIPA Georg Leinfelder, Schwedt,
Germany.
Lee & Man, Jiangsu, China.
Board and packaging papers
Papier- u. Kartonfabrik Varel,
Varel, Germany.
Chung Loong Shanghai Paper,
Shanghai, China.
Papierfabrik Adolf Jass,
Rudolstadt/Schwarza,
Germany.
W. Hamburger Pitten,
Spremberg, Germany.
Bohui Paper Group, Shandong,
China.
Installation and rebuilds
Stora Enso Baienfurt, Baienfurt,
Germany.
Abitibi-Consolidated Alma,
Canada.
Stora Enso North America,
Kimberly, WI, USA.
Stora Enso North America,
Biron, WI, USA.
Georgia-Pacific, Wauna, USA.
Georgia-Pacific Green Bay, USA.
Marcal Paper Mill,
Elmwood Park, New Jersey,
USA.

19/05

72

Recent large orders

Fiber Systems
Stock preparation systems
and sub-systems for graphic
papersStora Enso North America, Biron,
WI, USA.
International Paper, Augusta,
USA.
Bowater Newsprint, Calhoun,
USA.
International Paper, Norway,
USA.
Atlantic Newsprint, Whitby, USA.
MeadWestvaco,Wickcliffe, USA.
Jiangsu, China.
Huatai Paper, Dongying, China.
Mondi Paper, Merebank,
South Africa.
Holmen Paper Papelera
Peninsular, Madrid, Spain.
UPM-Kymmene Austria,
Steyrermühl, Austria.
UPM-Kymmene, Kaipola,
Finland.
Cartiere Miliani, Italy.
Stock preparation systems
and sub-systems for board andpackaging papers
Longview Fibre, Longview, USA.
Inland Paperboard, Orange, USA.
United States Gypsum, South
Gate, USA.

19/05

Weyerhaeuser, Valliant, USA.
Thai Kraft Paper, Bangkok,
Thailand.
SAICA – Sociedad Anónima
Industrias Celulosa Aragonesa,
Zaragoza, Spain.
Stock preparation systems andsub-systems for tissue papers
Georgia-Pacific, Green Bay,USA.

Paper machines
Graphic papers
Gold East Paper, Dagang,
China.
Shandong Huatai Paper Group,
Huatai, China.
Holmen Paper Papelera Peninsular, Peninsular, Spain.
Feinpapierfabrik Dr. Franz
Feurstein, Traun, Austria.
Mudanjiang Hengfeng Paper,
Hengfeng, China.
Binzhou Huanghe Paper Group,
Binzhou, China.
Zhejiang Purico Minfeng Paper,
Purico, China.
Board and packaging papers
SAICA – Sociedad Anónima
Industrias Celulosa Aragonesa,
Zaragoza, Spain.

Installation and rebuilds
Norske Skog, Kawarau,
New Zealand.
Norske Skog, Albury, Australia.
Holmen Paper, Braviken,
Sweden.
August Koehler, Kehl,
Germany.
Sappi, Cloquet, USA.
Mead Westvaco Cooperation,
Chillicothe, USA.
Banque de France, Vic le Comte,
France.
Kunshan Banknote Paper,
Kunshan, China.
CBPC Banknote Paper, Chengdu,
China.
Baoding Banknote Paper,
Baoding, China.
Ziegler Papier, Grellingen,
Switzerland.
Golg Huasheng Paper, Suzhou,
China.
Yue Yang Paper Group,
Yue Yang, China.
Radece papir. d.d, Radece,
Slovenia.
Mondi Paper, Merebank,
South Africa.
Kaysersberg Packaging,
Kaysersberg, France.
Korsnäs, Korsnäs,
Sweden.
SCA Packaging Containerboard,
Aschaffenburg, Germany.

Siam Kraft Industry, Banpong,Thailand.
Coating technology
Papier- und Kartonfabrik Varel,
Varel, Germany.
Papierfabrik Adolf Jass, Rudolstadt/Schwarza, Germany.
Zheijang Purico Minfeng Paper,
Purico, China.
Papeteries Emin-Leydier,
Nogent-sur-Seine, France.
August Koehler, Kehl,
Germany.
SCA Packaging Containerboard,
Aschaffenburg, Germany.
Korsnäs Aktiebolag, Gävle,Sweden.
Khanna Paper Mills Private,
Khanna, India.
Union Industrial Papelera, Uipsa,
Spain.
Mundanjiang Hengfeng Paper,
Hengfeng, China.
Mondi Paper, Merebank,
South Africa.
SAICA – Sociedad Anónima
Industrias Celulosa Aragonesa,
Zaragoza, Spain.
Winding technology
Holmen Paper Papelera
Peninsular, Peninsular, Spain.
Shandong Huatai Paper, Huatai,
China.

