twogether
Paper Technology Journal

28

Residual materials: instead of disposal, generate energy I Unique inIndia: Bhigwan PM 2 I Product world: smart products – great effects

2

CONTENT

4	Residual materials as potential recyclables 12	Bhigwan PM 2 is the first paper machine– Palm paper mill in Wörth, Germany.

Report4 Instead of disposal, generateenergy – Palm paper mill in Wörth

New Plants
12		 Unique in India: Bhigwan PM 2
with online coating method
16 Standardized tissue machines
ensure cost-efficient productionin India with online coating methods.

32		 Interview about the new BoostDryer
with Dr. Jan Klingele – Manager of

18 Goals exceeded with combiscreening in stock preparation
20 Satinage made to measure –potentials tapped for improvements on calenders
23		 Modular controller retrofits formatical stock modeling andsize press
37		 Conversion to PLURALIS refiner
fillings pays off
40		 OnQ ModulePro – a water-air
moisturizer for every application

conditions
46		 LED lighting saves energy –OnV PaperVision camera systemnewsprint
50		 PrintForm I – new fabric generation

not just for photocopying paper

2

stock preparations

Research & Development
70 Solutions for preventing barringon calender rollsNewswith unique warp concept73	Important future market for Voith

53		 Increased efficiency in the press– joint visit of the Voith Group56		 LunaReel – new reel drum rollgreat effects

actuators
68 Worldwide service for durable

48		 Forming fabrics for challenging

on the clothing

28		 Single NipcoFlex – proven concept

stock analysis
67 OnS FindSet closely examines

43		 OnC WebDetect detects breaks,

section – it doesn’t depend justproduct world: smart products –64 PerfectFit at the stock mix –lowering costs through mathe-capital expenditure26		 News from the Voith Paper

Servicethe Klingele Weener Groupwinders: more reliability with low

Products

concept not just for photocopying paper.

34		 SizeWings AT – the kick for every

even under the most difficult

Rebuilds

28 The Single NipcoFlex press – provencovers for a perfect paper reel58		 SkyTop doctors – ideal for hardroll coating60		 Lightweights: rolls made ofcarbon fiber

Executive Board to China
74	World record at Rhein Papierin Hürth74	QualiFlex press sleeves – double
anniversary
75	Something new at Voith Hydro– optimal supplement for windenergy62		 Service on spreader rolls –maintenance without a long wait

28 I 2009 I Voith Paper I twogether

EDITORIAL

Dr. Hans-Peter Sollinger,
Member of theManagement Board
Voith AG and Presidentof Voith Paper.

Dear customer, dear reader,

How do paper manufacturers deal

effect on the paper quality, forwith waste materials? With theexample, or whether it protects theincreasing use of recovered paper,

environment. You can learn morethis question has been gaining impor-about this from page 26 on.

tance worldwide in the last few years.
Our title story shows how the Palm

Innovations require a great deal of

paper mill found an answer to thiscourage. In the twogether interview,question. With a multi-location con-our customer Dr. Jan Klingele tells us

cept, Palm uses waste materials as awhy he was ready to be courageous

valuable source of energy. The result:with Voith Paper. His company, thenot just lower energy costs, but also

Klingele Group, was the first to use

lower disposal costs.

the new BoostDryer drying technology. The results of this project andSavings remain an important topic inwhat he expects of the future canthe paper industry. For that reason,

be found on page 32. We would

we at Voith Paper are constantly

like to take this opportunity to thankworking on offering our customers

Dr. Klingele for the interview.

products and services that generatesavings. Often small investments

We bring into play our entire know-

are rewarded with a high return on

ledge base and all our commitment

investment. An example of this is thefor the satisfaction of our customers.

SizeWings AT component, which gets

Therefore, we are happy when we

size presses going (p. 34), or the

can look back at successful projects.

OnV PaperVision camera system,

Just three examples are projects

which prevents breaks and at the samewith SEPAC in Brazil (p. 16), withtime saves on operating costs (p. 46).

Rhein Papier in Germany (p. 18) andwith Sappi in Belgium (p. 23).

So that you can grasp the specificbenefit of individual products andI wish you lots of interesting reading!

services from Voith Paper at a glancein the future, we’ve introduced newsymbols in the magazine. In this way,
you see whether the product has an

28 I 2009 I Voith Paper I twogether

on behalf of the Voith Paper Team3

Report28 I 2009 I Voith Paper I twogether

5Report

Heaps of plastic, mountains of sludge and coarse impurities such as metal
were a considerable cost factor for disposal, until recently. Now some paper
mills are using their rejects and residual materials as potential recyclables forenergy production. The Palm paper mill has built a facility using state-of-the-art
technology at its Wörth location in Germany.

6

28 I 2009 I Voith Paper I twogether

REPORT

Paper machines and stock
preparations are subject to a
constant optimization process.
Over the last few years, energy
production and the peripheral
processes such as disposal of
rejects and residual materials havegained considerable significance.
“Paper manufacturers still have aremarkable potential in the recyclingof residual materials for reducing
costs and increasing the profitabilityof their production,” says Lucas
Menke, Manager at Voith Paper
Environmental Solutions (VPES).
Residual materials and rejects canno longer be conveniently and easily
disposed of, as was still the caseonly a few years ago. But due to theincreased use of recovered paper,
their portion is increasing. In Europe,for example, the paper industry
used around 53.3 million tons ofrecovered paper for paper production
in 2007. By comparison, consumptionof recovered paper was around50 million tons in China and 30 million
tons in the USA. Worldwide, around
208 tons of recovered paper wereconsumed; that corresponds to autilization rate of 53%.
The high utilization of recovered
paper and thus higher portion ofresidual materials lead to increasing
disposal and landfill costs. Stricter“With a system for processing residual materials,
you can not only save these disposal costs but
also obtain energy at the same time and thus
noticeably lower their energy costs.”
Dr. Andreas Haas, Director of the Planning Department
at the Palm paper mill.

waste management laws in many
countries further tighten the situation.
“With a system for processing residualmaterials, paper manufacturers can
not only save these disposal costs
but also obtain energy at the sametime and thus noticeably lower theirenergy costs,” explains Dr. Andreas
Haas, Director of the Planning

28 I 2009 I Voith Paper I twogether

7ReportResidual materials and rejects

Rejects(high-calorific,
easily combustible waste)

Residual materials(low-calorific waste)

tails/pulper rejects

consist mainly of film and are connected withiron wires due to the process design

rejects/coarse rejects

sorting residues, e.g., wrong insertions in recovered
paper collections, CDs, film packages, high fuel value

deinking sludge

sludge that arises from the separation of fibers andprinting inks, low fuel value

mixed sludge

sludge that accumulates from the process stagesof cleaning, sorting and deinking, low fuel value

bio-sludge

sludge that accumulates from the aerobic stagesof the biological clarification plant, low fuel value

Rejects and residual materials are differentiated according to fuel value and physical composition (size, dry content). This classification
then also defines the sequence of pretreatment.

Department at the Palm paper mill.

and energy concept. The core of theof companies has made itself widelyPalm, the German paper mill, reacted

new system is a gas and steam facility

independent of external disposal

to the challenges by building therunning on natural gas that has been

companies.

most modern system for recyclingin operation at the Wörth location

residual materials in the world. We

since 2008. It is supplemented by a

The foundation of the new system

took a closer look at how the system

residual material boiler that burns

was a thorough investigation offunctions and its advantages.

nearly all residual materials from thethe accumulating reject andthree production locations. So far, theresidual material flows from all

facility is unique worldwide and thethree mills, looking at their quality,

Multi-location concept

most modern of its kind. Eltmann anddegree of contamination, foreign

Annually, the Palm paper mill produces

Aalen, the headquarters of the group,

matter, degree of dewatering

altogether 600,000 tons of newsprintdeliver their residual materials to Wörth.

and absolute quantity.

“In 2005, we disposed of all rejects and residual materials
via third-party companies, which cost several million euros annually.”
Dr. Andreas Haas, Director of the Planning Department, Palm paper mill

8

in Aalen and Eltmann and 890,000 tons

“In 2005, we still disposed of all

Wörth is the largest locationof corrugated cardboard base paper

rejects and residual materials with

with an annual production of

in Aalen and Wörth – all from 100%

costs to third-party companies,

650,000 tons of paper. Since

recovered paper. The company has

which cost several million euros

Wörth thus has the highest energy

found a solution for the accumulating

annually,” says Dr. Andreas Haas.

consumption of the three locations,waste and included its three German

Today, the waste produces energy,

Palm installed the new power

locations in a comprehensive waste

and within three years the groupplant technology there.

28 I 2009 I Voith Paper I twogether

REPORT

Energy from residual materials

the goal of the integrated paper

rejects, tails and heavy parts aremill,” explains Lucas Menke.

sorted out in the stock preparation

With the gas and steam facility andThat means striving for a raw

and wastewater treatment area of thethe residual material boiler, steam

material and energy cycle inpaper mill. Metal, iron and aluminumand energy can be produced frompaper production that is as closed

remain at the location for scrapping.

the combustion of rejects andas possible. In Palm’s case that

However, the combustible residual

residual materials.

means all residual materials

materials start their journey to Wörth:“With our system, we are pursuing the goal of an integrated paper mill.”
Lucas Menke, Manager at Voith Paper Environmental Solutions
Meri, a Voith Paper company,

are sorted and used for energy

large claws, buckets or conveyor

supported Papierfabrik Palm in

production.

belts put them in transport

planning the new facilities, utilizing

containers that are loaded on

its expertise in process technology

The journey of the residual

trucks. Then it’s off to Wörth.

and mechanical engineering formaterials

Soon, they will be transported by

the residual materials treatment

rail with a newly developed special

that was required in this project.

We accompany the residual materials

transport container system. Once

“With our system, we are pursuingfrom Aalen, and sludge, getter,they arrive there, the individual
fractions are tipped into various
pits called residual material pits.
First, a modern shredding facility in
Wörth shreds tails, coarse rejects
and fractions from the dissolution
directly in the stock preparation.
Ferrous metals are separated fromthe material flows with the aid of amagnetic separator.
The accumulating fiber residues,
fillers and sludge from wastewater
treatment are dewatered for thehighest dry content. Two systems
running in parallel then convey thefractions with high fuel value(dissolution rejects) and mixed
sludge and fiber sludge with low
fuel value over about 200 meters ofcarrier air conveyors to the residualmaterial storage or to the power
plant. If one conveyor fails, the otherPreparation of the various rejects and residual materials (left) for combustion is today
an important part of a modern integrated paper mill and contributes substantially to
profitability.

28 I 2009 I Voith Paper I twogether

is available. The conveyed residualmaterials can either be directly
burned without interim storage or9

Reporttemporarily stored in the residualmaterial storage. The amount ofresidual materials that come from
Aalen and Eltmann varies due to
production and logistics of theplants.
“We designed the storage concept
in such a way that larger amountsof residual materials can be stored
in order to have a suitably good
supply of fuel,” explains Dr. Haas.
Shredding and metal separation is the precondition for combustion of the high-calorificrejects.

The mix is what does it
An intelligent crane system canremove partial amounts from thehigh-calorific fuel (rejects) and lowcalorific fuel (mixed sludge) stored
in the residual material storage andfeed the secondary systems.
The secondary system for sludge
allows mixing and homogenizing of
the low-calorific fraction from which,in addition, metallic impurities are
separated. The secondary system
for rejects has several process

An intelligent self-propelled crane system takes fuel out of storage and feeds thesecondary treatment stages, mixing and feeding systems.

steps: first magnetic separation,
shredding, second magnetic
separation, separation of nonferrous metals, e.g., aluminumand extremely small iron particles.
Depending on the requirementsof the power plant, the two fuels
can be mixed so that the fuelvalue required by the power plant
is obtained. The mechanicalengineering solutions delivered byMeri and described above also
allow adaption to fluctuations in
the quality of individual fuels tomeet the power plant’s requirements. For the first time, a pouch
belt conveyor system was used

A closed pouch belt conveyor also allows fuel transport on complicated stretches.

10

for conveying this fuel material.

28 I 2009 I Voith Paper I twogether

REPORT

Main suppliers
Residual material preparation,
storage and feeding system:
Voith Paper Environmental Solutions
Power plant:
Austrian Energy & Environment
Power plant planning & engineering:
EPROPlan Stuttgart
Dr. Wolfgang Palm, owner and Executive Director of the Palm paper mill (left), enthusiastically cuts the special gift from Meri at the official
opening ceremony in Wörth at the end of April 2009. He is assisted by Dr. Andreas Haas, Director of the Planning Department at Palm (right).

With the new materials handling

into the residual material storage andourselves and avoid expensive

equipment, it is possible toremixed there.” EDP ensures that

disposal.” Did the investment pay

implement challenging routes

both types of material, the low-off? “Definitely,” says Dr. Haas. “We(inclines, corners) with a closed

calorific sludge and the high-calorificwould immediately install the systemsystem – a big advantage.

rejects, are uniformly broken down.

again just like this. The waste and“The system is sophisticated,”

Boiler with optimum efficiency

energy system absolutely pays off.”
Contact

reports Dr. Haas. “If the desired fuelmixture ratio cannot be kept within

Now the new system has been runningthe defined limits even just for two

for a few months, Dr. Andreas Haas

minutes – for example, due tosums it up: “With the residual material

obstruction or material change – theboiler and the gas and steam facility,

fuel is automatically transported back

we produce our energy completely by

Lucas Menke
lucas.menke@voith.com“We would immediately install the system again just like this.
The waste and energy system absolutely pays off.”		Dr. Andreas Haas

Possible savings in waste disposal costs in Europe
Recovered paper use:

53,3 Mio t /year

Rejects and residual materials that are created:

2,9 Mio t /year *Possible savings in waste treatment:

139 Mio euro/year *** In the board and packaging area, between 3 and 8% residual materials are created. For calculation purposes 5.5% was assumed.
** The price fluctuates between 30 and 65 euros. For calculation purposes, waste disposal costs of 48 euros per ton were assumed.
Note: This can only be implemented in about 1/3 of the systems, generally with several interconnected plants.

28 I 2009 I Voith Paper I twogether

11new plants

The first paper machine in India with the online coating method – Bhigwan PM 2.

Bhigwan PM 2 with online coaters sets new standards

Unique in India
The new PM 2 of Ballarpur Industries Limited (BILT) in Bhigwan, in the state of Maharashtra in India,
is setting new standards for graphic coated paper. Bhigwan PM 2 is the first and so far the only paper
machine in India featuring the online coating method. Ultimately, BILT decided in favor of the online
method because, along with lower investment costs, it also has lower operating costs.
BILT operates the Voith PM 1 offline

the five production locations through-and Voith ultimately agreed on amachine at the same location veryout the country, BILT produces morenarrower Perfect Fit online variant. It

successfully and can, therefore, directly

than 50% of the wood-free coated

met the market requirements in India.

compare the two methods daily.

paper needed in India. In doing so, an

The extensive technical discussions

annual output of over 500,000 tons ofand negotiations with BILT’s technical

BILT, as part of the approximately

pulp and paper is achieved. BILT isteam stretched out for over a year

US $3 billion Indian group Avantha,

thus among the top 100 of the largest

altogether. On March 22, 2007, theis India’s largest paper manufacturer

paper manufacturers worldwide. After

negotiations ended with the signingand one of the most efficient produc-

discussing an offline coating methodof the contract for supply of theers of printing and writing paper. At

initially, and a wider machine, BILT

Bhigwan PM 2 production line.

12

28 I 2009 I Voith Paper I twogether

New plants

Large delivery

same location, two older paper
machines, manufactured in 1988.

Voith Paper’s delivery includes theentire line, starting with stock prepa-

The entire wet end process, i.e.

ration, the approach flow system in-

the approach flow system including

cluding broke preparation, the com-

TurbAir vacuum system, broke

plete paper machine with auxiliary

preparation, fiber recovery, headbox

equipment and the online coating

pump and also process pumps andmachine all the way to finishing withthe complete instrumentation are

the offline Janus calender andalso included in Voith’s delivery.

VariFlex winder.

Together with the basic engineering

Stock preparation includes both preparationlines for short and long fibers.

originating from Voith and the excelStock preparation includes bothlent teamwork with BILT, this allowed

The press concept was also

preparation lines for short and long

optimal coordination and integration

convincing

fibers that are equipped with TwinFloof all process components. The

double disc refiners. Mixed tropicalresult was a speedy and successful

The Tandem NipcoFlex press was

hardwood from sustainable timber

start-up in December 2008.

selected for low two-sidedness ofstands and pine are primarily used

the paper, high dry content afteras the raw materials. The raw

The structure and design of thethe press with the lowest possible

material is supplied on the one hand

PM 2 is modeled heavily on thevolume loss and the highest runna-

via market pulp and on the otherworld’s largest wood-free coatedbility. Like the online coating method,from their own pulp production.

paper machine, the Dagang PM 3

this press concept is a novelty for

Sabah Forest Industries (SFI) in

in China. There are differences

India and first had to win over the

Malaysia, which was recently

though, especially in the area oftechnical team at BILT.

acquired by BILT, also ensures awidth and machine speed and also

more independent and sustainable

in the former. The Bhigwan PM 2 isIn addition, the single-tier TopDuoRun

supply of raw material. It operates

equipped in the front wet end with apre-dryer section, the 1x2 EcoSoft

a pulp mill on Borneo in the Sipitang

ModuleJet headbox and DuoFormer

calender and the SpeedSizer used

Province in Malaysia and, at the

D for the best formation.

for precoat and sizing are included

Technical specifications
Bhigwan PM 2Paper grades: 	online wood-free coated (single and double),wood-free uncoated
Production capacity (gross):

655 tons / 24 hours (based on 100 g/m²)

Wire width:

5,400 mmMax. paper web width at the reel:

4,810 mm

Design speed:

1,100 m/min

Max. operating speed:

1,100 m/min

Raw material: b l. short-fiber pulp
bl. long-fiber pulp
filling

70 - 85%
15 - 30%
10 - 15%28 I 2009 I Voith Paper I twogether

The DuoFormer D provides for the bestformation.

13

new plants

A 10-roll Janus MK2 calender provides for optimum
surface treatment.

The successful start-up team in Bhigwan.

in the delivery. Finally, the online dual

MK2 calender provides for optimum

system (MCS/ DCS) and quality

top coat coating machine followedsurface treatment after coating. The

control system (QCS) of the machine,

the flotation dryer and the two-tiersophisticated and stable 45° design

including five scanners from Voith.

