nextlevel
by Voith Paper — N° 05

20Leading the way:
The world’s
most modern
board machineis setting
benchmarks at
BillerudKorsnäs

Sustainability
DigitalizationNew
perspectives
for
paper

28

Winning formula:
New Progroupfacility uses
customized Voith
solutions40

Vote ofconfidence:
Sun Paper
orders machinefor graphic
papers

Efficiency

Editorial
nextlevel N° 05

20

Technology benchmark:The BM 7 board machine is setting standards.

Paper is not a thing of the past but ofthe present, and it has very goodprospects for the future. This is not justthe view of the paper industry; thepotential of paper is also recognized bysociety and policy makers. Paperis highly rated as a renewable, biodegradable alternative to petroleum-­
based products. This represents a huge
opportunity for all paper manufacturers. We believe it is our role to support
them – with solutions for the digitaltransformation of existing processes
that enable efficiency improvements
along the supply chain and reduce energy requirements. And with researchthat addresses not only major issues ofthe future but also helps to incre­
mentally improve sustainability today –through a large number of productimprovements. In this issue of nextlevel,
we will be sharing with you someprominent examples. First and foremost, the game-changing major board
machine project in Gruvön and theorder for two new machines from ourlong-standing customer Sun Paper.
I hope you find it an interesting andinformative read.

Contents
Zoom
04	Pluralis Conical
The new filling transfers the Pluralis
design to conical refiners.

News
06	A quick round-up
from the world of Voith Paper.

02 Editorial

innovate

A look at key trends

08	R&D – Shaping the futureof paper
The purpose of the Model Factory
Paper is to develop newconcepts for the paper industry.
12	“The future is paper”
The paper foresight process
analyzes the significance ofpolitical, social andtechnical de­velopments.
14	DuoShake digital
Digital connectivity extends
functionality of shaking unit.
15	SmartBasket
SmartBasket monitors
screen baskets across sites
with RFID chips.
16	Voith Paper Webshop
Extended functionality now
means faster access to the rightspare parts.

08
Andreas Endters
President & CEO, Group Division
Voith Paper

07

The Model Factory Paper
is designed to provide
answers to the questions affecting
the future of the industry.

18	OnEfficiency.StrengthAI-based concept optimizes
fiber consumption and strength
values at Metsä Board.
nextlevel N° 05

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36	“Paper does have a future”
Voith Paper CEO Andreas
Endters outlines approaches thatcan benefit the paper industry.

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20	Think big!
In Gruvön, Sweden, Voith has
built the world’s most modern
board machine. With its high-end
components and digitalprocess monitoring, the BM 7 at
the BillerudKorsnäs mill
is a sign of things to come.

32	The small capital of paper
With its three plants in andaround Appleton, Voith serves theNorth American paper industry
and brings innovations onto theworld market.

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28	No trifle
In eastern Germany, the Progroupis building one of the world’s
most modern packaging paper
mills. Voith will supply thePM 3, including equipment, andhas developed completely new
solutions for this facility.

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for its two new paper machines.

19	New facilities and services

26	More than just lip service
Voith achieves maximum quality
and minimizes downtimes
for headbox lip maintenance.

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Editorial Team:
Faktor 3 AG,
Hamburg/Berlin, Germany

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as per German Media Act:
Kristine Adams,
Voith GmbH
Editor-in-chief:
Gudrun Köpf,
Voith GmbH

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Publisher:
Voith GmbH & Co. KGaA
St. Poeltener Str. 43
89522 Heidenheim, Germany
nextlevel@voith.com

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Credits

Insights and insider views

40	New milestone
Sun Paper orders another two
Voith paper machines andextends its long-standing collaboration with the company.

Printing:
EBERL PRINT GmbH,
Immenstadt, Germany
Copyright:
No part of this publication may be copied,
reproduced or otherwise disseminated,
nor may any of the content in it be used in partor in whole in other works in any form
whatsoever, without the express written
permission of the editor.
Photo credits:
Cover page: Axel Pfaender (illustration),p. 8–13: Axel Pfaender (illustration),p. 12: Jan Walford, p. 16, 35, 45: s&f (illustration),p. 18: shutterstock, p. 19: gettyimages,
p. 20–25: Jan Hosan, p. 26: Oliver Vogel,p. 28: Progroup AG, p. 32: Graham Images LLC,
p. 36–39: Thomas Dashuber.
All other photos are from Voith.
Your feedback:If you have any questions and comments on
this issue of nextlevel, please contact us by email
at nextlevel@voith.com or via:
www.twitter.com/voith_paper
www.linkedin.com/company/voith-paper
www.youtube.com/user/VoithPaperEN

42	Roll-out
New polyurethane roll coverSupremeFilm achieves
very consistent 2-sigma profiles.
45	Q & A
Professor Markus Biesalski
wants to develop new areas ofapplication for paper.

carbon neutral
natureOffice.com | DE-141-1V4HFJ3print production

15

SmartBasket helps
monitor screen basket
inventory efficiently.
Contents 03

Pluralis design

ensures efficientand gentle refining.

Pluralis
Conical
Conical refining newly defined
Thanks to Pluralis Conical, fillings from the Pluralis family can now also be used in refiners with aconical refining zone. With the new filling, Voith has transferred the proven Pluralis designfor gentle refining with optimum intensity to the conical shape. In addition, innovative backflow
channels have been integrated to enable the suspension to flow through the refining zone
several times. This increases the share of fibers treated, which is a key factor in achieving optimum
fiber quality. Thus, the filling uses the energy applied most efficiently. As with existing Pluralis Lineproducts, Pluralis Conical will offer a range of fillings that allow many fiber types to be refined.
Voith offers the service of converting existing machines from full cone fillings to segmented refiner
fillings. Our refiner filling segments also fit existing holders, in case the customer is already using
segment holders.

Recirculation

allows the pulp to pass the refiningzone several times.

04 Zoom

nextlevel N° 05

Feeding channel

for a direct flow into the refiningzone of the filling.

Backflow channels

integrated into the filling, increasing
the efficiency of fiber treatment.

nextlevel N° 05

Zoom 05

Major order:
complete production
line for SCA
In its capacity as a full-line
supplier, Voith will build an
innovative kraftliner production
line for SCA’s Obbola paper
mill in Sweden. In addition to
the BlueLine stock preparation
unit and XcelLine paper machine, the scope of supply for
the PM 2 project also includes
detailed engineering, all
sub-systems and a long-term
service and efficiency agreement. The objective is to set
new benchmarks for strengthand downstream finishingproperties through intelligent
controls with digital solutions
from the Papermaking 4.0
concept. The paper machineis set to go into operationin the first quarter of 2023.

130,000
spare parts
are available
immediately fromthe new Voith Paper
Webshop(see page 16).

from the world of Voith Paper

New pilot calender

XCal1
1M
spare parts
can be identified
online andrequested from
Voith.

Customized
asset management
Voith helps companies improve their efficiency. Basedon its specific domain expertise, Voith offers the scalable
solutions SmartBasket, pmPortal and OnCare.Asset.
With their intuitive user interface, these solutions help tomanage inventories, avoid unscheduled downtimes
and identify replacement parts.
“SmartBasket allows customers to track and manage
their screen basket inventories,” says Michael Thoma,
Vice President E-Commerce & Digital Supply Chain Man­
agement at Voith. “The next stage is pmPortal for the
management of consumables, wear and replacement parts
including graphical navigation options.” OnCare.Assetthen provides extended functionality through complete
downtime planning and interfaces with ERP systems
like SAP. Customers can start with an entry-level solution
and then extend it, as required, without losing any data.
Recently, Mexican paper producer Grupo Gondi wasthe first customer in North America to order OnCare.
Asset for its Guadalupe facility.
06 News

News

Voith has unveiled a new pilot calender thatcovers all finishing processes in combination
with the pilot coater in the Heidenheim Paper
Technology Center.
The XCal1, which has a web width of 800 mm,
uses a modern 1x3 design and enables aflex­ible web run with one or two nips, in hardand soft nip configuration. The hard and softrolls are designed as Nipco rolls and enable thesimulation of operating conditions that are
as realistic as possible. The pilot calender canprocess all relevant paper grades and basis
weights; the maximum speed is 2,000 m/min.
One of the special features of the calenderis an inductive external heater that achieves
a surface temperature of up to 280°C on theheated roll. Thanks to two climatic chambers,
the paper rolls can be preconditioned so that,for the first time, it is possible to replicate the paper properties of moisture and temperature
to exactly mimic those of production operation.
By combining of preheating with infrared
heaters, moistening with nozzle moisturizers
and the application of steam with a steam box,
moisture gradient calendering is also possible.
nextlevel N° 05

P. 07

18

innovate
A look at key trends

Faster jumbo roll changes with new double unwinder
To speed up paper production at the winder, Voith is launching a particularly efficient unwinding solution.
The new double unwinder has an up to 20 percent higher winding capacity and allows automaticroll changes during the winding process. The resulting time and efficiency gains pay dividends, especially inthe case of high production rates. The system meets the latest safety standards and is easy to operate
thanks to a user-friendly design. The double unwinder can be fitted with either a FlyingSplice or ButtSplice.
Thanks to the short installation time, the solution is not only suitable for new paper machines but also
for upgrading existing systems.

