twogether
Paper Technology Journal

30

Integrated solutions ensure growth I Yueyang Paper: Start-up
double feature I MasterJet Pro: New energy-efficient headbox

Content

10	Commissioning world record double
feature at Yueyang Paper.

24	New headbox combines optimum paper
quality with energy efficiency.

Rebuilds
14		 New shoe press solves raw material

twogether
Paper Technology Journal

Integrated solutions ensure growth I Yueyang Paper: Start-up
double feature I MasterJet Pro: New energy-efficient headbox

problems at Alberta Newsprint
16 Nettingsdorfer relies on energyefficient drives
18		 Simple performance increase foranaerobic high-load reactors

Products
21		 Mechanical deaeration of whitewater as alternative to using
30

chemicals
24		 New headbox combines optimum
paper quality with energy efficiency
28		 First NipcoFlex T shoe press

Cover picture
The NipcoFlex technology
shown is used e.g. in the Single
NipcoFlex press; matched with theappropriate press sleeve and felt it
represents one of Voith Paper’s“integrated solutions”.

impresses tissue manufacturer
30		 New seam felt enhances

4 Integrated solutions ensure
growthNew plants
10 Commissioning world record
double feature at Yueyang Paper2measuring technology.

48		 Integrated automation for tissue
producer SCA Barton
51		 Be our guest: journalist visits
production facility
54		 Coordinated products improve
calender performance57		 VariFlex winder in operation at
Stora Enso Fors

Service60 Dresden Paper producing an
extra 10,000 t/a thanks tomachine audit
64 Interview: new Service Center as
central contact point
67 Total Press Management increases
production and reduces costs

performance of press section

68 Interview: Arctic Paper Kostrzyn

33		 Innovative online sensor measurescounts on press optimizationwater weight in former
36		 Using Intensa technology forrecovered paper brings energy

Research & development

savings of 20%

70 New polyurethane cover for press

38		 Saving energy with sophisticated

Cover story

51 Visit to production site for quality

screen plate design
40		 Reducing costs in approach flow
section with energy-efficientsystems
42		 PrintForm IS forming fabric wins
over customers worldwide
45		 Optimum combination of roll coverand press felt improves dewatering

rolls

News
72	“twogether” magazine celebrates
its anniversary
74 Results of reader survey
75		New at Voith Industrial Services– contract engineering as growthmarket30 I 2010 I Voith Paper I twogether

EDITORIAL

Dear customer, dear reader,
You hold in your hands the 30th issue of twogether magazine. In this15th year of the magazine’s existence Voith Paper will continue toreport on issues of importance and relevance to the paper industry.
On the occasion of this anniversary we have once again carried out areadership survey. The results from the more than 500 interviews are
gratifying, as the majority of our readers are very satisfied with ourcustomer magazine (see p. 74). We will certainly consider thesuggestions you have made and incorporate them into the magazine.
In the current issue we look at the exciting topic of “Integrated
Solutions”. However, it‘s not just the lead article (see p. 4) that illustrates
how the integrated solutions offered by Voith Paper are a response to
the key issues affecting our industry. SolarMax, an ingenious
combination of roll cover and press felt (see p. 45) or the automation
package for SCA’s tissue mill in Barton, USA (see p. 48)
are also prime examples of integrated solution approaches put into
practice.
The goals we are pursuing for the paper industry are clearly defined:
to improve paper quality, increase productivity and at the same timesave energy, virgin fibers and fresh water. All our development
deliberations, innovations and projects are designed to further theseobjectives. It takes this kind of mindset to achieve the start-up record
set on the PM 9 and PM 10 at Yueyang Paper (see p. 10); and it also
takes this kind of know-how to increase the dry content in the press by
6% through a rebuild at Alberta Newsprint (see p. 14).
The 30th issue of our twogether magazine is therefore a special edition
highlighting further examples of how Voith Paper is actively pursuing theabove goals. For more information I’d like to recommend that you readthe articles about our CycloMech deaeration system (see p. 21) or the
new MasterJet Pro headbox (see p. 24).
Happy reading!

Dr. Hans-Peter Sollinger, Member ofthe Management Board Voith AG and
President Voith Paper.

30 I 2010 I Voith Paper I twogether

On behalf of the Voith Paper Team3

Cover story

4

Cover story

Ideas for resource-saving production:

Integrated solutions ensure growth
Industries worldwide are occupied with the question of how growth can beensured while at the same time saving resources. Voith Paper, for decades
at the cutting edge in the development of modern technologies, offers realanswers for paper manufacturing that can be summarized by the term
“integrated solutions.”5

Cover story

Integrated solutions
Focus
Increase in paper quality

Increase in productivity

Saving virgin ﬁbers,
fresh water and energy

Consumption of virgin fibers, fresh water and energy can be significantly lowered by means of integrated solutions.