CombiDuoRun after-dryer section.

allows the quickest roll changing

That was advantageous for theHere DynaCoat AT coaters withtimes and partial deadweight relief insmooth and speedy start-up, since

JetFlow technology for optimum

the nip. The VariFex winder with its

there were hardly any interfaces

coat application are used.

two specially rubberized reel drums iswith an external system. Initial general

responsible for optimum reeling con-coordination problems with optimizing

In addition to the main components,

ditions during winding of the second-the drives of the customer’s motor

auxiliary equipment such as hood

ary rolls.

supplier, especially in setting thetechnology, steam and condensate
systems, central oil lubrication, paper“pulls” in the various areas, were
Speedy start-up possible

web run, edge trimming preparation

eliminated through the cooperationof all parties.

and splash water system are also partIn addition to the proven machine

The machine operators who wereof Voith’s delivery. A 10-roll Janus

units, there was also the entire control

originally accustomed to various

Customers visit Voith Paper in Heidenheim,
Germany (from left to right):
Joachim Huber, Regional AccountManager Asia;
Dirk Thomas, Start-Up Engineer;
R.R. Vederah, Managing Director BILT;
Kurt Brandauer, CEO of the Division ofPaper Machines;
SK Khurana, Senior Vice President
Projects & Engineering;
Carl-Heinz Becker, Project Manager;
and Manfred Wagner, Project Manager.

14

28 I 2009 I Voith Paper I twogether

New plants

2008. Twenty days after installation
was completed, the start-up was
authorized and at the beginning ofApril 2009 the operation test run

Location
India
New Delhi

requirements for wood-free coatedBhigwan,Maharashtra
Ballarpur Industries
Limited (BILT)

paper were already met. Along withthe extremely professional and cooperative collaboration between BILT
and Voith, Voith’s Indian joint venture
partner of several years, Larsen &Toubro Limited (L&T), also contributed
to the successful installation of
The DynaCoat AT with JetFlow technology
provides for optimum coat application.

the new Bhigwan PM 2. From the
Kansbahal plant in the state of Orissa
in India, L&T supplied essential parts

external units were won over byof the dryer section, especially thethe easy operability of the Voithmachine frame and also dryer cylinder

Automation solution. The customer’sand various other rolls and parts ofpersonnel were all intensively trained

stock preparation, all the way to thefor the start-up and to maintaincalender machine frame.

The city of Bhigwan in the state ofMaharashtra in India has about 9,000
residents. The BILT paper mill is 5 km
outside the city. Baramati, a gold andsilver city with a large industrial area
and about 100,000 residents, is 40 km
from Bhigwan.
Contact
Joachim Huber
joachim.huber@voith.com

lasting success for the project. An
extensive training program wasNow, due to the Bhigwan PM 2, BILT

carried out for the future operating

can further expand its market leadershipand maintenance personnel by start-in India and together with Voith has

up supervisor, Peter Spreng, andcreated a showpiece for online coated

other Voith experts. About 13 months

wood-free paper production in India.

after the contract came into effect,

Production capacity for wood-free coat-

installation of the PM started in May

ed paper at the Bhigwan location can

2008 and successfully concluded

now be increased from the previous

after seven months on November 28,

125,000 to 315,000 tons per year.

“We look to the future with confidence and are sure that thissuccessful project will advance our economic success.”
R.R. Vederah, Managing Director“Since start-up, the performance of the PM 2 has completely met the high aims that we set when selecting Voith as ourmachine supplier. Along with their partnership during the design phase and prompt completion, Voith also supported us in
the further development of paper qualities. We look to the future with confidence and are sure that this successful projectwill advance our economic success.”

28 I 2009 I Voith Paper I twogether

15

new plants

The VTM 2 tissue machine at SEPAC.

Dr. João Ferreira Dias, President of SEPAC (left)
and Nestor de Castro, President of Voith Paper
South America (right) in front of the VTM 2.

Standardized tissue machines ensure cost-efficient production

SEPAC relies on tissue technology from Voith
Voith Paper has defined five standardized machine types for tissue production which lead to costefficient production. At the same time, they meet the high quality standards that the market demands.
At SEPAC in Mallet, located in the state of Paraná, Brazil, a tissue machine of the type VTM 2 hasbeen successfully producing high-quality tissue paper since summer 2008.
With the aim of making tissue machines even more cost-efficient, Voith
Paper defined standardized machinetypes for tissue production. The
VTM 1

VTM 2

VTM 3

VTM 4

VTM 5

Web width at
the reel [mm]2,200-2,800

2,700-3,000

2,700-3,600

2,700-5,500

4,500-5,600

Design Speed[m/min]

1,300

2,000

2,200

2,200

2,400

Yankeediameter [m]

3.66

3.66
4.57
4.88

4.57
4.88
5.49

4.57
4.88
5.49

5.49

Production at thereel [to/day]

75

125

150

230

245

requirements of various customers
worldwide can be met within thisrange. In addition, economical
production with high quality
standards is made possible.
Altogether, five standard tissue machines from the VTM 1 to the VTM 5
are offered. The main differences arein the machine widths and the sizeof their Yankee cylinders, which resultin different speeds and production
quantities (Fig. 1).
This standardization is of special

Fig. 1: Standardized machine types for cost-efficient production.

16

significance for markets in emerging

28 I 2009 I Voith Paper I twogether

New plantscountries and developing countries

Voith Paper Yankee cylinder andsuch as in Latin America, Asia

the standardized MR 100 reel withand Eastern Europe. But it is also

hydraulic primary and secondary

important for markets with high costarms.

Location
Brazilpressure such as Western Europe.

Brasilia

Here, the need for the most techno-

Thanks to the outstanding teamwork

logically modern systems with

between SEPAC and Voith Paper

simultaneously reduced investment

and the efficient project coordinationbudgets has to be met.

during the construction phase andalso during start-up, the system

A perfect example of the competitive-

successfully went into operation on

ness of standardized Voith tissue

July 6, 2008. Since then, SEPAC has

machines is the new VTM 2 standard

continuously increased the produc-machine, which was sold in May

tion speed towards 1,600 m/min

2007 to SEPAC, a fast-growing tissue

and has produced tissue paper in the

producer in Brazil. The VTM 2 wasbasis weight range of 14 to 35 g/m2.

designed for a speed of 1,600 m/min

A new product from SEPAC is partand a working width of 2,760 mm.

of this: two-ply toilet paper.

Mallet, Paraná
SEPAC

The small city of Mallet, with 13,200
residents, is in the federal state of
Paraná in Brazil. Curitiba, the capital cityof Paraná, is 230 km away.
Contact
Rogerio Berardi
rogerio.berardi@voith.com

It produces up to 80 tons of tissue
This successful project has strength-

paper per day.

ened the relationship between
Among the main components of

SEPAC and Voith even further andthis system are the Crescent former

shows that Voith Paper is on theand the new single-layer MasterJet II

right path with the standardization

T headbox which was speciallyof tissue machines. The significant

developed for optimum formation.

cost reductions through standardiza-In addition, among the key compo-

tion allow globally cost-efficientnents are a suction press roll in thetissue machines to be offered withpress section, the well-known 4.57 m

the most modern technology.

“SEPAC is now prepared to meet the increase in demand forhigh-quality tissue paper on the Brazilian market.”
Dr. João Ferreira Dias, President SEPAC“Due to the excellent performance of the new Voith Paper tissue machine, we were in a position to increase our
production capacity to 72,000 tons/year and noticeably improve the quality of our products. SEPAC was thus able
to develop a unique product range and expand into new market niches such as two-ply toilet paper. SEPAC is now
prepared to meet the increase in demand for high-quality tissue paper on the Brazilian market.”

28 I 2009 I Voith Paper I twogether

17

REBUILDs

World record for efficient stock preparation set at Rhein Papier in Hürth

Combiscreening helps exceed targets
The PM 1 paper machine from Voith Paper runs at full speed at Rhein Papier, where, in March 2009,it set a world record of 2,010 m/min. To achieve this production level, Voith Paper set up an effective
new Combiscreening arrangement for stock preparation, at little expense.
Since 2002, the Myllykoski Group has

However, the arrangement, in

new machine in pre-screening. It

produced newsprint made of 100%concert with the fine screening atforms the intelligent link between hole

recycled paper on the PM 1 at their

Rhein Papier, experienced veryscreening and slot screening, re-Rhein Papier plant in Hürth. Althoughgood removal efficiency, including

moves all coarse impurities, and cali-

only in its first years of operation,effective stickies removal.

brates the stock for treatment withthe paper machine had alreadyfine slots. The two first-stage screens

tapped its full speed potential by“Our challenge was to maintainremain unchanged, while the screens

2005, and the stock preparation

the quality of the stock at a higherof the second and third stage now

system could no longer keep pace

production quantity,” reports Guido

form the slot-screening arrangement,with the machine. As the machine’s

Clemens, Director of Technology

coupled in partial stream. They are

production capacity increased andat Rhein Papier.

equipped with the FiberLoop, whichstock preparation lagged, moredecreases rejects thickening and re-impurities accumulated. The result

Combiscreening instead of holeduces fiber loss, in the new third andwas operational malfunctions andscreening

fourth stages.

increased maintenance work.
Voith Paper found the solution in

The Combisorter has already proven

An analysis by Voith Paper and Rhein

combiscreening. It combines robust,

itself several times in graphic paper

Papier found a bottleneck in the

two-stage hole screening with effec-

and packaging systems. Its applica-

three-stage hole screening arrange-

tive slot screening, and it no longer

tion to stock prep in Hürth wasment. Up to that time, the screens

requires two slot-screening arrange-

quickly successful as well: Since

had perforated cylinders with aments in full stream.

the autumn 2007 retrofit, production

1.0 mm hole diameter. In addition,

capacity of pre-screening is up to

reject lines, valves, and screens were

The Combisorter, coupled with a

20% higher than before. In addition,

overloaded.

cleaner, was installed as the only

flotation was optimized. Stock

Richard Thalhofer (left) and Guido Clemens (right) in front of the new Combisorter.

“What impresses me is that Voith Paper very effectively implemented the changes in stock preparation with little expense.”
Richard Thalhofer, Process Engineer in stock preparation, Rhein Papier

18

28 I 2009 I Voith Paper I twogether

REBUILDs

After the retrofit:

Before the retrofit:

Dump tower

Dump tower

Before the retrofit: hole screening as pre-screening.

After the retrofit: Combiscreening as pre-screening.

preparation now exceeds the 1,000 tons

consistencies and overflow rates cantonnage of 302,000 tons. In April

per day that Rhein Papier had aimed todrop by approximately 20% overall.

2008, the PM 1 reached world-record

achieve. By comparison, the previous
best result was 880 tons per day.
Records celebrated

speed with 1,980 m/min over
“What impresses me is that Voith

24 hours. At the beginning ofPaper very effectively implemented

March 2009, the bar was raised

the changes in stock preparation witheven higher with 2,010 m/min.

little expense,” says Richard Thalhofer,“We have not only maintained

Process Engineer in stock preparation

the quality of the stock, but evenat Rhein Papier. “We had low invest-

improved it: Sticky removal inment costs and low retrofitting

pre-screening improved by about

expenses. At the same time, the30%,” sums up Guido Clemens.

specific energy costs have not risen.”

Even critical impurities, such as

Along with the stock preparation

Styrofoam™, are effectively removed.

retrofit, Voith implemented additional

The two end stages of hole screen-

upgrades to optimize the PM 1. It

ing, the Combisorter and the Multi-

did not take long to set records:

Sorter, can be set to handle whatever

In 2008, Rhein Papier surpassed its

impurity range comes up. Stockproduction target with a record annual

Location
Germany
BerlinHürthRhein Papier
Myllykoski GroupThe city of Hürth is in North Rhine-Westphalia, just 9 km from Cologne. It owes
its origin to the development of the
Rhenish brown coal district at the endof the 19th century. Today, along withlarge-scale industry, the media areamong the significant economic factors“We have thus not only reached ourtargets, but exceeded them.”
Guido Clemens, Director of Technology at Rhein Papier

28 I 2009 I Voith Paper I twogether

in this city of 60,000 residents.
Contact
Armin Volkarmin.volk@voith.com

19

REBUILDs

Fig. 1: Space can be saved with the 1x2 Delta and the
1x2 V-framing of the EcoSoft calender.

Tapping potential for improvement on calenders

Satinage made to measure
Good printability, optimal running characteristics and outstanding visual characteristics are theessential requirements for modern paper. Today, many calenders are no longer up to these requirements without undergoing some modernization. Two current cases show how calender rebuilds areplanned exactly according to the needs of the respective customer.
Case 1: Palm paper mill,the customer’s paper at Voith

Making best possible use of

Eltmann plant

Paper’s Paper Technology Center

little spacein Krefeld (Fig. 2).
Standard newsprint (coldset offset)

The solution was optimal utilization

was for a long time the successful

As a result, the Voith satinageof the existing space through afocus of the PM 1 in Eltmann. To

specialists recommended a con-combination of a 1x2 Delta and aensure competitiveness, it ought tofiguration of the EcoSoft calender

1x2 V-framing (Fig. 1). In addition to

be possible in the future to producewith 2x2 rolls. To be sure, thisthis, the reel spool was moved 2.5 m

an additional grade, newsprint forsolution did not require anin the direction of the winder. With

heatset offset.

additional steam moistening

simultaneous adaptation of the pulper

unit – however, difficult conditions

under the reel, the space needed forExperiments at the Paper Tech-

resulted due to the additional

implementation was provided. The

nology Center in Krefeld

space requirement. In the end,

EcoSoft calender was equipped witha 2x2 solution had to be fitted inwater-heated FlexiTherm rolls andAs preliminary steps, extensive

place of the smaller, old 1x2 roll

deflection compensation rolls of theexperiments were carried out withcalender.

Nipcorect FX type. Well-preserved

20

28 I 2009 I Voith Paper I twogether

REBUILDs

components of the old calendersystem were integrated into the
new calender concept. The othercomponents were newly designed
and manufactured.
Successful course of the project
The calender was completely
preassembled, put into operationand tested before being transported

Fig. 2: Combination test facility at the Paper Technology Center in Krefeld.

to the installation site. Already five
weeks before the planned downtime

offset and, alternatively, newsprint formeasures introduced did show im-of the PM, the first system units wereheatset offset. Use of the deflection

provements, but were not sufficient

assembled parallel to production.

compensation roll subdivided into

to lift the gloss level from 35-40%

As much as possible, they were

32 zones allows a CD caliper profile

according to Gardner to the desired

piped, electrically connected andof 2 Sigma < 0.7.

46%. Voith was commissioned withinvestigation of the possible solutions.

preliminarily put into operation. In
addition, to support the site supervi-

Case 2: Kübler & Niethammer,

sion and to ensure that there waspaper mill Kriebstein AG

Preliminary investigations
confirm the assumptions

no delay, 24-hour stand-by on callservice of all departments was set up.

This case as well shows how an

The PM 1 went back into production

individual customized calender

It quickly became clear that theafter only 8 days of downtime. All

rebuild can noticeably increase one’s

existing calender was not up to thedeadlines were met; the PM started

competitiveness. Since the LWC

higher requirements and that in the

up promptly and produced the first

papers of the PM 1 based on recov-

end only a fundamentally new calen-reel spool with marketable paper on

ered paper was an outstanding sales

der concept could do justice to thethe afternoon of the same day.

engine for Kübler & Niethammer,

new tasks. Experiments at the Paper

the management decided to further

Technology Center in Krefeld con-strengthen this grade segment. A de-firmed this judgment. An important

cisive factor was the further increasesecondary condition in the implemen-

All goals were achieved with regard toin the quality or gloss level. For thistation of the project was to continue

paper technology as well. The system

purpose, the coat color formulation

using as many parts of the existing

now produces newsprint for coldset

was changed in a first step. The

calender as possible. Within the

An impressive result“Our trust in Voith was warranted.”
Helmut Liesen, Operations Manager PM 1, Palm, Eltmann“Our requirement of being able to produce newsprint for coldset and heatset with our calender was high. Our trust
in Voith was warranted. The qualities we require can now be easily produced by the rebuild calender.”28 I 2009 I Voith Paper I twogether

21

REBUILDs

framework of a detailed analysis of

On target in eight days

the system, considerable optimization
potentials were discovered in the

The specified deadline of eight

threading process of the calender.

days for assembly and commission-

After consultation and discussion of

ing of the calender and the thread-the possibilities, the customer decided

ing system could not be exceeded.

to make use of these potentials andComplete preassembly and – as far

expanded the project accordingly.

as possible – functional tests of all

Locations
Germany
BerlinKriebstein
Kübler & Niethammer
Eltmann
Palm paper mill

new parts assured an orderly
A completely new concept

course of events.

The new calender concept envisioned

The rebuild of the existing calendera modern 2x3 roll Janus MK2 calen-

and the installation of the threadingder. Existing deflection compensation

system took place with high preci-rolls, FlexiTherm rolls and the mainsion. All projected completion dates

drive of the existing calender were

were kept. Already seven hours

integrated. Even parts from previous

after start-up, the first reel spool

rebuilds such as oil heating, edge

was produced on the PM and thetrimming and bearing lubrication cansecond reel spool proved to be

be found in the new concept (Fig. 3).

marketable.

Fig. 3: Rebuild concept for the Janus calender.

Kriebstein: The township of Kriebstein,with approximately 2,500 residents, is in
the district of Mittelsachsen. The medieval
castle and the Kriebstein dam attract thousands of visitors annually to this area.
Eltmann: The city has around 3,400 residents and is in Bavaria’s district of Lower
Franconia. The township in the Main valley
is regarded as the northern entrance gate
to the Steigerwald Nature Reserve.
Contacts
Peter Herbrik
peter.herbrik@voith.com
Article Eltmann
Franz-Josef Otto
franz-josef.otto@voith.com
Article Kriebstein“In Voith, we see a strong and reliable partner.”
Klaus Ziege-Bollinger, Chairman of the Executive Board, Kübler & Niethammer“We are very satisfied with the rebuild that was carried out. Our expectations have been met without exception. We felt
relatively secure and well-advised during the project phase. The measurable results now confirm this feeling. The gloss
level of the paper produced was raised to exactly 46%. Downtimes due to paper breaks were substantially reduced bymeans of optimizations of the threading system. In Voith, we see a strong and reliable partner on whose competence
we will certainly rely in future cases.”22

28 I 2009 I Voith Paper I twogether

REBUILDs

Modular control system rebuilds for winders

More reliability with low capital expenditure
Sappi eliminates risks at the winder with the modular control system rebuild. The plant in Lanaken
is now protected against unplanned downtimes. The planning of the project according to the
Perfect Fit concept accurately uses investments and seamlessly integrates existing, functionallystable components. Possible later use of further rebuild packages makes the control system rebuild
future-proof.

