Paper Technology Journal

News from the Divisions:
New process technology for highquality deinked pulp.
Large order from Palm paper millfor the Eltmann mill.
“ahead – Together with our customers
towards superior solutions
Toro – a breath of fresh air
with the winder.

6

International Paper Technology:
Bahia Sul changing perceptions about
Brazil and our industry.
Paper Culture:
Paper’s flying career.

1

Dear customers, dear readers,
We have now put the first six months of the 1997/98 fiscal year successfully
behind us and exceeded our own ambitious targets. This is surely reason
enough to cast a brief glance back.
Asia has been one of the major markets since the formation of Voith Sulzer
Paper Technology, contributing more than 30 % of the overall bookings of
DM 2.2 billion for the 1996/97 fiscal year. And this in spite of the ongoing
economic turmoil in an area which, with the exception of China, cannot be
expected – even in the most optimistic of views – to undergo any decisive
upturn before the start of the next century.
Hans Müller,
President and CEO
Voith Sulzer Papiertechnik

The European market and the North-American free-trade association, NAFTA,
including South America, made contributions of 40 % and 25 % respectively
to our order book and are developing during the current fiscal year muchbetter than anticipated during the planning stage. Even if the markets inEastern Europe and South America only show slight signs of improvement,
the major projects under consideration in South America in particular arecloser to being realised than ever before.
Altogether, new orders received in the current fiscal year have reached thesame level as the comparable of last year, with an ongoing upward trend inevidence.
You can see which developments, innovations and records are primarily
responsible for this optimistic outlook in this sixth issue of the “twogether”
magazine. In particular, it is our innovative concept solutions which have
served to improve quality and productivity, impressed our customers andhelped to set new standards.
Without an active dialogue with you, our customers, this would not havebeen possible. I would therefore like to take this opportunity of thanking
you for your cooperation and hope you enjoy reading the interesting articles
in this issue.
Yours sincerely,

Hans Müller

2

The managers of Voith Sulzer Papiertechnik on the current situation
secure a strong foothold for our
future in Asia.
Dr. Lothar Pfalzer
Stock Preparation Division

For the Stock Preparation
Division, this year will be marked
by the market launch of our new
screening machine series. For thereycling of secondary fibres, amajor task in stock preparation,
this screening technology has adecisive part to play.
The new series represents theresult of some years of researchand development on the processes that take place at the screenand between screen and rotor.
With the aid of complex computer simulation and advanced
ultra-sound measurement
technology we have obtained
essential knowledge on theactual flows in the screening
zone. This has led to the development of new casing geometry
and rotor design concepts. With
the launch of this new screen
generation we expect to boost
our business in the updating andimprovement of existing plants.
Of course, Stock Preparation is
also affected by the current crisis
in Asia , since this region has
become one of our most important markets in the past few
years. However, we are relying
on long-term dynamics and on
the potential of this economic
region. For this reason we recently acquired a majority stakein R. Dan, Manila, a partner ofours for many years, in order to

Despite the crisis that is currently
shaking Asian markets, the Paper
Machine Division Graphic has
continued to make progress.
Investment activity within theEuropean and American paperindustries has gone up substantially. In addition to the purchaseof some new machinery, the industry is concentrating its effortson the extensive updating andimprovement of existing plants.
Innovative concept solutions
aimed at boosting productivity
and improving quality have given
us a satisfactory starting basis.
The excellent results achieved
with innovations ranging from
ModuleJet to Sirius, including
our new DuoFormer TQ former
concept in Jämsänkoski, alllaunched within the past few
years, have helped us to convince
many customers to place theirinvestments with us.
As far as investments in newplant are concerned, two specificorders deserve attention: a newnewsprint machine featuring
trend-setting press technology
which is bound to evoke greatinterest in the entire paperindustry, and one of the world’s
most advanced machines for online calendered SC papers.
The tissue business in North andSouth America also developed
satisfactorily. Investment here
was concentrated on new plant,
enabling us to book in several
worthwhile orders.
Dr. Hans-Peter Sollinger
Paper Machine Division Graphic

The Board and Packaging Division is the youngest operating
division within Voith Sulzer

mers – all for the never ending
quest of achieving better paper
quality at higher machine speeds.
And, of course, lower cost per
ton too!
Containerboard machine speeds
are approaching newsprint levelsof only five years ago, resulting
in tremendous productivity gains
and lower capital cost. Thisshould provide the impetus
needed for replacement of older,less efficient production lines.
Our customers seem to agreewith us, booked orders are atrecord levels for our division.
Otto L. Heissenberger
Paper Machine Division
Board and Packaging

Paper Technology: we have justcelebrated our third birthday.
Our mission is simple: to be thebest in our field! Best in operating performance of our machines,
best in serving our customers.
Our team is knowledgeable, weare there when our customers
expect us.
The narrow focus on folding
boxboard, containerboard andpackaging papers, with a dedicated Research and Development
Center, allows rapid productdevelopment and high efficiency
during customer trials. To date
we can show two new machine
concepts and two new gap for-

When the Finishing Division
introduced its new calendering
technologies to the expert world– key words: Janus and Ecosoft –the opinion was unanimous: ahighly innovative approach.
The only question that remained
was whether it would genuinely
be possible to translate thebenefits of the new concepts –solidly founded in theory – into
practice according to a “one-toone” ratio?
The first reassuring answer camefrom tests carried out with ourcustomers’ papers at the Janus
Technology Centre in Krefeld,
Germany. Of course, final proof
could only be obtained in continuous operation.
In the meantime the new solutions have proved their worth:3“systematic finishing”: complete,made-to-measure solutions
based on the use of advanced
modular technology.

In addition to the world’s firston-line Janus at the Lang company in Ettringen, Germany,various off-line Janus calendering machines are running at theMaastricht and Gratkorn millsof KNP LEYKAM, while at Oji in
Yonago the first Janus is runningin an off-line coater.
With these installations we are
now able to present – only two
years after introduction of theinnovative Satinage concept –examples of successful practicalapplications.
But finishing is more than justproducing satisfactory surfaces.
It also encompasses the cutting
and packaging of rolls. Economical, high-quality roll packaging
was obtained by using theflexible, space-saving Twister.
More than ten plants, somealready in production, haveconfirmed this concept too.
The Toro roll cutting machine is
our latest product. Not only thename but also the entire winding
concept is new. The first orders
confirm that customers greatly
appreciate the Finishing
Division’s innovative power.
With Janus, Ecosoft, Twister andToro, the Finishing Division canoffer the paper industry

Our declared target is to convinceusers with our performance inthe future as in the past – and we
certainly have enough good ideas
in reserve to achieve this aim!
The Finishing Division still has
one or the other surprise or
secret “in stock”. And in due time
we will unveil them – maybe in
one of the next “twogether”
magazines. It’s worth keeping aneye on the latest news from theFinishing Division!
Dr. Dieter Kurth
Finishing Division

The “Status-Quo” for the paperindustry today is one of change.
The dynamics of the current
situation for the papermaker andthe supplier base require all of us
to maintain stable operations
while meeting new challenges.
The Service Division of Voith
Sulzer Paper Technology today
is concentrating on maintaining asolid, stable base of local Service
Centers nearby our customers/

partners so that we can provide
the best in support services.
As we strive to deliver maximum
value, return and dependability,
we realize that our main objective
must be service that yields top
quality and the lowest possible
cost per ton.
While we maintain this focus on
stability, we are also concentrating on strengthening our market
presence with new products,
services and locations. In thisissue you will read about ourpartnership with RIF Roll Covers
in Italy. We have recently approved the expansion of ourWest Monroe, LA (USA) Service
Center to begin offering rubber
and polyurethane roll covers.
We will open our newest Service
Center in Farmington, NH (USA)in July and we have recently
approved the acquisition of afirst class roll grinding supplierin Sweden which will be expanded to a full line Voith Sulzer
Paper Technology Service Centerfor the regional area.
Additional plans are in progressfor expansion of Service Centers
into Asia, additional Scandinavian
locations and also in SouthAmerica.

Thanks to consistent, intensive
effort we have succeeded insupplying our customers continuously with further developed
plants that have improved productivity and quality still more
for a wide range of paper andcardboard grades.
The vast, constantly growing
capital requirement needed forthe operation of a new completeor technically modified production unit is also a reason why
efficiency must be boosted still
further.
In this context, plant machinery
is an essential element from thetechnical and technological pointof view, but once the investment
has been made, efficiency depends solely on the degree of
production plant optimisation.

So, we are on the move, in anever changing environment.
Our goal is to continue to be atrusted partner, around theworld, in assisting our customer
in achieving maximum optimization of their activities andinvestments.

Providing our customers withprocess support in a manner as
consistent as possible with thejoint aim of achieving a highly
efficient production process is –along with the further development of plant technology – anincreasingly vital task to which
we are willing to devote all ourefforts.

R. Ray Hall
Service Division

Dr. Hermann Jung
Finance and Controlling4

Do you remember? Three years ago Voith and Sulzer merged their paper
technology product sectors in order to go forward jointly into the future.
They summed this merger up by coining the phrase “twogether”. This waswell received. For two traditional paper technology companies, whose
production locations were not at all far away from each other, to combine
their experience, production and research potential was well received in thisage of globalisation. “We need powerful, internationally competitive partners”.
This was the accurate, majority view within the paper and board manufacturing industry, which is undertaking its own consolidation process for
similar reasons.
The marriage has been celebrated. The house has been set up and areas of
responsibility defined. Joint business activities have proved to be highly
successful. The two previous companies have merged successfully into one.
Voith Sulzer Paper Technology has won recognition as a company. Should the“twogether” company now break away from its highly original logo? Yes and
no! In terms of the consolidation of the two areas of paper technology into
one individually responsible company, the term “twogether” has indeed
served its purpose. As a vision for an even better level of cooperation between
Voith Sulzer on the one hand and the paper and board manufacturing industry
on the other, this applies just as much as it ever did. It is precisely thiscommon bond, this customer loyalty, that we have been aiming for on that
distant horizon.
Therefore we shall now desist from using the term ”twogether” in as far as
it relates to Voith und Sulzer. As a term for co-operative processes andhandling, for constantly improving products, for the bond between Voith
Sulzer and the paper and board manufacturing industry, we will continue to
use it. As a result, our customer magazine will continue to bear the title“twogether”, which has become a worldwide recognised link and a communication tool between the paper industry and our company. I hope that you too
will concur with the sentiments expressed by the term “twogether”.

Yours sincerely,

Dr. Wolfgang Möhle, Corporate MarketingN e w s F R O M StockT H Preparation
E DIVISIONS

5

Stock Preparation Division:
New process technology
for high quality deinked pulp

The author:
Harald Selder,
Stock Preparation
Division

Following comprehensive trials carriedout in the pilot plant of the Voith Sulzer
Stock Preparation Division in Ravensburg, Germany, UK Paper, a paper milllocated in Kemsley, Great Britain, andbelonging to the Fletcher ChallengeGroup, placed an order for the supply ofa turn-key deinking plant for the preparation of recovered mixed office papers.
The following is a report on the process
installed at Kemsley.
The report comprises the following sections:
I Procedure in developing the system
I Pilot plant trials
I Project realization based on the
results of the pilot plant trials.

Procedure in developing the system
Factors influencing the designof the plantFig. 1 shows the factors of particularimportance to the customer in designing
his deinking plant. The two most impor-tant factors are the type of raw materials
and the requirements for the finishedstock. Other factors are fresh water consumption, the amount of rejects material
and personnel as well as control and instrumentation costs. Combining personnel and control and instrumentation
costs into one block is because of theclose relationship between these twoparameters. Experience generally showsthat where control and instrumentation
costs are high, personnel costs can be
reduced to a certain extent. The twomost important parameters of influence,
finished stock requirements and grade of
raw material, are now dealt with in detail.
Finished stock requirements
In Central Europe, UK Paper is one of theleading manufacturers of high quality,
wood-free business papers, including
copy papers. This exacting production
program thus automatically places great
demands on the raw material. The following lists the most important optical,
technological and colloidal-chemical criteria for enabling the use of deinked pulp
in UK Paper’s products:
1

Finished stock
requirements

Type ofraw material

Chemicals

EnergyWater
consumption

Plant design

Control,
instrument. andpersonnel costs

Amount ofrejects

6

Fig. 1: Factors influencing the design ofthe plant.
Fig. 2: Characterization of recovered mixed office
papers (after pulping and coarse screening).
2

I Finished stock brightness 80-85%
ISO without UV luminance
I Cleanness 10 ppm
I Stickies 150 mm 2 /kg
I Ash 5%I Freeness 420-370 CSF
I Low/constant cationic demand
I Low COD value.

65
Mean 59.7
60

2s

ISO brightness without
UV luminance [%]

70

55
1

2

3
Trial

4

5

With the exception of freeness, ash andstickies content, the requirements areroughly the same as for virgin fibres.

4000

Mean 2827
2s

Dirt speck area [mm2/m2]

6000

2000

0

1

2

3
Trial

4

5

Raw material
Following comprehensive research andstudies carried out by UK Paper, the decision was made to use recovered mixed
office papers from the London area.
This decision was made on the basis ofprice, quality and availability.

3·104
Mean 13,580

2·104
2s

Stickies [mm 2/kg]

4·104

1·104
0
1

2

3
Trial

4

5

Mean 20.6
202s

Ash (575°C) [%]

30

10

0

1

2

3
Trial

4

5

Technological characterization ofrecovered mixed office papers
5 pilot trials, each with 3 tonnes ofrecovered mixed office papers from London and surrounding areas, were carriedout in the pilot plant facility of Voith
Sulzer’s Stock Preparation Division inRavensburg. This enabled an optical andtechnological characterization of this raw
material to be made. In view of the large
amount of recovered paper processed
during these trials, the characterization
results can be taken as representative.
These comprise the characteristics ofbrightness, cleanness (expressed as thedirt speck area), stickies and ash.
The characterization results are shown in
Fig. 2.

As regards brightness, the recovered
mixed office papers have an average ISO
value of 59.7% (without UV luminance).
The standard deviation here is ± 5%
ISO points. The average cleanness,
expressed as specific dirt speck area,
is 2827 mm 2 /m 2 . The fluctuations incleanness are ± 1600 mm 2 /m 2 . As for
stickies, the average contamination is
13,580 mm 2 /kg, with the values showing
a standard deviation of ± 11,600 mm 2 /kg.
These large fluctuations are typical forrecovered mixed office papers, andcan be attributed to the varying content
of self-adhesive (pressure sensitive)
envelopes.

The average ash content of recovered
mixed office papers is 20.6% ± 5%, basedon an incineration temperature of 575°C.

These average values must now be set
against the requirements placed on thefinished stock. From this comparison therequired system efficiency as illustrated
in Fig. 3 is derived.

As regards ISO brightness (without UV
luminance), an average absolute increaseof 22.8% points is necessary. With stickies, the required reduction is 98.9%,
while with ash it is 75.7%. The highest
required system efficiency concerns
stock cleanness, where the reduction is99.65%. To achieve these objectives, thestock preparation technician can use thefollowing system modules. The processmodules have, as Fig. 4 shows, very specific ranges in efficiency. As far as theincrease in brightness is concerned, theStock Preparation

7

Fig. 3: Determining the necessary systemefficiency.
Fig. 4: Efficiency ranges of the process modules.
Fig. 5: Absolute efficiency of the process modules
in the preparation of recovered mixed office
papers (average values from approx. 20 trials).

flotation and bleaching stages are themost effective modules. The main components for achieving a high degree of
cleanness are flotation and dispersion
whereas for an efficient reduction in
stickies the important modules arescreening and dispersion. De-ashing ismost effective with the washing module.
If recovered mixed office papers are tosatisfy the finished stock requirements,
all modules need to be installed becauseof their very specific ranges of efficiency.

3
TechnologicalcriteriaRawmaterial

Finished stock
requirements

Required systemefficiency

Brightness without UV luminance59.7% ISO

80-85% ISO+22.8% points

Dirt speck area

2827 mm 2/kg

10 mm 2/m2

99.65% reduction

Stickies

13,580 mm 2/kg

150 mm2/kg

98.9% reduction

Ash

20.6%

5%

75.7% reduction

Technologicalparameters

ModulesFig. 5 shows the absolute efficiency values of these modules which can be expected in the preparation of recovered
mixed office papers. This efficiency
quantification is based on approx. 20 trials with recovered mixed office papers
carried out in Voith Sulzer’s stock preparation pilot plant in Ravensburg.

Brightness

Dirt specks

Stickies

Flotation–

Washing
Centrifugal
cleaning–

Heavy contraries

–

–

–

Light contraries

–

–

–
–

–

Dispersion–

Reductive bleaching

Fig. 5 shows that it is impossible toachieve the required cleanness and reduction in stickies, even with the use of
all available system modules. The dirt
speck area is reduced with an efficiency
of only 93.4%, resulting in a finishedstock load of approx. 200 ppm.

This corresponds to the cleanness levelof central European newsprint, produced
from 100% recovered paper. As far as
UK Paper’s products are concerned, thisis a completely inadequate level of cleanness.

To achieve a significant improvement incleanness, double treatment with the

4

–

–

Screening

Ash–

Oxidative bleaching
averagehighTechnologicalparameters

–
–
–

low

no efficiency

Absolutechange inbrightness% points

Dirt speckarea
reduction%

Stickies
area
reduction%

Screening

0

20

80

0

Flotation

+ 3

65

30

30

ModulesAshreduction
%

+ 3

-20

0

85

Heavy contraries

0

30

30

0

Light contraries

0

0

30

0

Dispersion

- 1

65

70

0

Reductive bleaching

+ 8

10

0

0

Oxidative bleaching

+10

10

0

0

Overall efficiency

+23

93.4

97.9

89.5

Washing
Centrifugal
cleaning

5

8

Fig. 6: Improvement in cleanness throughadditional modules.
H Basic modules, C = 93.4%;
H + 1 additional flotation, C = 97.6%;
H + 1 additional flotation + 1 dispersion,
C = 99.15%;
H + 2 additional flotations + 1 dispersion,
C = 99.7%.
Fig. 7: Improvement in Flotation II efficiency witha preceding dispersion stage.

must be achieved using two additional
flotation modules. This method of extrapolating the results is illustrated inFig. 6.