New double unwinder

nextlevel N° 05

innovate 07

R&D
Shaping the futureof paperThe digitalized
paper industry needs
to combine
efficiency andconservation of
resources
to satisfy economic
and statutory
requirements.

08 innovate

nextlevel N° 05

Like all resource-intensive
industries, the paper sector needs
to become more sustainable.
This is why Voith is working on
improvements at the productlevel while also developing
fundamentally new concepts
for the future of the entire sector.
A special example of this is
the Model Factory Paper, which
is being supported byan industrial consortium.

“It is not predicting the future that matters, but
being prepared for it.” This might sound like acomment on the current discussion about climate
protection and sustainability, but it is actuallya quotation by Athenian statesman Pericles fromthe 5th century B.C. And yet it describes in anutshell the requirements with which the paper industry is currently confronted. As a resource-­
intensive sector, it is subject to social andlegis­lative pressures to become more of a closedloop system with respect to carbon neutrality,
water consumption and energy efficiency. It’s aherculean task.
“Improving the existing manufacturing processincrementally will not be enough to achieve thegoals that the European paper industry has set foritself by 2050; we need new and more radical
solutions,” explains Dr. Michael Weiß, Vice President New Business & Research at Voith Paper.
“This affects the entire paper supply chain, and wewant to make this visible across the industry as
well.” The plan is to work together as an industry,
in close collaboration with the research com­munity, to tackle problems that none of the stakeholders can resolve alone. The Model Factory
Paper will provide the means.

Improving the existing
manufacturing
process incrementally will not
be enough.
Dr. Michael Weiß,
Vice President New Business & Research,
Voith Paper
nextlevel N° 05

innovate 09

Open to industry and research
At the moment, the Model Factory Paper exists
only as a concept, but a consortium has alreadybeen formed in Germany to realize it. As wellas paper producers and the Association of German Paper Mills (VDP) as its patrons, the con­sortium also includes universities and research
institutes, as well as Voith in its capacity as atechnology group. Other interested parties fromindustry and the R&D community are welcome to
get involved, says Weiß, emphasizing the non-­competitive nature of the project. Basic research
will be an important aspect of the work to bedone, which will be pre-competitive and based on
open innovation approaches.
As of January 2020, the planning for the Model
Factory Paper has been stepped up. Following
prompt implementation, the plan is then for themill to quickly become a center for disruptive
innovation projects in the paper industry. Gerhard
Hochstein, CTO of Felix Schoeller Group, saysthat these will include the reduction of CO emis²
sions and carbon neutral production, as wellas energy efficiency, the industrial use of artificial
intelligence, raw material substitutions andclosed-loop recycling. He describes the model
factory as a platform to allow cutting-edgeknowledge to be exploited at an early stage andpromote climate-related topics. The project
aspires to develop attractive solutions that are
crucial for future paper production and also
help other industries facing the same challenges
to make headway.

Voith Paper’s BlueLine stock
preparation unit is alreadythe most resource-conserving
process concept
on the market worldwide.

CO²

Reducing
emissions
One of the areas that
the Model Factory
Paper production will
work on is research
into solutions to
reduce carbon
dioxide emissions.

2020
LaunchFrom the start of theyear, the project
participants aim topress ahead with
their planning so theModel Factory
Paper production canbe realized as
quickly as possible.

10 innovate

The location for the model factory is currently
being identified. In addition, the content of thevarious work areas needs to be definitively agreed
upon by all stakeholders in the coming months.
From the perspective of Weiß, it is crucial to exhaust all potentials and utilize important ex­pertise and capabilities. These range from paper
manufac­turing to machine and plant con-­struction and from technologies for producing
and storing regen­erative energies to artificial
intelligence and data analysis. Industry knowledge
as well as the latest scientific and researchfindings from universities and institutes need toflow into the project, the R&D manager em­
phasizes, across the boundaries of all disciplines
and to all participants in the supply chain. This is
why the Model Factory Paper will provide forflexible test and pilot installations and “digital twins”
of process steps to ensure end-to-end interconnectivity along the entire manufacturing process.
In this context, Voith will contribute as amember of the consortium and technology vendor
to the paper industry. “Together, we want todevelop paper production of the future and create

nextlevel N° 05

Research
examplessustainable, future-proof production locations inGermany and the rest of Europe,” says Weiß.
“To achieve this goal and tap into future businesspotential, we need innovative and integrated
solutions that we can only develop by working
together.”
Knowledge platform for the future
The concept of the Model Factory Paper is basedon others on the ETA learning factory that serves
as a center of expertise for energy efficiency in industrial manufacturing and is affiliated with theTechnical University of Darmstadt, Germany. The
research focus of the Model Factory Paper production will be on the paper industry. “The
networking aspect is a very important one,” Weißemphasizes, especially in the context of digital­
ization. “Previously, a lot of know-how was kept
in-house. Today, speed is crucial, and due tothe high level of complexity and uncertainty, open
approaches to finding solutions are called for.”However, given the large number of thematic areas
under investigation and their overlaps, it would
be naive to expect fast results. The Model Factory
Paper production is therefore designed for a longservice life.

Innovative and integrated
solutions are requiredthat we can only develop by
working together.
Dr. Michael Weiß,
Vice President New Business & Research,
Voith Paper

Fiber treatment

Vendorneutral
Basic research
The Model Factory
Paper will be
pre-competitiveand basedon open innovation
approaches.

To improve the efficiency ofprocess engineering in fiber
treatment and at the same timeincrease strength values,
Voith is conducting detailed investigations in collaboration withcustomers at its Heidenheim Fiber
Technology Center (FTC).
The objective is to better exploit
the potential of the fibers to
be able to manufacture the end
product more energy
efficiently and economically.

OnEfficiency.Strength
The OnEfficiency.Strength softwaredeveloped by Voith substantiallyreduces the use of resources andoperating costs. It uses virtual
sensors to measure various parameters and analyzes themauto­matically to provide a prediction of the strength value. The
information flows into the current
production process and helps
continually optimize it (see page 18).

Refiner fillings
In the case of the Pluralis Conicalrefiner filling, speciallydeveloped backflow channels
ensure that the pulp flows throughthe refining zone several times.
This not only improves fiber quality
but also saves energy
and raw materials (see page 04).

nextlevel N° 05

innovate 11

“Thefutureispaper”

What does the future of the paperindustry look like? The paper foresightprocess delivers answers. Along withmore than 50 experts from industry,
think tanks and universities, Voith has
analyzed trends and developed
scenarios that provide a concrete outlook and enable economicallyattractive, sustainable and future-proof
solutions to be developedin association with customers.

Dr. Weiß, Mr. Kalefe, you use the paper foresight process to analyze the meaning of social
and technological developments for the
future of the paper industry. What are the mostimportant trends that define this future?
Kalefe: The future business environment will bevery strongly influenced by the two mega-trendsof sustainability and digitalization. The paperindustry uses a renewable raw material. In addition,
the majority of paper products can be recycled.
Already, we are able to meet to a great extent thebasic precepts of a closed loop for sustainable
paper solutions. This will become increasingly important in the future due to the growing mountains of waste worldwide and the accumulation ofplastic in the world’s oceans.
And the second trend, digitalization?
Kalefe: The paper industry is a very mature industry that has undergone very few technologicalleaps in recent years. So, the issue of efficiency –in production and in the complete supply
chain – is all the more decisive. And this is where
digitalization plays a very large role, because it
can exploit new efficiency potentials, for example,
via more control in the manufacturing process
as such or through closer interconnection of theentire supply chain. The availability of pro­d uction lines and production resources can also be
substantially increased using digital solutions.
In this context, the paper industry can still makemuch more progress and exploit potentials,
and we are going to see this happening in the future
as well. Even if not all specific manifestations of
this mega-trend can be predicted, these twodevelopments are going to affect us decisively inevery future scenario.