28 I 2009 I Voith Paper I twogether

23

REBUILDs

Fig. 1: The old DOS computers (left)
are replaced by new Windows-based
PCs with current technology (right).

Winders have worked reliably andto failure of individual assemblies.

control desk and technology

safely over many decades. But

Exacerbating this is a lack of supply

components that belong to thecontrol system technology hasof replacement parts, which often

control system can be adapted toadvanced significantly over the last

can no longer be obtained. For thistoday’s requirements, independently

few years. Previously, standardized

reason alone, longer downtimesof one another and in any order.

controllers in Z80 technology

have to be expected.

Due to the fact that the rebuild or

were used to carry out technicalfunctions such as positioning

replacement is limited to at-risk
Modular concept – Perfect Fit

tasks or linear load controls.
Today, a standard Siemens S7
PLC can do these tasks (Fig 1).

components, the risk of downtimes
is drastically reduced, on the one

Modular control system rebuilds

hand, and the investment budget

for winders are part of a series ofis spared, on the other. Elements

Perfect Fit solutions from Voith. Itthat are not so prone to error and

The age of control systems fromis an excellent example of how

have a good supply of replacement

the ’70s and ’80s makes them acustomized solutions can achieveparts remain fully integrated. They

downtime risk. In addition, their large

set goals with a reasonable

can be modernized at a later time withnumber of components often lead

investment budget. The controller,a further rebuild package.

Fig. 2: VariTop winder at Sappi in
Lanaken, Germany.

24

28 I 2009 I Voith Paper I twogether

REBUILDs

ControlInterface

Technology

S5

Control desk

Teleset,Telebock
LDS, ZHZ
Jagmatic DOS

S5Control desk

S7 VariTronic WinCC

BeforeAfterModernization
options

Location
Belgium

Brussels

Lanaken
Sappi Fine Paper

S7 VariTronic WinCC

Fig. 3: Comparison: before - after, including further possible modernization options.

The township of Lanaken is in theeast of Belgium. Close to the Dutch
border, Lanaken has approximately

Field report

the entire wiring was retained and25,000 residents.

costs and time were saved.
Contact

Sappi Fine Paper produces coatedgraphic paper with a capacity of

Separately, the stop counter was

500,000 tons/year at the Lanaken

eliminated and the angle encoders

location. After some age-related

were replaced by new types or bydifficulties with the control system ofa magnetostrictive sensor for thethe VariTop (Fig 2), the company

slitter positions. The system can bedecided in favor of a technology up-

comfortably operated via an industrial

grade on the winder. The requirement

PC with a WinCC user interface.

for an open system that is easy to

Maintenance and replacement parts

maintain had to be met.

procurement is thus assured. Smaller

modernized, then the machine

Egon Bildegon.bild@voith.com

repairs can be carried out with little

functions can be smoothly integrated

The existing computer systems weretraining expense by a company’s

in the S7 that is now installed (Fig 3).

replaced by a Simatic S7. Whenown operating personnel. If at a

Operation is then done exclusively

replacing the old computer cabinets,

later time the PLC is also to be

via the operator station.

“Voith only suggested to us what wereally needed in this situation, nothing more.”
Alfons Loyens, SHEQ Engineer Finishing PL8, Sappi Limburg – Lanaken plant“It was important to us that we didn’t have to replace functioning elements of the control system. The integrationof old and new was no problem. We were thus able to use our investment funds in a targeted fashion and despitethat eliminate the problems and risks of the old control system. Voith only suggested to us what we really neededin this situation, nothing more. And that was convincing.”

28 I 2009 I Voith Paper I twogether

25

Products

News fromthe Voith Paper
product world

26

28 I 2009 I Voith Paper I twogether

Products

Optimization goals at a glance

Smart products – great effects
It doesn’t always have to be the construction of a new paper machine or the major retrofitting of an
existing system – even small solutions can achieve a big effect. Voith Paper offers over 200 clever
optimization products and services with major customer benefits. That’s over 200 ways to improve theproduction process with low investment costs and a high return on investment. We present a selectionof them in each issue of twogether.
So that you can see at a glance the

ProSafety – improves work safe-

ProQuality – increases surface

goals that can be achieved with eachty and thus health protection

efficiency and achieves a higher
level of quality

product, we have introduced symbols
that can now be found at the end of
the product and service articles.

• Protection from injuries (intervention
protection, maintenance of safetyrelevant parts)

By assigning up to four points per• Reduction of noise and emissions

goal, the benefit of a product can bequickly illustrated.

ProEnvironment – conserves
resources and thus the environ-1 means “minimal” influence,ment

2 = significant,3 = above average and
4 = used primarily for this reason.
In the text it looks like this:• Lowers water consumption• Reduces energy consumption• Reduces use of chemicals

ProSafety
ProEnvironment
ProRunnability
ProQuality
ProSpeed
ProSpacecross profiles• Improves formation• Reduces two-sidedness• Increases specific volume• Improves printability• Improves paper characteristics• Reduces the amount of broke, reduces changeover broke (quicker gradechange)• Increases usable paper web width(retention agents, cleaning)• Uses raw materials better
On Focus• Improves surface longitudinal and(increases raw material efficiency)

ProSpeed – increases the production capacity• Reduces oil leakages
ProRunnability – increases
the running time efficiencyof the PM• Increase in production speed due to:• higher dry content after press• higher drying performance in thedryer section• drives that allow higher speed• Reduces downtimes (for cleaning,
upkeep, clothing change)• Reduces downtimes, increases

ProSpace – with limited spaceconditions

security against unscheduled
The optimization goals of ProSafety,
ProEvironment, ProRunnability,
ProQuality, ProSpeed and ProSpaceare differentiated.

stoppages• Reduces breaks• Quicker threading after breaks,
change or transfer at production
speed/higher speed, e.g.,

What lies behind these various labels
is explained in more detail below:

28 I 2009 I Voith Paper I twogether

through flying splice• Reduces time for grade change• Retrofits that also function withlimited space conditions or allow a
production/quality increase without
extension of the machine• Products that require less spacethan comparable products fromcompetitors

27

Products

Single Nipco
Experts are always seeking out new application areas for the Single NipcoFlex press.

Proven concept – not just for copy paper

Single NipcoFlex – breaking out to new paper grades
It is now more than six years since the first Single NipcoFlex press was put into operation. It quickly
developed into a bestseller. Then, as now, the low investment and energy costs were especiallyappealing. Today seven Single NipcoFlex presses are being used to produce wood-free copy, writing,and printer paper. In the future the presses will also be able to be considered as alternatives forcoated and wood-containing paper.
These days budgets for new

dream. However, installation of a

A valuable treasure trove ofmachines and rebuilds are being

Single NipcoFlex press can makeexperiencecut massively, leading to the obvious

this dream come true.

desire for a low-cost but high-There are currently seven Single

performance press section, which

Apart from investment and energy

NipcoFlex presses in operation.

should then also be characterizedsavings, maintenance andIn August 2006, PM 1 in Docelles,

by low operating and especiallyclothing savings are also possible.

France, was converted to a Single

low energy costs. The requirements

The cost advantages of the single

NipcoFlex. This represented a tech-list sounds like an unattainable

press are summarized in Fig. 2.

nological challenge. For one thing,28

28 I 2009 I Voith Paper I twogether

Products

with high smoothness values, are

Khon Kaen PM 1

made on this paper machine. For

Basis weight

70 g/m²

another thing, a multitude of grades

Filler content

14%

are produced, meaning that speed,

Bulk

1.30 cm³/g

furnish, and additives as well as

Bendtsen roughness(mean)

110 ml/min

Bendtsen roughness(two-sidedness)

5%basis weight must be changed
frequently. The latter, especially,

Solids content [%]very demanding qualities, in partwas classified as critical in advance

60
58
56
54
52
50
48
46
44
42

400

500

600 700 800 900 1,000
Line load [kN/m]

because a real test of the process
Fig. 1: Khon Kaen PM 1: The paper exhibits a high bulk with a high smoothness and a low
two-sidedness at solids contents after the press of much higher than 50%.

stability with frequent grade changes
cannot be realized on the pilot paper
machine.
Through the combination of the single

With the experience from the single

the outstanding furnish, a very

press with two Softnip calenders,presses that was now available,

good bulk and a high smoothness

the quality specifications could bestart-up of the next two new machines

can be achieved in Khon Kaen

achieved. The machine speed andwith Single NipcoFlex presses waswith the Single NipcoFlex press

stability improved step-by-step, withnearly child’s play.

at extremely high solids contents.

the use of Voith press felts especially

Even with the load on the press

contributing to the progress. The

In April 2008, PM 1 in Khon Kaen,

eased considerably, press solids

moisture profile was significantly im-

Thailand, was put into operation, andabove 50% are achieved on thisproved. This, in turn, enabled thein February 2009 the PM 1 in Tres

machine (see Fig. 1).

moisture after the predrying section

Lagoas, Brazil, was started up. The

Good news can also be reported

to be increased. The drying capacity

stable, high solids contents of bothfrom the six-year-old single press

thereby gained was then immediately

machines made it possible to in-being used on PM 18 in Ruzomberok,

converted to an additional increase increase the speed significantly in the

Slovakia. It is continuously improving

speed.

shortest amount of time. Thanks to

its production speed.

Maintenance

EnergySingleTandem DuoCentri
NipcoFlex NipcoFlex NipcoFlex+ 4thWire Width

Max. Production
Speed (Design)

Start-Up

Ruzomberok PM 18 Copy

7,300 mm1,400 m/min

Sept. 2003

Ledesma PM 1

Copy (wf: 60–140 g/m²)

4,220 mm

1,000 m/min

May 2004

Merebank PM 31

Copy (wf: 60–100 g/m²)

6,370 mm1,300 m/min

Sept. 2005
Nov. 2005

PM

Main Products

Vacuum requirements[Nm³/h]100%

Installed drive power [kWh]

100%

190%

165%

Downtime

100%

130%

135%

n.n. USA

wf: 75–90 g/m²

9,500 mm1,200 m/min

Press sleeves

100%

200%

100%

Docelles PM1

Copy (wf: 60–160 g/m²)

4,350 mm1,200 m/min

July 2006

Clothing costs

100%

130%

100%

Khon Kaen PM 1

Copy (wf: 60–120 g/m²)

5,850 mm1,300 m/min

April 2008

Investment costs

100%

155%

165%

Tres Lagoas PM 1

Copy

5,850 mm

1,250 m/min

Feb. 2009

135%

155%

wf=woodfree
Fig. 2: The cost advantages speak for themselves:
Comparison of investment and operating costs for various press
designs for manufacturing copy paper with no two-sidedness.

28 I 2009 I Voith Paper I twogether

Fig. 3: Reference list for currently installed Single NipcoFlex presses.

29

Products

By now copy paper has already been

tions around the world. Two referenc-

The challenges are manifold. Produc-

produced at over 1,600 m/min. This is

es are in Europe, three in America,tion of wood-free coated paper arises

an impressive achievement for thisone in Africa, and one in Asia. A

as the next application case. Purely

paper grade and simultaneously astrong exchange of information isin terms of the dewatering behavior

world record for single-nip presses.

maintained with all customers. The

and the expected pollutant load,

PM 18 was originally designed for acorresponding service employees

the furnish qualities used are very

maximum speed of 1,400 m/min.

and technologists are always

similar to those used for copy paper.

available. Through the local presence

In extensive process trials with

In contrast, PM 1 in Ledesma, Argen-of the service employees, strong

subsequent print tests, the quality

tinia, is the first machine with a Single

on-site support is ensured. Thisdifferences in comparison with

NipcoFlex that is being used in partallows the best design regarding

conventional press designs wereto produce high-quality coatedmachine construction and clothing

investigated. The quality of the paper

grades. This demonstrates the poten-

to be provided to every Single

from the Single NipcoFlex wastial of this design.

NipcoFlex operator.

definitely convincing. Fears that the

Further development as aSingle NipcoFlex – what’s next?

surface quality in particular could
key to successsuffer from the hefty pressing in asingle press nip were clearly crushed.

Due to the success of copy andDevelopment of a press design iswood-free uncoated paper, the ques-

As expected, papers from various

never over, even after the machinetion naturally arose as to whether orpress systems differ in terms ofhas been started up. Each installation

not a Single NipcoFlex could also be

parameters such as bulk, porosity,

brings with it new challenges. Hence,used for projects with other paper

and internal bond strength. For this

it is important that the machine op-

grades. Within the framework of anreason, for every single customer

erator and the supplier are always inextensive development project, Voith

project, the advantages and dis-a dialog – even long after the start-up

investigated the possibilities andadvantages of the various designphase. The Voith single presses arelimitations of the Single NipcoFlex

alternatives must be weighed. The

now distributed over numerous loca-

for other paper grades.

single press can now also be viewed

Fig. 4: In March 2009, PM 18 achieved a world speed record forsingle presses by running at 1,600 m/min.

30

Fig. 5: Simple concept, sophisticated details:
Design of the Voith Single NipcoFlex.

28 I 2009 I Voith Paper I twogether

Products

as an alternative to the tandem press

55

machine design provides a precalender and a starch application.
Greater obstacles must be overcomein the use of the Single NipcoFlex
with wood-containing grades.

Solids content [%]in particular, especially if the overall

Special clothing
Single NipcoFlex

53
51
49
47

Considerably higher peak pressures

Standard market clothing
50

75
Line load [% of design maximum]

100

Fig. 6: Solids content
after the Single NipcoFlex
press on the pilot paper machinefor newspaper production at
1,800 m/min.

in the press nip are necessary inorder to achieve the required solids
content for fast machines. Besides
this, the furnish used contaminates

How, though, are these highstandard design for wood-containing

the felts more than it does withsolids contents possible after astocks and extremely high speeds.

woodfree paper. This occurs,

single shoe press nip?

for example, with recycled

Despite this, in the future thepaper-containing furnish with highEven in classic press systems

Single NipcoFlex press design will

stickies content. Particular attention(considerably lower), and even in theincreasingly come into considerationmust hence be paid to the combina-

two shoe press nips of the tandem

as an alternative for projects in thetion of clothing used and suitablepress together (barely higher),wood-containing area. It is simply

machine construction during

dewatering performance is achieved.

unbeatable in terms of investment

development. Voith is ideally

Two factors are decisive for this.

and operating costs.

equipped for these development
types in particular. Clothing and

The Single NipcoFlex uses a shoemechanical engineering experts

length that achieves a considerably

work hand-in-hand so that thishigher dwell time in the press nip

goal can be promptly achieved.

than in the sum of three or fourroll nips in series. In addition, theOn Focus: Single NipcoFlex Press

fiber web is dewatered on both

ProEnvironment

sides along the entire press length.

ProRunnability

How high can the press solids

The two felts in the Single NipcoFlex

ProQuality

actually be for wood-containing

have a difficult task to accomplish.

ProSpeedfurnish with the use of the corre-

They have to handle the total water

ProSpacespondingly adapted clothing?

and pollutant load in the press

The answer even surprised thesection. In doing so, they must

Section: press

Voith experts.

work stably to ensure that process

Width: all

fluctuations have practically no

Paper grade: woodfree coated andWith just a single press, newspaper

effect on the dryness after theuncoated

could be produced on a trial scalepress.

Trials with surprising results

at a speed of 2,000 m/min, with

Contacta solids content after the press

The compensating effect of several

being much higher than 50%. The

press nips in series does not exist inbasic requirement that a press

the single press. Hence, it will still

design must fulfill for high-speed

take some time before the Single

machines was, therefore, met.

NipcoFlex press also becomes a

28 I 2009 I Voith Paper I twogether

Georg Kleiser
georg.kleiser@voith.com

31

Products

Dr. Jan Klingele trusts in
new innovations, true to the motto:With Tempo, Techniqueand Teamwork
Dr. Jan Klingele, Managing Director of the Klingele Group,
is an entrepreneur with an enthusiasm for innovations. He is
the third generation of his family to manage the German,family-owned enterprise founded in Weener in 1920.

Dr. Jan Klingele, Managing Director of the Klingele group.

twogether: Dr. Klingele, your company

Voith Paper “Ahead” Customer

You see, it’s not only about thoroughhas been the very first to invest in the

Conference in May 2004, when I

research and careful realization – you

new Voith Paper BoostDryer technol-

heard about the BoostDryer

also always need a share of luck toogy. Why has Klingele dared to be theconcept for the first time. After thechoose the right future technology.

first?

presentation, I told the Voith staff toKlingele: We trusted in the BoostDryer,

contact me if they needed a partner

twogether: Trusting in new technolo-

for BoostDryer trial operation.

gies may also be risky. What was yourbecause we were highly interested in

major concern beforehand?

improving the technological values by

twogether: How much courage doesa densification of the web. Apart fromit take to make such a decision?

that, the reduced space requirements
were attractive for increasing the drying

Klingele: Even though we had, andcapacity of our pre-dryer section.

still have, great trust in the reliability

BoostDryer enhances the technologicalvalues of the paper.

and performance of our Voith parttwogether: How long did it take youners in the BoostDryer project, it

to decide that you wanted to take thisstill takes a considerable amount of

step?

courage to go first. After all, it’s in
the nature of things that not all trials

Klingele: About half an hour – that isfor fundamental innovations can

how long the presentation took at thebe successful.

32

28 I 2009 I Voith Paper I twogether

Products

Klingele: That our paper production

Klingele: In times of crisis, competi-

reaction and flexibility, our readinesscould be heavily affected by installingtion grows fiercer, and it’s getting

to invest in new technologies and our

the BoostDryer prototype – after

more and more important to produce

aspiration for long-term partnerships

all, we have only one paper machine.

better paper less expensively thanin line with our slogan “With Tempo,

That’s why it was extremely important

fellow competitors. That’s where theTechnology and Teamwork.”

to us that we can bypass the Boost-

BoostDryer boasts advantages over a

Dryer in case any problems occur.

conventional extension of the dryer

twogether: Where do you see yoursection: It offers the possibility tocompany in the future? Where is

twogether: What have been yourimprove the technological values ofthe paper and packaging industry

expectations of the BoostDryer? And

the paper and/or reduce starch andheading?

so far, how have they been fulfilledenergy consumption.
Klingele: I’m optimistic as far as theafter the first phase of operation?
twogether: Your enterprise comprises

future of the Klingele group is con-

Klingele: We expected an increase ofboth paper and packaging production

cerned: We have satisfied and loyal

our drying capacity in combination

facilities. How important is it nowa-

customers, dedicated and qualified

with significantly improved techno-days to combine both branches under

personnel, as well as advanced andlogical properties of our paper. And

one roof?

efficient technological equipment.

of course a reliable, efficient machineThis way, we should be prepared forKlingele: We are happy to combine

the severe competition that I’m ex-

both value-added activities, as it

pecting for the paper and packaging

twogether: What is most important inhelps to somewhat mitigate theindustry in the years to follow.

a pilot project in your opinion?

heavy price fluctuations on the paperthat is easy to operate in practice.

market. Nevertheless, both market

twogether: What is your next goal?