6

Spec. dirt speck area [mm 2/m 2]

200
160

Raw materialload
B 2827120

Prerequisite for achieving the required
efficiency with the additional modules isa correct system integration. The trials
showed that the additional flotation
stages will only achieve the required efficiency when preceded by intensive
mechanical treatment of the stock. Thismechanical intermediate treatment on
the one hand achieves a further loosening of remaining ink particles from thefibres and on the other hand produces ageometric reshaping of disturbing tonerparticles.

80
40
0

Rel. dirt speck area reduction [%]7100
Flotation II
80
60
Dispersion
40
Flotation I
20
0

2

4
6
2
No. of flotation cells

46

most effective modules, i.e. with flotation and dispersion, is required. With aresidual load of 200 ppm and a cleanness target of 10 ppm, the efficiency
must be increased by an additional 95%.
This corresponds to three additional
modules with an individual efficiency of
65% each.

To avoid mechanical overstressing of thefibres, the number of dispersion stages
within a system should be limited to two.
The remaining increment in cleanness

The flat-shaped toner particles are compacted in hot dispersion and become
cubic in shape. The results in better
floatability. The synergy relationship between flotation and dispersion modules
is graphically illustrated in Fig. 7.

It can be seen that no worthwhile dirt
speck area reduction takes place after six
flotation cells. An increase in the numberof cells in Flotation I would therefore notachieve any further improvement incleanness. Only after an intermediate
dispersion stage is it possible to achievea further improvement in cleanness withthe help of flotation technology. In summary, one can say that, to achieve therequired characteristics as regards
cleanness, brightness, stickies and ash
contents, the papermaker needs to install
all available system modules as well as

two additional flotation stages and one
further dispersion module.

Pilot plant trials and project realization
The machine sequence for the pilot trials
was determined based on extrapolated
results and the synergy relationshipbetween the flotation and dispersion
modules. Fig. 8 shows the processarrangement used for the pilot trials in
the form of a simplified block diagram.

The system diagram shows that all available process modules are involved, andthat the required additional modules
have also been integrated. It also showsthat the synergy advantages between the
flotation and dispersion modules havebeen fully exploited. In other words, mechanical treatment in the form of a dispersion stage takes place between eachflotation stage.

This arrangement was used in Voith
Sulzer’s Stock Preparation pilot plantfacility in Ravensburg for a total of five
trials. In four trials the finished stock
requirements were fully met. The required
cleanness was not however fully
achieved in one trial. The reason for thiswas a change in the additives used in the
flotation stages.

In general, however, the trial results
showed good correlation with the extrapolated results. The reduction in dirt
speck area in the process stages is used
to illustrate the efficiency of the system.

Stock Preparation

9

Fig. 8: Process arrangement used for the pilot
trials.
Fig. 9: Reduction in specific dirt speck area
through the individual process stages.
Fig. 10: Simplified block diagram of UK Paper’s
RCF (Recycled Fibre) plant.
89HC pulping

10
Inlet coarse screening

Pulping (PreClean)
Dump chest

Discharge Fiberizer
Inlet Flotation I

HD cleaning

HD cleaning
MC hole screening B
MC slot screening //Process loop I

MC hole screening 1.2 B

After Flotation I

MC slot screening 0.2 //Flotation I
HW cleaning I

After HW cleaning I

Fine slot screening 0.1 //Flotation I

Double wire press I
Dispersion I

HW cleaning I
LC screening

DAF I

VarioSplit/thickening I

After fine screening

After washing

Reductive bleaching

Process loop II
Washing/thickening I
Dispersion I + Y bleaching

After dispersion I
and reductive bleaching

HW cleaning II

Inlet Flotation II

LW cleaning

Flotation II

Flotation II

After Flotation II

Double wire press II

LW cleaning

After HW cleaning II

Oxidative bleachingThickening II

After dispersion II
and peroxide bleaching

HW cleaning II

Dispersion II

Dispersion II + P bleaching
Flotation III
Thickening III

The initial dirt load in Fig. 9 was 1400
ppm. The first significant increase incleanness is obtained with Flotation I,
whilst the second increase is with Dispersion I including reductive bleaching.
Then follow noticeable reductions after
Flotation II and Dispersion II.

In Flotation III cleanness is improved
from approx. 20 ppm to under approx.
5 ppm. Overall the dirt speck area isreduced in this system from 1400 ppm to5 ppm, which represents a system effi-

DAF II

Disc filter II

100

200

300

400

Flotation III
Disc filter III

After Flotation III
0

Process loop III
DAF III

Storage chest
1200 1400

Specific dirt speck area
(B > 50 mm) [mm2/m 2]

ciency of 99.65%. The process arrangement, as simulated in the Voith Sulzer’s
trials, was exactly taken over for UK
Paper’s project. The result is the new
RCF (RCF = Recycled Fibre) plant in
Kemsley as illustrated in Fig. 10. The
following report by Peter Christmas, Operations Manager of UK Paper, Kemsley,describes the plant in detail.

Summary
The special features of the Voith Sulzer
system are summarized as follows:

Wet lapPM

I 3 separate process loops with
3 flotation stages, 2 dispersion stages,
3 separate water loops, including
3 water treatment stages
I Combined MC hole and slot screening
and additional LC screening with a slot
width of 0.1 mm
I 2 bleaching stages in Y-P sequence
I In-line brightness and dirt speckmeasurement
I No intermediate chests, with the
exception of the pulper dump chest
and finished stock storage chest.

10

Stock Preparation Division:
The deinked pulp plant of UK Paper
in Kemsley, Great Britain
As already described in the previous

RCF (Recycled Fibre) plant in detail,report by Harald Selder, UK Paper had, af-

dealing with the following areas:

ter a number of comprehensive trials andstudies, decided to realize the deinking
project using the system design developed by Voith Sulzer Paper Technology.
We also decided to transfer total responsibility for process engineering, control
The author:
Peter Christmas
UK Paper, Kemsley,
Great Britain

andinstrumentation

technology

and

I Chronology of plant construction andprocess description
I Quality development during the
optimization phase
I Cost structure and comparison
with other market DIP plants.

commissioning to Voith Sulzer. The reason was that we did not want to start

The Kemsley RCF plantsuch a project without an experienced

General details

and competent complete systems part-The overall site on which the Kemsleyner. Voith Sulzer has considerable spe-

RCF plant was built covers 54,000 m 2 .

cialist knowledge and was also able to

The site includes two building complex-

provide suitable plant references. The

es, – the warehouse for recovered paper

following report describes the Kemsley

and the machine building.

1

Stock Preparation

11

Fig. 1: View of the RCF plant buildingsin Kemsley.

The recovered paper warehouse canstore up to 15,000 tonnes. All main stock
preparation machines as well as the

Table 1: Process data
Pulping consistency

18 - 22%

Specific pulping energy

28 - 30 kWh/t

Reductive bleaching

0.65% stabilized dithionite (Hy-Brite)

house for recovered paper.

Oxidative bleaching

1.3% peroxide (H 2 O 2 , 100%)In the surrounding industrial zone, two

Flotation additives

1% soap + 0.01% synthetic foaming agent

Overall specific dispersion energy

160 - 180 kWh/twater treatment equipment are locatedin the machine building, with a floorarea of 7600 m 2 . Fig. 1 shows the machine building with the adjacent ware-large paper mills are located quite nearby. This enabled us to enter into an appropriate service contract with the service organization already supplying theTable 2: Quality comparison

two paper mills with power and steam

Parameters

Unit

Brightness% ISO with UV 100% ISO w/out UV 86.5

91
91

90
90

90
90

85
85

Dirt speckarea

mm 2 /m 2
(ppm)

1-5

1-5

1-4

1-6

UKP
DIP

and also taking care of effluent andwaste material disposal. Total investment
for the deinking plant was 43 million
poundsSterling.

Plant

capacityis4-6

100% SF
50% SF chem. pulp 100% LF 100% SF/CTMP
chem. pulp 50% LF chem. pulp chem. pulp (bleached)

110,000 tonnes per year finished stock.

Stickies

mm 2 /kg

< 80

< 20

< 20

< 20

< 40

This

Freeness

CSF

400

460

420

500

470

Tensileindex

N · m/g

50

49

66

81

41

Tear
index

mN · m 2 /g

10.8

7.1

10.9

11.1

9.3

Burst
index

kPa · m 2 /g

3.3

3.8

5.8

7.8

2.9

requiresprocessing

approx.

180,000 tonnes of recovered paper per
year. The recovered paper consists ofunsorted,

mixed

officepapers.

Toachieve the necessary tonnage, the plantmust operate 363 days per year.

(SF = short fibre, LF = long fibre)

Chronology of the plant construction

November 1995. At the end of January

ment and Advisory Service). The average

Construction work started in September

1996 optimization work commenced. The

content of inorganic components (ash) in

1994 with the demolition of unused

amount of sludge “produced” annually

the sludge is around 70%. Apart frombuildings, and the foundations were laidin the RCF plant is 70,000 tonnes. It

sludge, some 3% of plastic and metalin October 1994. The first machines werecomes out of the system with a dry con-waste is removed and then disposed of

installed in March 1995 and installation

tent of 60% and is used to improveon the communal rubbish dump.

of the plant was completed by September

neighbouring agricultural land. This form

1995. The first phases in commissioningof sludge utilization is carried out under

Finished stock production was 73,000

the plant then began, and production

thegovernment

tonnes in 1996, the first year of opera-

of deinked pulp started on the 11th of

authority ADAS (Agricultural Develop-

tion, and production for 1997 was set at

supervision

of

the

12

Fig. 2: Development in deinked pulp cleanness
Still acceptable
Targettions. Up to now the only change has

245

been the installation of an additional discfilter before the VarioSplit. The filter

40

is used only when
Dirt speck area [mm2/m 2]

35

required. It is thus

possible to vary yield and finished stock
quality over a wider range. Table 1

30

shows some typical process data.

25

Plant efficiency and results
20

The quality requirements can be divided
into two areas:

15

I Visual/physical requirements
I Colloidal-chemical requirements

10
5

The visual/physical requirements comprise the following quality parameters:
11 ’979 ’97

10 ’97

8 ’97

7 ’97

6 ’97

5 ’97

4 ’97

3 ’97

2 ’97

1 ’97

12 ’96

11 ’9610 ’96

9 ’96

8 ’96

7 ’96

6 ’96

5 ’96

4 ’96

3 ’96

2 ’96

1 ’96

12 ’950

I Brightness
I Cleanness
I Stickies

96,000 tonnes. The utilization rate of thehave to go through a learning process

I Freenessdeinking plant depends primarily on thesimilar to that of the stock preparation

I Stiffness

amount of deinked pulp used in the pa-

technicians and papermakers. They have

I Strength characteristics

per mill. It requires a considerable learn-

to learn how these recycling products

ing process for the stock preparation

can be marketed most effectively as

Table 2 shows a quality comparison be-technician and, in particular, for the pa-

regards pricing and sales markets.

tween Kemsley DIP and various virgin

permakers, to be able to use a high pro-fibre pulps. The most important quality

portion of deinked pulp without detract-

Process description

parameters of wood-free deinked pulp

ing from paper machine efficiency and

The process realized in Kemsley is illus-

are without doubt cleanness, brightness

product quality.

trated in Harald Selder’s article, Fig. 10,

and stickies content. These parameters

page 9.

are dealt with in greater detail in the fol-

At present UK Paper produces copy

lowing.

paper grades on a 7500 mm wide four-

The special features of the Kemsley

drinier machine at 950 m/min using

system are the 3 process loops with

Cleanness

100% deinked pulp. The papers are sur-

3 separate water circuits, with each cir-Fig. 2 shows our successful optimization

face treated using a film press.

cuit having its own water treatment. The

as regards cleanness. For a greater pro-system was installed according to Voith

portion of deinked pulp in the existing

Sulzer Paper Technology’s recommenda-

production lines of our main customers,

The sales and marketing personnel also

Stock Preparation

13

Fig. 3: Development in deinked pulp brightness
Still acceptable
Targetwe had to reduce the originally specified

388

dirt speck area from 10 to under
6 mm 2 /m 2 for uncoated grades and to

86

These revised levels of cleanness allow
up to 35% of the previously used hardwood chemical pulp to be substituted bydeinked pulp. A further increase in the
DIP portion is foreseen for the near
future. It has been noted that coatedpapers calendered in a supercalender
react very sensitively to residual dirt
specks. Under compression in the supercalender, even the smallest of dirt specks

ISO brightness without UV luminanceunder 4 mm 2 /m 2 for coated grades.

84

82

80

78

76

show up again.
11 ’979 ’97

10 ’97

8 ’97

7 ’97

6 ’97

5 ’97

4 ’97

3 ’97

2 ’97

1 ’97

12 ’96

11 ’96

9 ’96

8 ’96

7 ’96

6 ’96

5 ’96

4 ’96

3 ’96

2 ’96

1 ’96

10 ’96

100% deinked pulp have excellent clean-

12 ’9574

The new recycling grades produced fromness and their visual qualities are very
convincing. Customer acceptance anddeinked pulp. By using alternative bleach-

Colloidal-chemical cleanness

sales of this product are consistently in-ing agents, such as ozone, for instance,

Colloidal-chemicalcreasing.

a greater fibre brightness is possible, butusing a high percentage of deinked pulp

there is the danger of destroying the ef-

are connected withfect of the optical brighteners.

I Conductivity

Brightness

disturbances

when

I Cationic demand andToday, the original target for brightness,

I pH value.

85% ISO without UV luminance, is, infact, being exceeded. As shown in Fig. 3,

Stickiesin

The deinked pulp produced in the Kems-

To solve the colloidal-chemical prob-

ley plant has never yet been the subjectlems, individual solutions in the reten-

November1997

brightness

was

86.5%.

of any complaints about stickies. Thetion systems of the paper machines andBased on brightness with UV luminance,

wide range of process principles is thein the deinking processes need to bevaluesaremain reason for an effective stickies

found. These solutions can differ greatly.

achieved. This high value is due to opti-

reduction. Particularly important here is

What is important is whether the paper

cal brighteners in the recovered paper.

the 4-stage fine slot screening withmill is producing coated or uncoatedSince copy papers generally have a high

0.1 mm slot width and the two disper-

papers. Experience has shown that it iscontent of optical brighteners, their use

sion stages, with their high specificthe broke systems that set off the col-can be reduced considerably when using

dispersion energy.

loidal-chemical disturbances.

ofapprox.

100%

ISO

14

Fig. 4: Cost structure.

Table 3: Applications for the deinked
pulp
Qualitatively high-grade, wood-freewriting and printing papers
45%
Qualitatively high-grade, coatedwriting and printing papers

30%

Wallpaper and standard writing
and printing papers

10%

Tissue products

15%

Geographic location

deinked pulp costs. To keep this very im-

I The deinked pulp plant must be near

portant cost factor as low as possible,

to the source of the recovered paper.

the cheapest grade of recovered paper

Transport costs for recovered paper are

which still produces the required quality

an important cost factor, and it is there-asfore vital to be as near as possible toused. The Kemsley RCF plant uses only

its source. In the case of Kemsley, therecovered mixed office paper from Lon-

London business centres supply the

don and the surrounding areas. The effi-

RCF plant with the necessary recovered

ciency of the chosen system with its

paper.

3 process loops was calculated such thatwell as an acceptable yield, must be

printing inks coming from different printI The deinked pulp plant must be nearing processes can be removed.

to the buyer of the deinked pulp.

4

Other
variable costs 21%
Recoveredpaper 40%
Processchemicals 13%

Major cost reductions not only in capital

Another line of strategy would be to

expenditure, but also in operating costs,

process qualitatively higher-grade recov-

can be secured if the deinked pulp can beered paper with a low process expendi-delivered in wet form. A drying plant for

ture. This strategy failed because of diffi-

deinked pulp is extremely capital- andculties in the availability of the higher

operating cost-intensive. Approx. 75% ofqualities and because of the uncertain

the deinked pulp currently produced atprice development for these types.

Kemsley is delivered to customers locatFixed costs 9%

Energy costs 4%

I Yield is primarily a function of theed within 3 miles of the RCF plant.

recovered paper.
Personnel costs 7%

Amortization 6%

I A suitable infrastructure must be

European office papers (recovered mixedavailable for the deinked pulp plant.

office grades) have an ash content of

If the deinked pulp plant can make use of

between 22% and 26%. The ash content

existing power, steam and waste dispos-of American grades, on the other hand,

Applications for deinked pulp

al services, the capital and operatingis in the region of 12% to 15%. This dif-

Table 3 shows the applications forcosts can be drastically reduced. A

ference is due to the higher share ofdeinked pulp produced in the Kemsleyneighbouring paper mill with sufficientcoated products in the European materi-plant.

utility reserves represents the ideal loca-

al. The two qualities also differ greatly intion. The RCF plant of UK Paper is locat-

the proportion of wood-containing fibres.

ed between two large paper mills.