12 innovate

nextlevel N° 05

What changes do you expect in the core areaof resources consumption?
Kalefe: The issue of CO emissions is set to gain²
massive relevance in the future. The paper in­
dustry will be working even harder on this in the
future and will develop new solutions. The foresight process came up with promising breakthrough technologies in this area and generated
new ideas that are now being pursued intensively in our development departments. Alongside
CO emissions, water consumption will²
also continue to be a focus in many regions.
What do you think of the “paper,
not plastic” debate, and what is the development potential?
Dr. Weiß: Already there are some solutions thatclearly show potential but are not yet satisfactoryin all areas of application. Cost is an important
aspect. Plastic packaging is extremely cheap to
produce, but that is not always the case for paper
products. This fact is currently limiting the sizeof the market for paper as a substitute for plastic,
but it is an issue that is increasingly being
addressed by legislation and will definitely become
an important driver. In addition, consumers
are showing more and more interest in sustainableproducts. This issue will continue to gain im­
portance, with steadily growing opportunities andmarket shares for paper as a substitute for plastic.
What other technologies will we need to take
into account in the future?
Kalefe: We expect a number of new and functional materials to be developed in the future that
we believe will offer interesting applications
for packaging and specialty papers. Due to newtechnologies like quantum computing, the IT
environment will continue to evolve rapidly again
in the coming decades and will open up completely new possibilities in the research field.
Last but not least, providing an efficient transport
infrastructure in what are known as megacities
will be one of the major challenges in the next 10
years. We expect this to have a significant effect on the online retail business and, consequently, on the market for packaging papers as well.

nextlevel N° 05

Outlook
Sustainability anddigitalization,in particular, willchange the paperindustry.

Dr. Michael Weiß(photo left)
As Vice President
New Business &Research at Voith
Paper, he identifies
and evaluates,
among other things,
technologicaldevelopments andtheir effects
on the industry.

Timo Kalefe(photo right)
The Innovation
Manager
at Voith Paper is
responsible
for the ongoing
managementof the paper
foresight process.

You have developed various scenarios
for the paper industry in the year 2040. What is
the result?
Dr. Weiß: We are currently seeing a very highprobability of a scenario we are calling “same but
different.” In this scenario, there will be a large
number of new technologies, especially from thedigital area. However, overall the paper industry
will be similar to how it is today, for example
with respect to market shares of the various paper
grades and the production process as such.
There will be radical approaches and disruptionsin specific areas such as the substitution ofplastic packaging. Improving efficiency and reducing costs will continue to be major drivers. In
this context, digitalization will play a role as one of
the key technologies that enable the efficiencyof paper manufacturing to be further improved,
resulting in a reduction in costs. It is absolutely
essential to analyze these extreme scenarios properly – in terms of positive and negative outcomes
for the paper industry – and also to have strat­egies and approaches on hand to deal with them.
For the next five years, however, the starting
points will primarily be for a “same but different”
scenario.
Kalefe: Niche markets are another important
aspect. One such area is functional papers, whichmight be electrically conductive, for example,
or used as solutions for energy storage. These premium niche markets are certain to grow andwill represent an attractive business area for paper
manufacturers in the future. However, comparedwith the general paper market, the production volumes involved will be relatively small.
If you had to describe in one sentence thekey message of the paper foresight processfrom the perspective of the paper industry,what would it be?
Dr. Weiß: “The future is paper.” Paper is a fan­tastic material that is natural and renewable, andthe raw material it is made from is sustainable.
However, the industry still needs to do a lot of work,for example in further reducing CO emissions.
²
Nevertheless, the already 75% closed-loop supply
chain is very stable and will be consolidated evenmore in the future due to the growing interestin sustainable products on the part of consumers.
And that’s an ideal basis for meeting the challengesof the future!

innovate 13

Better in combination: Digital connectivity extends the functionality of thetried-and-tested DuoShake shaking unit. This results in improved
machine availability and process reliability along with reduced operating
and maintenance costs.

DuoShake
digital11	Familiar interface
The intuitive user interfaceof the operating softwarede­veloped by Voith is similar
to that of smartphones
and tablets.
2	Mobile devices
can also be used, e.g., toadjust shaking stroke and drive
frequency. The effect of
the changes can be observed
directly at the wire section.

14 innovate

2

nextlevel N° 05

Digital future-proofing
After more than two decades on the market,
DuoShake has been installed hundreds of times
and continually improved and developed. The
DuoShake shaking unit optimizes fiber orientation
yet is so mature that it is increasingly difficult tofind ways of improving it me­chan­ically. However,there is huge potential for added functionality
through digitalization. The new DuoShake DG(Digital Generation) is now tapping into this potential in line with the Papermaking 4.0 concept.
The product update offers paper manufacturers comprehensive benefits and a new levelof transparency in production and maintenance.
For example, all relevant operating parameters
can now be set using a fixed operator panel on
the control cabinet or via mobile devices liketablets or smartphones. The intuitive interface
using touch control provides a real-time overview
of all the main parameters like availability, strokeac­curacy and drive frequency. The softwarepresents important information like air, oil andmotor temperature as an easy-to-see traffic
light system. “Data visualization is important tobe able to make decisions about efficiency,”
says Benjamin Kitze, Global Service & ProductManager at Voith Paper.
This is also supported by the service function.
DuoShake DG records actual operating times
and provides real-time data on maintenance intervals and service life of the most important
machine components. Because the operating
condition is known at all times, maintenance canbe planned and scheduled more efficiently.
“With DuoShake DG, we are turning time-based
maintenance into needs-based maintenanceand in doing so are extending the service life of
the product,” the service and product manager
explains.
An optional service that Voith offers for
DuoShake DG is also designed to achieve maximum availability. Via a cloud interface, theshaking unit can be connected to the lloT platform
OnCumulus. On the basis of the transmitted
data and trends, Voith experts can then analyze
the operating parameters, which ultimately improves the overall efficiency of the paper machine.
“Thanks to the visualization and analysis options
in combination with our service concept, we
can already increase availability to almost 100
percent,” says Kitze.

nextlevel N° 05

innovate 15

SmartBasket

SmartBasket
with RFID

Scanner

Monitoring and tracking screen baskets is anever-ending task in the paper industry.
The stock preparation unit uses countless
screen baskets that all need to be regularly
replaced, re-chromed or put in the warehouse, necessitating a major administrative
effort. Voith is now reducing the workloadwith its SmartBasket, an intelligent solution for
asset and life cycle management. Each
screen basket is fitted with an RFID chip (radio
frequency identification), which gives it
a digital identity. It can be read with a handscanner and the data transferred to a
database using a cell phone or tablet. Thismeans that paper producers have access at
all times to important data like the location,
inventory and life cycle of their screenbaskets. This information provides complete
transparency across the entire supply
chain and various locations. This in turnincreases availability while reducing the costof inventory management.

Mobile app

Database

Corporate
cockpit of global
inventories

SmartBasket creates transparency
Scanned screen basket data
can be monitored with mobile devices
or a web app.

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Products can now be appended with notes,
for example, to provide purchasing departments withadditional information about delivery times.

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Time-saving search for material numbers
The search for material numbers in particularquickly gives customers all the information
they need. After the information has been enteredinto the search field, the Webshop immediately
indicates if the respective item is available as aspare part, if it was already included in the original
delivery, or if a current quotation is available.
The multiple search function even allows several material numbers to be queried in the shopat the same time. These numbers can be imported
from an Excel list or taken from the customer’s
ERP software. “Our customers really appreciate
the option of being able to search using their own
material numbers,” says a delighted Thoma.
The shopping cart, too, has been given an update. Notes and documents can be added toevery item stored in the cart, which facilitates cooperation between customer teams. For example,
a staff member from the technical department
uses a note to tell the purchasing department the
purpose of the spare part, which machine theyity
ant
need it for andQu when. 1In addition, the cart can betransferred from one department
to another.
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innovate 17

Fiber amount
Productivity
Sheet strength

Stiffness
Quality

OnEfficiency.
Strength
Metsä Board is counting on the
Papermaking 4.0 product
OnEfficiency.Strength to optimize
fiber use and strength values.
Monitoring sheet strength
Every year, Finnish company Metsä Board produces two million metric tons of cardboard
packaging at its eight plants, including folding box
board, food service board and white kraftliner.
However, like all paper and board manufacturers,
Metsä does not have the option of measuring
and adjusting sheet strength values during production. The result is quality fluctuations.
The Metsä Group now aims to change that with
Voith’s help. At one of its mills, the company istesting the digital concept OnEfficiency.Strength,
which determines paper quality using virtual
sensors during operation. This process provides
information on the expected quality, particularly
bending stiffness and plybond strength,
during production and not just at the end following
elaborate lab tests on the finished reel.