Klingele: Reliable and committed

levels must be competitive on theirpartners with know-how, patienceown. Some companies find it easier

Klingele: Our goal has been, and will

and persistence.

to achieve high efficiency if they focus

be, to remain successful by offering

on one level. This may be an equally

our customers a good value.

twogether: The BoostDryer has

successful strategy than verticalbeen running now for more than aintegration.

year, and global economy is currently
suffering as never before. How do

twogether: What makes Klingele

you evaluate your decision from thespecial, compared to other family-

present point of view?

owned enterprises working in thesame business?
Klingele: Generally, I’d say that on

average, the other family-owned companies in our industry are more similar
to ours than the groups working inthe same business. Maybe you could
say that at Klingele, we are moreconsistently trying to benefit fromOn Fous: BoostDryer
ProEnvironment
ProRunnability
ProQuality
ProSpeed
ProSpace
Section: drying
Width: max. 7,500 mm
Paper grade: packaging papers
Contact
Norbert Karnernorbert.karner@voith.com

the advantages of a family-owned
company managed by the owner.
This includes, in particular, speed of

28 I 2009 I Voith Paper I twogether

33

Products

The kick for every size press

SizeWings AT boost young and old paper machines
You don’t have to be big to be great. Even small equipment can give the essential kick to increase
production or quality. SizeWings AT (Advanced Technology) are one of these small, but clever
products for the paper machine.
Increasing production speeds, while

The SizeWings AT installed up to

Fantastic experiences from

improving paper quality, pose new

now confirm their effectiveness.

Switzerland

challenges to all machine compo-

Every time, significant improvements

nents. In existing size presses, higher

could be achieved. Starch applica-

In Weinfelden, Switzerland, Thurpapier

speeds cause increased splashing intion behavior and size press

Model AG operates two paper machines,

the sump. Heavily soiled size presses,

cleanliness improved considerably

PM 1 and PM 2. The machines are al-

however, are extremely detrimental

in all cases.

most identical in design:Thanks to the improved sump

They produce testliner and corrugat-

behavior in the size press, higher

ing medium in a basis weight range

SizeWings AT are a clever equipment

production speeds are possible.

of 100-220 g/m² on a wire width ofallowing non-splashing starch supply

Production increase, combined with

2,500 mm and are equipped withto the roll nip, thus ensuring a uniform

low investment costs, results in aconventional size presses. PM 2

sump level across the entire web

short amortization time – the cost-produces testliner in a basis weight

width.

benefit ratio could hardly be better.

range of 110-200 g/m². Starch is

to paper production. This is where
SizeWings AT should be used.

Left:
SizeWings AT with moving device forflexible operation of the size press(one-sided or double-sided).

Right:
Without SizeWings, the sump was rather
unsteady.

34

28 I 2009 I Voith Paper I twogether

SizeWing

Roll

Roll

Roll

Capillary action

Sump level

Paper compression

Distribution pipe
RollPaper web

Products

Hydraulic pressure

turbulentlaminar

Starchpenetration

Sump level

Speed
Nip pressure
Roll diameter
Hardness of roll cover

Secondary capillary action

turbulentlaminar

Paper webStarch penetration is influenced by many factors, such as
speed and roll diameter.

SizeWings stabilize the sump behavior.

mainly applied to one side. After

SizeWings AT ensure uniform

plied from the same starch kitchen.

PM 2 had faced increasing problems

paper quality

Cleanliness in the size press increased

with uneven CD strength profiles,

considerably since SizeWings AT

Voith Paper was commissioned toUsing SizeWings AT in PM 2 resulted

have been used. Now, it takes about

eliminate the quality problems. In

in a 50 m/min speed increase to

five shifts for the size press to be

addition, clean size press operation

780 m/min. At the same time, thesoiled as much as before after only

was to be ensured, thus improving

strength values of the end productone shift. The number of web breaks

runnability.

remained unchanged or were evenat the size press has also been

increased at lower basis weights. The

significantly reduced.

“The component meets all papermaker’s demands.”
Ernst Herzog, Technical Manager at Thurpapier Model AG,
Weinfelden/Switzerland

28 I 2009 I Voith Paper I twogether

increased sump level in the size press

Mill Manager Andreas Klumpp andproduces a longer penetration time,

Technical Manager Ernst Herzog havethus improving starch efficiency.

been observing the SizeWings since

A direct comparison of PM 1 andthe start-up in August 2008 and are

PM 2 showed another advantage.

delighted. The equipment has been

The size press of PM 2, which had

functioning since without any prob-

been equipped with SizeWings AT,

lems worth mentioning. “The compo-

hardly reacts to fluctuations of thenent meets all papermaker’s de-starch quality. Whatever the starchmands. Since its start-up, it has not

quality, the end product is always

required any special attention. This is

excellent.

a great advantage,” says Ernst Herzog.

This is easy to prove, since the size

Andreas Klumpp summarizes thepresses of both machines are sup-Swiss experiences:35

Products

Project/Customer

Country Start-up

Paper grade

Basis weight[g/m²]

Paper web Working speed[m/min][mm]

Weinfelden PM 2
Thurpapier Model AG

CH

2008

Testliner

140 – 280

2,500

650

Nine Dragons PM 17
Nine Dragons Paper
Industries (Taicang) Co., LTD

CN

2008

CM

80 – 145

6,860

1,000

Zhejiang LCPC PM 6
Zhejiang Long Chen Paper Co., LTD

CN

2009

CM

90 – 110

6,660

825

Wuxi LCPC PM 3A
Wuxi Long Chen Paper Co., LTD

CN

2009

CM

90 – 110

6,660

825

Zhejiang LCPC PM 5
Zhejiang Long Chen Paper Co., LTD

CN

2008

Testliner

125 – 250

6,660

825

Frastanz PM 2
Rondo Ganahl AG

AT

2007

TestlinerCM

105 – 200

2,600

900

Mannheim PM 6
SCA Mannheim

DE

2004

Grease-proof

29 – 60

3,150

530

Pitten PM 3
Papiererzeugung W. Hamburger AG

AT

2000

Fluting

100 – 200

2,500

1,050

SizeWings AT are suited
for any paper grade.

“I wouldn’t want to do withoutof 125-250 g/m². The maximum

On Focus: SizeWings

SizeWings AT any more!” On theoperating speed is 825 m/min,

ProEnvironment

contrary: The next step is to equipand production is laid out for

ProRunnability

PM 1 with SizeWings AT as well,

400,000 t/year.

ProQuality

thus increasing starch concentration.

ProSpeed
Wuxi PM 3A and Zheijiang PM 6

Three upgrades for Long Chenare identical machines with regard

Section: sizing

to the stock preparation system andWidth: max. 7,500 mm

The Chinese papermaker Long Chenmachine equipment. They achieve

Paper grade: all

Paper chose another way. The

an annual output of 250,000 tons

company immediately orderedof corrugating medium in a basis

SizeWings AT for the three new paper

weight range of 90-110 g/m² withmachines: Wuxi PM 3A, Zheijianga maximum speed of 825 m/min.

PM 5 and Zheijiang PM 6.

Wuxi PM 3A was put into operation

Contact
Martina Eibelhuber
martina.eibelhuber@voith.com

early in 2009 and Zeijing PM 6 by
All three of them are large machines

the end of April.

with a wire width of 7,250 mm
and a design speed of 1,000 m/min.
Voith Paper delivered the complete
stock preparation and approachflow systems for each line.
The three-ply PM 5 in Zeijiang
was put into operation shortly“I wouldn’t want to do		 without SizeWings AT any more!”
Alexander Klumpp, Mill Manager at Thurpapier Model AG,
Weinfelden/Switzerland

before Christmas 2008. It produces
testliner in a basis weight range

36

28 I 2009 I Voith Paper I twogether

Products

Fig. 1: With the PLURALIS family of fillings, the specific edge load is reduced considerably.

Save energy with new refiners and refiner fillings

Changeover to PLURALIS pays for itself
Cost reduction is a top priority in the paper industry. Three examples show how optimizing refiner
fillings can improve energy balance and stock quality – and hence operating costs. The savings can besubstantial: In one case, the mill lowered its annual costs by 193,000 euros (approximately US $257,000).
Fiber refining is assuming an impor-the properties of the paper produced.

Optimization and development oftant role in paper manufacturing:

The high-energy input that refiningrefining machines, and state-of-the-art

It is a key technology in stock prepa-

requires, however, has a negative

components, have a long tradition atration, with far-reaching effects on

effect on operating costs.

Voith Paper.

28 I 2009 I Voith Paper I twogether

37

Products

Refining degree [CSF]
600

100

450

350

250

150

Tensile index [Nm/g]

Tensile index [Nm/g]

80

100

60

80
60
40

Filling
Cutting angle

SEL
Spec. edge load

40º

0.3 J/m

20

20

40º

0.6 J/m0040º

1.2 J/m

40

10

20

30

40

50

60

Refining degree [SR]

1.2

1.3

1.4

1.5

1.6

1.7

Specific volume [cm³/g]

1.8

Bleached eucalyptus sulfate
optimum spec. edge load at 0.6 J/mFig. 2: There is an optimum specific edge load (SEL) for each fiber.

To ensure optimum, energy-savingedge load requires refiner fillings thattechnological properties. Introducing

operation, Voith Paper has developed

exhibit high cutting-edge lengths

PLURALIS also saved energy by elimi-

a wide range of refiner fillings. Our

because the effective refining power

nating the need to run two refiners in

new PLURALIS fillings represent theof the refiner usually must remain con-series in order to achieve refining levellatest addition to that range.

stant (see Fig. 3). To meet these re-specifications. The introduction ofquirements, Voith Paper developed

PLURALIS has also prevented over-

Each fiber has an optimum specificthe PLURALIS family of fillings, tested

loading damage to refiner fillings,

edge load (SEL) for its refining treat-them with customers, and placed

sharply reducing downtimes for thement. For example, the optimum val-

them on the market. These cast fillings

fillings. The Varel papermaker, satis-

ue for eucalyptus is 0.6 J/m (Fig. 2).

make it possible to lower the specificfied with these results, plans to use

Loads above or below the optimumedge load to a very economical level.

this technology in other refining.

Reduction in edge load

10 to 25 percent less energy

refining unit. The refiner filling serves

The Varel paper and cardboard mill,At the M-real Zanders paper mill inas an actuating element here. In prac-for example, used PLURALIS refiner

Bergisch Gladbach, obsolete steep-

tice, the SEL is often too high for thefillings to replace standard refining fill-angle refiners were replaced. They

fiber used. Lowering the specificings. In the production of high-quality

had proven to be uneconomical, very

cardboard grades, PLURALIS resulted

high maintenance, and lacking ade-in a considerable improvement in for-quate capacity for a planned produc-mation and a decisive improvement intion increase. instead, Voith Paper in-quality. A reduction in specific edge

stalled a new short-fiber refining unitload enabled high-quality fibers to bewith four TwinFlo TF1E double diskrefined more intensively, resulting in

refiners. The PLURALIS refiner fillings

improved formation of the outer layers

represented the technological heart

and in lower costs. For high-quality re-of the improvements. Through them,cycled paper grades, the new refining

the specific edge load was lowered asunit fillings enabled significant lower-much as necessary for the eucalyptus

ing of the basis weight of the outerfiber predominantly in use. The pre-layers without compromising theirliminary pilot plant trials performed in

SEL deliver lesser strength values.
Hence, the SEL should be set at alevel appropriate to the design of the

SEL =

Peff
CEL

[J/m]

Peff = Effective power of refining
machine [kW]CEL = Cutting edge length ofrefining unit filling [km/s]

Fig. 3: Formula for calculation of SEL.

38

28 I 2009 I Voith Paper I twogether

Products

Fig. 4: At M-real Zanders in Bergisch Gladbach, this TwinFlo double disk refiner, in combination with a PLURALIS
refiner filling, forms the ideal solution for eucalyptus fiber.

Ravensburg in advance of the invest-

their capacity transferred to an exist-

they enable optimal high capacity

ment were confirmed in practice.

ing refining line with two Beloit double

operation with existing refiners. Now“Through the rebuild, we havedisk refiners. On its own initiative, theStoraEnso in Uetersen has converted

achieved energy savings of 10% tocustomer converted the double disk

another refining line to PLURALIS.

25%,” reports Oliver Kalmes, Produc-refiners from MonoFlo to DuoFlo totion, Papermaking, and Finishingincrease hydraulic capacity. Addition-

These three projects show thatof Cast-Coated Paper Manager atally, the mill needed to transfer theappropriately chosen PLURALIS fillings

M-real Zanders. The rebuild enabled

total refining energy that two double

can help to lower operating costs

manufacture of denser paper without

disk refiners required — without

significantly. The result is more eco-sacrificing its technological proper-

greatly increasing the SEL for thenomical product manufacturing andties; with some grades, long-fiber

fiber mix. Voith Paper achieved

improved product quality. In all threecontent was lowered without losing

this goal by equipping the Beloit

projects, the basis for success was thethe paper’s good strength properties.

DD3000 refiner with PLURALIS

good partnership with the customer.

“Through the rebuild, we have achieved				energy savings of 10% to 25%.”

On Focus: PLURALISProEnvironment
ProRunnability

Oliver Kalmes, M-real Zanders

ProQuality

Because of these modern double

refiner fillings, which can supply the

Section: stock preparation

disk refiners, the mill’s maintenancerequired cutting edge length.

Width: alland filling costs are lower today.

Paper grade: all
The result was convincing: According

Annual savings:

to the papermaker, the sum of all

193,000 euros (US $257,000)

these measures led to annual savingsof 193,000 euros (approximately US

At StoraEnso in Uetersen, an old$257,000). Investment costs wererefining line with five shallow angle

comparatively low. PLURALIS refinerrefiners was to be eliminated andfillings cut costs decisively because

28 I 2009 I Voith Paper I twogether

Contact
Achim Schröder
achim.schroeder@voith.com

39

Products

OnQ ModulePro water-air moisturizer –				the all-rounder for existing systems

OnQ ModulePro compact is the ideal re-moisturizer for systems with a maximum speed of 1,500 m/min.

Water-air moisturizers for every case

OnQ ModulePro – the measure of all things
A high investment budget is not always needed in order to obtain outstanding optimization results.
An improved moisture profile, increases in speed or energy savings can already be obtained withinstallation of re-moisturizers in the dryer section.
A distinction is made between mois-

cally atomized, attain a noticeably bet-

pose outstanding spray quality andturizers with single-substance andter atomizing effect.

exact spray quantity monitoring.

dual-substance nozzles. Moisturizers
with single-substance nozzles are

The OnQ ModulePro product line
All-rounders for existing systems

simply water moisturizers with whichmeets these high requirements with
its innovative dual-substance nozzle

the water is hydraulically atomized

For years, OnQ ModulePro nozzle

and valve technology. Along withand applied. So-called “water-air

moisturizers have been providing

OnQ ModulePro for systems thatmoisturizers” with dual-substancefor high quality and increased cost-have the highest quality requirements

nozzles, in which the spray water isefficiency with modern systems.

(thermo paper, SC paper before thefed into the nozzle air and pneumati-

Optimal moisturizing results presup-

calender), with OnQ ModulePro

40

28 I 2009 I Voith Paper I twogether

Products

compact there is now a solution for

Due to these quality defects, in the

Whereas a water-air moisturizer also

paper machines with somewhat lower

printing plants there are problems

shows its full effect at the last dryer

requirements. However, there are nowith runnability of rolls and therefore

cylinders where the paper still has a

trade-offs in the result.

complaints because of web tension.

residual moisture of 7-9%. Due to theespecially fine atomization of the wa-

OnQ ModulePro compact was newly

Thanks to “Perfect Fit” theter application, it is possible todesigned with two rows of nozzles

cost-benefit ratio is rightinstall OnQ ModulePro compact at

and a 50 or 75 mm zone width espe-

this position in the paper machine

cially for older, existing systems with

With the OnQ ModulePro compact,because the homogeneous spray pat-a maximum speed of 1,500 m/min

Voith Paper has created a “Perfect Fit”

tern with the smallest droplets allows

and a paper web width of up to

solution as an alternative to the simple

an altogether smaller quantity of water

8,500 mm. Moisture problems

water moisturizers. Usually, the invest-

to be applied at the end of the dryer

often appear with these machines,

ment costs for a water-air moisturizer

group. Thus, in contrast to simple

although they are already equipped

are higher than for a water moisturizer

water moisturizers, less drying inwith a water moisturizer or profiler.

with a single-substance nozzle.

the dryer section is required. This

However, for some applications the

But OnQ ModulePro compact pays off

advantage can be used by the pro-

simple water moisturizers are techno-

thanks to its innovative nozzle andduction manager, depending on

logically at their limit.

valve technology, in contrast to simple

the requirement. Either the paper

water moisturizers. With the latter,machine is run faster and thus

This shows in the paper quality:

large droplets come about when

produces more, or with unchanging• Poor moisture profile before theatomizing that take substantiallyspeed less drying is required toreel, the calender or the coater

longer to penetrate the paper. Thus,

save energy.

• Generally unsatisfactory moisturethese simple water moisturizers arelevel (overdrying)• Curling problem (curling tendency)

limited in use roughly up to the middle

By means of the nozzle and valve

part of the dryer group.

technology used, OnQ ModulePro

rizer
moistuSpray pattern during
application

Distribution after 0.5 sec.

Distribution after 1 sec.

Water
-air

Water
m

oisturizer

A simulation test shows: smaller droplets penetrate the paper substantially more quickly and achieve a homogeneous moisture distribution.

Water moisturizer = moisturizer with hydraulic atomizer nozzle
Water-air moisturizer = moisturizer with pneumatic atomizer nozzle,
such as OnQ ModulePro compact

28 I 2009 I Voith Paper I twogether

41

Products

Optimum droplet size

Deflector

Air
Water
Air

Nozzle – othermanufacturer

Air

Air

Principle of operation

Droplet size (quality)

OnQ ModulePro nozzle

Water

OnQ ModulePro
nozzleNozzle – othermanufacturer

Small spray angle

Spray amount (quantity)

The high-performance nozzle from Voith is attractive due to its spray quality over the large spray quantity range (1-25 l/h; 0-70 μm dropletsize). The finer marking-free spray application leads to better paper quality, since the water penetrates the paper surface more quickly.

compact ensures a uniformly remoist-

technical examination in advance thatof the paper was considerably

ened paper and an optimum moistureis carried out by experts from Voith

reduced by dissolving frozen

profile over the entire paper web.