Because of a higher CTMP content in

Cost structure and cost comparison with

European wood-free grades, the propor-

different market DIP plants
The main reasons for the economic suc-tion of wood-containing fibres is around

Recovered paper

cess of a deinked pulp plant are listed as

According to Fig. 4, the cost of the

10% to 15%, while the American equiva-

follows:

recoveredlent, on the other hand, has a proportion

paper

represents

40%

of

Stock Preparation15of < 5%. Through washing, some clear

Freight costs

sold at considerably less than the pricedifferences in substance losses can be

Freight costs for the deinked pulp arefor short fibre virgin chemical pulps. Fol-seen. The differences in yield can repre-

determined by the distance from the milllowing stabilization of chemical pulp

sent 8 percentage points or more. A rep-using it and by its dry content.

prices, it is expected that deinked pulp
prices will stabilize, too. In the long-resentative yield value for the RCF plant
Fixed costs

term, UK Paper expects the DIP price to

Due to the low land requirements andstabilize around 100 US dollars under the

lower infrastructural needs, these costs

average price for northern long fibre

Personnel costs

are below those of a pulp mill. The main-chemical pulps. An additional price re-

Personnel costs are determined by thetenance and material costs are about theduction can be expected for wet lap pulp.

following parameters:same as those for a pulp mill.

is 58% to 60%.

I Plant design
I Ratio of employees with fixed job

Cost comparison for various MDIP plants
Capital costs

A recent study in which an independent

specifications to employees withSince most plants for producing market

institute compared 17 wood-free deinked

variable job specifications

deinked pulp (MDIP) have only recently

pulp plants showed the RCF plant of UK

I Wet lap plant/drying

started up and have been financed with

Paper to be the plant with the most

I Power and steam generation

public money, the amount of capitalfavourable cost structure.

I Effluent treatment.

expenditure is known. A recent compari-

The advantages of the Kemsley plant lie

son produced the following specific capi-in the low freight costs due to the ideal

Energy costs

tal costs:

local situation as well as in the low per-Energy costs are mainly determined by:

I 800 US dollars per annual tonne

sonnel and disposal costs. Yield is com-

I Plant design(design capacity) for a deinked pulp

parable with that of other similar plants.

I Availability of a drying plant for theplant with wet lap plant.

The costs for process chemicals, fixeddeinked pulp andI Availability of an existing power
station.

I 1400 US dollars per annual tonne

costs and personnel costs are compara-(design capacity) for a deinked pulp

ble with those of other wet lap plants.

plant with drying plant.

The more recent, large deinked pulp
plants with drying plants are very cost-

Chemical costs

Sales priceintensive as regards operation and capi-

The chemical costs depend on plant de-

It is extremely difficult to give the latest

tal investment. Financial difficulties are

sign and finished stock requirements.

representative sales prices for deinked

therefore to be expected during phases

pulps, the reason for this being the dropof over-capacity. Provided the smaller,

Disposal costs

in prices for virgin fibres. The market

less capital intensive deinked pulp sys-

The disposal costs for the sludge “pro-price for wood-free deinked pulp is gen-tems with wet lap plant can satisfy the

duced” depend on the one hand on theerally oriented on southern hardwood

demands of the writing and printing pa-

disposal possibilities and costs and, on

chemical pulps. Due to over-capacity in

per manufacturers and freight charges

the other hand, on the possibilities for

the USA during 1995, 1996 and the be-

can be kept within limits, operation in

local re-utilization.

ginning of 1997, deinked pulps had to be

the profit zone can be expected.

16

1

Stock Preparation Division:
Leading edge technology for soft products –translating practical experience into systemdesign in a tissue millThis report is about the further upgrading of a plant for preparing recovered
papers for tissue production. The resultsof analyses in the plant, experience fromanother preparation plant in the samemill and trials carried out in the machine
supplier’s pilot plant were used successfully for upgrading the plant to tackle themain problem of stickies.
The author:
Helmut Berger,
Wepa Papierfabrik P. KrengelGmbH & Co. KG, Giershagen,Germany

At its two locations in Müschede andGiershagen, Wepa manufactures around
125,000 tonnes of paper a year on five
paper machines. The production programme ranges from multi-ply toilet
papers, kitchen rolls, paper handkerchiefs and cosmetic tissues to single-ply
products such as towels and toilet paper(Fig. 2).
2

The company
Wepa Papierfabrik P. Krengel GmbH &Co. KG was founded in 1948 by Paul
Krengel senior as a paper wholesalecompany and has grown to become aleading manufacturer of hygiene papers
in Europe. Today, the company is managed by the founder’s four sons.

Stock Preparation

17

Fig. 1: The new crescent former at the
Müschede mill.
Fig. 2: Wepa´s product range.
Fig. 3: Recycled paper with 100% closed loop.
Fig. 4: Aerial view of the Wepa mill at
Giershagen.

Wepa is a company with a clear commitment to the environmentally correct useof recovered paper as a raw material forthe manufacture of hygiene papers. 85%
of Wepa’s production is based on recovered paper as raw material. In the environmental segment of hygiene papers madefrom 100% recycled paper, Wepa is market leader for paper handkerchiefs in Germany with its brand name “Mach mit”.
A further major step towards the consistent use of available resources was theinstallation of an industrial power station
at the Marsberg-Giershagen location.
Here, the residues left over after recycling the reusable fibre content are converted into energy by incineration.

recycled paper with a 100% closed production loop
3 Preparation ofrecovered paper inmodern production
plants (recycling).

Non- uRe

2 Collection(sorted where
possible) inrecovered paper
containers or bins .

1 Use of paper inhouseholds for a varietyof purposes.

cycl

sab

i n g fib

re

le f

ib r essRe

si d ual f i b r es

1 Residual fibres (residue) which
are no longer suitable for sheet
formation and used to be
dumped are now recovered.
2 Incineration of
the residual fibres in
the residue incineration
plant.

Finishedproducts

3 Electricity for the
production of paperand generation of
steam for drying thepaper.

4 Residual ash is used as material for thebuilding industry (e.g. road construction) in
the form of slag, etc. Residues are re-used;
raw materials are used carefully.

4

The resulting steam and power are usedin the production process. In this way,
Wepa manufactures recycling papers
using a 100% closed production loop
(Fig. 3).
80% of Wepa’s sales are domestic withthe remaining 20% in neighbouring European countries. With a total of around
700 employees, the family-run company
sells to all major food store chains inGermany. Wepa is one of the few medium-sized suppliers in Europe and customers profit from this. The advantages
are nearness to customers, fast decisionmaking and the resulting high degree of
flexibility.
Toilet and kitchen papers are manufactured on two tissue machines at the
Müschede mill. Cosmetic tissues areproduced on the newest machine (Fig. 1)
which started up in December 1996. Thismachine, a crescent former, is designed

3

for a speed of 2200 m/min. At the Giershagen mill (Fig. 4) there are two tissue
machines and a fourdrinier machine on
which towels and crêped papers are manufactured. While the fourdrinier machine
has a maximum speed of 920 m/min,speeds of 1600 to 1900 m/min are normal on the tissue machines.
With the installation of a new twin wiremachine from Escher Wyss in 1983,
Wepa took the plunge into the (at thattime) difficult era of recovered paper re-cycling. Problems with stickies, shutting
down the machine for cleaning – sometimes once a day – were commonplace inthose early days and still “stick” in thememory of all tissue-makers who began
using recovered paper at that time. Yet
it is worth remembering that our new
machine already had a production speedof 1500 to 1600 m/min.
Use of recovered paper and problems
with stickies
Stickies which are not eliminated during

18

Fig. 5: Stickies area in the finished stock.
Fig. 6: Ash content in the raw material(wood-free recovered paper).
Fig. 7: Brightness of the raw material(wood-free recovered paper).

Stickies area in finished stock [mm2/kg]

5

6

stock preparation – and are therefore
still in the stock going to the paper
machine – have three possibilities of
causing trouble:

2500
2000
1500

I They form deposits on the wires orYankee dryer felt – thus causing holes
in the web – or they collect on the outer guide rolls, are flushed into thesewers and end up in the effluent
treatment plant.

Mean: 1170

1000
500
0

0

4

8
Days [–]

12

16

25

Ash content [%]20

15

I They go through the machine with thepaper web and are reeled up with theparent roll. In subsequent converting
operations, the danger is that on
rewinding the layers of paper stick together, causing sheet breaks.
I They get into the paper machine
whitewater loops from where they canbe discharged through dissolved air
flotation (DAF).

Mean: 15.6

10

5
0

7

5
10
15
Individual deliveries [–]20

The stickies area in the finished stock
ranged between 600 and 2000 mm 2 /kg(Fig. 5). The mean value was about1200 mm 2 /kg. Generally, no production
problems were experienced on the paper
machines within this range. On the other
hand, in individual cases there were production problems on the paper machineswith a very low stickies area in thefinished stock of under 1000 mm 2 /kg.

Brightness [% ISO]

85

75

65
Mean: 64.5
55

45

0

5

Analyses in stock preparation and observations on the paper machines PM 4 andPM 7 at the Giershagen mill showed thefollowing:

10

15

Individual deliveries [–]20

The conclusion is that it is not possible
to deduce any clear relationship between
measured stickies area and production

problems on the paper machines. In other words, there is no limit for the measured stickies area beneath which one
can guarantee there will be no production problems.
Experience with other paper machines
has shown that the stickies area, however, has to be reduced as far as possible. This saves frequent flushing, i.e.
intermittent cleaning of wires and felts
with the paper machine running or, in
extreme cases, the machine having to be
shut down completely for cleaning. Normally, the wires and felts are sprayed
continuously with a detergent which also
avoids problems in converting.
Two demands are made on the ideal
stock:
I First, there must be no problems withthe runnability of the paper machineand converting plant, e.g. due to holes
and tears.
I Even more important, however, is thatthe stock has the properties that theend product must have later. These include optical characteristics such as
brightness and dirt speck levels as wellas mechanical properties such as
strength, bulk, wet tensile strengthetc.
Recovered paper as raw material is oneof the decisive factors influencing thequality of the finished stock. Figs. 6 and7 show the quality characteristics of atypical grade of recovered paper – in thiscase wood-free office papers. The ash
content and brightness of 22 deliveriesof recovered paper were analysed over a

Stock Preparation

19

Fig. 8: The stock preparation plant of PM 4/7
prior to upgrading.
Fig. 9: VarioSplit for removal of ash and fines.

What configuration of stock preparation
is installed that on the one hand reliably
achieves the required end-product quality while at the same time more or lessbalances out the enormous fluctuations?
Stock preparation plant of PM 4/7
A high consistency pulping system pulps
down the paper and ensures early removal of disturbing components without
reduction in size (Fig. 8). This is followed by high density cleaning and hole
screening with 1.6 mm perforation. After
this is a flotation stage with six cells, operated without secondary stage and in
the neutral pH range, without chemicals.
Then comes cleaning of heavyweightparticles, followed by low consistency
screening with a slot width of 0.25 mm.
Lightweight cleaning is followed bywashing. High-consistency thickening isnecessary for the dispersion stage.
Reductive bleaching is then carried out
after which the stock is pumped to storage.
The approach flow systems of PM 4 andPM 7 include a further heavyweightcleaning system as well as hole screening as a policing function. Tissue products with approx. 1% ash content are
manufactured with this plant using various grades of recovered wood-free office
papers. A brightness from 74 to 84% ISO
is achieved, depending on the raw material and end product. The stock prepara-

DAF 2
Rejecttreatment

Sludgetreatment

Landfill

Thermalutilization

PM 4/7

LC screen. B 1.6 mm

HW cleaning

Storage tower

Red. bleaching

Dispersion

HC thickening

Washing

LW cleaning

LC screen. // 0.25 mm

HW cleaning

Flotation

MC screen. B 1.6 mm

HD cleaning

8

PM loop

Loop IHC pulping system

period of 12 days. An enormous spread
was found within these deliveries. The
ash content varied from 10.2% to 23.7%.
Brightness fluctuated by more than
30 points from 47.3% ISO to a maximumof 77.9% ISO.

DAF 1

Biology9tion yield is about 70% and the specificeffluent volume is about 7 l/kg of paper.
With this low volume of effluent and thealready mentioned problems with stickies, the water systems are of decisive
importance. Process water is circulatedon the counter-current principle. Freshwater is supplemented on the paper
machine. Excess water from the PM loop
is sent to stock preparation. The systemis opened to biological treatment at the
point where the water is most contaminated and this is the filtrate from sludge
treatment.

The high ash content of the raw materialmust be reduced to about 1%. This ismainly undertaken in stock preparationby the washer (Fig. 9). Unwanted fines
are also removed at the same time as theash.
Ash and fines carried out in the filtrateduring washing have to be removed fromthe water by microflotation. Any disturbing components not yet removed, suchas residual ash, fines and ink particles
separated by dispersion, are washed out
by the paper machine. Here, too, the20Fig. 10: Reduction in dirt speck and stickies areain the stock preparation plant of PM 4/7.
Fig. 11: Reduction in stickies area during system
trials in the Voith Sulzer stock preparation pilot
plant.
10

Dirt speck area (> 50 mm) [mm2/m2]
0

1000

3000

Stickies area [mm2/kg]

Pulper Dirt speck area
dump chest Stickies area

4000

0

5000

8000

12000

Pulperdump chest

After
MC screening
B 1.6 mm

11 Thestickies area in mm 2 /kg is also
shown in Fig. 10. Measurement of the
stickies area was carried out based on
the Haindl-Escher Wyss method. Three
process stages are of particular importance for the reduction in stickies area:
I MC hole screening reduces the
stickies area by 25 %,After
MC screening
B 1.2 mm

After flotation

30%

I LC slot screening by 50% andI dispersion by 68%.

After
HW cleaning

After
MC screening// 0.2 mm

62%

After
LC screening// 0.25 mm
After
LC screening// 0.15 mm

Afterwashing andthickening

70%

After
dispersion
Afterdispersion
0

67%

4000
8000
12000
Stickies area [mm2/kg]

filtrate is also cleaned by microflotation.
The sludge from water treatment and rejects from flotation as well as from allfollowing process stages are dewatered
to 60% dry content and then incinerated
in the mill’s own power plant.

Fig. 10 shows mean values from sevenmeasurement series. The dirt speck area
is examined in mm 2 /m 2 for particles witha diameter of greater than 50 µm. The
main reduction in dirt speck area isachieved by

The rejects from pulping, high-density
cleaning and hole screening are dewatered and go to landfill.

I high density screening by 50% and

And what does the mean dirt speck andstickies reduction look like for the
PM 4/7 stock preparation plant?

The reduction in dirt speck area throughout the complete process amounts to
92%.

Spread over the complete process, a reduction of 88% is obtained. Can thesefigures be improved still further? And if
so, how?
Further development and the 1997
upgradeTo answer these questions, we can use
the experience gathered from anotherplant, – PM 5 stock preparation. Mainly
towelling is manufactured on PM 5. With
“cold towel rolls”, i.e. towel rolls comingfrom intermediate storage, there were often problems in converting due to layersof paper sticking together, caused bystickies.
This was the reason why the MC screening was renewed on this stock preparation plant in 1994.
A reduction in stickies area of 76% wasachieved with a perforation of 1.2 mm
and a slot width of 0.25 mm.

I dispersion by 75%.
The installation of the new MC screeningstages solved all production problems
and, in particular, all converting
headaches.

Stock Preparation

21

Fig. 12: PM 4/7 stock preparation plant following
upgrading.

PM 4/7

LC screening B 1.6 mm

HW cleaning

Reductive bleaching

Dispersion

HC thickening

Washing

LW cleaning

LC screening // 0.15 mm

HW cleaning

Flotation

MC screening // 0.20 mm

MC screening B 1.2 mm

Storage tower

PM loop

Loop IHC pulping system

I The perforation of the hole screen
stage was reduced from 1.6 mm
to 1.2 mm.

12

HD cleaning

Experience with PM 5 led to the decision
to carry out trials in the Voith Sulzer
Paper Technology pilot plant facilities inRavensburg in order to improve stock
quality for the tissue machines PM 4 andPM 7 as well. The basis for this was theexisting stock preparation plant PM 4/7,
but with the following changes:

I A complete new MC slot screeningstage was installed.
I The slot width of the LC slot screeningstage was reduced from 0.25 mm to0.15 mm.

It was gratifying to have the results
obtained with PM 5 confirmed by thesetrials. A reduction in stickies area of
74% was achieved in Voith Sulzer’s pilot
plant with the MC screening stages(Fig. 11).

I The perforation of the hole screeningstage was reduced from 1.6 mm to
1.2 mm.
I A complete new MC slot screeningstage with a slot width of 0.20 mm
was installed.
I The slot width of the LC slot screeningstage was reduced from 0.25 mm to0.15 mm.
I A new washer was installed for
improved reduction of ash and fines.

Further considerable reductions of 70%
and 67% respectively were achieved withthe low-consistency screening and dispersion stages, the latter with a specificenergy consumption of approx. 90 kWh/t.
In all, a stickies area reduction of 97.5%
was achieved, compared with 88% with
the PM 4/7 plant.
The decision to change the plant concept
was made on the basis of these trial
results (Fig. 12). The upgrade has since
been completed and put into operation.
The detailed changes were:Latest measurements from the PM 4/7
plant confirm the expectations:
I The MC screening stages reduce thestickies area by 70%,

Conclusions
Analyses of the stock preparation underinvestigation, experience from anotherplant in the mill and trials in the machine
supplier’s pilot plant led to an upgrade of
the stock preparation plant.
The objective was an improvement inproduct quality, advantages in converting
and a reduction in cleaning work on thepaper machines. To achieve this, the perforation of the hole screening stage andthe slot width of the LC screening stage
were reduced, an MC slot screeningstage was installed and the washer was
replaced by a new one.

I dispersion by 67%.