AI-supported optimization
Virtual sensors for sheet strength values achieve ahigh prediction accuracy and form the basis foran efficient control process. As the volume of data
grows, OnEfficiency.Strength can increasingly
optimize production and automatically offset
fluctuations in sheet strength. This results in fewer
deviations in production output and a more efficientuse of resources. The productivity of the machine also increases because the system speeds
up grade changes.
“We opted for the Voith solution because Voith
has sound expertise in the board manufacturing
process,” says Ari Kiviranta, SVP Development at
Metsä Board. “This makes it easier to use an
AI application rather than solutions from vendorsthat are not familiar with the specific processes.”

OnEfficiency.Strength has been
optimized for the paper industry.
The virtual sensors for strength values
achieve a high prediction accuracy
and therefore form the basis
for a highly efficient control process.

AI
Artificial
intelligencecan produce
accurate
strengthforecasts
from processdata andstatis­ticalmodels.

Dr. Jens Haag,
R&D Manager Advanced Controls &Data Analytics, Voith

18 innovate

nextlevel N° 05

P. 1934transform
New facilities and services

Added value through modernization
Umka is growing. In business since 1939, the Serbian paper mill today supplies 30 European countries
with different board grades. To be able to tap into other markets, it commissioned Voith in 2017
to modernize the stock preparation for its board machine. The goal was to ramp up annual production
from 105,000 metric tons to more than 200,000 metric tons and still ensure the quality of the end
products despite ever-worsening raw materials. Voith installed the space-saving InjectaCell Compact
flotation system in combination with the robust InfiltraDiscfilter with bagless technology forseparating the water circuits. It was a success. “The performance of the InjectaCell Compact and theInfiltraDiscfilter fully met our expectations,” explains Umka Project Manager Dragoslav Nešković.
The interim balance shows higher paper quality at optimized operating costs and growth in volume tocurrently 130,000 metric tons per year – and the production trend is improving.

During flotation, air bubbles
carry the hydrophobic particles
from the suspension to thesurface, where they flow off at
the overflow edge.

nextlevel N° 05

transform 19

Thinkbig!
The world’s most modern board machine is located in Gruvön, Sweden.
The entire machine, from headbox to winder, was built by Voith forBillerudKorsnäs. With its high-end components, the BM 7 doesn’t just define thelatest state-of-the-art installation. Thanks to the large degree of component
interconnectedness and extensive monitoring of all process data, it is actually
pointing the way to the digital future of the paper industry.
20 transformnextlevel N° 05

The 350 m long BM 7 isaccommodated in a new hallthat had to be built on
a particularly problematic
subsoil.

2017

Kick-off on site,
design andconcept meetings
in Heidenheim,
Germany

2018

Building work starts
with thefoundations followedby assembly

2019

Installation of DCS
control softwareand functional tests;
operation
starts in June

BillerudKorsnäs
Gruvön1	Building withpaper machine
2	BM 73	Stock preparation
4	Roll warehouse

Patric Romes is not inclined to exaggerate. But
when he’s talking about the board machine that
Voith built for BillerudKorsnäs in Sweden,
even the voice of the seasoned senior project
manager resonates with respect. “To myknowledge, such a fully equipped system forhigh-­quality board has never been realized anywhere else in Europe in recent years. It is anout­standing achievement that is setting benchmarks,” says the 58-year-old. The BM 7 is an
end-to-end system and the world’s most modern
board machine. Romes and the Voith teaminstalled the machine at the company’s mill at
Lake Vänern in Gruvön, Sweden. It went into
operation in June 2019.
The standards it now has to meet areexacting. The BM 7 produces four different
board grades with a total annual volume of
550,000 metric tons from virgin fibers from sustainably managed forests. To achieve thiscapacity, the machine works with a web widthof 8,800 mm at the headbox and a design speedof 1,200 m/min.
Software optimizes the processes
But the general parameters only provide a roughpicture. In fact, it is primarily the precisely
matched combination of high-end components
and Papermaking 4.0 software that makes
the machine in Gruvön so outstanding. This islargely due to the digital solutions OnEfficiency
and OnCare, which allow BillerudKorsnäs
staff to manage all process data online. In thecontrol room, they monitor more than 20 con­tinually updated production parameters.
Using the OnEfficiency Forming module, the operating team coordinates and stabilizes thede-watering, retention and flocculation at thesame time, for example. The OnCare package
handles the asset management and helps
the paper manufacturer ensure the greatest possible machine availability through preventive
maintenance, which ultimately reduces operating costs.

1
2
4
3

Stockholm

Gothenburg

nextlevel N° 05

transform 21

Board machine
The BillerudKorsnäs BM 7 is currently the mostmodern board machine in the world. Apart from its
proven and in some cases newly developed
components, the XcelLine machine impresses above
all with the highest level of integration of Paper­making 4.0 functions, ensuring higher quality
and improved efficiency through the digital monitoringof the production process.

Tandem NipcoFlex shoe press
EvoDry steel cylinders
EcoCal hard calender2 SpeedSizer AT
2 DynaCoat AT
Sirius winding system
VariFlex Performance winderComplete initial clothing package

m/min

Headbox: 3 MasterJet Pro
Three-ply wire section: 2 TopFormer F,
1 DuoFormer D II

design speed

Voith scope of supply

1,200

Design speed: 1,200 m/min
Wire width: 8,800 mm
Capacity: 550,000 metric tons per year
Basis weight range: 120 – 290 g/m²

Automation:
OnEfficiency and OnCare packages

wire width at headbox

SiriusThe Sirius winding system gently winds the paperor board and is especially suitable for surface-sensitive
papers and large winding diameters.

mmObstacles overcome with teamwork
Nevertheless, the project participants did haveto overcome some obstacles first before the
BM 7 could be commissioned. For example,
the start of assembly with the foundation rails
was scheduled for January 2018, as PatricRomes recalls. “However, they couldn’t be installed at that time because the building wasn’t
ready.” This was due to problematic subsoil;
the loamy soil had subsided unexpectedly, delaying the construction start for the foundationsof the 400 m long hall. In addition, there werealso problems with the cabling in the building. The
digital control system (DCS) for monitoring machine functions could not be installed until these
problems were resolved.
All these delays had consequences: The
stock on wire deadline, originally scheduled
for November 2018, was achieved during April
2019, and first roll was produced early June.
It is not unusual for unforeseen events tooccur in a project of this scale. The large
number of subcontractors and suppliers involved increases the number of interfaces; thiswas the case for the Gruvön BM 7 project.
Accordingly, the need for coordination was great,
which created additional pressure and led
to delays.

BM 7

8,800

The XcelLine board machine specificallytailored to BillerudKorsnäs also reflects the latest
state-of-the-art at the component level. Various
innovations have been incorporated from headbox through to winder. In the dryer section,for example, EvoDry steel cylinders are being
used in a board machine for the first time.
Their thinner walls mean that they transfer heat
better and are particularly safe, because theirflexible material prevents the spontaneous ruptures that can occur in cast iron cylinders. In
the finishing section, the BM 7 is the world’s first
board machine to feature Curl Control, whichis generally used to reduce paper curl in single-­tier dryer sections. Another new feature is
the highly efficient VariFlex Performance winder,
which will be increasing productivity in a European paper mill for the first time.

22 transformnextlevel N° 05

Film press
The BM 7 is fitted with two DynaCoat AT
coaters and two SpeedSizer AT film
presses that offer good runability for long,steady production runs.
Taking charge
Magnus Haldor Johansson, Area Manager
BM 7, BillerudKorsnäs, supervised theinstallation of the machine along with Voith
Commissioning Manager Christian Merz.

nextlevel N° 05

transform 23

Jumbo rolls
The standout features of the highly
efficient VariFlex Performancewinder include a high design speed
and short set change time.

The BM 7 is thefirst newboard machinein Swedenin the past 15
years to bebuilt as a com­plete system.
Christian Merz,
Voith Commissioning
Manager

24 transformnextlevel N° 05

production capacity

tons per year

550,000

Raw material
The primary fiberused for board
production comesfrom sustainable
forestry. The BM 7
processes them in an
efficient and resource-conserving
manner withfew emissions.

The quality ­producedby the machine,even shortly
after startup,
is very
promising.
Göran Korsfeldt,
Project Manager
BillerudKorsnäs

Capacity
The capacity of
the BM 7 isdesigned tohelp BillerudKorsnäs
cover theexpected demand
for sustainableboard from climate-­friendly production
processes.

Availability
The cut rolls will be
kept in a new
20,000-square-­meter warehouse forfast delivery tocustomers aroundthe world.