Paper. The OnQ ModulePro producttension. The result: a decline in

A homogeneous moisture distribution

line contains the suitable solution,in the paper and reduced curlingaccording to the customer’s require-tendency are the result.

ment. Several examples show thatof an existing external system atcustomer complaints.

• After the upgrade of 200 zones

not only can problems in the moisturea European SC-A facility, it turned

Upgrade solution for existing

profile be solved with the products

out that by means of a changeover

re-moisturizers

described, but also increases into the V30 nozzle a substantially

productivity can be obtained:

better moisture cross profile canbe achieved.

An inexpensive alternative to acomplete replacement of an installed• In the case of a newsprint machine,

moisturizer is optimization with new

OnQ ModulePro was used with adual-substance nozzles. For this,water application of more than

On Focus: OnQ ModulePro Product Line

Voith Paper has developed a nozzle

3.5 g/m² at speeds of over

ProRunnability

that can be mounted on existing

1,900 m/min for moisture cross

ProQuality

external systems.

profile control and curl control.

ProSpeed

A moisture cross profile improveIn contrast to competitors’ nozzles,

ment (2-sigma profile) of over 65%

Section: drying

the OnQ ModulePro V30 upgrade

was achieved. OnQ ModulePro

Width: all

nozzle has a finer spray pattern overallowed a stable moisture profile

Paper grade: alla larger volume area. Nozzle replace-even with machine speeds of morement is done trouble-free by screwing

than 2,000 m/min.

out the old nozzle mouthpiece and• With the installation of OnQ Module-

screwing in the Voith V30 upgrade

Pro compact with a zone width

nozzle. The spray beam and the con-of 75 mm for corrugated card-

trol remain untouched. Replaceability

board, by means of one-sidedof the nozzle requires a detailed

remoistening the curling tendency

42

Contact
Uwe Fetzer
uwe.fetzer@voith.com

28 I 2009 I Voith Paper I twogether

Products

Thanks to its special measurement, OnC WebDetect detects breaks even under the mostdifficult optical conditions.

No more faulty detections

Brown isn’t just brown any more
Optical differentiation between brown board and brown dryer
fabric is a challenge for break systems. Unfounded break detections are thus often the consequence. However, thanks to anothermeasurement procedure, OnC WebDetect functions more reliably
than any other system.

28 I 2009 I Voith Paper I twogether

43

Products

Intensity
100%

Intensity
100%

Web break

Activationthreshold

Large
ΔI
0%

Intensity
100%

Web break

Small
ΔI

Activationthreshold

Small
ΔI

Time

Time

A slight color difference, for example, with transparent or packaging paper, make differentiation between paper web and dryer fabricdifficult for color detectors.

The optical systems for web breakon a new product – OnC WebDetect.

so that external light influences

detection that are current today

In contrast to conventional color

are compensated for and theusually do not work flawlessly.

detectors, OnC WebDetectmeasurement signal is filtered.

Since they detect a break by means

employs a measurement principle

The activation thresholds can thusof RGB detectors, they malfunction

which uses special optical character-be precisely calculated for a breakwith difficult color relations such as

istics of the dryer fabric and thealarm and adapted to the current

in the case of a slight color difference

paper web.

production conditions on an ongoing

between paper web and fabric inbasis. Since OnC WebDetect offers

the dryer section. Thus – especially

The measurements are recorded

no image evaluation or cause analy-

in the production of board andsuccessively at start-up and after-

sis but instead a pure break detection

packaging material, faulty detections

ward used as references. Slightsystem, the measurements can be

regularly occur since only withcolor differences, such as the ones

evaluated almost without time lag.

difficulty could existing systems

that occur due to aging and fadingThis allows a quick reaction in the

differentiate between the brown

clothing, are thus effortlessly copedcase of breaks.

web and the brown fabric. Transpar-with. Changing paper characteristics

ent paper webs, as occur with low

in the dryer section, e.g., moisture

Comfortably from thebasis weights or high moisturefluctuations, are likewise no longer

control room

contents, lead to the same problem.

a problem for break detection.
OnC WebDetect is integrated into

With OnC WebDetect, slight color differences
are effortlessly coped with.

the customer’s existing processcontrol system by means of a
Profibus interface or conventional
inputs/outputs. Thus the referencing
of fabric and web and further operation can be done comfortably from

However, as a papermaker, if you

Quick processing

don’t want to run the risk of unneces-the control room. An adjustment
directly at the electronic systemsary downtimes due to faulty break

Along with the new measurement

on site is not necessary. Even at

detections or even put up with theprocedure, use of a microchip also

start-up, no special calibration or

danger of machine damage due tocontributes to reliable results. All

parameterization of the sensor

undetected breaks, you can now relymeasured values are processed in it

electronic system in the field is

44

Activationthreshold

0%

0%
Time

Web break

28 I 2009 I Voith Paper I twogether

Products

required. Only the sensor head has

corrugating medium or test liner ismicrochip with OnC WebDetect,to be adjusted, which can be done

produced, color detectors thus hadchanging production conditions

by an automation expert from Voith.

difficulty in reliably detecting breaks.

have no influence on the functioning

Since OnC WebDetect was specially

However, things were very different

detections are prevented. The

developed for and tailored to the pa-

with OnC WebDetect. After a shortcustomer profits from increased

per industry, handling of the systemtime, the system worked flawlessly

production, since the machine isis extremely user-friendly. In addition,and thus contributed to the smooth

not shut down unnecessarily.

OnC WebDetect is almost mainte-

operation of the facility. Especiallynance-free, since the sensor head

the simple referencing, which can

is protected from contamination by

be done manually or automatically

air flushing.

via the process control system,

On Focus: OnC WebDetectmake life easier. The operating

ProSafety

personnel no longer has to run

ProRunnability

back and forth in order to set the

ProSpeed

Already before the official launch,sensors; instead, two mouse clicks

ProSpace

the first customers were convinced

suffice.

of the sensor and thus faulty breakFirst customers convincedby the new product. OnC WebDetect

Section: drying

was tested for several months under

Due to the much lower outlay,

Width: all

production conditions on the PM 1

referencing is done more frequently

Paper grade: allof the Adolf Jass Schwarza GmbHand thus there is very high reliability

paper mill in the Thuringian city ofof the break detection.

Rudolstadt.
The times in which the measurement
The conditions in the dryer section

signal fluctuated or slowly fadedof the PM 1 were until now aafter a detected break are also achallenge for break systems: sincething of the past. Through use of theContact
Bernhard Dellekart
bernhard.dellekart@voith.com“We will also rely on
OnC WebDetect in the future.”
M. Habeck, Plant Manager, Jass Schwarza“It was a big advantage for us that we were able to reliably detect web breaks in the pre-dryer section with
OnC WebDetect. Thanks to the referencing on fabric and paper and the sophisticated technology, reliablebreak detection can be done even with a slight color difference. Constantly changing production conditions
are no problem for the system as well. For that reason, we will also rely on OnC WebDetect in the future.”

28 I 2009 I Voith Paper I twogether

45

Products

New technology with OnV PaperVision camera system

LED lighting saves energy
Investment in an efficient camera system pays off in the paper industry within a few months.
Thanks to a new lighting technology, OnV PaperVision is also attractive due to noticeably lower
operating costs than comparable competitors’ systems. It is a development that also saves costs
over the long term.
It is well known in the paper

costs over the service life of ain the lowest operating costs.

industry that with a fully integrated

camera system (so-called total

The system, which combines web

camera system, 50% or more ofcost of ownership, TCO), theninspection (WIS) and web breakthe costs associated with web

there are substantial differences

analysis (WBA), uses LEDs.

breaks and undetected defects

between the various providers.

They are pulsed, i.e., the light

can be lowered. The purchaseis not permanently on, but insteadTechnology reduces costs

costs of such a system are thus

is flashed in very short intervals.

quickly recuperated.

In comparison to conventional
The OnV PaperVision system

illumination, the operating costs

In addition to the investment, iffrom Voith is attractive due to use

are minimized by means of thisyou now consider the operatingof the latest technology resulting

method.

OnV PaperVision

Conventional technology

Costs

Costs

Total
cost
savings

Total costs (TCO)

Total costs (TCO)
Operating costs

Operating costs

Investment costs0

Investment costs

10

Years

0

10

Years

Investment costs + operating costs = total cost of ownership (TCO)

OnV PaperVision is also attractive over the long term: In the case of a web break analysis system with 20 cameras, the operator saves
140,000 euros operating costs over ten years - only by the lower energy consumption.

46

28 I 2009 I Voith Paper I twogether

Products

The new pulsed LED lighting of OnV PaperVision saves energy both during web inspection and also during web break analysis.

With a selected pulse duration

the cameras produce brilliant

the intensity of illumination canof 100 microseconds and a pulse

images in previously uncommon

thus be adapted to the need – asequence of 100 Hz, the light isresolution of all details – including

characteristic that is only insuffi-

switched on only 1% of the time.

formation.

ciently or not at all available

Due to the high frequency, thewith conventional technology.

human eye admittedly has the

However, since the light isimpression that the light is on

switched on only briefly, thefor the entire duration. In thissurface of the LEDs remains

example, illumination of one LED-lukewarm. The danger of fire,

Cam thus requires only aboute.g., under the dryer section,

On Focus: OnV PaperVision

1% of the 712 W nominal power.

and the burning in of dirt are

ProSafety

Including the additional losses inthus avoided. A further advantage

ProRunnability

the electronic system, altogether

is the noticeably longer service

ProQuality

only ca. 23 W are consumed.

life of LEDs as compared to

ProSpeedcurrent industrial lamps, which

ProSpace

In the case of a web break analysis

leads to lower maintenance costs.

system with twenty cameras,

In addition, the combination ofSection: total paper machine

about 140,000 euros in energy

cameras, electronic system andWidth: allcosts can thus be saved over a

LEDs in an enclosure reduces thePaper grade: allservice life of ten years.

installation outlay, so that fewer
costs accrue in this area as well.

Image sharpness thanks tolight flash

Moreover, the LEDs can beContact
Günther Jordan
guenther.jordan@voith.com

equipped with different lenses
The short flashes of light are ofand delivered in movable mod-very high light intensity, so thatules. Both the type and also

28 I 2009 I Voith Paper I twogether

47

Products

Example for SSB Design:
PrintForm HS.

Forming fabrics for a challenging grade

Demands for newsprint fulfilled
The introduction of color printing has caused a revolution in newsprint quality demands. The correct
forming fabrics will help the papermaker to produce a top quality sheet without marking that willmeet the current high quality standards for smoothness, porosity, formation, two-sidedness, etc.
The best forming application to meet all these requirements is a balanced choice based on the specificperformance demands and wishes from our customers.
The main catalyst for this quality

and is still seen as such today.

minimum two-sidedness were new

improvement in newsprint grades

Not only the print quality had to betargets to meet.

was the growing interest from

improved, but simultaneously theprofessional advertisers for thisspeed of the printing presses in-

As if these challenges were not yet

medium. Newspapers have a hugecreased significantly. New printing

interesting enough, other industry

advantage of high circulation

techniques have been introduced

trends also had to be dealt with atnumbers at relatively low costs,

and modern, fast drying printing inks

the same time. Paper needs to bewhich enables advertisers to reach(often with an increased tackiness)

produced on ever wider and fastermillions of people almost daily with

were developed.

paper machines. Higher percentages

up-to-the-minute offers andof recycled fibers are used andTo keep up with the wishes andthus furnish quality deteriorates.

demands of the printing houses,

Finally there is also the trend towards

In order to keep the early adopters

the producers of newsprint werelighter paper weights to save costs,

satisfied and attract new advertis-

faced with some pretty interesting

which makes things even more

ers, the newspaper had to becomechallenges. Significant improvementscomplicated. How to control print

a competitive medium in thein surface strength and smoothness,through, dusting, hickies, smearing

world of advertisement papers

a clear reduction of porosity and a

and linting?

messages!

48

28 I 2009 I Voith Paper I twogether

Products

Many disciplines in the chain of the

SSB fabrics. With its plain weave

will have consequences for the surface

modern papermaking process needed

fabric surface and the fine MD and CD

open area if the diameter of the yarns

to come up with inventive solutions toyarns on the paper side, SSB fabrics

is not reduced. And this is the very

help the paper producers to meet themore than tripled the amount of

crucial point! The physical properties ofdemands of the printing houses.

support points and more than doubled

the finer yarns are a major concern to

the FSI numbers in comparison with

the industry. How can the necessary

the fine DL designs.

stability be achieved from 0.08-0.10 mm

Paper machine builders, producers of
paper machine clothing, chemicalyarns? How can the elongation figurescompanies and filler suppliers have

The reduction of marking whenbe controlled? Will these super finehelped the paper maker with theirreplacing a fine DL with an SSB

yarns have enough resistance against

challenges. The result is impressive:

fabric is evident, especially on thosehigh pressure showers, etc.?

a top class 45 gsm newsprint sheet

machines that use 100% recycledfrom 100% recycled fiber, produced

furnish. The typical 8 shed diagonal

At first glance, two contradictoryat 120 km/h on an 11 meter wide

disappeared and the very fine “screen”

trends are running simultaneously.

machine can meet the quality andfrom the SSB surface is often hardly

On the one hand, paper machines arerunability demands required by thevisible with the naked eye.

getting wider, faster and running withmost modern printing presses.
Forming fabrics for newsprint

higher fabric tensions, while on the
Also a clean fabric run, with low fiber

other hand, the forming fabrics arecarry back and reduced fiber bleedinggetting finer and finer!

are positive effects of the higher
Nowadays, SSB fabrics are the number

support points and FSI numbers.

one design for modern newsprint

Today, PrintForm HS and HQ arevery successful designs on the market

machines. The benefits from this“We are convinced there is an SSB

that help papermakers improve thedesign versus conventional fabrics

solution for every newsprint machinequality of their paper and increase

have been widely recognized andin the world. The right application will

efficiency of the machine. But there

accepted. The newsprint industry

provide our customers certain benefits

is more to come in the near future.

has been among the first to try thisversus conventional designs. We proved

new fabric design and are still

how successful our clothing is on thereceptive to new ideas.

fastest newsprint machines,” said
Martin Serr, Business Development

On Focus: SSB fabrics

Benefits of SSB fabrics

Manager Forming/Europe.

ProEnvironment

The answer to this question could differ

New challenges

ProRunnability
per individual user. However, the most

ProQuality
ProSpeedcommon advantages are:Among the major PMC suppliers,

1.

Reduced fabric marking

there is a fierce competition going

Section: forming

2.

Reduced chemical consumption

on to have the finest SSB design in

Width: all

3.

Reduced porosity levels

their product range. However, all

Paper grade: all graphical grades

4.

Improved fabric life

PMC suppliers are facing certain

5.

Clean runlimitations when going finer and6.

Good profile quality

finer with their SSB designs.
In order to further increase the FSI

Most of these benefits are a result of

numbers and the amount of support

the huge step in FSI and support

points, more yarns per centimeter

points when changing from a fine DL tohave to be used in the weave, which

28 I 2009 I Voith Paper I twogether

Contact
Tom Meijer
tom.meijer@voith.com

49

Products

New forming fabric generation with a unique warp concept

PrintForm I combines a fine paper sidewith a stable machine side
In order to meet the higher quality demands of the customer, even finer and thinner forming fabrics
were developed for graphical papers. They guarantee very good formation and an even paper surface.
The new Voith Forming Fabric PrintForm I combines the advantages of a fine forming fabric with thosehaving a very stable machine side structure. The main advantages are lower water and fiber carrying,higher dimensional stability and less rewetting.

Warp yarn ratio 1:1

paper machine. This is achieved

The advantages of the PrintForm I

through the use of weft and warp

Series are illustrated in Fig. 2.

PS warpyarns with clearly different diameters

MS warpon the top and bottom fabric layers.

Less water and fiber carrying

A finer fabric top side and more

The paper side warp and weft

Warp yarn ratio 1:2

stable or rather durable machine

yarns have very thin diameters

PS warpside can be achieved in thewhich are tightly woven to achieve

MS warp

PrintForm I with its 3:2 warp counta monoplane surface. In spite of theratio that has been introduced.

resulting high fiber support index(FSI) and over 11,600 support points

Fig. 1: Cross section comparison of SSB
fabrics with warp yarn ratio 1:1 and 1:2.

With this new warp concept, a fine

per in² (1, 800 support points per cm²),

paper side fabric layer is combined

the PrintForm I has a sufficiently large

with a stable wear side fabric layer toopen surface area. The thin yarns

create a new type of forming fabric.

lead to a lower fabric caliper and

The fabric construction is the same

The warp cross section of thisconsequently to a lower, moreas an SSB forming fabric (SSB =PrintForm I and one of a standard

open void volume. This provides

Sheet Support Binder). This is triple

SSB forming fabric with a warp ratio

the following advantages for thelayer with a paper side and wear sideof 1:1 are laid on top of each other.

papermaker:

layer as well as a binder connecting
these layers, which joins the structureon the paper side. Until now fabricFig. 2: Warp yarn ratio standard SSB 1:1 over PrintForm I with yarn ratio 3:2.

constructions have had a warp ratioof 1:1 or 1:2 (paper side and wear

1.

PS warp

Beneﬁts PrintForm I

side respectively). The paper side2.

layer is principally responsible for theideal formation of the paper and inorder to do this must have the finest

3.

structure possible. The wear sidelayer must fulfil the fabric’s
requirements for stability in themachine and cross machine
directions as well as lifetime on the50

MS warp

PrintForm I

Quality

Stability

1. Homogeneous paper side
= FSI and SP higher

4. More space
available
on MS forlarger weftdiameters

2. Lower caliper, less water
carrying
4.

3. Impulse absorption forlow marking tendency

Standard SSB

28 I 2009 I Voith Paper I twogether

ProduCTS

High flow
speedMore balanced flow with PrintForm I

Slow flow
speed

Locally high speed flow with Standard SSB

Fig. 3: Flow speed through the warp system.

• Higher dewatering capacity due
to an open fabric structure.

Less rewetting into the

Results with PrintForm I

paper web• Build up a homogeneous fiber

Trials were carried out on several

web as a result of high number

The concept of the unique 3:2 warp

pilot paper machines underof support points.

ratios of the PrintForm I makes thecomparable conditions. As aoffset of the warp layers to eachreference, fine graphical SSB fabrics,

other possible. The offset of thewhich are standard for the paper

yarns prevents rewetting into thegrade, were used. As an example,• Higher mechanical retention
properties.