“By integrated solutions, we mean

Integrated solutions can lead topotential in this area for our

products and processes coordinatedincreases in machine productivity

customers. At the same time, ofwith one another that make it

and paper quality. “In addition, today

course, we can protect thepossible for our customers to

we are turning our attention toenvironment, which nowadays is a

produce high-quality paper while

integrated solutions that are oriented

must. The investment costs of our

optimizing their >>> resource use,”

to our green technology concept,”

integrated solutions are impressive

explains Dr. Thomas Wurster, who

explains Dr. Wurster. “Our customers

as well, since we also have an eye

is responsible for New Technologies.

can thus save virgin fibers and energy

on them.”

As he oversees all innovation

and at the same time get by withprojects within Voith Paper he canminimal consumption of fresh water.

ensure that the various competences

Consumption of natural raw materials

in the company are used to develop

and energy ultimately accounts for

integrated solutions in the beston average 70% of production costs

way possible and new projects canin paper manufacturing. For that

get off the ground.

reason, we see very good saving

6>>> Info: Resources
While the term “resource” is usuallyassociated almost exclusively with raw
materials and energy, the originally French
word is in equal measure synonymous withfunds and, in economic terms, withpersonnel.

30 I 2010 I Voith Paper I twogether

Cover story

Three levels of activity for integrated solutions

Level I

primary energy in half; 2nd, reduction

The entire value creation chain
Starting with removal of raw materials fromthe environment, creation, distribution anduse of the products, all the way to returningthem back to our ecosystem.

Level II

solutions: 1st, cutting the use offor integrated solutions

The paper mill
Coordination of all processes on site opens
up considerable potential for cost reduction
and protection of the environment.

Level III

Three levels of activity

The production line
When products and processes are perfectly
coordinated with one another, resources
such as primary energy and raw materials
can be saved.

of fresh water consumption to at
There are three levels which aremost 1 l/kg of paper; and 3rd,

relevant in considering integrated

maximization of the recycling rate.”

solutions. The first and superordinate
level considers the entire valueOver the last few years, Voith Paper

creation chain, starting with thehas demonstrated with numerous

removal of raw materials from thedevelopments that energy savings

environment, creation, distribution andare possible in all areas of theuse of the products, all the way to

production line through the use of

returning them back to our ecosystem.

new and integrated solutions. Up to“As a renewable raw material that

25% savings with modern pulpers,

decomposes naturally but can also be

up to 30% with new heated roll

technically recycled, paper – invented

coatings and likewise up to 30%

more than 2,000 years ago – is an

by using a Single NipcoFlex press or

was completely appropriate that theideal material for mass products. And

10% through using the EcoProcesscoordinated combination of bioreactor

because it is a mass product, evenconcept in stock preparation – theand lime trap received the Green

more consistent paths have to belist could go on. “Despite all theseApple Award for sustainable develop-

taken so papermaking can becontributions, our long-term goalments and it is incidentally a very

resource-saving and at the same timeremains the cutting of paper

good example of an integrated

cost-effective,” says Dr. Wurster.

manufacturing energy consumption

solution at the paper mill level.”in half – a big challenge for Voith
The second level refers to thePaper,” says Dr. Wurster.

He sees bigger difficulties in thecase of recycling. “In the paper

paper mill and the third refers to theactual production line, from stock“Reduction of fresh water consump-

manufacturing cycle, we have

preparation to the reel. Voith Papertion will be implemented more quick-material components that are notcomes into play on both of thesely,” believes the engineer, however.

yet sufficiently capable of being

levels and already today offers

Given the internationally distinguishedrecycled. Here I’m thinking primarily

various solutions. Dr. Wurster

fundamental developments so far fromof additives, printing inks andexplains: “With our green technology

Voith Paper Environmental Solutions

adhesives. Thus there is still a needfocus, we are also pursuing three

regarding water preparation, he

for action within the value creation

specific aims for our integrated

seems confident: “In my opinion, it

chain level."

IntensaPulper IP-R: Savings up to 25%

TerraGloss: Savings up to 30%

By the use of new and integrated
solutions from Voith Paper, energy
savings in all areas of the production
line are possible.