Final product
The finished rolls are transferred to the packaging
facility on a conveyor belt.

basis weight range

Strategic investment
For BillerudKorsnäs, the new board machine is
not just the biggest investment in the company’s
history but also an important strategic move.
When announcing the building plans at the endof 2016, former President and CEO Per Lindberg spoke of a “historic decision.” From theirmill in Gruvön, the Swedes want to do their partto help satisfy global demand for board, liquid
packaging, food board and liners. In doing so,they are focusing on the growing need forsustainable solutions on the part of increasingly
more brand owners, food retailers and con­sumers. To be able to cover this demand, thegroup is increasing its production capacity
through the BM 7. But it is not just about thevolume. “The quality that the machine isproducing is promising,” says BillerudKorsnäs’
Project Manager Göran Korsfeldt.
For Voith, the BM 7 is not only a technological showpiece and impressive reference.
The successfully completed, large-scale projectdelivered many insights that will give the com­pany a crucial lead – for example, when refining
the Papermaking 4.0 concept and also in
conjunction with the ongoing improvement anddevelopment of expertise in board machine
construction.

Global aspirations:
The board
produced in Gruvön
is intended forthe world market.

g/m²

120 – 290

However, the Voith team always found solutions through pragmatic discussions with thecustomer. “We got together and agreed on how
to deal with obstacles. The collaboration was
exceptionally good. Close communication wasnecessary and was genuinely put into practiceon site,” emphasizes Voith manager Romes. “We
found the collaboration to be very friendly andconstructive,” adds Magnus Haldor Johansson.
As Area Manager BM 7 at BillerudKorsnäs,
he supported the construction work from start
to finish. His colleague Maria Engnes, Directorof the NEXT Generation Program, was also
often involved on site to make sure that, despite
all the hurdles, production could start as soon
as possible.

nextlevel N° 05

transform 25

lipserviceMorethan just

Double the benefits for the customer: Voith’s headbox service offers amaintenance solution for the headbox lip that guarantees maximum
quality while simultaneously reducing downtime to a minimum. It is available
for all machines with replaceable lips.
1
Intervalmaintenance
The headbox lip
suffers wear
due to abrasion andneeds to be
replaced at regularintervals.

1

26 transformnextlevel N° 05

The countdown is on. The lower headbox lip needs
to be serviced every three to five years, becauseby this time the abrasive solids and fillers inthe suspension have worn the lip to such an extent
that paper quality is impaired. Not only can thiscause reduced CD profile quality, but there is also
a risk of sheet breaks and high consequential
costs due to production downtimes. Even worksafety may be compromised.
Saving time and reducing stoppage costs
To avoid these consequences, preventive main­
tenance is absolutely essential. Through its
headbox service, Voith offers paper manufacturers
an especially efficient maintenance solution thatdrastically reduces downtime costs. It also
allows a very high-quality refurbishment of thelip, because it is not ground directly in themachine under difficult working conditions but removed and completely overhauled in one ofVoith’s workshops.
Complete removal and re-installation service“Our scope of supply always includes a re­placement lip that is used while the original lip isbeing refurbished in one of our workshops,”
explains Benjamin Kitze, Product Manager atVoith Paper. In the workshop, the lip can bereconditioned under ideal conditions by experts
with specific know-how. Following refurbishment,
the lip is as good as new and is then available
to the customer again as a replacement lip. As
part of the complete headbox service, Voith
service technicians also inspect the entire head­box area for deposits, damage and wear.

2

2

3
Machining abottom lip

70

percent
shorter downtimes
thanks toheadbox service.

In the wet section
the headbox has a major influence on theoverall quality of the paper produced.

Preventive
maintenanceand effective
spare parts
management
are crucial
for thesmoothoperation of
the headbox.
nextlevel N° 05

3

Reworkinga top lip

“We achieve better quality than an in-situ refurbish­
ment and save the customer a lot of time,” Kitze
concludes. He estimates that this process
reduces paper machine downtime by around70 percent compared with conventional headbox
services, while the manpower requirement isreduced by 40 percent.
For all replaceable lips
The headbox design of Voith’s MasterJet Pro
makes provision for this highly efficient form of lip
servicing, which is already being used by manycustomers. “However, this kind of service can also
be performed on the machines of other suppliers
provided the lips are also replaceable,” says
Kitze. This maintenance concept underscores
Voith’s position as a full-line supplier that not only
provides machines and spare parts but alsodelivers end-to-end service tailored to thespecific requirements of customers through its
Servolution portfolio.

transform 27

In northeast Germany, Progroup AG
is currently building one of the most modern
packaging paper mills in the world.
As a full-line vendor, Voith is supplying the paper
machine and BlueLine stock preparation unit.

No trifle
28 transformnextlevel N° 05

860,000
tons ofrecovered paper
The plant is set
to produce newpaper from 860,000
metric tons ofrecovered paper
per year.

The production facility, which has been underconstruction since January 2019 on a 450,000 m²
site in Sandersdorf-Brehna near Leipzig, is nosmall thing. The 32 m high production hall alone
will have an enclosed space of 750,000 m³.
On completion, the roll warehouse will be 29 m highand will provide 230,000 m³ of storage space.
The centerpiece of the facility is the new paper
machine with a working width of 9.2 m. It is set to
produce 750,000 metric tons per year of testliner and corrugating medium in the basis weight
range of 80 to 150 g/m².
The Progroup from southwest Germany is relying entirely on Voith Paper to supply the tech­nical equipment for the production facility. “As far
back as 2006, we supplied the Progroup with astock preparation unit for its machine at the company’s production facility in Burg,” says René
Bauer, Project Manager Division Projects at Voith
Paper. “The fact that we are to supply the newplant with the entire equipment for paper pro­duction, from recovered paper feed to the finishedand cut paper roll, is a fantastic success and agreat vote of confidence in us.”Everything from a single source
In addition to the XcelLine packaging paper machine with a wire width of 10 meters, the scope of
supply also includes the VariFlex Performancewinder with an operating speed of 3,000 m/min,the new IntensaDrumDuo pulping drum, theBlueLine stock preparation unit, as well as air systems and hall ventilation. Voith has also won afive-year contract to supply roll covers and clothing. This will be the first time the new Voith double
unwinder will be used.
From the perspective of René Bauer, what is
important, apart from the purely technical aspectsof the project, is the close consultation between
Voith Paper and the customer. “In our collaboration,
we were able to benefit in many instances fromthe experience and expertise of our client. Representatives of Progroup were closely involvedin the manufacture of machine components andalso visited the Voith workshops where the rolls
and IntensaDrumDuo were fabricated.”

750,000
ton capacity
The packaging
machine will produce
750,000 metrictons of testliner andcorrugating
medium every year.

nextlevel N° 05

transform 29

The new plant will play animportant role in our
Two Twentyfive growth strategy.
Maximilian Heindl,
Chief Development Officer, Progroup AG

2020
startup
The plant isscheduled to start
production in
the second halfof 2020.

Dimensions that impress
The IntensaDrumDuo consists of a 48 m longpulping zone and 23 m long screening zone andhas a diameter of 4.5 meters. Thanks to these
dimensions, the pulping drum can process almost
3,000 metric tons of recovered paper per day.
“Due to its size, the IntensaDrumDuo will be theplant component that we install first while thefacade of the factory building is still open,” says
Bauer. Only when it has been successfully installed can the rest of the construction work proceed on the pulper charging building, recovered
paper storage yard and rainwater basin.
State-of-the-art for sustainability, too
A closed water loop and modern processing technology for waste water treatment by Meri En­
vironmental Solutions, a Voith subsidiary, allow
the plant to be operated in a very sustainablefashion. For example, all the process water occurring in the paper manufacturing process is treatedin the company’s own water treatment facility
on site and then returned to the production process. This results in both sustainability andefficiency gains, according to René Bauer. “In thisway, the new paper machine produces more
paper of the highest quality while reducing energy
and raw material use.” Progroup is making ad­
ditional investments in environmental protection to
the tune of around EUR 100 million. Part of its
philosophy as a family-managed company is tothink and act sustainably with a view to the longer
term and, in doing so, assume responsibility.

1,600
m/min working
speed
The paper machine
will work at an
operating speed of
1,600 m/min.