• Reduced risk of fiber carrying
because of the fine paper side.

paper web, as can happen whenwith SC-A pulp, a super fine SSB• Reduced risk of water carrying

the fabric meets drainage elements.

bottom fabric was interchanged with

due to a reduced fabric void

Consequently this leads to a uniform

a PrintForm I, both with the same

volume.

paper structure and results in a better

permeability. The top fabric was notformation. The open machine sidechanged. Higher initial dewatering

warp structure supports the drainage

results were obtained with theHigh dimensional stability

flow and ensures optimal dewatering.
The I-Series warp mesh is lower

Because of this even higher dewater-on the machine side through theing results may be achieved.

use of yarns with the same diameters.
As a result, more space is created for

In Fig. 3 the influence of the warpa higher number of weft yarns orgeometry on the drainage isbigger weft diameters. Consequently,

simulated, while with the 1:1 warp

in both cases, the dimensionalratio local, higher speed flows

stability and in particular, the crossoccur. These are more balanced

dimensional stability of the fabricwith the 3:2 warp ratio. The result

is increased. The advantages are:is a more uniform and higher flow
capacity in comparision to the 1:1• Good cross machine paper profile
as a result of the higher fabric crosswarp yarn ration. The advantages for

Cross dimensional stability
Abrasion Index (ARI)+25 %Caliper-0.03 mm

Open area
wear side+2%

the papermaker are:high wear volume.

• Efficient fabric cleaning because of
the open warp structure.

28 I 2009 I Voith Paper I twogether• Better and more homogeneous
formation.

• Higher dry content due to reduced
rewetting into the paper web.

100
80

Support points
+54%

60
40

machine stability.

• Good lifetime properties due to the

Void volume-4 %PrintForm I

20

FSI
+20%

0

DI
+16%
Open area
paper side±0 %Standard SSB

Fig. 4: Comparison of the technical data of astandard SSB and PrintForm I.

51

Products

PrintForm I in all cases. All other• Higher dimensional stability, flatmachines which have highdewatering conditions in the former

fabric surfaces in the return part ofdemands for dimensional stability

remained constant. The dry content

the PM.

and higher paper quality at theat the Pick-Up is increased by up to
1.5% (Fig. 5).

• Lower water and fiber carry.
• Lower fresh water consumption

same time.

due to pressure reductions in the
These results have been confirmed in
production plants, where formation
has been clearly and immediately
improved. On a Fourdrinier paper
machine, producing wood containing
papers, the formation, all measuredby Ambertec, was already improved

cleaning system.
On Focus: PrintForm I• Higher dewatering capacity.
• Improved formation and paper

ProEnvironment

cross machine profiles.

ProRunnability• Increased dry content at the

ProQuality

Pick-Up.

ProSpeed• Higher fabric life potentials.

at the first tambour after installation

Section: formingof the PrintForm I and again after

As a result of the unique warp

Width: all

opening the headbox slice up to

concept of the PrintForm I, a finePaper grade: graphical grades,

0.12 [√g/m] (red curve in Fig. 6).

paper side can be combined withhigh quality board &As a reference, when the standard

an extremely stable wear side.

packaging

SSB forming fabric was used, a

The open wear side in particularformation value of 0.65 [√g/m] wasensures highly efficient dewatering.

achieved (grey curve).

The offset of the warp layers leads

Contact
Matthias Höhsl
matthias.hoehsl@voith.com

to a homogeneous drainage and
The qualities of the PrintForm I haveenables good formation. This

been confirmed in performance andforming fabric design is especially

additional benefits have been seen:

suitable for positions on paperco+1

Bottom fabrics
Superfine SSB
Printform I
Sum bottom
21.86%
35.94%

0.70

Sum top27.70%
27.67%

0.66

Suction box
Zone 2: 3.55%
3.74%
Zone 1: 12.27%
11.56%
Skimmer
9.59%
24.38%

Fig. 5: PM Drainage Results with SC-A+. Increase of dry content
by + 1.5%.

52

Formation normalized [√g/m]

Dr y

nt
nte

.5 %

SCR
1.63%
1.62%

Top fabrics
Superfine SSB
Superfine SSB

Competitor
Improved by anaverage of
0.12 [√g/m]

0.62

0.58

PrintForm I
Immediate improvement
after start-up

0.54
PrintForm I: Improvement
after running 6 days
0.50

FS

MiddleTS

Fig. 6: Sheet Formation – Measured with Ambertec.

28 I 2009 I Voith Paper I twogether

ProduCTS

PrintFlex V3 Planar for critical pick-up positions.

E-Flex, optimally structured felt for maximum dry content.

Increase efficiency within the press section

It’s not only the clothing that matters
If the dry content after the press can be increased by 1%, the steam consumption for drying thepaper web is reduced by 4%. To achieve this target, every dewatering opportunity in the wet section
must be exploited. Points of approach could be the clothing, the rolls and roll covers as well as thedoctoring.
Provided the web leaves the forming

in tonnage, not so much the energy

and allow only minimal deviations ofsection with maximum dry content,

saved. But since the cost of energy is

the relevant operational parameters,then the greatest possible dry content

rather unpredictable, except for asuch as the permeability or themust be achieved in the press

constantly increasing trend, the energy

active felt volume. All of this should

section. This can be achieved notconsumption of all the potential

preferably not require the use of

only by optimizing the design ofconsumers in the press section issuction box dewatering and condi-

the clothing, but also by suitable

increasingly scrutinized. Dry content

tioning. Every press makes its

roll covers and roll surfaces. The

and drive power are under constantown demands. To meet these,

method of doctoring as well as theobservation. The values for vacuum-

Voith Paper places its bets on theconditioning of rolls and felts must

consuming units (suction rolls, suction

advantages of modularly structured

also be taken into account.

boxes or guiding equipment for thepress felts. Using only a few compo-web) and of course also the line loads

nents combined according to

are recorded.

specification, optimal designs are

A press felt is expected, with consistentclothing characteristics, to deliver
highest dry content with relevant paper

created for every type of press
Contribution of clothing

quality. It is true that the dewatering

position, based on woven and nonwoven technology.

performance was and still is seen not

The objective of a modern press

so much as an energy saver, but rather

felt design is to meet the changing

as a means of increasing the machine

requirements. From the start, press

speed to its limit. The important

felts should require the lowest

The latest press felt designs areparameter was seen as the increase

possible mass per square meterbased on non-woven technology,

28 I 2009 I Voith Paper I twogether

Non-woven technology

53

Products

i.e. fibers running lengthwise andNew technologies for press felts

across, with no interconnection

felt surfaces and permanently elastic
felt structures are revolutionizing

within or between fibers.

Structurally optimized felts offer

Non-woven structures hardly

additional options for optimizingchange their properties required

dewatering, paper web transfer andfor paper production. These felt

also paper and cardboard quality.

designs therefore start up very

The first possible option is the side

The support of the relevant rollquickly and offer excellent dewater-of the press felt in contact with thecover in the press position is requireding performance in the nip, overpaper. The intention is to maximize

in order to fully exploit the dewatering

their entire lifespan.

the contact area. The possibilities

potential of a felt in the nip. The

press dewatering.
Roll covers

include modified batt fibers

Solar family sets new standards for

To date, these advantages were of(bi-component fibers) on the oneroll covers, especially for highly

use only in the production of graphic

hand, and optimized steps in battstressed positions. The open sur-paper. After targeted development

production and application (PrintFlex/

face and especially the associatedwork and thanks to a special

MultiFlex P and PRO) on the other.

groove design provide clearly

manufacturing process, Voith

improved water drainage. This inPaper opened up the fast-moving

Two further topics have recently

turn forces dewatering of the felt inpackaging sector as well for the non-appeared on the horizon:

the nip.

woven technology. To date, these

the elasticity of the substructure andapplications were not amenable to thethe distribution and size of the felt

This illustrates the interactionuse of non-woven felts due to soiling

pores. These two characteristics

between felt and roll cover design.

and specific dewatering properties.

decisively determine the dewatering

Voith Paper supports the optimization

Apart from producing a new design,

performance and preservation ofof the open surface of the press roll,

the modularity of this technology also

the properties through the life of theespecially of the grooves, by using

produced an entire product range, thefelt. The desired characteristics cansuitably stable press clothing.

Planar family. Planar designs can be

be controlled by the introduction

This bridges the grooves andapplied with almost all paper typesof special polymer particles into

simultaneously maximizes the flow ofand press positions.

the felt structure. Extremely smoothwater into the surface of the cover.

On Focus: Planar Family
ProEnvironment
ProRunnability
ProQuality
ProSpeed
Section: press
Width: all
Paper grade: a ll graphic papers,
all boards

Planar Family
PrintFlex O2 Planar:

Extremely fast start-up, good dry content

PrintFlex O3 Planar:

High dry content, reduction of two-sidedness

PrintFlex V2 Planar:

High nip dewatering, long life

MultiFlex O3 Planar:

High dry content, fast start-up

MultiFlex V2 Planar:

Good cleansing properties, constant dewatering performance

MultiFlex V3 Planar:

High resistance to compaction, easy cleaning

MultiFlex S3 Planar:

Elasticity and uniform dewatering performance at high speeds

Overview of the Planar Family.

54

28 I 2009 I Voith Paper I twogether

Products

Nipmaster, analyses the interaction of roll cover and felt.

Analysis of the press nip

Press section of the Paper Technology Center in Heidenheim,
Germany.

press clothing manufacturers. In

highlight potentials for saving andmost cases, these are instantaneous

optimization.

NipMaster is a software package

recordings, with the commensuratethat simulates the press gap

difficulties of interpretation. For

Reducing the solid content after

considering the line load, roll cover,definite trends in support of decision

the press by 1% yields a 4% saving

felt and paper quality. The programmaking, reference is made to FeltView,

in steam. Therefore, the equation

was developed to calculate theinstalled for on-going monitoring+1 = -4 is no arithmetic error – itthermo-mechanical conditions underof the felt. FeltView measures thehighlights the hidden potential ofwhich a roll cover operates. Using

moisture, permeability andthe press.

NipSense, these theoretical results

temperature of the press felt during

can be tested on site by measuring

production. The data is always

the actual conditions in the machine.

available and evaluation of long-term

The results of the measurement

trends assists optimization with

On Focus: PrintFlex / MultiFlex PRO

form the fundamental base forrespect to energy savings, fresh

ProEnvironment

further nip calculations.

water and roll clothing.

ProRunnability

The parameters of the press clothing

Voith Paper offers a total package

are continuously updated to ensure

focusing on efficiency improvementsthat they are as realistic as possible.

in existing press sections. This

Section: press

The predictive power and insight ofincludes simulation of thermo-

Width: all

NipMaster is demonstrated by themechanical conditions in the press

Paper grade: a ll graphic papers,

results – up to 120 values per Nipnip (NipMaster), steady state analysis

calculation.

of the press nip (NipSense), theProQuality

selection of optimal roll covers andOn-going supervision of the rollassociated efficient doctoring, aspress clothing

well as the ideal clothing. The total

ProSpeed

all boards
Contact
Corinna Ißler
corinna.issler@voith.com

package also includes the option of
A certain control of the press felts isinvesting in FeltView for permanent

provided by the service staff of thepress felt control. Overall, they

28 I 2009 I Voith Paper I twogether

55Products

Solving winding problems for paper producers

LunaReel: A new generation of reel drum covers
Paper producers know: winding problems mean wasting paper. Plus, winding problems also mean big
trouble for printing presses and copying machines. To reduce these problems, years ago Voith Paper
developed rubber reel drum covers. And now, Voith Paper is introducing a new generation of high-techreel drum covers: LunaReel.
In the past years, practically all new

Illustration 1 shows the function ofhigh-speed paper machines produc-a soft reel drum cover. The soft nip,

• Will a rubber reel drum cover reallysolve the winding problems?

• Are the technical controls compatible

ing coated and/or calendered paper

between the reel and the tambour,

have been equipped with rubber

allows the paper to be pressed uni-or should they be adapted?

reel drum covers. By comparison,

formly. During paper winding, this• Are mechanical modifications

older machines without rubber covers

soft nip minimizes trapped air pockets

often waste considerable amounts

and other disruptions which are aof paper due to unwanted winding

main reason for winding problems.

problems. Typical winding problems
include: misalignments, blow-outs,

The following questions however,creasing, stretching, glossing marks

should be answered before installingand interlocking.

a reel drum rubber cover:Fig. 1: Reel drum in contact with paper.

required?

Through a Voith Paper pre-audit,
these and other questions can be
answered. Current problems arethen examined in detail and the entire
system’s improvement potential
can be evaluated. These are key
considerations, because rubber reel
drum covers need to be routinely
regrinded, and a spare roll is usually
recommended. In general however,for older paper machines it takes 12 to
15 hours to change over the reel drum.
The LunaReel Concept
The new LunaReel concept offers
paper mills two different types of reel
drum covers – to match their operating needs: the LunaReel S and the
LunaReel E.
The LunaReel S is the standard version
with high-tech fiber-reinforcements.
While the LunaReel E is the extrastrong version, offering added
mechanical stability with higher
abrasion resistance and runningtimes of over 18 months.

56

28 I 2009 I Voith Paper I twogether

Products

Fig. 2: Examples of winding defects.

Both versions of the LunaReel aregrip or hold on the paper. Here,based on Voith Paper’s extensive

special filling materials are usedproduction experience and advanced

which give the covers a roughermaterials research.

appearance – but this does not affectthe paper’s sensitive surface. ThisAs a result, LunaReel offers customers

is big advantage, because uniform

major advantages:

reel friction means non-stop paper

Longer running times thanks to

production – without changing thefiber-reinforcements, higher abrasion

tambour’s winding settings.

resistance and mechanical stability.
LunaReel covers have a uniform

On the other hand, increased mechani-

nip which minimizes tearing as well

cal stability of the reel drum coveras other problems. Plus, LunaReel

occurs through fiber reinforcements.

covers retain these characteristics

As a result, tearing on perforations andthroughout their lifetime: LunaReel

splitting through paper winders cancovers barely weaken with age – they

be avoided or reduced to a minimum.

don’t get hard – they don’t crack;furthermore, a reliable, uniform

The start-up operation can becoefficient of friction throughout

supported by Voith reeling experts,

the lifetime for more precise handlingincluding the optimization of windingof the paper web.

settings and onsite training for local

On Focus: LunaReel
ProRunnability
ProQuality
Section: reeling
Width: all
Paper grade: c oated and/or calenderedpapersContact
Dr. Peter Höllwarth
peter.hoellwarth@voith.com

Volker Fäthke
volker.faethke@voith.com

production teams.
Throughout the development thefollowing aspects were considered:

The change to rubber reel drum covers
improves paper quality and the amountOn the one hand, high-tech materialsof waste paper can be reduced byin LunaReel covers give them a better

100 to 200 tons every month.

28 I 2009 I Voith Paper I twogether

57

Products

The ideal doctor for hard roll coatings

SkyTop delivers brilliant results
Roll covers enhance the efficiency of a paper machine. To gain the greatest possible benefit fromroll covers, doctor blades have to be perfectly matched to the cover’s properties. Voith Paper’s
SkyTop doctor blades offer a special product combination for hard roll coatings. The result: extended
operational life and enhanced paper quality.

At Norske Skog Bruck in Austria,
doctoring deposits in the third press
were affecting the operating properties of the central press roll. The useof >>> SkyTop doctor blades overa longer period reduced doctoring
deposits and extended blade life
from 14 to 21 days.
In addition, the company was notsatisfied with the original blade lifein the fourth press take-off position.
Because of extensive wear, theblades had to be replaced after sevendays, resulting in more downtime.
Installing SkyTop doctor blades
tripled blade life to 21 days. SkyTop
doctor blades are now being applied

SkyTop is tailored to the requirements of hard roll coatings.
25>>> Information: SkyTop
SkyTop is a fiber composite made up of carbon fiber and duroplast
matrix with finely distributed cleaning and polishing particles.
This combination results in excellent cleaning and conditioning ofLifetime [Days]

20
15
10
5

the roll surface. The surface roughness and excellent sheet releaseproperties of the roll coatings are maintained throughout the entire
roll life.

0Competitor

Competitor

SkyTopService life of SkyTop compared withcompeting blade products.

58

28 I 2009 I Voith Paper I twogether

Products

successfully in the third and fourthof the paper machine. The coatings

The success of SkyTop demonstrates

presses on the thermal-coated press

can only work to their full potential

how important it is to tailor doctorroll covers.

when the doctoring process isblade and cover to one another.

top-rate.

Particularly on demanding paper

The combination of SkyTop with amachine positions, a measurable

TerraGloss coating also produced

Reducing maintenance costs

outstanding results. After experienc-

the paper mill.

ing recurring problems in the calender

Another considerable benefit ofsection with lifetime and inadequate

SkyTop is a decrease in downtime,

gloss standards, the customer

resulting in a reduction in mainte-

applied a TerraGloss coating.

nance costs. A paper machine

The new installation allowed thecan be out of operation for up

default gloss factor of 60 to be

to 12 hours while a roll is being

maintained for far longer comparedchanged compared to only

On Focus: SkyTop doctor blade

to the uncoated rolls. However, after

30 minutes to replace a doctor.

ProRunnability

a time, initial signs of milky deposits

SkyTop increases roll lifetime by

ProQuality

again reduced the gloss factors

means of improved yet gentler

ProSpeedof the LWC paper.

cleaning of the thermal coatedroll surfaces. In the case of theSection: press, calender

Only after the conventional carbon

doctors used previously, the blade

Width: allblades were replaced with Voith

contact pressure had to be in-Paper grade: all

SkyTop blades could the roll surface

creased regularly to maintainbe kept clean and, consequently,

cleaning performance at the samethe gloss values in the productlevel. With SkyTop, this is no longer

maintained in the long term. These

necessary. This means that coating

examples prove that proper, precisely

and doctor blade are exposed to

tailored doctoring of the thermal roll

fewer stresses, and the lifetime ofcoatings enhances the efficiency

both components is extended.

1.2
Average Ra value [μm]added value can be achieved forContact
Ingo Schmidingo.schmid@voith.com

high

1.0
SkyTop0.8
0.6Competitor

0.4
0.2
0

low
1

2

3

4

5

6

7

8

fine

coarseMeasurements

SkyTop provides consistently high coating surface roughness over the entire
operating life.

28 I 2009 I Voith Paper I twogether

Filler particle sizes in cleaning andconditioning blades.

59

Products

Thomas Maurer standing beside one out of the 100 CarboTec rolls
which were produced for the Hainan (China) paper machine.

Special made OCS (oval cross-section) fibers to produce
composites with a more precise structure than standard fibers.