The stickies problem was significantly
reduced by these measures. The reduction in stickies increased from 88% to
97% and, consequently, the stickies
content in the finished stock was reduced by 75%.

In all, a reduction in stickies area of 97%
was achieved.

Our expectations for the upgrade havebeen completely fulfilled.

I LC slot screening by a further 70%
and

22

The Eltmann mill of the Palm paper producers as it
is today (lower photograph). The project drawing(top) gives an impression of the size of theplanned expansion. Parallel to the present machineroom for PM I is the building for the new PM III.

23

Paper Machinery Divisions:
Large order from Palm paper millin Aalen-Neukochen for the expansionof the Eltmann mill
The paper mill Palm GmbH & Co, AalenNeukochen, has placed an order with
Voith Sulzer Papiermaschinen GmbH,
Heidenheim, and Voith Sulzer Stoffaufbereitung, Ravensburg, for the expansion of their production facilities inEltmann am Main near Bamberg. The
centerpiece of this project is the new
PM III, another machine for Palm’s
very successful production of newsprint
paper made from 100% waste paper.
Since its foundation more than 125 years
ago, this enterprise, which has been kept
in the family for four generations without
interruption, has worked exclusively withsecondary fibres. Thanks to its wealth ofexperience in waste preparation anddeinking, the organization without doubt
occupies a special position within thepaper industry. Palm was the first paper
mill in Germany to make a success ofthe production of good newsprint paper
exclusively from waste paper.

During the course of its expansion andwith its consistent secondary fibre strategy, the company has repeatedly had
to explore new territory with regard toboth process and machinery. However,courage is always ultimately rewarded bysuccess. With its three paper mills, Palm
is now one of the leading producers ofnewsprint and packaging paper in Germany. A large part of the packaging
paper production is further processed in
the 8 mills which produce corrugatedboard and finished packaging and also
belong to the group of companies.
Palm and Voith Sulzer Paper Technology
are joined together by more than just geographical proximity of the corporate
headquarters in Aalen, Heidenheim andRavensburg! Many progressive ideas,
from the first paper machine to thepresent-day dimension of production
facilities, have been implemented andtested jointly.

24With a considerable total investment ofaround DM 500 million for the whole of
the Eltmann mill expansion, a considerable part of which is directed towards the
new pulp preparation system and PM III,
this innovative and cooperative joint venture is being continued.
Apart from proven and successful system components, the PM III Eltmann will
also receive some new features, which
both Palm and Voith Sulzer Paper Technology are convinced will write a newchapter in the future of newsprint production purely from waste paper.

num, speed more than 1800 m/min and atrim width up to 8050 mm.
The technical design is as follows:
ModuleJet headbox with zone-controlledwater injection for optimum CD profile;
DuoFormer TQ for optimum sheet forming; the new Tandem NipcoFlex press;
then the TopDuoRun, a single-tier dryer
section with 38 dryers for very gentle
drying; HardNip calender as optimized
calender and finally Sirius, the new economic winding concept for large dimensional, smooth winding up.

Pride of place here must go to the newpress, the Tandem-NipcoFlex, which has
two shoe presses, one behind the other,for optimum gentle dewatering at low
specific pressures. The Tandem NipcoFlex press is being used in this form
for the very first time for a newsprint
machine at unprecedented production
speeds exceeding the 1800 m/min mark,and for which the PM III Eltmann has
been designed. A further plus of the newpress configuration lies in the improved
quality. As there is no separation pullfrom the last press, the stretchability ofthe paper is increased.

With regard to stock preparation, Voith
Sulzer Paper Technology received an order for the delivery of two complete
stock preparation lines, each with acapacity of 600 t/24 hours. Both stock
preparation lines are laid out identically,each consisting of a conveyor system
supplied by the Voith Sulzer Group
member B + G in Euskirchen, a highconsistency pulper with suitable waste
disposal facility and downstream protector system. A highly efficient screening
system, together with hole and screening
and partially equipped with C-bar
technology (0.15 mm slotted screenbaskets), completes the line-up.

Here is the main data for Eltmann PM III:
Production capacity 250,000 t per an-

At the heart of the plant is the Flotation
with the latest EcoCells. Thanks to theirhigh efficiency, these cells are now market leaders in flotation of printing inks
and other contaminants. A special feature of the system is the kneading dispergers with double-acting kneadingzones, with which Eltmann have alreadyrecorded some excellent results.
Other machines and assemblies, such as
the cleaner system, the agitating propellers and reject compactors as well as
total responsibility for the process technology are also included in the scope of
supply. In addition, Voith Sulzer Paper
Technology supplies the basic as well as
the detailed engineering know-how forthis part of the plant, including the C & I
technology, erection and start-up supervision.
Together with the new stock preparation
system, Voith Sulzer Paper Technology
also received an order for the expansionof the deinking plant. This rebuild includes the expansion of the existing
Flotation system with EcoCells.

According to Dr. Wolfgang Palm, “Theexpansion of our Eltmann mill is designed to meet demand and ensure successful sales of our newsprint grades
made from secondary fibres. But wewant more! It is our opinion that thePaper Machines

25

The project drawing of the new PM III.
Together with PM I (see photograph below) the
Eltmann mill will have a production capacity ofaround 400,000 t per annum of newsprint of
between 34 and 60 g/m 2 .

Federal Republic of Germany has one of
the most modern and comprehensive
recycling systems in the world. We areon our way to exemplary recycling management, but only on our way – we are
not there yet! The outstanding collective
results achieved in just a few years
cannot yet be compared with the corresponding processing capacities. At present some 3 million tonnes of waste
paper are exported every year. Whatappears economically and ecologicallysensible to us represents only medium
to long-term processing in the respective

country of origin, and not an exportorientated, export-dependent waste disposal industry. Only well-balanced
cycles, with short paths between thepaper industry, the media, print andpackaging producers and the end users,
makes any sense. In our corporate andproduct strategy we see a good opportunity to contribute to such a wellbalanced cycle system. We are optimistic
and convinced that looking after your resources has a future, and we therefore
invest and take chances in the pursuit of
testing innovative technology”.

This point of view is also confirmed at
Eltmann by the application and testing ofa new sludge process for waste water
processing by means of additional nanofiltration with concentrate treatment,
something not yet in major industrial use
anywhere else. New routes are also being
opened up with the introduction of newenergy technology.
The first technical equipment will be in
use at Eltmann in late autumn 1999.
Official start-up is planned for November
1999.

32

Paper Machinery Divisions:
The SpeedFlow – first time: free jetapplication in film presses

The author:
Bernhard Kohl,
Paper Machinery Division
Graphic

The Voith Sulzer Paper Technology
Organisation is true to its precept: “Innovation in paper technology, Innovation in
the coating technology”.

uniform film onto the rolls. Subsequentequalization can, as previously, be carried out with the proven metering elements.

Voith Sulzer Paper Technology were thefirst to develop the Speedsizer. Since
the introduction of this equipment the
combination of nozzle application andmetering bar has dominated the market.
84 Speedsizers and/or Speedcoaters in
25 countries speak for themselves.

The new design
Within the field of metering beams, newcompound materials, designed to meet
specific requirements, enable a completely new design, optimally adapted tothe operation.

1998 promises to be the year when Voith
Sulzer Paper Technology will write a newchapter in the annals of coating technology.

The new Idea
A new revolutionary idea was transformed into the technical solution of the
SpeedFlow, proven in practice and all
within 12 months! The coating colour is
now applied to the rolls in the form of afree jet which means, that the pre-metering is carried out via a number of special
MultiJet nozzles, which apply a thin and

New advantages
Min. quantity of colour in circulation
The MultiJet nozzles guarantee very thin
and uniform film application, which reduces the amount of colour in circulation
to a minimum. In addition the applied
film is perfect pre-metered.
Edge deckle adjustment at its simplest
The MultiJet nozzles apply the colour
without contact onto the rolls. Edge
deckle adjustment is possible by meansof specific jet deflection in the area ofthe edges. The expensive, closed nozzle

Paper Machines

33

Fig. 1: SpeedFlow.
Fig. 2: Application principle.
Fig. 3: Field of film coating applications.
Fig. 4: Web run from top to bottom.
2

Starchapplication

Coating weight[g/m 2] per page

Solidscontent [%]Viscosity
Brookfield 100 [mPas]

0,15 - 4

5 - 18

10 - 60

Max. penetration

3

Target: improved Strength characteristics

2-6

Pigmenting

10 - 50

50 - 350

Target: improved Whiteness and Smothness

CoatingMin. penetration
P&J

chamber over the whole width of the machine as well as the edge deckle adjustment device inside the nozzle are nolonger required.
Good profiles
Pre-metering and levelling with the metering element are thermally disengaged.
This guarantees stable operating conditions and good profiles from the very beginning and throughout operation.
Simple adjustment
Pre-metering and levelling with themetering element are mechanically disengaged. This avoids any complicatedadjustments during roll and metering
element change.

Field of application
Like using Speedsizer and Speedcoater
the whole range of film coating applications can be covered. From low viscosity
starch solutions to pigment suspensions
and up to high viscosity coatings, allstate-of-the-art formulations can be metered onto the rolls.

The Technology
Optimum web run
The paper industry needs optimum solutions for its individual requirements.
Maximum coat weights or starch application with minimum installation length are“normal” requirements, to which is also
added the best runnability with greatest
flexibility.
The SpeedFlow permits all proven rollallocation, but practice has shown that
two typical construction forms can cover5 - 1550 - 65

300 - 1600

Target: Best Coverage, Smoothness and Gloss

all applications with the greatest productivity.
Concept 1: For new paper machines orrebuilds with sufficient space:
I Inclined web run
I Sheet run from top to bottom
I Airturn, infrared
I Air drying (when necessary).
Advantages:
I Excellent sheet run
I Short free draws
I Best runnability.
4

34

Fig. 5: Web run from bottom to top.

must be capable to adjust different working widths. Coated or uncoated edges
can be adjusted easily and in a reproducible manner.

5

The MultiJet nozzles of the SpeedFlow
are simply covered by a guide plate in
the edge areas, which ensures contactand wearless format adjustment.
The metering system
Papermakers today use metering bars
with varying diameters and in smooth or
profiled form. Surfaces are either uncoated or coated (chrome, ceramic).
With the SpeedFlow the pre-metering facility is separated by the free jet and thefinal metering facility by the meteringbar. This makes it much simpler to install metering bars of different diameters
or to change the rod beds.
Concept 2: For installation into existing
paper machines with restricted spaceconditions:
I Steep web run
I Sheet run from bottom to top
I Airturn, infrared
I Air drying (when necessary)
Advantages:
I Short installation length
I For max. drying installation
I Drying facility on top.
Less quantities of colour in circulation
The paper maker demands a film coating
unit with minimum amounts of colour incirculation. Smaller quantities of colourin the system also save time (whenchanging the type) and money (lessloss).

The SpeedFlow satisfies both demands.
The SpeedFlow is operated with approx.
40% less colour in circulation than standard systems. At the same time there will
be approx. 70% less coating colour inthe coating system.
Optimum cross distribution
Coating colour or starch is only fed
through a small colour distribution pipewith MultiJet nozzles. Allocation and dimensions guarantee optimum cross distribution for high and low viscosity media. The flow system is clean and simple.
A sealing blade is not needed any longer,
so that one of the most sensible parts
disappears.
Simple edge deckle adjustment
With paper machines the SpeedFlow

Disengaged system –application/metering beam
Operating personnel constantly demand
good coat weight profiles right from thestart. The metering beam must therefore
be stable, mechanically and thermally.
With the SpeedFlow the metering beams
and application unit are disengaged.
Manufacturing the metering beam fromthe most modern thermal and mechanically stable compound material makes aweight reduction of up to 80% possible
for wide machines. The heating system
required earlier is no longer necessary.
Push-button operation
A modern coating unit must of course
satisfy the requirements of extensive automation, something the SpeedFlow does

Paper Machines

35

Fig. 6: Quantities of colour in circulation.
Fig. 7: Edge deckle adjustment.
Fig. 8: Application unit and metering beam.
Fig. 9: Start-up
Pigmenting/Coating
Starch applications

I Tail transfer
I Starting
I Metering element change
I Stop sequence and
I Break sequencein functional as well as time sequence
are optimally initiated.

8

Quantity of colour in circulation

admirably. Operation via a touch-screen 6
display is standard. The integration into
a process control system is possible
without any problems. In both cases thesteps

Sealing blade

SpeedFlow

Application onto paper
Speed

7

9
SpeedFlow introduction

Practical experience
In January 1998 the SpeedFlow pre-metering unit was installed for the first time
into a production machine. In an existing
Speedsizer the nozzle application devices
were closed and replaced with the colour
distribution pipes fitted with MultiJet
nozzles. Immediately after installation it
was possible to re-start production unhindered and of high quality. In comparison with the conventional system all expectations were fully satisfied.
It was also possible to drastically reduce
the quantities of colour in circulation,
which also reduces the size of the colour
pumps considerably.
The starch coating profiles are much
more uniform than before. Especiallyduring the starting process (with “cold”beam) the SpeedFlow demonstrates goodand stable profiles.
Plugging and wear are issues of the past,
thanks to the tested and proven nozzle
construction of the individual nozzles,

80
70
60
50
40
30
20
10
1986 1988 1990 1992 1994 1996 1998

neither are deposits to be found in the
distributing pipe.
Although in this case the old metering
beams were retained, a clear reduction in
the beam temperature could be noted,
thanks to mechanical disengagementwith the coating system. Despite a starchtemperature of more than 50°C the beam
only will only accept the ambient temperature.
The customer evaluated the new edge
deckle adjustment and the low quantityof colour in circulation within the system
as especially positive and operatorfriendly.

Market introduction
Orders for three new SpeedFlows werealready received between January and
April 1998. The first start-up of a completely new SpeedFlow will take place
during this year. With this Voith Sulzer
Paper Technology will again demonstrate
successful and fast realizations of futureorientated innovations.

36

Paper Machinery Divisions:
The Ningbo model mill in China –an enormous step forward
Carton for China

On the other hand, there were thousands

China’s economy has developed astonish-of small mills turning out anything from a

ingly fast over the last few years, withfew kilograms to a few tonnes per day.

proud 2-digit growth rates likewise in thepaper industry.

Ningbo is an excellent example of how
this situation has changed in the mean-

The author:
Harald Weigant,Andritz AG, Graz

To meet this steep rise in demand,

time. At a plant on the outskirts of thisdomestic production capacities are being

one-million town south of Shanghai, aincreased accordingly.

board machine for 34,000 t.p.a. had been
installed during the first construction

Foreign investors such as the Indonesianphase ten years ago. The manufacturing

Sinar Mas Group predicted this trend

know-how thus gained, together with theyears ago and took action in good time.

existing infrastructure and adequate land

Ningbo is only the first link in a whole

facilities, offered ideal conditions for sub-chain of new paper mills and machinery

sequent expansion.

for supplying China with high-grade products – starting with the Shanghai area.

After founding a joint venture with Sinar
Mas, phase II of the expansion project

Hardly five years ago, only very few paper

went ahead in 1994. Several alternatives

mills in China could produce more thanwere studied, and the final choice was forabout 100,000 tonnes per annum. Lessa capacity of 400,000 t.p.a. This is sharedthan 30 mills had a capacity of 25,000

between two almost identical board

t.p.a., and just about 100 mills could han-machines in parallel, each with a width ofdle up to 5000 t.p.a.

4.2 m and capacity of 200,000 t.p.a. Right1

Paper Machines

37

Fig. 1: Ningbo paper mill south of Shanghai.
Fig. 2: The new KM3 board machine.

2from the beginning, it was clear that thismedium. This will increase total capacity

team which installed a sister machine inwill be China’s biggest paper mill by far –to nearly 1.5 million t.p.a., thus making

Serang, Indonesia, where Voith Sulzer

covering almost 50% of domestic demand

Ningbo one of the world’s largest mills.

Paper Technology took over the technicalmanagement as against Andritz in Ningbo.

for coated board.
Concept
Even if more paper will soon be produced

As a basic principle, Sinar Mas always

Another Sinar Mas principle is to assign

at other sites, Ningbo will still remain theselects new plants according to the latest

the consortium with overall delivery

highest output mill if things go the way

state of technology. The order in 1994

responsibility. Practically all the millSinar Mas are planning them. In expan-

was

an

machinery is included in scope of supply,

sion phase III, four more machines are toAustrian/German consortium comprisingfrom the first conveyor belt in the stock

be installed for liquid packaging board,

Andritz, Voith Sulzer Paper Technology,

preparation line to the paper machineivory board, kraft liner and corrugatedJagenberg and Siemens. This was thepope roll.

therefore

placedwith

38

Fig. 3: Waste water processing.
Fig. 4: Stock preparation.
3

As a general concept for these board
machines, recycled paper is used as lowcost furnish for the 4-layer sheet lining,
the top layer being made of chemical pulp
produced in-house, and the under andback layers of deinked waste paper. An
on-line coater gives the board an opticallyappealing surface finish.
Stock preparation
The stock preparation line is designed forsupplying both board machines at thesame time, with a total capacity of nearly
2000 tonnes/day. It comprises the following sections:
I For the top layer: a 60 t/d NBKP line
and 230 t/d LBKP line
I For the under layer: a 260 t/d DIP line
for both ONP and OMP

4I For the liner: two 340 t/d mixed waste
paper lines
I For the back layer: two 135 t/d lines
for ONP.
Also included in the scope of supply are
four rejects lines of 130 t/d each for dry
and wet rejects as addition to the board
liner lines. On one of these lines CTMP orlight coloured waste paper can also beused, while one of the back layer lines
uses LBKP and BCTMP. This layer separation arrangement gives the operator plenty of flexibility for optimally combining
chemical and recycled furnish into various types of end product.
Board machines
After careful comparison, Sinar Mas

Paper Machines

39

Fig. 5: The new KM2 board machine.
5

decided for the modern and already well-

200 tonnes of board per metre working

loss of volume. One machine includes antried multi-fourdrinier formation concept.

width. To reach this capacity, however,offset press in order to improve smooth-This enables greater flexibility for opti-

the machines have to operate at speeds up

ness on the wire side. After passing a total

mally adjusting board quality.

to 500 m/min.

of 69 drying rolls

The heart of the wet section in these board

1.8 m in diameter, theweb goes through a FilmSize press. Thismachines comprises four high-turbulence

The top layer wire is fitted with a dandy

in turn is followed

headboxes, one for each layer. Adequateroll, so that formation can be optimized in

the first afterdryer section. Andritz hoods

drainage and optimal formation on thethe same way as on a fine-grade paper

ensure optimal temperature and humidity

filler wire is ensured by an additional SP

machine. A double-felted vacuum press

conditions in the dry section.