30 transformnextlevel N° 05

“Basis forlong-term
collaboration”
Five questions for Maximilian
Heindl, Chief Development Officer
of Progroup AG

What is the importance of the new facility in Germany
for your company?
The new plant will play an important role in our Two Twentyfive
growth strategy. This strategy is helping us to secure theintegrated raw material supply for our growing number of cor­rugated board plants. But we are also implementing adivision of labor and a higher level of specialization in our paper
mills. At the new location we will be producing mid-range
basis weights. The PM 1 will focus on high basis weights
and high-quality paper grades, while the PM 2 can specializein the lighter-weight papers.
What was the deciding factor that prompted you toaward the order for the paper machine to Voith?
We have worked with Voith ever since we have been involvedin paper production. Both family companies pursue similarvalues, have known each other a long time, and work very welltogether in a spirit of trust. Voith has a technologicallyconvincing machine concept that covers all process steps
from a single source, from recovered paper feed to winder.
Moreover, Voith will continue to offer us flexible support
even after commissioning by supplying clothing, rolls and services to ensure the best possible operation.
How important was it to work with a full-line
supplier like Voith and its subsidiary Meri Environmental
Solutions GmbH?
It certainly was an important aspect. Having a full-line supplier on board means there are fewer interfaces for us to
manage. In addition, the development of the closed-loop water treatment facility was only possible through very close
cooperation between Progroup, Meri and Voith. This enabled
the various facilities to be carefully matched to one another with the common goal of optimizing the overall process.

nextlevel N° 05

The timetable for building the new paper mill is very
tight. What are the greatest challenges?
With a project of this size, there are a lot of partners on
the construction site at the same time. The building shell isstill being built as equipment is already being installed.
You need reliable and competent partners to keep track ofso many interfaces simultaneously. And we have foundthat partner in Voith.
What is it like to collaborate with Voith?
We find Voith to be solution-driven, cooperative and witha clear customer focus. We achieve the best outcomesby working together. This means we are not only creating afacility that is unique worldwide but also establishing thebasis for long-term collaboration over and beyond the project phase.

100
million euros
is the additional sum
being invested by
Progroup in environmental protection.

Maximilian Heindl
The son ofcompany founder
Jürgen Heindl
is a member of the
Executive Boardof Progroup AG.

transform 31

Appleton’s role in the U.S. paper industry isbigger than the city itself. With three plants
in the Fox River Valley region, Voith uses thislocation to serve all of North America – andfrom there, brings product innovations onto
the global market.

The
small
capital ofpaper

32 transform

Appleton has a long tradition in
the paper industry and with
Voith that stretches back into
the 1800s. Current Appleton
mayor Timothy Hanna can personally attest to the town’s
deep connection with the paperindustry, as his father once
worked for Voith.

nextlevel N° 05

Framed by farms and forests, Appleton has a population of 70,000 and lies on the northern tip of
Lake Winnebago in the state of Wisconsin. The
peaceful Fox River meanders through the city –one of the 10 most family-friendly in the U.S., as
Mayor Timothy Hanna points out. The city, about
195 miles from Chicago, has numerous amenities, including museums, shopping centers andseveral universities.
Most notably, Appleton is truly a hub for the
North American paper industry, and it is here
where Voith employs about 600 people. Appleton’s papermaking tradition began in 1853, four
years before the city was even founded. Startingin 1882, one of the world’s first hydroelectric
power plants began supplying electricity in thecommunity – and it was built at the request of
papermaker Henry J. Rogers. The following year,
a small blacksmith’s workshop started manufacturing grinding machines and water wheels,among other things. This workshop soon became Valley Iron Works, which, by the 1920s, entered into a licensing agreement with Voith,marking Voith’s entry into the U.S. paper machine
market.
Today, nearly 100 years later, Voith continues
the region’s paper tradition with three manufacturing and service facilities. From here, Voith delivers machines, replacement parts and fabrics forthe paper industry. There are two locations inAppleton. One was established from a joint venture

1857

The city of Appleton
is founded. Since
1853, a paper mill has
been operatingin the region, whichhas plenty of
paper­making resources, including
the Fox Riverand nearby forests.

1920

Through a licensing
agreement with
Valley Iron Works,
Voith enters
the North American
paper market.

with Allis-Chalmers and produces machines andreplacement parts. The other resulted from theacquisition of Appleton Mills. This marked Voith’sentry into paper machine clothing and is where
the company produces press fabrics for the North
American market. But that’s not all – just southof Appleton is the city of Neenah, where Voith
manufactures new roll covers and also offers
mechanical roll services for customers’ existingrolls. Voith’s Neenah location is particularly
ideal; the facility’s immediate neighborhood is home
to numerous paper companies.
The concentration of paper producers in thearea is further evidenced by Voith’s proximity
to Green Bay, the home of Green Bay Packaging(GBP). Voith and GBP recently announced that
Voith will serve as the single-source supplier for
GBP’s new testliner production line in Green Bay,and it is the first contract of such a wide scopein U.S. paper industry history. The contract includes the wastewater treatment and stock preparation systems, paper machine clothing, winder,
Papermaking 4.0 products and a multi-year rollservice contract for several machines. GBP’s new
installation, PM 4, is expected to start operations in early 2021.

Appleton, Neenah andGreen Bay are important locations for the entire
North American paperindustry.

Green Bay
NeenahFox River

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Appleton

Lake
Winnebagotransform 33

The three Voith plants in the Appleton area cov­
er the entire range of paper industry components, and customer visits are often coordinatedbetween the three to show guests Voith’s overall capabilities. “Our extensive capabilities in theFox River Valley region showcase the depth andbreadth we have in the paper market, considering
Voith is the largest full-line supplier in North
America – from complete paper machines to stock
preparation systems, fabrics, rolls, shoe press
sleeves, services, digital tools, spare parts andpaper machine rebuilds,” says David Buchanan,
President, Voith Paper Products & Services, North
America.
“Also, this footprint in the market makes us
one of the significant employers in the area, which
is important for us as we seek to employ skilled
trade and salaried workers in our facilities here,”
explains Buchanan. “Appleton and the surrounding region are home to high schools, tradeschools and universities where we have the opportunity to let potential talent know there are exciting careers in the paper industry, right in theirbackyard.”
And, in this “backyard,” the papermakers of
Wisconsin see themselves as being well-positioned. In 2018, as the fifth largest industry in Wisconsin, papermaking and its related industries
added more than 18 billion dollars to the state’s
economy and employed around 30,000 people.
These papermaking companies are technologically state-of-the-art and are growing, notes
Scott Suder, President of the Wisconsin Paper
Council (WPC). “Papermaking has a great legacy,
but also a great future,” he says.
To secure this future, Voith is investing further
in the location of Appleton, for example, in a
new Infinity loom at Voith Paper Fabric & Roll Systems. “The loom will produce defect-free basecloth for press fabrics and will offer quality unparalleled in the industry. This leads to improvedpressing uniformity and best-in-class seam felt installation time,” explains Jonathan Antes, Business Development Manager, Voith Paper Fabric &Roll Systems, North America.
“These press felts enable us to advance further into the market of board and packaging papers,” adds Jeff Berg, Vice President Operations,
Voith Paper Fabric & Roll Systems, North America.
“Our Infinity press felts offer good runnability
and dimensional stability. We see a global market
for these felts.”

34 transform

1977

Following a joint
venture with
Allis-Chalmers in
1974, Voith Paper
establishes its
first production
facility in Appleton.

1983

Voith acquires
Appleton Millsand expands into
press felts.

1999

Voith purchases
SCAPA rolls
and paper machine
clothing.

2008

Over 160 years after its founding, Appleton
remains a prime location for technology innovation and continues to serve an importantrole in the North American paper industry.

New loom:Update for Infinity press felts
In November 2019, Voith Paper Fabric & Roll Systems,
Inc., in Appleton installed a new Infinity loom. This
investment in new technology enhances both productquality and efficiency. “Quality, speed, capacity andflexibility,” says Pamela Leisgang, Plant Operations Man­ager, Voith Paper Fabric & Roll Systems, North America,
summing up the advantages coming from the new machine. “This loom, which supports the continued growthin the board & packaging and tissue markets in North
America, provides us with a more precise and repeatablemanufacturing process for seamed products. With it,
we further our capabilities to produce press felts thatmeet our customers’ exact requirements. The technology allows us to produce a defect-free base fabric andan improved seam product that can be used in customer
machines that have historically not been able to run
seamed felts.” Also, the Infinity loom works about threetimes faster than a conventional loom, stresses Leisgang. For papermakers, this means not only higher paper quality but also shorter lead times overall.

Voith Paper Fabric& Roll Systems, Inc.,is established.

Present
Voith operates threefacilities in theFox River Valley region
as a full-line supplier
covering all areas ofthe paper production
process.

Infinity press felts have
proven themselves throughtheir uniformity, dimensional stability and goodrunnability.

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P. 3545

reflect
Insights and insider views

Shaping change
Sustainability and digitalization are mega-trends that are not just going to shape the future; in the paperindustry they have already been driving the present for some time now. Without improved efficiency,
it will be impossible for companies to remain competitive while meeting the ambitious targets imposedby legislators and society to reduce the use of natural resources and cut CO -emissions. In this²
context, significant improvements are obtained, above all, through digital solutions that allow elevatedmonitoring of all processes and therefore more accurate production control. Efficiency thus plays a
key role when it comes to reconciling ecological and economic requirements. On the following pages,
we will describe how change can be shaped and what perspectives this offers the industry.