Voith develops its own advanced materials for CFRP rolls

Lightweights: Carbon fiber rolls
The new Boeing 787 uses it. And the Airbus A350 does too. Formula 1 cock-pits are even made out ofit, as well as tennis rackets. What we’re talking about is “carbon fiber reinforced plastic” or CFRP. And
Voith Paper also uses this advanced composite in its premium rolls.
For 15 years, Voith Paper has

The reason for these reduced vibrations

characteristics to satisfy a particular

produced advanced “CarboTec” rolls

is the higher dampening ability andapplication. And Voith Paper uses thisfrom CFRP in its Wimpassing, Austria

stiffness of CFRP rolls. In technicaltechnology for its CarboTec rolls.

facility – and since 2006 they haveterms, the higher a material’s elasticity

been made using an ultra-modern

modulus or >>> e-modulus is (i.e.

Through precise arrangement of the

production line. The latest installation

the relationship between the applied

carbon fibers, CFRP composites canof CarboTec Rolls was at the Mondi

tension and the resultant expansion

be made with extremely effective

Business Paper plant in Hadera, Israel.

shown by a material), the stiffer adampening characteristics and a

There, CarboTec Rolls from Voith

product becomes. For example, steel

specific thermal expansion coefficient.

Paper are especially admired for theirrolls have an e-modulus rating ofIn addition, unlike steel rolls, CFRP

ability to absorb vibrations. Thanks to

220 gigapascal (GPa) while carbon

rolls do not need to be run-up in

the structure of their CFRP composite,

composite rolls have ratings from 240

advance to reach a uniform operating

the paper mill’s new dryer fabric rolls

to 700 GPa. CFRP rolls therefore also

temperature. As a result, the waste

have significantly lower vibration

permit more precise online calibrations

paper associated with productionlevels. When compared to conventional

during production as well as improved

start-ups can now be significantly

steel rolls, which had serious vibration

workplace safety.

reduced. CFRP rolls can also be

problems, CarboTec Rolls having thesame diameter are now far stiffer. As aoperated at temperatures up to 125°C,
Multi-Directional Fibers

result, the paper machines can be run

and for short periods even up to
140°C. Plus, thanks to their internal

at even higher speeds without the rolls

Fiber composites can now be manu-

structure, CFRP rolls usually have adeveloping critical vibrations.

factured with precisely the right material

smaller diameter than steel rolls.

60

28 I 2009 I Voith Paper I twogether

Products

In its CarboTec rolls, Voith uses its
own specially made OCS (oval crosssection) fibers to produce composites
with a more precise structure than ispossible with standard fibers. Thanks
to this improved structure, Voith
composites reduce air and moistureinclusions and minimize microcracks.
This means CarboTec Rolls have amajor advantage, especially when
operating in moist or humid conditions.
CFRP rolls are also comparative>>> Information: E-Modulus
The e-modulus (also called: elasticity modulus, coefficient of elasticity
or Young’s modulus, being named after the physicist Thomas Young)is a characteristic value of solid materials. In the material sciences,e-modulus values describe the relationship between the applied tension
and the resultant expansion of a solid object when it is deformed. Simply
put - the e-modulus measures elasticity. The term “elasticity modulus”
is often abbreviated as “e-modulus” or “E.” Large e-modulus values fora material indicate a high resistance to deformation. For example:
Construction materials with a high e-modulus value, such as CFRP, arestiff. Materials with a low e-modulus value, such as rubber, are flexible.

lightweights: a cubic meter of carbon
fiber composite weighs 1.5 tons,

special epoxy resins. These resins

100 CFRP rolls – all of which have

while a cubic meter of steel weighs

further strengthen the roll and absorb

special coatings made fromfive times that amount. For that same

vibrations. This is particularly importantcomposites, polyurethane or rubber.

reason, the CFRP rolls in paperin the drying section of a paper mill,

Even the re-coating of a CFRP rollmachines are easier to operate andwhere aggressive steam is part of theis simple. Seeing the stiffness of

have lower power requirements.

operating environment and rolls needa CFRP roll doesn’t change after

to be both heat as well as hydrolysis

use and practically no bending

resistant. In the prospective world’s

occurs – an old coating can bemost productive fine paper machine

easily removed and renewed using

Voith also uses specially developedin Hainan, China for instance, Voith

special TLT (thermo layer technology)

materials for its roll covers, such as

Paper supplied a press section withcoatings.

100 CFRP Rolls for Hainan, China

On Focus: CFRP rolls
ProSafety
ProEnvironment
ProRunnability
ProQuality
ProSpeed
ProSpace
Section: total paper machine
Width: all
Paper grade: all
Contact
Thomas Maurer
thomas.maurer@voith.com

Schematic illustration of a CarboTec roll with composite cover.

28 I 2009 I Voith Paper I twogether

61

Products

Rapid repair of spreader rolls

Minimized waiting & maximized service
Spreader rolls are critical for the wet and dryer part of every paper machine: directly affecting
processing felts as well as paper web quality. Voith Paper experts use their great experience withrolls for the maintenance of spreader rolls.
“The main thing is, the roll is runningagain” – This kind of comment ispretty typical when spreader rolls
are repaired. But it’s not the wholestory. Truth is, there are huge
differences in “how” these expensive
rolls are serviced. Voith Paper has
a comprehensive service concept
and an entire department dedicatedjust to spreader rolls. What makes
Voith Paper services so fast is
firstly the longtime manufacturing
and installation know-how:Voith Paper experts know eachand every type of roll configuration.
Secondly – Voith Paper service
teams prepare precise inspection
reports that really pay-off forcustomers.
“Our service reporting sets a new
standard,” explains Martin
Bassmann, Sales Manager Austria,
Germany and Switzerland. During an
on-site analysis, Voith Paper experts
examine roll problems in detail.
Most importantly – they track down
and correct the causes of breakdowns, so problems don’t re-occur.
Here, detailed reporting adds transparency by listing all essential timesensitive repairs as well as possible
improvements, including a clear costestimation. Altogether, this makes it
easy for customers and Voith experts
to identify the best and most costDisassembling of a spreader roll.

62

effective solution. “Thanks to these28 I 2009 I Voith Paper I twogether

Products

reports, customers always have an

Service in Laakirchen. This involves

long and then breakdown unsched-

overview of their services. Added to

not only construction modifications,uled,” comments Bassmann. Routine

that, once customers select a repair

but also special coatings, such as:scheduled maintenance of these rolls– these reports help ensure thetungsten-carbide-teflon or chrome-

however, makes good sense:

fastest possible service,” adds

carbide-teflon coatings. In addition,

Production outages can then be

Bassmann.

roll segments can be converted

managed – rather than just happen-from rubber to steel, or steel toing, and major damages can be

rubber. For example: in a paper

avoided. Regardless of a roll’s origi-

machine’s sizing press, several spreader

nal manufacturer, Voith Paper offers

Most spreader roll problems startrolls were used with conventional

services that can extend every roll’swith their bearings. And often, that’s

rubber covers – but due to a heavy

lifetime.

because the wrong lubricants were

fouling, they only lasted a few

used. Here too, Voith Paper’s exper-

months. In 2004 however, these rolls

A spreader roll’s performance can betise helped to develop an innovative

were replaced with steel rolls having

enhanced by using approved sparelubricant specifically designed fora carbide-teflon coating and everparts: such as clutch components or

spreader rolls.

since – they’ve run problem-free.

seals. Today, Voith Paper service

Lubricants are important too

centers are located in: Laakirchen(Austria), Kunshan (China) and		“We can modify each roll, to match

Jakarta (Indonesia). Voith Paper has

its operating conditions.”

including spreader rolls in the world’s

Helmut Bammer, Voith Paper Laakirchen, Austria

The results: an extended lifetime andmany successful service projects,
fastest (2,000 m/min) and widest(11 m) paper machines.

The fastest service

minimized bearing wear. In manycases, the installation of a central

Voith Paper offers very fast spreader

lubrication system or the conversion

roll services. Here the broad supplierof an existing system may also be a

network gives the service a head-sound investment.

start – assuring quick deliveries of

On Focus: Spreader rolls

suitable bearings, couplings and

ProRunnability

Before and after each Voith Paper

seals. Added to that, Voith Paper

ProQuality

service, rolls also undergo vibration

operates its own in-house repair

ProSpeedtesting and a frequency analysis –facilities.
Section: total paper machine

onsite in the paper machine as wellas on a test rig. If desired, additional“On average, we service steel rolls in

Width: allsensors can also be installed toabout four weeks, and it only takes

Paper grade: allpermit online monitoring of a roll’s

six or seven weeks for rubber rolls,”

vibrations and temperatures for moresays Martin Bassmann.

effective preventative maintenance.
Despite Voith Paper’s quick response“We can modify each roll, to match

times, customers still shouldn’t

its operating conditions,” reports

postpone routine inspections. “ManyHelmut Bammer, Manager Rolltimes, spreader rolls are just run too

28 I 2009 I Voith Paper I twogether

Contact
Jochen Honold
jochen.honold@voith.com

63

SERVICE

Cost reduction by mathematical furnish modeling and potential analysis

PerfectFit for furnish recipes
Voith’s furnish modeling and furnish potential analysis is a tool for cost optimization for graphicalpaper grades. The main focus of these studies are furnish recipes, refining of the components, filler
content, basis weight and machine speed. The critical weak points concerning furnish strength can be
identified and proposals for their amendment can be discussed.
In today’s economic situation, over-

Up to now, it was not possible to de-Balance out requirements andcapacities and predatory competition

termine the optimum future operating

possibilities

force every papermaker to reduce

point concerning furnish composition

costs to stay competitive. There are

and the resulting furnish strength.

The basis for such a study is, of

two main ways to reach this goal:

Neither was it possible to calculate

course, the paper machine itself. This

optimizing the furnish recipes or in-

the possible maximum machine

may be an existing machine which iscreasing the machine speed. Which

speeds. Voith’s furnish modelingto be optimized or a planned new

way promises more leverage is mainly

and furnish potential analysis closes

machine. The machine requirements

determined by the machine concept.

this gap.

concerning the sheet and therefore
the furnish strength properties canvary hugely; The main influenceparameters defining the machine
requirements are the paper grade,basis weight, machine speed and,of course, the machine concept.
The furnish compositions have tofulfill the requirements in every caseunder all circumstances (Fig. 1).
In order to evaluate the balance ofthe furnish strength potential and the
PM requirements, the single fiberand filler components are analyzed indetail. The available fiber and filler
components are evaluated together
with the customer with the aim of
optimum cost efficiency. At the sametime, more advantageous alternatives
are looked for and discussed.
As a next step, the selected single
components are evaluated and optimized individually. Subsequently,© Falko Matte/Fotolia.de

64

Fig. 1: PM requirements
and furnish properties inbalance.

the suitability of the optimized single
component for mixtures is tested. For
the assessment of existing machines,

28 I 2009 I Voith Paper I twogether

SERVICE

5.5
4.5
Draw [%]

2

Co

nt

mp

one

one

nt

mp

3

Co

Tear-Index [mNm2/g]

5.0

4.0
3.5

Operating window

3.0
2.5
2.0
1.5
1,400

1,500

Component 1
Fig. 2: Tear-Index diagram for a furnish model with threefiber components.

1,600
1,700
Reel speed [m/min]

1,800

1,900

Fig. 3: PTC draw trials allow furnish limitation predictions.

the furnish samples are mostly taken

mandatory because the mixtures

With different raw materials, basis

directly from the stock preparation

typically do not follow linear mixing

weights and machine concepts, trials

lines. If this is not possible, e.g. forrules but show complex non-linear

have been run to determine the mini-planned new machines, the chosen

dependencies.

mum necessary and maximum pos-fiber components can be refined insible draw for different speed levels.

lab scale or full scale in the Voith

The strength parameters measured

At the same time, hand sheets wereresearch facilities.

for the different furnish mixtures

produced from the trial furnishes andare then described by fitting

the strength properties of the wet andContinuous prediction of themathematical equations. As adry sheets were measured.

mixtures’ strength properties

result, predictions of the strength
properties are also possible forWith the operating windows defined

The properties of the single compo-

furnish compositions that have notduring these trials (Fig. 3), predictions

nents are now known. But how is it

been measured on hand sheets.

can be made concerning:that can be achieved with a certain

The results of the mathematical• the maximum speed that can be

furnish composition?

modeling can then be displayed inreached with a certain furnish

interactive software tools and instrength and a defined machine

diagrams (Fig. 2).

concept

possible to predict the sheet strength

For this goal, a series of mixtures of• the minimum draws and therefore

the base components is made in thelab and hand sheets are produced

Wide knowledge base from thethe minimum necessary strengthfrom every mixture. The necessary

PTC

properties at a certain speed and adefined machine concept

minimum number of different mixtures depends exponentially on the

Depending on the selected machine

number of base components. From

concept, especially the press con-Nevertheless, the results from thethese hand sheets, all important

figuration, different requirements

pilot paper machine have to be

paper properties are measured. The

for the sheet strength are resulting.

examined critically in every case tocenter of attention focuses on the

In order to determine the strengthverify their validity for full scale paper

strength properties, the initial wet

requirements, comprehensive trial

machines.

web strength at different dryness

series have been carried out at thelevels as well as the commonly

Voith Paper Technology Center (PTC)

Comparative evaluations with actual

used static and dynamic strength

in Heidenheim on the pilot paper

production machines show the trans-of the dry sheets. This procedure ismachine XPM 6.

ferability of the pilot scale strength

28 I 2009 I Voith Paper I twogether

65

3

Co

nt

knowledge base. The data base

mp

mp

2

Co

nt

is continuously expanded andone

requirements and complete theone

SERVICE

improved by using all available
information from PTC trials, customer projects and optimization work.

sufficient strength
insufficient strength

Leveling out the balance
The mathematical modeling of thestrength properties on the one handComponent 1
Fig. 4: results of the furnish potential analysis for 3 fiber components: Furnish mixtures with
sufficient (blue area) and insufficient strength (red area).

and the machine requirements on
the other hand allow it to divide
the model space into possible
and impossible furnish mixtures(Fig. 4).

• How much can be saved by optimized furnish usage and/or refining?

Contact
Cordula Mraz
cordula.mraz@voith.com• What possibilities are there toincrease the machine speed?

This division is made for each• How fast will investments pay

examined basis weight andfo themselves through possible

machine speed. Proposed rebuilds

furnish cost reduction?

Dr. Michael Schwarz
michael.schwarz@voith.com

changing the machine requirements
are also accounted for. TheseThus, furnish modeling andconclusions allow the customer

potential analysis can contributeto estimate the answers to thedecisively to cost reduction andfollowing questions:increased competitiveness.

“Alberta Newsprint Company (ANC) is extremely
pleased with the front end research work performed
by Voith to aid in the design of our shoe press.”
Gary Smith, Technical Director, ANC Whitecourt“Alberta Newsprint Company (ANC) is extremely pleased with the front end research work performed by Voith toaid in the design of our shoe press. ANC will be faced with the challenge of utilizing inferior Mountain Pine Beetle
killed fiber from saw mill residual chips. The chip moisture content will range down to 25%. We also expect higher
pitch extractives from the freshly attacked trees. Voith lab work illustrated the potential benefits we would derivefrom installing a shoe press. This will allow ANC to increase the use of inferior fiber while maintaining paper quality
for the printers ensuring ANC’s long-term viability.”66

28 I 2009 I Voith Paper I twogether

SERVICE

Once the OnS FindSet is connected to an actuator and power
supply, there is nothing else in the way of the check.

Safely stowed away but easy to access, thanks to thepractical service case.

Reliable and easy diagnosis

OnS FindSet closely examines actuators
Trouble-free quality control is one of the foundations for smooth operation of every paper machine.
For that reason, Voith has developed a new analytical tool to quickly and comprehensively check thefunctional capability of cross-profile actuators.
If an alert of an actuator malfunction

is easy to operate and localizes

without cause, e.g., because its

appears on the screen, the search

any malfunctions within a few

functioning is impaired due tofor the cause of the fault begins.

minutes.

contamination, the purchase costs

As a precaution, the reported
actuator is replaced, but often theare already paid. In addition, theClear malfunction assignment

malfunction is not so easily eliminat-

paper mill service personnel canidentify malfunctions in a targeted

ed. If further messages appear, itWith OnS FindSet, any possible mal-fashion, and thus, much trouble-

becomes difficult to determine thefunctions can be quickly diagnosed

shooting time can be saved.

fault. Without exact diagnosis, theand the full functional capability ofoperator is dependent on a “trial-

an actuator can be identified. Thus,

and-error” procedure until the

only faulty actuators are dismantled

On Focus: OnS FindSet

respective actuators are either

and only error-free replacements are

ProSafety

cleared or determined to be thereinstalled. With OnS FindSet, all

ProRunnability

cause of the malfunction.

functions, operating states and theindividual components of a motor-

Section: C D profile controls in headbox,

Actuators can now be localized

operated actuator can be checked.

more quickly and in a much more

Even sporadically occurring mal-Width: alltargeted fashion with OnS FindSet.

functions can be discovered with aPaper grade: all

The device allows a comprehensive

longer test lasting several days.

check of all motor-operated cross-Contact

profile actuators from Voith – regard-

With an average of 150 cross-profile

less of whether it’s done directly on

actuators on a paper machine, thethe paper machine or in a dismantled

new testing device is an investment

state on the workbench. Thanks tothat quickly pays off. Even if just one

the menu-driven analysis, the device

actuator is saved from replacement

28 I 2009 I Voith Paper I twogetherpress, and coating sectionPeter Biener
peter.biener@voith.com

67

SERVICE

8

1

2

9

5
4
7

Vaassen (Holland),2 Ravensburg (Germany),
3 Jakarta (Indonesia),
4 Tolosa (Spain),
5 Appleton (North America),
6 Sao Paulo (Brazil)
7 Dong Ying (China),
8 Karlstad (Sweden)
9 Nova Wies Wielka (Poland)

3

1

6

The recycling sector is experiencing a rapid increase in demand for
locally based, high-qualified service. As a result, Voith Paper’s “Refurbishment
Service” is now available at its Service Centers worldwide.