TopFormer. The wires themselves are fit-

followed by two high-pressure presses

Finally the web passes through a hard-roll

ted with enough drainage elements toincrease the dry content of the web to acalender prior to the coating line. To

enable a production capacity up to aboutcost-effective degree without excessive

ensure optimal effectiveness, the calenderby 12 drying rolls in40

Fig. 6: The control room.

ment is all the more astonishing in view of
the traditionally simple Chinese construction methods used for the enormous sitebuildings.
Perhaps not so astonishing after all –much more important than big earthmoving machinery for large civil engineering
works is organizational talent. The rest is
simply a matter of experience with local
methods, and sheer hard work.
The entire erection phase was a model ofinternational teamwork between various
nations. A good deal of understanding
was necessary to overcome initial differences of opinion, but in the end perfectcoordination between East and West6enabled punctual completion.
is preceded by an Andritz steam blow box

mode is also possible, however, for calen-

for surface moistening.

dering only one side at a time. The cus-

Shortly after commissioning the two

tomer is convinced that with a total ofmachines, the operations tests were suc-

Paper machine No. 2 has three coating

three calenders, similar results can be

cessfully completed. Today, with one year

heads, two of which for precoating andachieved to a Yankee roll but with signifi-

and six months of operation behind themcover layer coating. The third head iscantly better runability. Thanks to easier

respectively, the predicted startup curves

either used for coating the backing layer if

optimization and more user-friendly oper-of these machines have not only been

it is white grade, or for sizing if the back-ation, much steeper startup performancereached but exceeded. This applies both

ing layer is grey. Paper machine No. 3 iscurves are possible.

to production output and to quality.

ing dual coating on both sides. A central

Project handling

And as anyone who knows China will con-mixing unit supplies both machines.

Another record-breaking aspect of thisfirm, nothing could be more important

The coating aggregate is followed by two

project was the incredibly short comple-

here than keeping promises to the full.

calenders, both with hard heated roll andtion time. Although the final go-ahead was

How could it have been otherwise? Meet-

soft-covered floating roll. Since the hard

not given until the end of 1994, the firsting ambitious customer targets is matterrolls can be used on the top side and themachine went on line less than two yearsof course to Andritz and the Voith Sulzer

back side as well, both sides can belater in November 1996, followed by its

Paper Technology – Jagenberg – Siemens

calendered simultaneously. An operating

sister machine in May 1997. This achieve-

team.

equipped with four coating heads, allow-

41

Paper Machinery Divisions:“ahead – Together with our customers
towards superior solutions for board andpackaging papers“ahead – Under this motto, experts ofthe European board and packaging
paper industry met in Vienna from 26 to
28 April 1998 at the Customer Information Meeting of the Paper Machine
Division Board and Packaging.

The author:
Nicole Kreitmayer, Marketing,
Paper Machine Division
Board and Packaging

For one and a half days, the European
board and packaging paper industry
focused its attention on the event taking
place at the Austria Center Vienna, Austria´s largest conference center. At thismeeting, not only the most recent Voith
Sulzer Paper Technology developmentson this sector were presented but also
noted guest speakers held papers in particular on important market developments affecting board and packaging
papers. Additionally, four customers
offered us an interesting insight into thetechnological and economic results ofVoith Sulzer Paper Technology rebuilds
and the startup of PM6 at Zülpich Papier.

With “ahead, a discussion forum wascreated,thus fulfilling an important aim ofVoith Sulzer Paper Technology: Together
with our customers, we want to move on– “ahead – towards innovative and flexible
solutions. To realize this aim, we closely
observe the markets of our customers
and the requirements placed on board
and packaging papers. The conference
was organized by the international Centerof Competence of the Paper Machine
Division Board and Packaging in St. Pölten, Austria. Large sections of the European market have only been served from
St. Pölten for a short time and therefore
in particular European customers wereinvited to inform themselves about
the know-how and commitment of the“Board and Packaging” team of Voith
Sulzer Paper Technology. The conference
also offered the opportunity to meet themembers of the sales and technology
team in a relaxed atmosphere.

1

42

2

The Paper Machine Division Board
and Packaging
The conference programme of 29 April
was opened by division manager Otto
Heissenberger, who gave a short description of the activities of the division.
For Voith Sulzer Paper Technology,
board and packaging paper machines
have always been an important field. The
establishment of a separate division now
permits putting even more attention on
the special requirements placed on board
and packaging papers. The contract
awards speak for themselves: From 1995
to 1999 alone, 13 complete board
machines and 12 new packaging paper
machines have been (or will be) started
up by customers of Voith Sulzer Paper
Technology, and the current volume ofincoming orders of the division is at arecord level.

The division is represented by locations
worldwide: The major parts of Europe,Asia, Africa and Australia are served
from St.Pölten, the location of Tolosa is
responsible for the markets of Spain andPortugal, the location at Schio handles
business in Italy, Greece and Israel. Customers in North America are served from
Middletown, Ohio, and the South American market is handled by the location at
Sao Paulo by Brazil. In addition, there isa licensee in Japan, three joint ventures –one in Russia and two in China – and a number of representative offices and agents.
Wherever you need a specialist for board
and packaging papers, competent contact partners will be at your service.
Market and raw material trends
for board and packaging papers
These aspects were highlighted especially in the papers held by the guest speak-ers. So, for example, Dr. Helmut Stark,head of the Institute for Paper and Pulp
Technology of the Technical University ofGraz, presented a paper on the selectionof raw materials for board production.
The paper of Thomas Reiner, managing
director of Berndt und Partner, the Institute for Packaging Technology of theTechnical University (Fachhochschule)
Berlin, dealt with general packaging
trends on the European market. The special chances and risks for board andpackaging papers were discussed by thetwo representatives of the associationsof ProBox and Pro Carton, Guy Standaert
and Franz Rappold. Michael Gröller,
Chief Executive Officer of Mayr-Melnhof
Karton AG, described the concentration
tendencies in the European board industry and their impact on the industry.
Dr. Hermann Bernard, head of the Voith
Sulzer Regional Representative Office inJakarta, Indonesia, made an interesting
excursion to Southeast Asia. He reported
on the real scale of the economic crisis
in Asia and explained what problems but
also what chances this situation creates
for the Asian and European paper industry.

Focusing on board and packaging paper
requirements permits fast, innovative
product development and highly efficientcustomer trials on the pilot paper machine. On the one hand, this approachcontinuously improves the quality ofboard and packaging papers and, on theother hand, has significantly increased
machine speeds. Combined with the highrunability of Voith Sulzer machines,
these new concepts deliver enormous
productivity increases on the customers’machines and reduced capital investment.

Innovative product developement
for board and packaging papers
The second major topic at the conference
dealt with the most recent Voith Sulzer
3Paper Machines

43
Figs. 1: The conference hall at the Austria Centerin Vienna.
Fig. 2: An imperial reception at the Orangerie ofSchönbrunn Castle – Emperor Francis Joseph I
held his celebrations here.
Fig. 3: Executive Vice President, Otto
Heissenberger, holding his welcome address.
Fig. 4: 25 completely new board and packaging
paper machines between 1995 and 1999.
Fig. 5: The guests were welcomed by two baroquestyle stiltwalkers, thanks to the warm weather
our guests could enjoy the gardens all evening.

Paper Technology product innovations
for board and packaging papers.

4

A new generation of gap formers – theDuoFormer Base and the DuoFormer Top– sets new standards both for packaging
papers and board. Thus, the first newboard machine fitted with a gap former
will come on stream in 1999. The shoepress technology, which continues to deliver excellent results in the productionof packaging papers, is now successfully
used also for coated folding boxboard.
In addition, the JetFlow F, a new, highly
efficient coating unit, is available forcoated folding boxboard.

machines – at AssiDomän Skärblacka in
Sweden and at Zaklady Celulozy i Papieru
w Swieciu in Poland. The speakers,Håkan Krantz (Production Manager
AssiDomän Skärblacka) and Tadeusz
Koszur (Technical Director at Swiecie),focused on improvements of paper quality and productivity increases achieved by
the installation of an Extensible Unit andthe novel use of the shoe press technology for sack papers. The last speaker was
Lars-Erik Mellgren, Mill Manager at
AssiDomän Frövi, Sweden, who talked
about their experience with the rebuild of
BM 5. Frövi was the first to install a JetFLow F for liquid board, and the board
quality at the mill was significantly
increased by the installation of a new
DuoFormer D.

Papers held on the calendering of board
and packaging papers and the spectrumof services offered by the pilot paper machine of the division rounded off the programme.
A particularly impressive presentation of
the possibilities of web transfer on board
and packaging paper machines was given
by Ken Rooney, Vice President of Fibron
Machine Corporation, a new member ofthe Voith Sulzer Paper Technology groupof companies. Modern presentation techniques via computer and video beamer
permitted illustrating the transfer procedures in short video sequences.
On the second day, the programme
focused on the reports of customers.
Jean François Geleleens, Director ofTechnical Affairs Paper and Board of
KNP BT Packaging, started out by reporting on the technological and economic
results achieved with the new PM6 at
Zülpich Papier. This paper was followedby reports on two rebuilds of sack paper

Following these reports, the audience
was given the opportunity to take a look
into the future. The two product technologists of the Voith Sulzer Paper Technology team, Alexander Wassermann (board
product line) and Erich Brunnauer (packaging paper product line) talked about
the demands which will be made on the5

44

Fig. 6: The blue Pullman car.
Fig. 7: The “ahead steam train.

producers of board and packaging papers in the next decade and the machine
concepts of the future. Maximum production capacities at continuously increasing product quality were the key
words also here. The volume of incoming
orders of spring 1998 and talks with customers in the past few months showedthat the smart solutions worked out by
Voith Sulzer Paper Technology meet withextraordinary response from our customers even now.
The “ahead rail tour – social highlightof a successful meeting
For the evening of the first day of theconference the board and packaging
team came up with a special treat for
their guests. It was to be an evening
spent among friends, full of adventure,entertainment and Austrian “Gemütlichkeit” – something to choose for every individual guest.

6

7

Paper Machines

At 19:00 hrs, the trip started with a welcome cocktail at Wien Südbahnhof Railway Station, where a historical train witha gigantic steam engine was waiting for
departure. Each car had its own atmosphere – there was the club car, for example, with live piano music or the elegant
Pullman cars. After the hours d’oeuvres
had been served, the train stopped for awhile, during which the locomotive wasput before the other end of the train.
During this stop, artists, actors and jugglers took everyone in with their lively
performance.
When the journey continued, the maincourses and desserts were served andalmost every passenger took the opportunity to have a drink in the various carsand meet many different people.
Twelve of the guests were in for a special
adventure. They were lucky and had won
a ride on the steam engine. This involved
a lot of work, of course, but despite thenoise, steam and shovelling of coal all ofthem had a lot of fun.
When the train pulled into Wien Südbahnhof Station again just before midnight, time had passed much too fast andmany a passenger only reluctantly parted
with their favourite car.
We, the Voith Sulzer Paper Technology“Board and Packaging” team, would liketo thank all our guests for taking such agreat interest in “ahead. We will continue
to take care that the dialogue with ourcustomers goes on and we can work together to find superior solutions on theboard and packaging paper sector.

Since there has been great interest in the“ahead papers, more copies can be ordered,
as long as they are available, from:
Nicole Kreitmayer Marketing,
Paper Machine Division
Board and Packaging
Tel. +43 27 42 806 23 53
Fax +43 27 42 74307
e-mail: kreini@vs.voith.com
The Packaging Market in Europe and Current
TrendsDipl.lng. Thomas Reiner Berndt & Partner
The Selection of Raw Materials and
its Influence on Boardmaking
Univ.-Prof. Dr. Helmut Stark Institute of Paperand Pulp Technology, Graz University ofTechnology
Two-Layer Headbox with ModuleJet SD –State of the Art in Headbox Design
Klaus Lehleiter
Formers for Board and Packaging Grades –The New Generation
Günter Halmschlager
FloatLip Former – A Smart Solution for a
Proven Concept
Petra ReschPole Position for Voith Sulzer Shoe Presses
Due to Numerous Advantages
Wolfgang Schuwerk
JetFlow F – Coating for Fast and Wide Board
Machines
Wilhelm Gansberger
Latest Calendering Technologies
for Board and Packaging Papers
Reinhard Leigraf

45

Threading Board and Packaging Papers –Difficult Applications Require Creative
Solutions
Steve Rooney, Fibron Machine Corp.
Pilot Plant VPM 5 – Concepts and Trials for
the Customer
Jürgen Prössl
Obstacles and Chances for the Futureof Folding CartonsIng. Franz Rappold, Mayr-Melnhof Ges.m.b.H.;
Pro Carton
Packaging in the Logistic Supply Chain
Guy Standaert, ProBox
Successful Voith Sulzer Startups in Europe –RPE Zülpich Papier GmbHJ.F. Geleleens, KNP BT Packaging
Successful Voith Sulzer Startups in Europe –Zaklady Celulozy i Papieru w Swieciu
Tadensz Koszur, Zaklady Celulozy i Papieru w
Swieciu
Successful Voith Sulzer Startups in Europe –AssiDomän Skärblacka PM 9
Dipl.-lng. Håkan Krantz, AssiDomän Skärblacka
Successful Voith Sulzer Startups –AssiDomän Frövi
Lars-Erik Mellgren, AssiDomän Frövi
The Consequences of the Economic Crisis inSouth-East Asia for the Board and Packaging
Paper Industry
Hermann Bernard
The Packaging Paper Machine Beyond 2000
Erich Brunnauer
The Board Machine Beyond 2000
Alexander Wassermann
Concentration of the Carton Board Industry
Dkfm. Michael Gröller, Mayr-Melnhof Karton AG

46

Finishing Division:
New from old – upgrading of existingsupercalenders
As in 1995/1996 the Voith Sulzer Finishing Division presented the calenders with
the Janus Concept, even the greatest
optimist could not have foreseen that thisnew technology would not only replace
the traditional and well-known supercalender in such a short time, but that it
would set a new standard and clear the
long-standing boundaries associated withthis product.

The authors:Franz Kayser,
Michael Gwosdz-Kaupmann,
Finishing Division

Now more than a dozen Janus calenders
are in operation processing the mostdiverse types of paper, wood containing
and woodfree paper, coated and uncoated, offset and gravure paper and last, but
not least, off-line and on-line. The potential of the Janus Technology has, forinstance, contributed to the fact that awastepaper containing uncoated paper
which in former times would have been

similar to newsprint only can nowadays
be finished to a degree comparablewith classic supercalendered gravure
papers.
The advantage of the Janus Concept is,among others, in the fact that the modular design system permits optimum adaptation to a variety of different tasks, withthe result that a 6 roll Janus calender
processes gravure papers at the end of apaper machine and another Janus, basedon two 5 roll stacks, does the same towoodfree qualities in a coating machine.
Several 2 x 7 roll Janus calenders areprocessing woodfree special paper in the
USA and last, but not least, several
11 roll Janus calenders are producing
a quality spectrum from matte finish
to average gloss or even to high gloss(Fig. 1).

1

Finishing47

Fig. 1: Different Janus calender lay-outs,
1 x 6 rolls, 2 x 5 rolls, 2 x 7 rolls, 1 x 11 rolls.
Fig. 2: Modifications to a Janus calender with aheating roll surface temperature of 100°C.
Fig. 3: Quality target values.

It is exactly this wealth of variation and 2
the adaptability within the Janus Concept
which offers a particular opportunity to
upgrade existing calenders using thepotential of the Janus Technology.

3
Gloss Tappi 75° Hunter 50%

Roughness PPS-10 S 1,0Hm

Two recent examples can be used to provide food for thought for others running
existing plants.

Blackening index

 45

Loss of luminescence (ISO) 4,5%In a Finnish paper mill for uncoatedgravure paper it was decided to modify
the more than 25 years old Eck supercalenders to such a state that, together withmodernisation measures to the paper
machine itself, natural gravure paper
could be produced which would satisfy
the highest quality standards applicablein today’s industry.

Opacity reduction

 3,5%

replacing the filled rolls with plastic rolls.
The filled roll shafts, however, will be
converted into a MARUN roll provided
with a JANUTec cover and continue to be
used.
So as to provide the necessary process
heat within the Janus Technology, thenext logical step must be pursued on theheating side. In this particular case,extensive laboratory tests in conjunction
with the paper makers and calender manufacturers enabled a process to beworked out where 100°C of surface temperature of the heating roll proved to be
sufficient.