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reflect 35

36 reflect

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The paper industry continues to be in a stateof transition. It is facing cost pressures,
an increasing focus on sustainability, and ashortage of new recruits. Voith Paper CEO
Andreas Endters outlines some approaches thatwill enable companies to master thesechallenges and benefit from the growing
importance of paper as an environmentallyfriendly product.

“Paperdoes
have afuture”
Mr. Endters, what are the biggest
challenges for the paper industry in the
coming decade?
Currently, I see three major challenges that offer
huge opportunities. First, paper producers areunder constant cost pressure to compete internationally. Second, in many places nowadays there
is social consensus about the need to protect theenvironment and handle resources responsibly;
in many regions this is actually being required bylegislation to a massive extent. And third, ourcustomers are struggling to find qualified new recruits to operate their factories. These issues
don’t just affect the paper sector but apply to a
lot of industries.
What conclusions do you draw from this?
Because we offer a very wide range of products
and intelligent services, we can combine these on
an application-specific basis and as a result help
our customers to noticeably reduce their production costs. As paper is produced from renewablenextlevel N° 05

raw materials and is a biologically degradable
end product used in a wide range of applications,
it also has great potential to replace products
based on fossil resources.
We help conserve resources through our environmentally friendly technologies that continually
reduce the use of energy and water in paper production and minimize fiber losses. Incidentally,
this also reduces manufacturing costs.
To counter the shortage of new recruits, weare relying partly on our digitalization capabilities.
Through the effective use of the data generated,
we are in a position to further automate and stabilize production processes. In doing so, we help
our customers replace missing or lost expertise.
Which environmental imperatives do you
think are more urgent – reducing CO emissi²
ons, closing water loops or lowering fiber
consumption?
We are going to tackle all these issues at thesame time and with the same intensity. In R&D,
we are already putting this into practice by addressing some issues incrementally. In some cases, we can achieve smaller improvements andsavings in the various process stages that all add
up in the end. At the same time, we are pressing
ahead with research projects that aim to develop
disruptive technologies to market readiness.
By doing this, we want to achieve as soon as possible those savings that will be required by legislation by 2030 and 2050 in any case.

1
Paper structure
Professor Markus
Biesalski uses polymers to create
new applications forpaper with maximum
recyclability(see page 45).

Sustainability
Paper is based on
renewable raw materials
and is biologicallyde­gradable. This means
it has the potential toreplace products madefrom fossil resources.
reflect 37

2

Cost efficiency
Paper producers comBenchmark
peting with one another BillerudKorsnäs’
machine BM 7
are under significant board
increases efficiency
by networking
cost pressure. Intelligent components
to thegreatest extent
solutions can further possible and throughprocess data
reduce production costs
monitoring(see page 20).
to a significant extent.
Voith invented the recycling of recovered
paper. Has this technology been fully
developed, or is the goal of a closed-loop
economy providing new impetus?
Recycling technology has certainly not reachedits zenith. On the contrary, paper and board still
have huge potential as materials. Increasingly,
good recovered paper qualities are becoming arare resource. Following the ban on waste paper
imports to China, mixed recovered paper is being
disposed of in landfill because only a few paper
mills have stock preparation units capable of processing such low-quality paper. In other markets,
even higher recycling rates are being required than
before. As a reminder, in the early 2000s, Voith
had joined with other paper manufacturers from
CEPI (Confederation of European Paper Industries) to set for itself the very ambitious goal of increasing the recycling rate of recovered paper
for paper manufacturing from below 50 percent to
70 percent. Since that time, the recycling rate in
the EU has already exceeded 70 percent.

38 reflect

So, despite declining qualities, is theconcept of recovered paper recycling still
viable for the future?
Yes, but this will also result in higher and higher
contaminant loads, which present entirely newchallenges for recovered paper pulping andscreening, treatment of residues and water management. In addition, the high volume of stickies
disrupts the stable running of the paper machine.
As a market leader, we have been working
intensively on all these problems for a long time incooperation with customers and research institutes. As a result, we can offer stock preparation
systems that are world-leading with respect toenergy efficiency and fiber treatment. However,
the most important aspect is still the quality of thesuspension. The question of whether a paper
machine is going to produce high-quality paper islargely decided upstream of the headbox in thestock preparation unit, and this is definitely where
one of our major strengths lies.

3

Digitalization
Even the shortage ofSoftware solution
skilled personnel and Using
virtual sensors,
OnEfficiency.
lack of expertise can be Strength determines
the expected papercountered by using digi- quality
during operation and optimizes
talization to automate it with the help of AI
and stabilize processes. (see page 18).
What other strengths does Voith Paper offer
in its collaboration with the paper industry?
We have a unique product range from stock
preparation to paper machine and from winder towaste water and residue treatment. Voith Paper
not only covers its customers’ needs for new facilities and rebuilds; we also supply the necessary
spare and wear parts for efficient operation as well
as services and complete automation solutions.
As a result, we are not just capable of giving ourcustomers comprehensive expert advice on
the complete paper manufacturing process but
can also supply them with solutions from asingle source that require no other interfaces.

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We are going to further develop
our position as a full-line supplierand at the same time takesustainable and efficient paper
production to the next level.

This reduces their workload in-house. What
this means for our customers is not only a fast
startup of new machines but also a guarantee of
reliable production volumes over longer periods
and thus improved predictability of their processes and ultimately, their profits. As a full-line supplier, Voith Paper is therefore an exclusive partner
for the manufacturing of board, packaging
and graphic papers, tissue and various specialty
paper grades.
How are you aligning Voith Paper
strategically against the backdrop of economicand ecological change?
We are going to further develop our leading position as a full-line supplier. At the same time, weare taking sustainable and efficient paper production to the next level with our BlueLine stock
preparation units and XcelLine paper machines.
In this context, our Servolution service packages
and Papermaking 4.0 concept to increase resource-conserving machine efficiency will takecenter stage. We will continue to develop our
product portfolio, our organization and our footprint within these cornerstones.

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Andreas Endters,
President & CEO,Group Division Voith Paper

Complete package
As a full-line supplier,
Voith combines
ongoing sustainability-driven productimprovements andefficiency-enhancing
digital solutions
into a complete
package forthe paper industry.

Full-line supplier
Sustainability
Efficiency
Digitalizationreflect 39

New
milestone

Sun Paper is increasing its capacity for graphic and specialty papers withanother two machines. The PM 39 and PM 40 MG are to be installedat the company’s Yanzhou facility. Since 2007, the paper manufacturer hasordered a total of 11 Voith machines, an unprecedented collaboration
during which both parties have set several industry records.

2006

2007

2010

2014

2018

2019

A

B

C

D

E

F

IPO
Sun Paper listed on
the Shenzhen stock
exchange for the firsttime.

40 reflect

PremiereStartup of the PM 21,
the first paper
machine orderedfrom Voith.

New departure
Order for theconstruction of the
PM 24, Sun Paper’s
first machinewith online coating
technology.

Triple order
Sun Paper orders
the PM 29 (graphic
papers), PM 31 andPM 32 (corrugatedbaseboard andtestliner) from Voith.

New record
The PM 36 and PM
37 go into operation
with a new start-up
record; Sun Paper
orders the PM 1 andPM 2 for its Laos
facility.

Outlook
Sun Papercommissions Voith
to supply the
PM 39 and key
components for
the PM 40 MG.

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Cooperation built in a spirit of trust is a very valuable asset. This is true especially but not only in
China. The saying “Trust is achieved through honesty. Success is acquired through zeal.” isattributed to the Chinese philosopher Confucius.
Twenty-five hundred years later, the partnership
between Sun Paper and Voith is proof that thismaxim can be applied to the modern businessenvironment. The subsidiary of the Chinese Shandong Sun Holdings Group has engaged Voith
to supply the PM 39 paper machine for graphic
papers as well as key components including
the MG cylinder for the PM 40 MG. The latter willproduce flexible packaging papers that will be
used predominantly for foodstuffs. These papers
are smooth on one side, a quality that isachieved by drying them on an extra-large Yankee cylinder.
Through this order, Sun Paper is not only underlining its commitment to growth but also its
trust in Voith as a supplier, not least for graphic
papers. This is because the market for clothing
and other spare parts, components for rebuilds
and service packages continues to be an important area of business for Voith Paper.
Successful start
The order was preceded by a long-shared history.
Sun Paper, currently one of the most important
paper manufacturers in Asia, was established in1982 and has been a listed company since 2006.
Earlier contact with Voith had convinced Sun
Paper of the Group’s expertise. Voith then got theopportunity to put its capabilities to the test in
the same year as the IPO, when Sun Paper ordered
the PM 21 for wood-free coating base paper,
offset and copy paper. Assembly began at theend of September 2006, and the machine wascommissioned just six months later in April 2007.
In the process, a start-up record was achieved,
as there were just six hours between “stock onwire” and marketable paper on reel.