Keeping rotors in swing

Worldwide service for long-lasting stock preparation
Metal clips, wood pieces, glass and other garbage — recycled wastepaper contains much more thanjust cellulose fibers and fillers. These contaminants will, over time, wear down the rotating parts
inside the process equipment to such an extent that the equipment’s critical design geometry willchange. Voith Paper has launched a comprehensive service to restore these parts — saving substantial
energy, cutting maintenance costs, and ensuring reliable operation.
The effectiveness of stock prepara-and detrashing equipment as part ofany manufacturer. Because rotor

tion systems typically hinges upona fiber-recovery process. That’s why

maintenance is such a specialized,

how long the hardworking parts in-Voith Paper has created a specializedlabor-intensive, and time-consumingside the machinery can withstandservice that concentrates on repair

task, Voith experts have been special-

the constant wear and abrasion

and maintenance of rotors and ex-ly trained to meet the most exacting

posed by trash in the furnish. This istraction plates used in these criticalquality standards. Special welding

because changes to the parts origi-

stock preparation machines.

techniques and materials make rotor

nal design geometry will not only reduce production level and stock

surfaces abrasion-resistant, corrosionExpertise in welding technology

quality. It also can result in higher

resistant, and, most importantly, reweldable. Without removing the exist-

energy consumption as well as fiber

All Voith Service Centers can repair

ing material These resurfaced rotors

loss. These concerns are particularly

and refurbish the precisely tuned

show a high resistance to crackingtrue for rotors operating in pulping

working surfaces of worn rotors fromthat dynamic stress can induce. In

68

28 I 2009 I Voith Paper I twogether

SERVICE

addition, our experts weld high dense,

cost of 0.05 €/kWh, repairing the rotor

wear-resistant edges to the rotor’s

and restoring the original geometry

working surface, further extending the

could save 15,000 € (US $20,416).

lifespan of this critical component.

“That’s because a worn-out rotor, or

Our experts use a special welding

an overhauled rotor that does notwire, produced to Voith Paper specifi-

meet OEM specifications, has geom-

cations.

etry variations which increase thewhole system’s energy consumption

Proven to be more economicalin order to achieve the same flake
content levels,” explains Thomas Jap

Rotor geometry directly affects energy

from the Jakarta Service Center.

consumption in a stock preparation

Accordingly, Voith Paper always uses

system, and, accordingly, the produc-original equipment manufacturer

tion cost per ton of recycled fiber. Re-(OEM) specifications and guarantees

storing that geometry can sustain thethe high quality of all repairs. Voith Paper

optimal balance between minimized

technicians always begin with an onsite

operating costs and maximized tech-analysis to determine what repair is

nological performance. For example,

necessary and schedule the work to en-

suppose a recycled paper process

sure readily available replacement parts.

annually produces 100,000 tons ofThanks to the company’s global service

recycled fiber with acceptable flake

network, most rotor refurbishments cancontent at the pulping loop of 20%

begin immediately. In 2008, one of theand a design pulping energy con-newest Service Centers opened in Dong

sumption of 17 kWh/t. Wear on theYing, China. “In our new Service Center

pulper rotor adversely impacts energy

we benefit from our close working

consumption at this phase in the pro-relationship with Voith Paper in Kunshan.

cess to the degree that by the time theThanks to that, we can provide fast androtor is considered worn out. It re-reliable rotor refurbishment services,”quires 20kWh/t to maintain the 20%

says Jintao Zheng, Service Manager at

acceptable flake content. At an energy

the Dong Ying Service Center.

Flakes [%]In depth knowledge from welding technology and materials is required to bring therotor back to its original design geometry.

Contact
Geert Tichler
geert.tichler@voith.com

Pulping performance

Pulping performance

Without Voith
Worn Rotor
20

With Voith

100 %

100 %

80 %

80 %

Refurbished
Rotor

17

20

Specific Energy [kWh/t]

Energy savings: A refurbished rotor consumes 17 kWh/t toachieve a flake content of 20%. A worn-out rotor, however,consumes 20 kWh/t to reach the same flake content.

28 I 2009 I Voith Paper I twogether

Time

Time

Successful repairs: This graphic depicts the results of routine rotor refurbishments at a
Dutch paper mill. Since 1991, Voith Paper has refurbished these rotors, which still havetheir original geometry. Some rotors have been overhauled more than 30 times.

69

RESEARCH & DEVELOPMENT

Paper makers get active

Calender roll barring
Barring in calenders is a very old topic. But the
R&D activities around this vibration phenomenon
have increased. Now there are new solutions toprevent barring on calender rolls. This applies
both in the case of deflection compensationrolls in soft calenders and also with elastic
middle rolls in multi-nip calenders.

Fig. 1: Nipco axis with active support elements.

Barring means that an elastic roll in asurface can also be detected inother things, use of the especiallycalender has a polygon-like pattern

the paper. Then it is time to change

abrasion-resistant NanoPearl calen-on the surface in a circumferential

the elastic roll in the calender. If thisder roll cover. This cover features

direction. The pattern is always aroll change has to take place outside

the latest calender cover technology.

whole-number multiple of the roll’sof the normal downtime scheduled

Introduction of the two-component

rotational frequency. Sometimes it

for the machine, then overall efficiency

particle system further optimized thecan be seen with the naked eye. It cansuffers.

nano-particles. They improve thebe detected much more reliably via aconcentric running test with highfirmness and stiffness and at theWear as a trigger for barring

resolution (Fig. 2). In this example,

same time have a damping effect in
the case of impact stress.

36 waves can be clearly recognized on

Previous investigations show thatthe circumference of the roll. Thesebarring arises due to wear on the roll

Barring in the paper maker’s

waves on the roll surface arise within asurface in connection with a multitudedaily routine

few days; sometimes it takes a few

of natural frequencies and natural

weeks. In addition, a parallel soundmodes. This is because the elastic roll

The interplay of high-frequency

measurement clarifies the problem:

surfaces wear out due to the rolling

vibrations of the roll stack, the asso-

120 dB(A) at a distance of one meter

process in contact with paper during

ciated natural modes and wear in thefrom the calender. That is as loud assatinage by about 80 to 200 µm perdevelopment of barring has been

an airplane starting up. It is clear thatroll service life – even without barring.

studied in detail but is not well under-

there is a problem here for operation

If in addition to normal roll wear bar-stood. This has not prevented Voithof the machine, especially for the

ring arises on the roll surface, then it isfrom working out solutions that sub-paper makers who have to work at

audible with a wave of about 1 µm,

stantially lengthen the service life ofsuch a loud machine. Parallel to theand with a wave of about 20 µm aelastic rolls. An example of this is

rise in volume, for the most part thenoise level of +120 dB(A) or higher

the EcoSoft calender of the PM 2 at

paper quality also gets worse. In part,arises. Wear characteristics with bar-

August Koehler GmbH in Kehl. The

the barring pattern on the elastic rollring can be improved through, among

calender is for production of thermo-

70

28 I 2009 I Voith Paper I twogether

RESEARCH & DEVELOPMENT• The piezo-actuators produce abase paper at speeds of ca.

press from inside against the roll

1,600 m/min. Barring appeared again

sleeve and are supported at thehigh-frequency controlled pulsation

and again on the Nipco roll with an

stationary axis via the hydraulic oil.

of the chamber volume under the

average service life of ca. 20 days.

The hydraulic oil pressures under the

support element via the pressure

Measurements of operating vibrations

support elements can be individuallyplate.

showed that three different barring

set so that the desired line load

• A sensor support element delivers

patterns accumulated on the elastic

distribution is produced in the nip.

a control variable (acceleration) for
several adjacent actuator support

roll surface at the same time (170 Hz,
670 Hz and 933 Hz). A complicated

The principle of the newcase. Due to the simultaneous

solution

elements.

• The control algorithm developed
can suppress several barring

occurrence of three high frequencies,

frequencies simultaneously.

it quickly became clear that a simple

The principle consists in piezo-

passive measure or hydraulicactuators being used for targeted

damping alone could not solve theelimination of the dominant barring

If acceleration is detected in the

problem. An adaptive and at thefrequencies.

critical frequency range with thesensors, then an exactly opposedsame time active system for the
Nipco roll was thus developed in

Piezo-actuators are also used inpressure pulsation is introduced inorder to substantially increase thecars for injection nozzles withreal time via the piezo-actuators.

service life of the roll.

modern diesel motors, among

Through this, wear in the case ofother things. Fig. 3 shows thebarring is inhibited from the very

Nipco rolls are deflection compensa-

structure of the modified support

beginning. That is the advantage oftion rolls with which a defined line

element with the integrated piezo-

an active system. If the inversely

load is brought into the paper overactuator. There are 32 support

phased pressure pulsations are

the working width at exactly the rightelements installed with piezo-

brought directly into the nip withplace. The Nipco roll consists of a

actuator in the Nipco roll.

the correct frequency already at the
beginning of the wear process – thus,

stationary axis and a rotating sleevethat is covered with an elastic sleeve.

• The active principle consists of a

immediately after the roll change –The locally varying line load in cross-superimposition of inversely

then the development of barring is

machine direction is produced by aphased pressure oscillations

suppressed over the long term. Fig. 1

multitude of support elements that

(interference).

shows the modified axis of the opened

0.02000.0000-0.0200-0.0400-0.0800-0.1000-0.1200-0.1400-0.1600-0.1800-0.2000

Nipco head
Piezo-actuator

Cover
Piston space
Piston space
36 waves
110 dB(A) in +1m of FS

Fig. 2: Example of a concentric running test with high resolution.

28 I 2009 I Voith Paper I twogether

Feed line
Fig. 3: Support element with piezo-actuator.

71

RESEARCH & DEVELOPMENT

Technical specifications

also the mechanical engineer and

EcoSoft calender – August Koehler GmbH in Kehl, PM 2

customized solutions so that thisWorking width:
Speed:
Paper grade:
Basis weight:
Line load:
Surface temperature:

plant engineer. Meanwhile, there are

4,200 mm1,600 m/min
thermo-base paper
40-80 g/m2
80-150 N/mm
60-80° Cvibration phenomenon no longer
burdens the daily production routine.
The active system has by now beenin continuous operation for two
years and has proven itself industrially from the very first day. So far
there have been no failures, which

Fig. 4: Technical specifications of the active Nipco roll at August Koehler GmbH in Kehl,
PM 2.

also shows the durability of theindividual mechanical and electricalcomponents. The system can be

Nipco roll with the additional electrical

off for a short time, then within

used universally for deflection

connections. Fig. 4 shows the installed

minutes a natural mode forms atcompensation rolls with support

active system on the EcoSoft calender670 Hz (49-fold) which without active

elements and is not limited to justof the PM 2 at August Koehler GmbH

control makes disassembly of the

Nipco rolls. And it can be easilyin Kehl. Outwardly, only the two addi-

roll necessary after 20 days.

upgraded at a later date. Similarly

tional electrical plug connections caneffective active solutions have also

be seen; roll handling itself hasn’t

With active control switched on,

been developed for middle rolls inchanged. The required energy demand

this frequency is almost completely

multi-nip calenders.

is low: the installed overall infeed forsuppressed. The service life of theall piezo-actuators together amounts

active Nipco roll was thus more thanto only 7.5 kW.

doubled.
Contact

Getting active – lengthening

Outlook and further

the roll’s service life

developments

The active system is demonstrably

Barring on calenders has lost its

effective. If the controller is switchedability to scare the paper maker and

Dr. Jochen Niemannjochen.niemann@voith.com“Since successful start-up, we’ve still had no
failure of the system to record.”
Georg Streif, Production Manager PM 2/SM 2, August Koehler GmbH in Kehl

“At first, I could hardly imagine that we would achieve an improvement with this new technology - but it works.
The active system has been in continuous operation at our plant for two years. We have achieved an enormous
lengthening of the Nipco roll’s service life. Handling during roll change is trouble-free.
Since successful start-up, we’ve still had no failure of the system to record. Other negative influences could not
be detected. I can strongly recommend the system. It is a good solution for lengthening service life.”

72

28 I 2009 I Voith Paper I twogether

News

Important future market for Voith

Joint visit of the Voith Group Executive Board to China
At the beginning of March, all Executive Board members jointly visited the Middle Kingdom in order tosee first hand the economic situation in China and the situation of the Voith companies there.

Visiting the Dagang plant: Dr. Hans-Peter Sollinger (third from left) and Dr. Hubert Lienhard (fourth from left) receive a briefing using a modelof the plant facilities. They were accompanied by Mingming Liu, Chairman of Voith Paper China (third from right).

Along with a board meeting inwith his board colleagues that

Currently, around 2,000 people work

Shanghai, joint visits to the Voith

Voith is on the right path in China:

for Voith at a total of 24 locations inlocations were on the agenda.

“In the past few years, Voith has

China. They generated around 660

made great progress in the

million euros in sales in the past fiscal

In addition, Dr. Hubert Lienhard,

integration of all corporate divisions

year. A balance in the Middle Kingdom

Chairman of the Board at Voith AG,

in the Chinese and Asian markets

is very impressive and at the same timeand Dr. Sollinger, Chairman of Voith

and with their anchoring there.” Voith

inspires us in our future work. For

Paper, used the occasion for a visit

delivered its first paper machine to

Dr. Hubert Lienhard, one thing is clear:

to Dagang with an inspection of the

China over 70 years ago. Today, Voith“An important goal in the coming years

fine paper machine that Voith

Paper City in Kunshan is the center

is to further expand the integration ofdelivered – the largest one in thefor all paper activities in the entire

Voith in China. In that way, we canworld. Dr. Hubert Lienhard agrees

Chinese market.

better support our customers on site.”

28 I 2009 I Voith Paper I twogether

73

NEWS

Success at Rhein Papier in Hürth

New world record for newsprint
Rhein Papier has set a new world

period of 24 hours during the produc-

2,015 m/min was reached, which

speed record for newsprint on PM 1

tion of standard newsprint with a basis

shows the potential of this machine.

at their mill in Hürth, Germany.

weight of 42.5 g/m2. The time efficiency

On 10th March 2009, an average speed

was around 95.2%. Over a period ofThis new world record is the result ofof 2,010 m/min was achieved over a

20 hours even a maximum speed ofthe efforts made by Rhein Papier tofurther optimize the machine with respect to productivity and runnability.
PM 1 went on stream in July 2002
and produces newsprint from 100%
recovered paper in a basis weight
range of 40-52 g/m² on a wire widthof 8,900 mm. This is a machine with a
DuoFormer TQv, a Tandem NipcoFlex
press, a TopDuoRun dryer section,an EcoSoft calender and a Sirius reel.
The machine concept of the Voith paper
machine was drawn up based on the

The successful world record team in Hürth.

proven One Platform Concept.

QualiFlex – double anniversary

5,000 press sleeves in 25 years
In the area of press sleeves, Voith

characteristics. The result is numerous“The goal for the coming years will

Paper is celebrating an anniversary

world records regarding machine

be to continue to have solutions fortwice in 2009. On the one hand, thespeed, production rates, energy

optimum results of our customers

5,000th QualiFlex was delivered to aefficiency and running times on thethrough continuous development in all

customer in Bosnia-Herzegovina; onmost varied paper and board ma-

areas,” explains Herbert Reil, General

the other hand, industrial productionchines, regardless of manufacturer.

Sales Manager for QualiFlex.

of press sleeves for closed shoeOver the years, the market sharepresses began 25 years ago. During

was expanded to about 40%, asthis period, press sleeves that were

was the position as clear market

always high-quality were delivered

leader in this segment. Today more

for the constantly growing number

than ever, QualiFlex is again andof shoe presses – already overagain setting new standards by which

700 presses have been sold to date.

the performance of press sleeves ismeasured.

Through continuous developmentof new materials and surfaces andAlong with continuous further develop-

the right selection suitable for thement and optimally proven production

respective intended use, the users

methods, one basis of this success iswere always given the optimum

also extensive knowledge.

74

28 I 2009 I Voith Paper I twogether

Voith hydro News

Pumped storage power plant sets new standards after commissioning

An ideal supplement to wind energy
Pumped storage plants are ingenious hybrids. They can produce electricity in turbine mode, or store
energy when in pumping mode. Here, the new pumped storage plant, Kops II, in Austria is setting new
standards: Within seconds, it can feed up to 180 MW of energy into the grid during peak loads, or
remove up to 150 MW of unused energy from the grid for storage. Kops II has been connected to thepower grid since the beginning of 2009.
The Kopswerk, located in Austria’s

is necessary to compensate for this

thereby adapting perfectly to the

Vorarlberg mountains, is one of the

50 MW difference.

grid’s current load requirements.
This also means that wind powerlargest pumped storage plants in
Europe and the largest power station

Depending on the actual demand,

stations can be more efficiently

in the network of Austrian energy

up to 180 MW of energy can besupported, because fluctuating

provider, Vorarlberger Illwerke. Kops II

fed into the grid within seconds

wind speeds produce either too

supplies so-called “regulating energy”

during peak turbine operation, whilemuch or too little electricity.

to the European market. As a result

up to 150 MW of surplus energyof the increasing utilization of

can be removed from the grid during

intermittent wind and solar energy,

pumping operations. Thanks tothere is also a rise in demand forits short hydraulic circuit, Kops IIbalancing energy that has to be

can vary its operating modes toavailable within only a few minutes.

produce a turbine output of 180 MW

Contact
Marie-Luise Leonhardt
marie-luise.leonhardt@voith.com

or 150 MW of pumping power –Kops II has three machine sets, each
rated at 150 MW for pumping modeand 180 MW for turbine mode.
Each set consists of a Pelton turbine,

Kops Reservoir – the mighty concrete
dam wall of the mountain reservoir in
Vorarlberg, Austria.

a motor generator, a starting converter, and a storage pump. For goodreasons, Kops II uses separate
machine sets with individual pumps
and turbines rather than conventional
pump-turbines: The machine setsare designed to operate with shorthydraulic circuits, while the storage
pump and the turbine can operate
simultaneously. A certain amount ofwater is channeled to the turbine
and generates electricty. As a result,the machine set is able to absorb justthe amount of electricity available
from the grid. The pump always
works with 150 MW. If the gridprovides only 100 MW of excess
capacity, the turbine is fed withexactly the amount of water, which

28 I 2009 I Voith Paper I twogether

75

News magazine for theinternational clientele,
partners and friends ofVoith Paper“twogether” is published twice annuallyin German, English, Chinese and Russian.
Contributions by independent authors
do not necessarily reflect the opinionof the publisher. Please address allcorrespondence to the editor.
Published by:Voith Paper Holding GmbH & Co. KG
Editor:Stefanie Weber, Corporate Marketing
Voith Paper Holding GmbH & Co. KG
St. Poeltener Straße 43
89522 Heidenheim, Germany
twogether.voithpaper@voith.com
http://www.voithpaper.de
Design, layout and typesetting:Beate Hornischer
Corporate Marketing
Voith Paper Holding GmbH & Co. KG

Issue 28, June 2009

091113Copyright 6/2009: No part of thispublication may be reproduced or copied
by any means whatsoever without theexpress permission of the editor.

Printed on chlorine-free bleached paper manufactured with Voith Paper machinery.

Voith Paper

ReportInstead of disposal,
			
generate energy
428 I 2009 I Voith Paper I twogether