The elements, which are necessary toconvert this customer’s supercalender
into a Janus, are illustrated in colour in
Fig. 2. Compensation of the overhanging
loads form the basis for this, creating ageometrically straight nip.
This means, that the previously sliding
calender bearing housings are now
mounted on swivel levers, which are fitted with hydraulic cylinders and used toeliminate the detrimental effect from theoverhanging loads.
The existing antifriction bearings andbearing housings of the supercalender
are re-used.
The extremely complicated mechanicaland electric/electronic means that werenecessary when changing filled rolls withdifferent diameters have become obsolete
now. This facility provides the basis for

New
I
I

Lever position with OLC cylinders
Marun air stream rolls with JanuTec
coating

I
I
I
I

Water heating/cooling system
Rotary joints for heating rolls
MicroFlow steam moisturizers
Bearing housing for top and bottom

S rollI Bottom hydraulic cylinder
I
Auxiliary drives for guide rolls

In this project the restriction of surface
temperature to 100°C has the advantagethat the old heating rolls of the supercalender need not be changed, leaving only
the procurement of a more effective andnew heating installation.
The surface moistening necessary fornatural paper by means of steam is being
modified to the latest state-of-the-art aswell as to future use by the addition of
new micro-steam moisturizers. The resultof this is illustrated in Fig. 3. As can be

48

Fig. 4: Comparison of the blackening.
Top: supercalender; Bottom: Janus calender.
Fig. 5: Comparison of the production speed with
3 Supercalenders and 2 Janus calenders;Type of paper: SC paper, base weight: 48-60 g/m 2
Main type: 52 g/m 2 ; Web width: 7300 mm;
Roll diameter : 2800 mm;
Reel drum diameter: 700 mm.
4PM-speed m/min

1400

5

after PM rebuild

1300

1200

before PM rebuild
SC

Janus

1100

1000
300

500
700
900
1100
Calender speed m/min
v max.
v max.
Supercalender
Janus calenderseen, very ambitious quality targets canbe realized with the application of theJanus Technology, even with a modified
supercalender.

Apart from the elements which have a
direct influence on the paper quality,
well-known problem areas are eradicated during this modification.

Blackening or black calendering meansthat pulp fibres collapse locally at crossover points, thus becoming transparent
and, with regard to this calendered paper,
appear to have been blackened.

The integration of a rope feed system
not only simplifies the threading itself
to a considerable degree, thus avoiding
frequent complaints, namely marking ofrolls during threading, but it also eliminates the problematic nip guards.

Before Janus this knowledge was at best
shady and has only been researched during the development stage of this newcalendering technology to the extent
that a blackening index of 45 can bepromised. However, this number is quite
meaningless to most people. The higher
the index, the “blacker” appears to be thepaper surface, with a supercalenderedpaper having a normal index value of 55
and more.

Apart from the traditional surface parameters of gloss and smoothness, Fig. 3
also shows that a so-called blackening
index is defined as quality target. This
really is a fault which to date appears
and does not seem to be controllable
in any way by the classic calendering
process.

In direct comparison of two paper samples, a trained eye can detect anincreased blackening of two index points.
On a purely subjective point, all paperwith an index number of below 48 is classified as being free of any blackening. To
emphasize this, Fig. 4 shows in bold
markings the degree of blackening of anatural paper processed on a supercalen-

der and on a Janus calender. The difference speaks for itself.
This so positive influence of the Janus
Technology on even the optical characteristics of a calendered paper can always
be observed, whereby the absolute valuesof the improvements achieved are influenced considerably by the stock composition of the individual paper.

This leads us directly to the second
example, where the tests carried out withthe sample papers having been processedwith Janus laboratory calender show aconsiderable improvement in the blackening, but not a the lower level of comparable gravure paper produced by othermanufacturers.

In this case the combined know-how of
the Voith Sulzer Paper stock preparation
specialist together with his paper
machine colleagues and that of the calendering specialist and supported by reallyin-depth basic position investigations led
us not only to be able to provide a
recommendation for optimization of theexisting calendering installations, butalso to clear and specific instructions
regarding the effective relations in thepaper composition and manufacture.
The example of a calender rebuild, of
which we will now report, has completely
different project aims to those realized atpresent. This customer in Germany calenders his natural gravure paper on three
Wärtsilä supercalenders supplied in 1987
which, at a specified paper machine
speed of 1200 m/min were just about

Fig. 6: Existing supercalender for SC paper before
the rebuild to the Janus Technology.
Fig. 7: Calender after rebuild to theJanus Technology.

capable of processing the production
quantity.

In order to provide a degree of reserveson the part of the calender, also with aview to an increase of the PM speed to1400 m/min., this customer considered
to fit the three calenders with a zero
speed flying splice system at the unwind.

The result of discussions during the project phase was that one of these calenders could be taken out of operation once
the two remaining ones would have beenrebuild to the Janus Concept.

Fig. 5 shows that the two remaining
calenders, after the rebuild to the Janus
Technology, without the originallyplanned Flying splice retrofit, have a
speed reserve of 100 m/min, even if theunrealistically high availability of the PM
is based on 100%.

In order to achieve this great potential
and apart from all changes carried out
during the above described example, theheating rolls are also changed. Apartfrom the higher calendering temperatureof 140°C, these new rolls are also provided with smoothness and gloss promoting
SUME 2 CAL surface plating.

As, with a calendering speed of almost
1000 m/min, also high technical demands
are placed on the reel, Sensomat Plus-Eunits in the winding up system are usedwith this project.

7

Fig. 6 shows the original situation and
Fig. 7 the final condition of the calenders.
Although the drives of the supercalenders
supplied in 1987 were not designed forthe data normally applicable with theJanus Technology performance or speed,
they need not be exchanged, as the power requirement of the JanuTec plasticrolls in comparison with the old filled isso much lower and as the speed ratio
could be adapted by modifying the diameter of the new drive roll.
With both projects, the Janus Technology
and clever selection of the elements fromthe Janus modular design systemenabled not only the set target to bereached, it is also possible to plan for

future expansion and, and this is of special importance, any of the newly
installed elements can be used again.
In the case of our Finnish customer, thepotential for a further substantial qualitative and quantitative increase in performance lies in the heating rolls and their
SUME 2 CAL plating additionally promoting gloss and smoothness.

As far as our German customer is concerned, the automation of the winding(flying splice) process originally requested, in addition to the already existing
speed reserve, creates a potential forevery possible increase in the paper
machine speed.

50

Finishing Division:
Toro – a breath of fresh air
with the winder

On order since accepting the product responsibility for 7 Toro

11 Start-up trials of the Toro in Krefeld
1997 Two drum winder with air relief
7Take-over of product responsibility
1997 Sales, design, assembly/installation, service

6
R & D Toro Winder
1997 Implementation of new concepts, registration of patents
1995

1997

1998
4
Start of work of the innovation team1997 Analysis of existing concepts and generation of new concepts

3
Transfer of activities COC
1997 Organisation and personnel planning
Since Production of winders
1995 in Krefeld COM

On the 1.7.1997 the responsibility forwinders within the Voith Sulzer Paper
Technology was transferred to the Finishing Division in Krefeld. This was not a
precipitate decision, as winders had been
manufactured and pre-assembled in
Krefeld since 1995, among them theorders for Halla, Selangor, Skolvin andDagang.
The author:
Dirk Cramer,
Finishing Division

As it became clear in the Spring of 1997
that the total responsibility for thewinders would be transferred from Heidenheim to Krefeld, comprehensive measures were taken to meet this demanding
task (Fig. 1).
Apart from the necessary know-how
transfer it was also essential to enable
sales and design/planning to elaborate
customer specific quotations. Apart fromthe existing software, new programs
were introduced to support these activities. As far as the design activities wereconcerned, all documentation was transferred to Krefeld. At the same time andwith the help of the Heidenheim staff, thenewly formed Winder Group was pre-pared specifically for their future work.
As important as these transfer measures
were and apart from the basic idea ofcreating integrated finishing solutions(“all-in-one-solution”) the moving of thewinder activities to Krefeld also included
particularly the requirement to force thedevelopment activities into a situation tochange the image of the Voith Sulzer
Paper Technology winder. For this purpose a team was assembled, whose job it
was to analyze the existing systems critically as well as to develop new concepts.
The composition of the team from experienced specialists and “new blood” proved
to be most successful.

TORO TDIt was one of the most important tasks tofill the gap between the standard two
drum winder and the single drum winder.
The situation before the transfer activities
is illustrated in Fig. 2.
It can be seen that, from a certain rollweight per m onwards, (depending onroll diameter and specific paper weight),

1

51

FinishingFig. 1: Time table for taking over the
responsibility for winders.
Fig. 2: Field of activities for standard two
drum winders and single drum winders.
Fig. 3: Nip forces at two drum winders.
Fig. 4: Conventional two drum winder rollwith compressed air load relief.
Fig. 5: TORO TD with compressed air load relief.
2

3
1300

12

1200

10
Nip force kN/m

Density kg/m3

1100
1000
900
800

8
Critical area
6

SB-B/SC 1100 kg/m3

4

700

Critical area
2

600
800

4

5

Newsprint 680 kg/m 3
1000
1200
Rewind diameter

1400

150

300

450

600
750
900
Rewind diametera single drum winder had to be used. The
reason for this were the nip forces resulting from the great roll weights which,with the two drum winder, could lead towinding faults, such as crepe wrinkles,
breakages, excessive stretch etc. Fig. 3
shows an example of 2 types of paper on
this subject.
Assuming therefore, that nip forces of
4 or 5 kN/m are critical for the paper
selected, a roll diameter of approx.
1070 mm would be required fornewsprint. This roll diameter would beconsiderably smaller for SC paper(approx. 980 mm). A standard two drum
winder could therefore not be used withpresent-day typical rewind diametersof 1100-1250 mm – and particularly not
for the diameters of 1500 mm requiredin the future. It was for this reason thatin the past compressed air systems(Fig. 4) were used with two drum
winders, so that the depositing forces
resulting from the roll weight could be
reduced.
These requirements have been fully satisfied by the compressed air systems pro-

1050

1200

1350

1500

vided that the paper was air-permeable.
However, as shown in Fig. 4, these standard installations have a technologicaldisadvantage: The relieving air getswound into the paper roll. With more
dense types of paper, such as, forinstance, improved newsprint and/or
SC-B paper, the wound-in air causes
layer displacements leading to crepe
wrinkles even if the paper roll weights
and the nip forces are low. The situationis still worse with high-finished or coatedpapers, as these types are almost impermeable to air, e.g. the included air reallyhas no chance to escape.
This, of course, leads to the question as
to which modified winder concept weshould adopt in the future. With this inmind, solutions such as belt supports
and application of a soft cover on thewinder drum etc. were discussed. It
became clear, however, that these ideas
were linked in part with other disadvantages. The best concept, in our opinion,
is illustrated in Fig. 5.
The solution is characterized by the following features:

52

Fig. 6: TORO TD for Stora Grycksbo.
Fig. 7: Trial winder TORO TD in Krefeld.
6

7

I The basic two drum winder concept
remains unchanged.
I The web run is modified in such a
way that the proven air load relief
can be used without technologicaldisadvantages.
I Both nips are relieved.
I The air relief can be used as additional
winding parameter.
I With air-impermeable, smooth paper
the first drum is rubber coated. This
ensures that the drum adapts to the
profile variations of the paper roll thus
preventing that boundary air is wound
into the roll.
I The rider roll is rubber covered andtherefore suitable to contribute toa good build up of the paper rollhardness.
I The rider roll is driven and, up toa roll diameter of approx. 800 mm,
participates actively with theintroduction of the circumferential
forces.

Fig. 6 shows the first TORO TD ordered
for Stora Grycksbo in Sweden.

During the project discussions as well as
during the trials carried out the customer
has been able to convince himself of theadvantages of the TORO winders for processing of his sophisticated paper andhence he decided in favour of Voith Sulzer
Paper Finishing. Start of production isenvisaged for February 1999.
Trial winder
The above mentioned trials were carriedout in the test centre in Krefeld. We
decided at an early stage to install awinder in Krefeld for testing purposes.
(Fig. 7).
Here the basic functions as well as new
ideas are tested. When putting the JANUS
calender on the marked in 1995/96, we
immediately provided for a JANUS trial
calender in our Technology Center so as
to be able to run realistic trials with customers paper rolls. Naturally, we wanted
to do the same with respect to the new
TORO winder. Yet, the large dimensionsof gravure paper rolls (W = 3.6 m with atendency towards 4 m, Dia. = 1.5 m, rollweight approx. 8 t) made this impossible,

Finishing

53

Fig. 8: Winder TORO Combi for Lang Papier,machine width 4200 mm, max. speed 2500 m/min.,roll width 800-4000 mm, roll diameter 1500 mm.
Fig. 9: Development of the calender rewind
systems.

at least for the time being. Therefore it
was necessary to look for a partner in thepaper industry.

8

Winder TORO Combi
Fig. 8 shows the winder for Lang Papierin Ettringen. With this machine it waspossible to combine the wish of Lang
Papier to obtain an efficient winder for
SC papers and our desire to use thisextremely flexible installation for carryingout trial runs with paper rolls from ourother clients.
The new type of Combi concept is capable of winding up rolls in the winder roll
bed with air load relief. For rewinding oflarge gravure paper rolls, where it isimportant to achieve a hard core winding,the single drum winder with centre drive
will be used. With effect of the 9th June
1998 we will be able to use this plant tocarry out customer tests in the two drumas well as the single drum mode themax. width and the max. diameter of therolls being 4000 mm and 1500 mm.
TORO SD
The features of the winder roll havealready been discussed, let us now moveon to the single drum machines. Herealso is the question as to which of theconcepts we should adopt for the future.
Apart from the critical analysis of existing
systems, our experience, gained overdecades in the fields of calender as wellas the paper machine and coater rewinds,
were also utilized.
Fig. 9 shows the history of calenderrewinds as well as PM/Coater rewinds
from the Pope reeler right up to our modern and very successful Sensomat Plus E

91 Centre drive rewind 1892

5 Sensomat 1974

2 Pope reeler 1949

6 Sensomat Plus 1985
Sensomat Plus E 1994

3 Rider roll 1968

7 Sirius

4 Contact roll 1971

54

Fig.10: TORO SD.
Fig. 11: T-LIFT system.
Fig. 12: TORO Combi.
1011

system and/or the Sirius. The resume ofthis experience is as follows:
I The greatest influence in the rollhardness, particularly in the core area,
is derived from centre drives.
I The optimum roll build-up is achieved
through separate influencing of web
tension, torque and nip force, e.g.
horizontal winding and, therefore,
adjustment of the nip force
independent of the roll weight.
I Control of the roll weight forces is the
key to a perfectly wound roll.
Fig. 10 shows our single drum concept
TORO SD together with the main components.
Centre drives: The rewinding stations are
fitted out with centre drives.
Loading/relief devices T-LIFT: The loading/unloading units T-LIFT satisfy two
requirements:
I Control of the roll weights.
I Rider roll function.

12

The T-LIFT units therefore ensure perfect
fixing of the cores during winding up.
The increasing weight forces of the rolls
and the web tension are taken into
account. With increasing weight of therolls the T-LIFT units take over the reliefof the roll weights.
Central drum: The central drum is rubbercoated and perforated. Suction of thecentral drum provides two functions:
I Holding of the webs during introduction and changing of the rolls.
I Fixing of the webs during the winding
process to the rubberized drum
surface.

Finishing

55

Fig. 13: Winding processes within the field offinishing.
Fig. 14: TORO Online.

Automation: Modern components forautomation, such as core feeds, rollchange, reeling drum change etc. areintegrated.

13
PM/Coater

Fig. 11 clarifies the function of the T-LIFT
system.

With this type of winder, the many narrow offset rolls could be wound in thewinder roll bed, and the few wide gravure
paper rolls in the single drum mode. This
concept is also interesting for new paper
mills which want to produce only offset
after starting up, but later also want toproduce gravure rolls. In this case thecustomer would start to run the machinein the two drum mode which is considerably simpler and more effective. Later on– the design of the winder allowing sucha retrofitting – he can easily add a single
drum operation at any time.

TORO On-line
A further task we have set ourselves –our experience with calenders and rollwrapping machines has certainly been of
influence here – was to combine the various finishing processes.
Fig. 13 shows the multitude of winding
processes at the finishing stage. By

3
UnwindPM/Coater
1

TORO Combi
The principle of the Combi winder has
already been introduced with the example
for the Lang Papier machine. But thisconcept can also be of use for a winder
integrated in a production line. Therefore
our suggestion for a company producing
offset as well as gravure paper rolls
would, for instance, look like Fig. 12.

2
Rewind1
UnwindUnwind

1

4

6

3

4

UnwindRewindReel Storage

Toro Winder + Twister
3
UnwindTwister

8
RewindTwister2

2

7

Rewind Unwind

RewindRewindToro Winder

5

Rewind Unwind

Janus + Toro Winder

Reel Storage

PM/Coater + Janus

UnwindJanus

Re-reeler

Reel Storage

14

combination of the different processing
stages (Janus/Toro, Toro/Twister, Janus/
Toro/Twister) these winding processes
can be minimized, which will have a positive effect on the quality of the end product. It would also lead to a marked reduction in investment and personnel costs.
In place of the TORO on-line concept
Fig. 14 shows a Janus calender with integrated roll wrapping machine. In order tomaintain the paper quality by respective
adaptation of the line pressure and theroll temperature during speed alterations

at the time of set changes, the thermalrolls of the calender are fitted withinductive heater bars.
So as to be able to follow a modern
paper machine, the production speedof such an on-line plant should only
be 5 to 10% higher than the speed ofan “autarkical” JANUS calenders. With
the calendering potential of the JANUS
technology this should not be a problem, even with fast running paper
machines.