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Lightning-fast start
When put into
service, the PM 37
was able to produce
marketable paper
in record time.

Equipping Sun Paper for expansion
The lightning-fast start was followed by a rapid
expansion of the collaboration between the companies. In 2010, Sun Paper engaged Voith tobuild the PM 24 at the same location. It was thecompany’s first paper machine with online
coating technology. Then in 2014, the manufacturer ordered no less than three machines from
Voith: the PM 29 for graphic papers and the PMs
31 and 32 for corrugated baseboard and testliner. The PMs 36 and 37 went on stream in 2018,both earlier than scheduled, with the PM 37
also setting a new record for packaging paper machines. When it started up, it took just one hourand 57 minutes from “stock on wire” to marketable
paper on reel. One order in the same year was
game-changing. Sun Paper commissioned Voith
to supply the packaging paper machines PM 1
and PM 2 for its production facility in Laos, its firstoutside China.

Quality check
The paper producedby the PM 36 andPM 37 had to satisfy
rigorous quality
checks.

In cooperation with Voith,
the commissioning of
our PM 36
and PM 37
was verysuccessful.
Guangdong Ying,
Deputy General
Manager and Chief
Engineer at Sun
Paper

New chapter of cooperation
The PM 39 and PM 40 MG are now adding to thissuccess story. Both machines will be installed in
Yanzhou, where the PMs 21, 24, 29, 31, 32, 36
and 37 are already operating. With a wire width of
10.5 m and design speed of 1,800 m/min, thePM 39 is set to produce 450,000 metric tons per
year of graphic papers. For the PM 40 MG,
which will produce paper that is smooth on one
side (machine-glazed), Voith will supply the
MasterJet Pro F/B headbox including ModuleJet
automatic control system, a complete press
section, the single NipcoFlex shoe press and the
EcoCal Soft calender.
These latest orders reinforce the long-standing collaboration between the two companies.
“In cooperation with Voith, the commissioning of
our PM 36 and PM 37 was very successful,”says Guangdong Ying, Deputy General Manager
and Chief Engineer at Sun Paper. “We verymuch enjoy working with Voith.” Trust is a currency,
not only but especially in China.

reflect 41

Rollout:
Supreme
The established high-performance rubber rollcover eVenFilm has already set a lot of benchmarks.
New filler material concepts mean thatit can now continue to write its success story.

UniFi
OceanCSk

The rubber roll cover UniFilm can beused in film presses and helps
to substantially extend metering rod
service life.

The SkyCoat coating blade ensuresa uniform profile and long service life witha constant wear rate.

42 reflect

nextlevel N° 05

Voith is extending its product range with the new polyurethane roll coverSupremeFilm. Developed for film presses, it achieves very consistent
2-sigma profiles. In paper finishing applications, it complements other highly
durable roll covers like OceanCoat for coater backing rolls.

Film
ilm
eVenFilm
eVenFilm
ilm
ilm
oat
at
Coat
yCoat
SupremeFilm
SupremeFilm
kombiniert
combines
die material­
thespezifischenmaterial-specificVorteile vonbenefits
Polyurethanof polyurethanemit
einem with
neuen
a new
Füllstoffkonzept.
filler material concept.

OceanCoat
OceanCoat
Walzenbezüge
roll covers
fürfor coater­Streichgegenwalzen
backing rolls aresindespeciallybesonders
durable,­langlebig,
and ihrtheirstabilesstable Materialmaterialmuss seltenerneeds regrinding
nachgeschliffen
less often.
werden.

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reflect 43

ollout:
premeFilmeVen
UniFilm
eanCoat
SkyCo
Thanks to SupremeFilm, wewere able to maintain the 2-sigma
profiles constantly over anunprece­dented installation period.
Dietmar Muser,
Manager Paper Mill, Sappi Ehingen,Germany

Because the SupremeFilm roll cover combines thematerial-specific benefits of polyurethane (PU) with an inno­
vative filler concept, which maintains the surface roughness
over the entire service life, it achieves an especially homo­
geneous and consistent film transfer. The high abrasion
resistance also means that paper producers can extend theintervals between regrinds. But above all, it achieves anabsolutely uniform paper quality. “Thanks to SupremeFilm,we were able to maintain the 2-sigma profiles constantly overan unprecedented installation period,” says Sappi manager
Muser. “In addition, we benefited from reduced maintenancecosts and a longer running time between roll changes.”

New technology improves film presses
Dietmar Muser has a smile on his face. As the manager of
the Sappi paper mill in Ehingen in southern Germany,
his job is to constantly optimize production. Now he has
valuable support with the coating process. Sappi is
one of the first customers to use the new Voith SupremeFilm
roll cover for the film press.
“We aim to be constantly evolving and continually making
our production more efficient. To enable this, new tech­
nologies were necessary,” explains Muser. “For this reason,
we opted to use a promising new development from Voith.”

Suitable for all film presses
Adang Supriatna, PM 2 Production Manager at Indonesian
manufacturer Riau Andalan Kertas – another of the very first
customers to use the new roll cover – confirms a further
reason why it is well worth switching to SupremeFilm. “Theperformance of SupremeFilm met our expectations of
reducing the need to use our grinding machine,” he says.
Another advantage of the new polyurethane roll coveris its flexibility; SupremeFilm is not restricted for use in Voith
film applicators like SpeedSizer AT, but can also be used infilm presses from other manufacturers.

Benefits for film transfer“At the heart of the innovation is a polyurethane material
developed from scratch. With this development, we aremeeting the specific requirements for film presses, especiallywith respect to profile accuracy and film transfer, better
than with any other polymer cover on the market,” says Ralf
Moser, Global Product Manager Finishing Section, Voith Paper.

44 reflect

nextlevel N° 05

Q
A&
Questions andAnswers
At the Technical University ofDarmstadt in Germany,
Professor Markus Biesalski
conducts research into macromolecular chemistry andpaper chemistry. His objective
is to extend the functionalityof paper to give it new specificproperties depending
on application.
Professor Biesalski, as a scientist you are
involved in altering the structure of paper.
What deficits do you want to offset by doing
so and what benefits do you want to extend?
Due to its composition, paper has a whole raft ofvery exciting inherent advantages, mainly ofa mechanical nature. It is extremely tear-resistant,very light and not very dense compared withother materials. Even just a little bit of moisture
can impair its characteristics, but this can becountered using existing wet strength additives orwaterproof coatings. With the help of bio-based
coating materials made of polymers, known as
macromolecules, we are trying to systematicallyfind new approaches to increase the use ofadditives from renewable raw materials in paper.
What application areas are you targetingwith these papers?
In Darmstadt, for example, we are working on twolarger projects, the results of which are intended
to allow us to use paper to an even greater extent
as a lightweight construction material in building
applications. One of the challenges in this conjunction is to gain a sound understanding of how
the bond between paper fibers and a lightweightmatrix of plastic, glass or mineral materials can be
improved with bio-based polymer additives.

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Does functionally improved paper havethe potential to become a base material likeplastic used across industries?
Yes. Paper and lightweight paper construction
materials can play a major role in the future.
To achieve this, we need to manage to control
specific paper properties in such a way as toretain the described mechanical properties while
ensuring the re-usability of the products either
through recycling or cascade utilization. If thishappens, then I think there is a possibility that inmany areas we will see materials that can play
an important role across industries. In the caseof food packaging, this kind of trend is alreadyvery much in evidence right now. But in the future,
I can very well imagine paper also being usedin sports equipment, rowing boats or even bicycles, for a large range of components in theautomobile sector and in architecture.
How important could these new paper
applications be economically?
If we solve a few of the really big problems, this
could definitely result in significant economic
growth for the paper industry. If we manage todevelop paper fibers with thermoelastic andthermoplastic properties, then molding and shaping processes will be possible in the same way
they are for plastics or metals. If we tap into thesecompletely new kinds of applications, then I
envisage other exciting opportunities apart fromthose mentioned above.
Does recycling have to be part of theconcept?
It is actually the most important part, where paperin particular offers many advantages overother materials. Because in the future we will needto press ahead with CO -neutral, i.e., climate-­²
neutral, processes to an increasingly greater extent, our research is already taking account of
the need for recycling capacity or the possibility of
being able to continue to use materials in anotherform at the end of their lifetime.
You are already talking to paper producers
about paper with extended functionality.
What has the response been like?
It’s been broadly positive. So that we don’tlose any time in implementing research results,
there needs to be a concerted collaboration
between industry and universities. And this issomething that both sides have acknowledged.

reflect 45