73

Mondi Paper, Merebank,
South Africa.
Papierfabrik Adolf Jass, Rudolstadt/Schwarza, Germany.
SAICA – Sociedad Anónima
Industrias Celulosa Aragonesa,
Zaragoza, Spain.
SCA Packaging Containerboard,
Aschaffenburg, Germany.

FinishingJanus Concept
Gold East Paper (Jiangsu),
Dagang, China (2).
Ecosoft calenderZhejiang Xianhe Special Paper,
Quzhou, Zhejiang, China.
Zhangqiu Huashi Paper,
Zhangqiu, China.
Zhejiang Rongfeng Paper,
Rongfeng, China.
Holmen Paper, Fuenlabrada,
Madrid, Spain.
Shandong Huatai Paper,
Dongying, Shandong,
China.
Henan New Century Hengxing
Paper, Suixian, China.
Weyerhaeuser Pulp & Paperboard
Division, Longview, USA.
Cartiere di Guarcino, Guarcino,
Italy.

NipcoFlex calender
Weyerhaeuser Pulp & Paperboard
Division, Longview, USA.
Calenders
Mondi Paper, Merebank,
South Africa.
Gold East Paper, Dagang, China.
Norske Skog, Albury, Australia.
St. Regis Paper, Darwen,
Great Britain.
Tullis Russell, Glenrothes, GreatBritain.
Henan New Century Hengxing
Paper, Suixian, China.
Shandong Huazhong Paper
Industry, Zaozhuang, China.
Changde Heng An Paper Products,
Changde City, Hunan, China (2).
Twister / Roll Handling
Holmen Paper, Fuenlabrada,
Madrid, Spain.
MD Papier, Plattling,
Germany.
Ahlstrom, Osnabrück,
Germany.
Torraspapel, Motril,
Spain.
Sappi Lanaken, Lanaken,
Belgium.
Roll cutting machines
Gold East Paper, Dagang,
China (2).

Holmen Paper, Fuenlabrada,
Madrid, Spain (2).
MD Papier, Plattling,
Germany.
Stora Enso North America,
Kimberly, USA.
Norske Skog, Albury, Australia.
Papresa, Renteria, Spain (2).
Emin Leydier, Nogent-sur-Seine,France.
Papierfabrik Adolf Jass, Rudolstadt/Schwarza, Germany.
Papier- u. Kartonfabrik Varel,
Varel, Germany.
Parent reel cart
Gold East Paper, Dagang,
China (3).
Norske Skog, Albury, Australia.

Automation
Archangelsk Pulp and Paper Mill(APPM), Archangelsk, Russia.
First Quality Tissue, Boston, USA.
Nippon Paper Industries,
Fuji, Japan.
Nippon Paper Industries,
Iwanuma, Japan.
CMPC Celulosa, Laja, Chile.
LEIPA Georg Leinfelder, Schwedt,
Germany.
Stora Enso Magazine Paper,
Maxau, Germany.

Cartitalia, Mesola, Italy.
Procter & Gamble, Neuss,
Germany.
Radece Papir, Radece,
Slovenia.
Nippon Paper Industries,
Shiraoi, Japan.
Stora Enso Suzhou Paper,
Suzhou GHS, China.
Feinpapierfabrik Dr. Franz
Feurstein, Traun,
Austria.
UIPSA, Unión Industrial Papelera,
Uipsa, Spain.
Yueyang Paper, Yueyang,
China.
Vipap Videm Krsko, Krsko,
Slovenia.
Shanghai Chung Win Recycle
Technology, Shanghai,
China.
SCA Packaging Containerboard,
Aschaffenburg,
Germany.
SAICA – Sociedad Anónima
Industrias Celulosa Aragonesa,
Zaragoza, Spain.

Voith Fabrics
Graphic papers
Gold East, Zhenjiang, Jiangsu,
China.
Nine Dragons, Taicang City,
Jiangsu, China.

19/05

Newsmagazine for theinternational clientele,
partners and friends ofVoith Paper Technology

Published by:Voith Paper Holding GmbH & Co. KG
Editor:Dr. Wolfgang Möhle, Corporate Marketing
Voith Paper Holding GmbH & Co. KG
Tel. (++49) 73 21 37 64 05
Fax (++49) 73 21 37 70 08
P.O. Box 1970, D-89509 Heidenheim
wolfgang.moehle@voith.com
http://www.voithpaper.com

Editorial coordinator:
Manfred Schindler, D-73434 Aalen
Design, layout and typesetting:
MSW, P.O. Box 1243, D-73402 Aalen
Copyright 7/2004: No part of this publication
may be reproduced or copied by any means
whatsoever without the express permissionof the editor.
Issue 19, February 2005.

2/2005/27 MA Printed on chlorine-free bleached paper manufactured with Voith Paper Technology machinery.

Paper Technology Journal“twogether” is published twice annuallyin German, English, Chinese, Russia andFinnish. Contributions by independent
authors do not necessarily reflect theopinion of the publisher. Please address allcorrespondence and inquiries to the editor.