561Service Division:
The Rubber and Pu covering businessthrough the partnership with RIF SpA
Effective from January 1st 1998, Voith

Since that time Voith Sulzer Paper Tech-

Sulzer Paper Technology and RIF have

nology and RIF have been working close-

established the Joint Venture Company

ly, with RIF strenghtening its good repu-

RIF Roll Cover SrL having the rubber &tation as Voith Sulzer Paper Technology

PU covering of rolls as scope of supply

subsupplier mainly in the field of polymer

and Voith Sulzer Paper Technology ascoverings and machining and manufac-

major shareholder with a 51% partici-

turing of rolls and cylinders and Voith

pation.

Sulzer Paper Technology, in its positionas leading machine manufacturer, provid-

The first contacts between Voith Sulzer

ing qualifying references for RIF.

Paper Technology and RIF date back to

The authors:
Alessia Gasparutti, RIF SpA;Martin Scherrer,
Voith Sulzer Service Division

1989 when some preliminary investiga-

It was only in middle 1996 that Voith

tions were conducted to find out the

Sulzer Paper Technology approached RIF

potential areas of cooperation in the fieldwith a more concrete view to proceed theof roll service technology which could

negotiations focusing on the rubber & PU

result of common interests for bothcovering

Companies.

object of a partnership.

Department

asprospective

At that time RIF was in the process of
expanding its range of services due to the

As one of the leading suppliers for equip-

ever-increasing demand of an integrated

ment and complete production lines tocenter for roll service technology andthe paper industry, and in a move to con-

was consolidating its presence in thetinue strengthening it’s service support

domestic market and breaking into theto customers, Voith Sulzer Paper Tech-European scene.

nology could not afford any longer toService

57

Fig. 1: View of RIF’s premises from above.
(Photograph authorized by the Italian Air Force.)
Fig. 2: Backing roll covered with Bipatex on
the extruder for Burgo Verzuolo PM 7,
size of the roll: 645 x 696 x 4047 mm.

depend on external subsuppliers for such

Short overview of RIF Roll Cover’s

Yankee suction/blind drilled pressure rolls

critical products as the polymer cover-products

The peculiarly long lifetime of these cov-

ings of the rolls, which weight heavilily

Today RIF Roll Cover can provide a wide

erings and a well-tested bonding systemon the achievement of a good quality

range of rubber qualities suitable for all

are the outstanding characteristics of

end-product.

positions of the paper machine and otherthese coverings, appreciated to suchindustrial applications and a versatile

extent as to make ourselves first-rate

Also RIF, born and grown in the years as

Polyurethane coating, produced in close

supplier for this particular application ofa family enterprise, has found it neces-

cooperation with Bayer.

some italian Papermaking group in thefield of tissue production.

sary to adjust its philosophy as independent middle-size concern to a changed

Particularly satisfactory results from thereality and decided further growth could

customers have been achieved for the

New steps have been taken by developing

come from the agreement with Voith

following applications:for this position of the machine an alter-

Sulzer Paper Technology.
2

Organization of RIF Roll Cover
The newly-established Joint Venture Company has taken over 17 employees fromRIF SpA, among which 16 are productive
personnel and one is a chemical engineer
responsible for the technological Lab.
and R&D activities in close cooperation
with Voith Sulzer Paper Technology R&D
Center (see para. below).
All the other activities as management,
sales, after-sales technical assistance,
administration and purchasing are provided by RIF SpA and are regulated by aService Agreement.
Together with the personnel transfer, RIF
SpA has reassigned over all the machinery and equipment previously belonging
to its Rubber and PU Department. RIF
Roll Cover has rented the production area
covering a total surface of 4125 m 2 fromRIF SpA.

58

Fig. 3: Forming roll covered with Diamantite
put into the curing chamber for Andritz AG,
size of the roll: 1500 x 1512 x 3300 mm.

Polyurethane has been extended to suc-3

tion/blind drilled plain press rolls thanks
to the implementation of an effective
bonding system technology.
The follow-up of the coverings made has
shown encouragingly positive results.
Research and Development
Because of the ever changing chemical
environment, machine technology andsheet quality challenges faced by the
paper-maker, the roll cover customer andsupplier demand a strong commitment tosustain the technological edge as partners. That means Research and Development and customer support by the rollcover supplier. In order to fulfill thisnative compound based on a Nytrilhydro-

Backing rolls and size-press rolls

commitment, RIF Roll Cover will carry

genate polymer especially studied forfor the coating section

out its development activities as well as

those machines where the combination of

Excellent covering for backing rolls andcoordinating product development andhigh temperature and chemical inertia

size press rolls have been successfully

technical customer support services withrepresent peculiarly severe running con-employed in some high-demanding appli-

the new Voith Sulzer Paper Technology

ditions.

cations .

Service Division Roll Cover R&D Center

Suction and blind drilled press rolls for

Rubber coverings for guide rolls

center, headed by internationally recog-

the wet section(felt/wire/paper guide rolls)

nized roll cover expert, Professor Joseph

RIF Roll Cover’s offer has been recently

A full range of coverings for guide rolls

F. Cheatham, will focus on new polymer

implemented by producing and marketingmeets all the requirements of the Paper

development and improved roll covera new cover for heavy-duty presses (upmachine. In this sector RIF Roll Coversystems that will enhance current state of

to 300 KN/m) with encouragingly positive

has significant references all over thethe art technology in both rubber andresults. In addition, ebonite-based rubber

world through the machine manufactur-

polyurethane applications. The R&D cen-compounds for central presses as moreers with a considerable number of rolls

ter is equipped with a full range of test

cost-effective and safer alternative to na-

over 9 meters long.

equipment as well as polymer chemists

located in Tucson, Arizona, USA. The R&D

tural granite have been present in theand technicians to carry out advanced

market for some time and have stimulat-

Polyurethane coverings

research both on existing as well as new-ed the implementation of a new version

First applied for a large number ofly developed roll cover technology. In

which is now tested on the field.

spools, the application of RIF Roll Cover

future Twogether issues we will focus

Service

specifically on this exciting area of tech-

59

RIF SpA The key dates of development

nical innovation and report further on
advancements in the roll cover science.
RIF SpA, Udine

Market Growth
At the moment RIF Roll Cover is present
in the national marketplace as well as in
the European scene and some othercountries bordering the Mediterranean
Sea; moreover by covering rolls for themajormachinemanufacturers

selling

machines all over the world, it is impliedthat in an indirect way RIF Roll Cover isalso present overseas with the coverings.
Voith Sulzer Paper Technology will continue its expansion of roll cover centers

1966 Renato Ciani sets up RIF SpA as a small mechanical workshop specialized
in the regrinding of rolls over an area of 1000 Sqm. In the same year thefounder starts the activity of Service on Field with mobile grinders.
1970 Beginning of the Supercalender bowl refilling business with the acquisitionof hydraulic presses for small to middle-size rolls.
1982 Takeover of Pirelli’s know-how and machinery for rubber covering
Creation of the Lab and R&D department.
1984 Installation of twist drilling machine for the drilling of bronze and polymer
suction roll shells

beyond RIF’s current location in Udine,
Italy with the planned addition of new rollcover centers in Scandinavia, North andSouth America and Asia. Immediately, a
new Service Center is being built in Farmington, New Hampshire (USA), that will
coordinate single source roll service and1988 Acquisition of one heavy-duty balancing machine for the dynamic balancingof large rolls up to a maximum length of 12 meters.
1986 Purchasing of the 1st CNC regrinder and enlargment of the existing grinding department into a climatized workshop for high precision regrindings.
1987 Acquisition of 3 new hydraulic presses for the refilling of bowls with facelenght over 9 meters.

roll cover customer support with Samco,Inc. Planned opening for this center willbe July ‘98. We are also under construc-1989 Acquisition of the gun-drilling machine and development of the activityof machining and/or manufacturing of stainless steel and bronze suction
shells.

tion with a new roll cover center locatedin West Monroe, Louisiana (USA), which
will open mid ‘99. Other expansion activities and openings for new roll cover cen-1990 Acquisition of the 2nd heavy-duty CNC regrinder for the handling of
big-size rolls up to 15 mt in length and with a maximum weight of 70 tons.
Beginning of the chromium plating and thermal spraying business.

market. Voith Sulzer Paper Technology is1991 Starting with Polyurethane cover activity through the close cooperation
with Bayer technology and facilities.

committed to bringing advanced roll cov-

1994 Achievement of the UNI EN ISO 9002 Quality Assurance Certification.

ters will be announced soon to the world

er solutions and competitive pricing toour customers. We are proud to be associated with a first class supplier in our
new Joint Venture with RIF Roll Cover.

1998 Agreement with Voith Sulzer Paper Technology and make of over of RIF’s
rubber and polyurethane business lines to the new joint venture RIF Roll
Cover.

60

Service Division:
Martin Hennerici, new Europeanand Asian manager

On 1 October 1997 Mr. Martin Hennerici
took over the running of Voith Sulzer’s
European and Asian Service Division.
He had previously worked at various
locations for the Voith group of companies – most recently in the USA. In his
new position he is responsible for theservice centers in Ravensburg, Heidenheim, Düren, Weissenborn (all in Germany), Kriens (Switzerland), St. Pölten
(Austria), and Udine (Italy) as well as
for the setting up of other service centers in Europe and Asia.

Kirsten Kolvenbach in conversation
with Martin Hennerici, the managerof the Service Division in Europe and Asia

I had the opportunity to talk to him personally about service in general and thefundamental aims and future develop-

ments at Voith Sulzer Paper Technology
in this area.
Mr. Hennerici, you say that service isbecoming ever more important forthe customer. How do you assess
this current development?
We have noticed that our customers’
requirements are changing. Our customers no longer only want to be suppliedwith machines, but also want after-sales
service. The supplier who supports thecustomer and provides solutions to problems will be preferred. Service is now
just as crucial in the market as price andtechnology. Suppliers must therefore rethink their approach to the market.

Service

What factors do you consider to beparticularly important in this regard?

can be supported effectively and a trusting partnership can be built up.

There are various factors which in myopinion go to make up good service. For
example, to enable problems to be solved
efficiently, a comprehensive service, ranging from roll service through spareparts to technology service, is certainly
imperative. We have to be able to offer
the customer complete solutions. It isalso important that there is one person,
always the same person, who the customer can contact at any time.

The basis for this is a well thought-out
backup organization with additional specialists supporting the account manager
in specific matters. I am convinced thatin this way we can give more time andindividual attention to our customers andachieve shorter response times.

And as time is money for the customer,
rapid solutions within the shortest possible time are required. In emergencies
being able to reach the service partner at
any time can mean a lot.
What is being done in order to be able
to meet such customer requirements inpractice?
I think that we in the service field at Voith
Sulzer Paper Technology can build on thegood foundation that already exists. At
the same time, however, we want toacquire and form new potential for development and opportunities for improvement. Time and again, these emerge fromthe constantly changing market conditions and customer requirements.
What particular measures are meanthere?
In future we want, for example, to provide our customers with their own accountmanager who is available as a contact forservice and helps to find total solutions.
We think that in this way the customer

Over and above this we are constantly
working towards the progressive development and sensible expansion of ourservice range. Only recently Voith Sulzer
Paper Technology, together with RIF SpA,
set up the joint venture company RIF Roll
Cover Srl which is active in the area of
rubber and polyurethane coatings (seealso the article about RIF Roll Cover on
the preceding pages). With this company
we now have access to internal capacities
especially in the important field of polymer roller coatings and offer our customers a complete range. We were alsoable to make significant progress with
the GR cover through further developments so that it is now very well suited tothe most demanding applications. And
already over 100 GR covers are in use.
The service field in particular is to bestrengthened and expanded by increases
in personnel. This applies to the metrology & diagnosis and cylinder service areas
as well as to the technology service,where “Productivity Audit Teams” arebeing organized.
Another aspect, which in the future will
gain in importance, particularly in connection with the outsourcing of services inour service range, is that of maintenance61

62
Service Center
Heidenheim
Tel. ++49-(0)7321-37 6061
Fax ++49-(0)7321-37 7889
Ravensburg

Tel. ++49-(0)751-83 02
Fax ++49-(0)751-83 2999

Düren

Tel. ++49-(0)2421-499 205
Fax ++49-(0)2421-423 34

Weissenborn

Tel. ++49-(0)3731-35 420
Fax ++49-(0)3731-35 4215

St. Pölten

Tel. ++43-(0)2742-806 0
Fax ++43-(0)2742-71772

KriensTel. ++41-(0)41-329 5757
Fax ++41-(0)41-329 5758

RIF Roll
Cover SrL

Tel. ++39-(0)432-561 414
Fax ++39-(0)432-561 600

Middletown

Phone ++1-513-423 9281
Fax ++1-513-423-3256

PortlandPhone ++1-503-284 1440
Fax ++1-503-288 3248

AustellPhone ++1-770-948 8086
Fax ++1-770-948 4613

West Monroe

Phone ++1-318-387 1801
Fax ++1-318-322 3984

Farmington

Phone ++1-603-330 1088
Fax ++1-603-330 1089

TristarPhone ++1-604-946 1631
Fax ++1-604-946 0208

Sao Paulo

Phone ++55-(0)11-840 4040
Fax ++55-(0)11-840 4841

management as a form of contractual cooperation or partnership with the customer. This can be customized – from themaintenance of individual rolls to thewhole machine.

ple, open service centers in Scandinavia
and South-East Asia so as to be able tooffer a comprehensive service in theseimportant regions.

Up to now you have talked more aboutorganizationally and technically-oriented
aspects of the plans. Do the plans also
include location-related activities?

What do you consider to be the importance of Voith Sulzer Paper Technology’s
employees?

Yes, because as can be seen from myprevious remarks, our concept and measures are based on a certain philosophy.
Being close to the customer. This means
being close technically, organizationallyas well as geographically.
At the moment there are a total of sevenservice centers in Europe besides ninefurther service centers in South andNorth America (see drawing). We plan to
set up other service centers near to ourcustomers in Europe and Asia in order toimprove the service we provide locally. In
the foreseeable future we shall, for exam-

Let me tell you quite clearly. The wholeconcept depends on our employees. It isonly through them that ideas can be converted into actual deeds. For me threecomponents have particular importance:
the right attitude concerning service,specific and effective training and motivation.
Finally I would like to stress again that
our customer must always be the focal
point. Our customer will reap the benefitsof this, because efficient support by anexperienced machine manufacturer andservice provider enables him to concentrate on his core business.

Corporate NEWS63

New Voith Sulzer Paper Technology Office in Finland
On March 20th our new office in Helsinki
invited some 150 ladies and gentlemen
from the Finnish paper industry to an
evening party in the winter-garden of the“Sipuli” restaurant. It proved to be an
impressive event under the floodlit roofsof Uspensky Cathedral, giving our guests
an opportunity to meet the entire management of Voith Sulzer Paper Technology and to refresh old acquaintancesamong one other.
Although the official reason for thisreception was the opening of our new
office in Vantaa, we had laid on goodentertainment and our guests continued
dancing until well beyond midnight.
We also had every reason to be in goodspirits: following the updating andimprovement of PM 1 at UPM-Kymmene
in Pietarsaari, we were able to secure fur-ther interesting orders from Finnish customers within the past six months. Two
Janus calenders for Myllykoski, anothershoe press for UPM-Kymmene in Tervasaari, a two-layer headbox for Ensoboard machine 1 in Kaukopää and last
but not least a shoe press for the MetsäBotnia White Top Liner machine in Kemi,
representing our third NipcoFlex press inFinland.
In his address, Hans Müller, President andCEO of Voith Sulzer Paper Technology,
once again emphasised the great significance of the Finnish paper industry –and promised to sit down and learn the
Finnish language as soon as our market
share in Finland had reached 25 %. Now it
depends on our activities and our Finnish
customers just how soon he has to tackle
this task!

Mr. Jorma Vaajoki, President and CEO of
Metsä-Serla, expressed his thanks for theinvitation in perfect German and welcomed
Voith Sulzer Paper Technology to Finland (above).
Hans Müller cutting the tape (left).

64

1
2

3

Voith Sulzer Paper Technology
Philippines Inc., Manila –the new joint venture in the Philippines
Robert Dan and Co.

70 paper mill projects in the Asian re-

The original company Robert Dan andgion. Most notable are the 600 t/24 h

Co. (RDC) was founded in 1954 by thedeinking plants at Daehan Paper in Korea

late Robert Dan as a paper mill consult-and at TIPCO in the Philippines, two of

ing firm. Later it expanded to become aVoith Sulzer’s finest running plants.

well-known supplier to the paper industry.
However, the first contact with Voith

Aside from the paper industry, RDC isSulzer dates back to 1929 when Robertalso engaged in the supply of belting andDan bought an Escher Wyss paper

conveyor lines for other industries. For

machine for his father’s paper mill in

instance, the company has supplied con-

Foochow, Fukian, China.

veyors to Changi International Airport,
Singapore, rated by many as the world’s

Since 1954, Robert Dan and Co. has soldbest airport over the past few years. RDC

six Escher Wyss paper machines in theis also the exclusive representative in thePhilippines, including the first Escher

Philippines for Siegling Belts of Germany.

Wyss tissue machine to Kimberly-Clark
in 1961. RDC has also supplied stock

Voith Sulzer Paper Technology Philip-

preparation equipment for more thanpines’ current president, Raymond Dan,

Corporate News

65

Fig. 4: Shaking hands after signing the Joint
Venture Agreement: on left Raymond Dan,
President of Voith Sulzer Paper Technology
Philippines Inc. and Hans Maichel, Manager
Commercial Services, Voith Sulzer Stoffaufbereitung GmbH & Co. KG, Ravensburg.

Fig. 1: Aerial view of Makati City, a business
district of Manila, where mainly banks andinsurance companies are concentrated.

Fig. 5: The Manila offices of Voith Sulzer Paper
Technology Philippines Inc., in the Malate
District of Manila.

Fig. 2: Ortigas Center, a business district in Pasig,
Manila, where Voith Sulzer Paper Technology
Philippines Inc.’s manufacturing facilities arelocated.

Fig. 6: Pulper in the final stages of assembly.
Fig. 7: Mill installation of a Combisorter (on left)and drum screen.

Fig. 3: The Jeepney, – uniquely Filipino.

is the son of RDC’s founder, Robert Dan.

The joint venture with RDC represents a 5

Raymond was educated in papermaking

significant step by Voith Sulzer Stockin the USA at the College of Forestry,

Preparation in further strengthening its

Syracuse University, New York State andpresence in Asia since the company isreceived his Master’s Degree in Indus-

strategically positioned in the Philippines

trial Administration from Purdue Univer-with excellent access to major Asiansity, Indiana. Before joining RDC, he ac-countries. The Philippines has a growing

quired extensive experience in the paper

economy and a good supply of English-

industry while working in the United

speaking personnel at attractive salary

States for Electronics Automation Sys-levels. Wages in the Philippines aretems and Simons Eastern Consultants.

about 6 times lower than in Germany.
Highly-educated professionals for upper

The new joint venture company

and middle managerial positions are

Voith Sulzer Paper Technology

available, since each year some 600,000

Philippines Inc., Manila

new college graduates are welcomed into

In July 1993, RDC’s initial talks withthe job market.

6

Sulzer resulted in a respective equity
sharing of 75 and 25%. This partnership

Plans for paper mill projects are expect-progressed over the following years anded to increase in the coming years asa joint venture, called Voith Sulzer Paper

current annual per capita paper con-Technology Philippines Inc., was estab-sumption in the country is only 13 kg.

lished on December 19, 1997. Voith

The market is thus ripe for rapid devel-

Sulzer’s Stock Preparation Division owns

opment. In addition, infrastructure costs

51% of the new company.

are low, the democratic government ismarket-driven and the currency exchange

4system is open, paving the way for the 7
new joint venture to be a forerunner in
Asia.
Address:
Voith Sulzer Paper Technology
Philippines Inc.
1642 San Marcelino, Malate,
Manila, Philippines
Tel. (632) 523-9011 to 14, 526-5125 to 32
Fax (632) 521-7989, 521-7030
e-mail: dan_r@compass.com.ph

66International PAPER TECHNOLOGY

67

Bahia Sul – changing perceptions about
Brazil and our industry
Located on the Southeastern coast of Brazil is aworld class pulp and paper mill that is setting new
standards for our industry and capturing theimagination of those that strive to create theultimate model for the future. With a closer look at
this pulp and paper prodution center it is easy to
see not only the tremendous commitment that has
been made to making this operation a model for ourindustry, but an example that disproves the popularbelief that our industry is profiting at the expenseof the environment.
Allow us to introduce you to a world class operationthat is changing the perceptions of the Brazil andour industry.

The author:
Kirsten Kolvenbach,Marketing Service
Division. Special thanks
for their assistance:
Gustavo Camargo, Bahia
Sul and Ray Hall, Voith
Sulzer Service Division

1

2

3

Bahia Sul – more than a concept
One has to look no further than the management team to sense the leadershipand the energy that is transmitted into
the daily operation of Bahia Sul. They arebacked by a company and a team of people that believe that it is their task to not
only meet operational goals, but to do sowith the highest possible standards, infact world class standards. It only takes
about ten minutes of discussion the
management to not only appreciate theaccomplishments of the Bahia Sul operation, but to also see how infectious their
enthusiasm is to establishing and achieving even the most difficult targets.
From initial concept until today Bahia Sul
has:
4

5

I Established constantly sustained fiber

The eucalyptus plantation

The Bahia Sul eucalyptus plantation notsource from a Eucalyptus forest that is

The Bahia Sul eucalyptus plantation com-only covers all raw materials needs inin harmony with nature and the sur-prisescovering

timber and cellulose, but also makes therounding plant an animal environment.

66,000 hectares – about 90,000 footballplant independent of outside energy sup-I Become the first pulp and paper mill infields. Apart from the factory buildings,

plies. Power is generated by steam tur-

the world to be certified to the BS

roads and housing, etc. the other 49,000

bine units fuelled with waste lignin, bark7750 and ISO 14001 environmental

hectares of land (about 70,000 footballand other residues.

standards.

fields) also belonging to Bahia Sul are

I Developed from a green field status aninetymilliontrees

planted with indigenous non-cultivated

The high environmental standards

world class pulp and paper mill opera-

species.

The company became the first organiza-tion including the entire supporting in-

Eucalyptus is one of the fastest-growing

tion of the American Continent and thefrastructure of trained personnel, andhardwood trees in the world. And thefirst in the world in the pulp and paper

the social systems for those people in

Bahia Sul regional climate is extremely

section, to gain the BS 7750 standard

terms of housing, schools and health-favourable for this species, with heavy

certification, which establishes the requi-care facilities.

rainfall equally distributed throughout

sites for the environmental management

We invite you to read on to learn more

the year and only slight temperature vari-system. The BS 7750 was the base fordetails concerning this leader in our in-ations. As a result, the eucalyptus har-the creation of the ISO 14001. Bahia Sul

dustry.

vesting cycle here is only seven years.

was once again recognized for its pio-

70

Fig. 4, (page 68): Seedling productions.
Fig. 1, (page 67): A partial view of the fiber line.

Demands on the Environmental
Management System
I Environmental policy
Framework for action
I Planning– Establishing of the objectives andtargets– and programmes for achievingthem
I Implementation and operation– Structure and responsibility– Training, awareness andcompetence of the employees– Open communications(internal, external)– Environmental management
system documentation– Organisation of the operations– Emergency preparedness andresponse
I Checking and corrective actions
I Environmental management system
auditsI Management review
I Continual Improvement*

Environmental management systems:
definition
Environmental management systems
are officially defined as “that part of theoverall company management system
which is responsible for the organizational structures, responsibilities andbehaviour rules, formal procedures,processes and resources required forestablishing and implementing the environmental policy”..***Informations of: Norm der Umweltmanagementsysteme, Spezifikation mit Anleitung zur
Anwendung, Oktober 1996.
**Source: Integration of environmental
management in quality management systems
TÜV Southwest.

Fig. 2, (page 66): Overview of “mosaic” planting.

Fig. 5, (page 69): General view of the mill locatedin Mucuri.

Fig. 3, (page 68): The nursery.

Fig. 6: Paper Shipping.
6

neering when, in 1996, it received this

Therefore, the environmental protection

certificate.

is a system modul of the holistic man-

For example, to obtain certification ac-

agement system. It is the objective ofcording to ISO 14001, the requirements

such a combination of standards having

for establishing an environmental protec-

different orientations to bring about ation management system defined in theconsent of customer-oriented economic

standard and shown in chart must haveefficiency as well as responsibility to-

been met, where the individual modules

wards society and the environment.

are to be subject to a dynamic cyclic
process. Improved performance with re-Integrated cellulose and paper plant –spect to the environment is the objective

facts and figuresof this certification.

The cellulose plant has been operating

For succesful realization, the idea of pro-since March 1992, with an annual output

tecting the environment must be takenof 500,000 tonnes bleached eucalyptus

into account in each business decision,

kraft pulp. Hardwoods like eucalyptusof all levels and in all functions. All ofyield a short-fibred pulp ideal for pro-this is based on informed and motivatedducing wood-free papers which are easi-

employees.

ly printable, with smooth, bright and uni-

In the case of Bahia Sul, the environmen-

form surface qualities and high opacity.

tal protection management system islinked up with other systems, for exam-

That is why eucalyptus is used for a wide

ple with the quality management system

range of products such as printing andaccording to DIN ISO 9002, which views

writing papers, tissue, coated papers,

customer benefit as its main objective.

carton and special grades.

International Paper Technology

Since 1980 eucalyptus has played agrowing role in world production of71

Market: Pulp
(in thousands of tons, except percentages)

bleached hardwood kraft pulp, rising
RegionAmountSold

1995
Percentage
of Total

AmountSold

1994
Percentage
of Totalvinced that „this trend will grow: the rel-

Asia

101.5

34.1%

141.6

41.7%

atively low cost of eucalyptus pulp will

North America

76.0

25.5%

64.0

18.8%

make it more and more popular in global

Europe

60.7

20.4%

65.3

19.2%

production of bleached kraft pulp.“ Some

Latin America

2.0

0.7%

14.8

4.4%

of the pulp produced – 147,000 tonnes in

Total export sales

240.2

80.7%

285.7

84.1%

Domestic sales

57.3

19.3%

53.9

15.9%

Total sales

297.5

100.0%

339.6

100.0%

from about 28% (1.9 million tonnes) atthat time to 35% (5 million tonnes) in
1995. The Bahia Sul people are con-1995 – is used for making uncoatedwood-free printing and writing papers at
Bahia Sul paper mill, which started operating in February 1993. Rated output is
250,000 tonnes p.a. (medium grade paper with a basis weight of 80 g/m 2 ).
Bahia Sul – a special mission

Market: Paper(in thousands of tons, except percentages)

Bahia Sul not only regards itself as an
1995

employer of nearly 1500 people on the

1994

RegionAmount
Sold

Percentage
of Total

Amount
Sold

Percentage
of Total

more than 80 million US dollars wereNorth America

27.1

19.5%

43.0

23.8%

invested in 1995 alone for new or im-

Europe

17.8

12.8%

27.4

15.1%

proved housing, schools and medical

Latin America

10.0

7.2%

13.3

7.4%

services in the surrounding region.

Asia

8.8

6.3%

15.1

8.3%

Africa

3.4

2.4%

10.9

6.0%

Others

14.3

10.3%

19.6

10.8%

Total export sales

81.3

58.4%

129.2

71.4%

And also a good example of how higher

Domestic sales

57.8

41.6%

51.7

28.6%

goals should be set for daily labour than

Total sales

139.1

100.0%

180.9

100.0%

plantation and in the plant, but also takes
its social responsibilities seriously –Showing the way
Bahia Sul is an excellent example of how
product plants should be integrated into
their surroundings and the environment.

output alone. To all who are inspired tofollow this example, we wish you success and good luck.

72

P a p e r C U LT U R EPaper’s
Flying Career

Today paper makers and paper engineers
are what we generally consider as “Global
Players”, with the overwhelming majorityof their companies active on an international basis. Their staff, whether managers or mechanical engineers, take it for
granted that they will have to jet aroundthe world in order to attend conferences,
sign contracts or visit customers. Shouldsome of our esteemed readers also belong
to this modern species of occupational
globe trotters, we would ask you to observe at least a few second’s silence forthe inventors of such flying machines dur-ing your next take-off. And not without adegree of pride, either, since it was two ofyour colleagues from the paper industry
who turned humanity’s old dream of flying
into reality, going beyond all the oftenbold and daring but occasionally ridiculous visions developed so far. To achieve

73

their ambition they exploited to a large
extent the experience gained in their profession: paper and its characteristics.

Joseph Michel and Jacques Étienne Montgolfier

Joseph Michel and Jacques Etienne Montgolfier, two paper makers from the Lyon
region, had accumulated a substantial for-tune since their paper mill close to Annonay and family-owned for four centuries
was finally appointed “Royal Paper Manufactory” and official Purveyor to the RoyalHousehold in 1782. The regular income
ensured bythis honour gave Joseph, thenaged 42, and his five-years younger

74

Paper Culture

brother Etienne the financial independence needed to devote themselves fully
to their life-long passion. Their fancy wasdefinitely not sweet idleness! In the midstof the age of Enlightenment, when intelligent minds were engaged on the various
kinds of scientific study and experimentthat had become fashionable at the time,
the Montgolfier brothers were fascinatedby “lighter than air” flying machines .

A bronze medal coined by King Louis XVI
commemorates the aeronautic achievements of1783 – the first manned flights in hot-air andhydrogen balloons.

The excitement that seized the entire Frenchnation at the beginning of the balloon era
inspired numerous artists and craftsmen whose
works have been preserved until today andcommunicate a magnificent impression of theexciting events of that era (left page).

According to accounts supplied by theirfriends, the inspiration for constructing
the first workable flying machine came
one evening in front of the open fire, when
Joseph threw an empty pastry bag into theflames. Instead of burning down to ashes
the bag was filled and carried away up thechimney by the ascending hot air, never tobe seen again. Thus the idea of the hot-air
or Montgolfier balloon was born. Admittedly, some evil tongues claimed that itwas not the paper bag but the clothing of
the scantily-clad Madame Montgolfier
which the hot air caused to rise and thus
inspired the bold dreams of the master ofthe house while sitting up late in front of
the warm fire.
An unusual, though very amusing versionof the legend! And why should that worldfamous movie scene featuring Marilyn
Monroe’s dress fluttering in the hot air
above a New York subway sidewalk grid
not have a real historic model? Be that as
it may, from that time on the two paper
makers from the South of France, convinced of the practicality of their plans,
devoted all their efforts to balloon experiments. They began to construct increasingly large paper spheres and, in open-air
experiments, tried to make them rise into
the sky by holding them over open fires.

75

June 1783 saw the staging of their largest
test project so far, a linen envelope linedwith paper and with a circumference of
33.5 metres and a volume of 625 cubic
metres. The eyes of curious spectatorsand representatives from the Academy of
Sciences were all upon an experiment thatin the event surpassed all expectations.
An eyewitness noted: “…the hot smoke
created by an immense fire transformed
the voluminous bulk of fabric and paper
into a gigantic, oscillating sphere, witheight perspiring men holding on grimly tokeep it on the ground. When at Joseph
Montgolfier’s command the assistants
were allowed to release the balloon, thehuge sphere rose into the sky before theeyes of an amazed public up to a height of2000 metres, where it hovered for about
10 minutes, before descending approximately two and half kilometers from
where it had started its aerial voyage ...”
It took only a few months to accomplish
the leap from unmanned to manned flight
experiments. On September 19th, 1783,
in Versailles, watched by King Louis XVI
and a large crowd of spectators, a balloon
rose into the air carrying a wickerwork
basket with a sheep, a chicken and a duck“on board”. Two astronomers calculated
the actual altitude reached as 560 metres.
After this successful experiment and thesafe return of the “passengers”, the kingbeamed with satisfaction. However, when
Etienne Montgolfier stated his intention tosend a human being without delay on ahigh-altitude flight, the king proposedchoosing a convict sentenced to death
who as a reward could look forward to apardon, should he survive the trip. At thisstage a fierce quarrel flared up among themembers of the Academy of Science, who

76

Between 1784 and 1790 the artist Balthasar
Antoine Dunker of Bern completed this satiricalpainting of the “Huge Mail Air Sphere which isscheduled to fly to China on March 10, 2440”
shown on the right. For its journey to the Far East
the mad balloon carried “Church and Hospital”(K), “Exits” (U), “Passenger suites” (P), Inns andCoffee Shops” (X) and “Good-hearted girls
including the stairs to their cage” (R).

could not decide whether or not the honour of becoming the first aviator in thehistory of mankind should be left to a low
criminal. In the end science triumphedover the king’s plea. On the morning ofNovember 21, 1783 Monsieur Pilatre deRozier, director of the Paris Museum, andthe Marquis d’Arlandes took off in asplendidly painted aerostatic machine –as Montgolfier called his balloon – andhovered over the heads of the King and his
royal household at a height of about
85 metres. After covering a distance ofmore than eight kilometres the two men
landed safely, to tumultuous applause.
The whole of France was seized by “Montgolfier fever”. And as was to be the casewith many future technical developments,
in 1783 people were already of two minds
with regard to the new invention. Somesensed the approach of a terrible disaster,others predicted the onset of a heavenly
era for mankind. Regardless of the still
open end to all aeronautic adventures ortheir benefits, a tacky handicrafts industry

exploited the forthcoming balloon era for
all it was worth as Christmas approached.
Nothing was spared from adornment withballoon motives or from being produced
in balloon shapes. A flood of lamps,
clocks, toiletries and bottles of smelling
salts more or less successfully declared
to be replicas of Montgolfier’s balloon
swamped Europe and sold like hot cakes.
Unimpressed by all the fuss and excitement, the Montgolfier brothers continued
experimenting. In principle, paper remained their main material. At least as far
as the lining of their balloons was concerned, they continued to pursue theirprofession as paper makers. It was not
until some time later, when gases such ashydrogen started to replace the hot-air
principle, that the balloon constructionindustry disassociated itself from highly
sensitive paper as an envelope material.
lndeed it was almost a century later, whena new generation of aviation enthusiasts
started to construct elementary steerable
gliders based on the ideas of Otto Lilien-thal, that paper and board, known to be
the lightest modelling and cover materials
available, underwent a brief renaissance.
However, the start of powered aviation
paved the way for the use of heavier andmore stable materials such as light metalalloys.
When we today take a seat in the air-conditioned, pressurised cabin of a jet airliner, we hardly give a thought to thosemagnificent men in their (paper-covered)flying machines or in their baskets or
gondolas suspended beneath balloons or
Zeppelin airships. Yet it remains an incontestable fact that two paper makers were
the first people to prove that humanbeings can construct flying machines able
to bear their own weight and more besides. Is this not something to fill paper
makers with satisfaction and pride? Afterall, have they not always been famous fortheir outstanding ideas?

Manfred Schindler

Otto Lilienthal (1848-1896) and one of his
gliders. He is considered the actual pioneer ofaircraft construction, passing on for the first time
reliable knowledge of aerodynamics and aviationengineering.

Paper Culture772Paper Technology Journal“twogether” is published twice annuallyin German and English. Contributions by
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