30 I 2010 I Voith Paper I twogether

7

Cover story

Level I – the entire value

In addition, the use of energy formakes sense at the level of the paper

creation chain

extracting virgin fibers is still clearlymill. “There is considerable potential

higher than for extracting fibers fromhere for saving investment costs,

An ideal recycling process, of course,

recovered paper. Rising energy

energy costs, chemical and water

doesn’t just begin with flotation. If

costs and simultaneously growing

costs if all processes are coordinatedthe problematic materials can becompetition for wood as a resourceas needed with one another andidentified, they should not be brought

thus make recovered paper all thewith the local conditions at the

into the process at all. Today,

more important as a raw material.

location. The future belongs to mills

adhesives and colors can be used

“In view of these findings, processes

that in all aspects are a unified

that don’t pose any problems

have to be developed which ensure

whole,” Dr. Wurster says. Combined

during the recycling process. Voith

that the highest-quality recoveredheat and power generation with

Paper offers effective separation

paper possible is available to us asheat recovery via energy cascades

technologies. But how can recovereda raw material,” Dr. Wurster believes.

or perhaps water purification withenergy generation from the organic

paper be made into a harmless raw
material?

This presupposes an awareness ofload and targeted recirculation of

the problem on a global scale, since

purified water in the paper process

It is clear that recovered paper isthe entire value creation chain isare just two examples of highly

becoming more and more important

involved. To ensure good quality

efficient and cost-effective solutions

for the paper industry as a resource:

recovered paper is available,that at the same time go easy on

Currently around 400 million tons

collection has to be intensified in

the environment. With technologies

of paper are needed annuallysome countries, the separationfrom Voith Paper, modern paper mills

worldwide. By 2025 this number istechnologies further improved andare now in a position to manufacture

predicted to increase to 500 million.

some impurities have to be kept out

not just the classic packaging paper

It is caused above all by the growthof the paper cycle altogether.

from recovered paper. Even graphic
and tissue paper can be produced

markets of China and India. But
even if they don’t grow as much

Level II – the paper mill

at a quality that was previously
achievable only with virgin fibers.

as is legitimately forecast, the raw
material market for wood is limited.

Just as for the value creation chain,

For the paper mill, this means not

One main reason for this is the

an integrated perspective also

just an environmental advantage but

rising interest in renewable energy
sources, the use of which is still
heavily subsidized, especially in

Due to rising energy costs, and growing competition for wood as a resource, increasing
the use of recovered paper is all the more important in the paper industry.

the western world. Alongside that,wood as a renewable raw material
is also ideally suitable for alternative
production of fuels and basis
chemicals. In the foreseeable future,
afforestation programs will not be
sufficient to cover this growth. A
shortage of virgin fibers is thus tobe reckoned with. Just one reason
why the paper industry has toincrease its portion of recycling fromaround 50% so far in the directionof 70% if it wants to meet the risingdemand for paper.

830 I 2010 I Voith Paper I twogether

Cover story

a mechatronic unit was developed,
consisting of a dosing element,
valve, linear drive and control.
Development of the headbox canthus be revolutionized. The highest
paper quality and maximum energy
efficiency are united in this system(p. 24-27).
Or the SolarMax product combination, a unique combination ofroll cover and press felt. Not only
is dewatering in the press section
thereby improved, but energy isalso reduced due to the higher
dry content (p. 45-47).
Voith Paper is also explicitly
concerned with the effect ofchemicals in the paper process
Voith Paper conceived of the “urban mill concept” specifically for paper mills near
big cities like Shanghai. It takes into account the conditions there so that the paper
mill is optimally embedded in the region.

and is searching for mechanicalalternatives. One of them is
CycloMech, a new deaeration
unit with which the process canalso an enormous cost advantage.

Level III – the production line

Recovered paper as a raw material

be stabilized and efficient use ofchemicals can be ensured

is a good choice, especially for

It is not just completely new systems

paper mills that are near cities. Voith

that have to be discussed forPaper developed the so-called “urban

implementing integrated solutions.

Encouraged by such successes,

mill concept” specifically for these

Above all, for existing production

Dr. Wurster is optimistic: “Bymills. Mills that are geared to thislines there are also many

consistently taking cycles andconcept not only use the source ofimprovement possibilities. As aoverall interrelationships into

recovered paper that comes fromsystem provider, Voith Paper is in aaccount, in the future Voith Paper

the big cities as a raw material. They

position to analyze not just a detailwill create more integrated solutions

work with the most modern andbut also its effect on the entire

that offer our customers significant

energy-efficient systems and have

manufacturing process. With theseadded value. Cost-efficiency andlow consumption of fresh water,

integrated perspectives, products

environmental protection go

because the industrial water isand processes can be perfectly

hand in hand here.”completely prepared using thecoordinated with one another andlatest technology from Voith Paper

thus energy and raw material

and fed back into the production

consumption can be lowered. A

process. They also form symbiotic

current example of this is the new

relationships with the respective

MasterJet Pro headbox, for instance.

region and obtain the required virgin

Through the close linkage offibers from the densely wooded

mechanics, process engineering

areas there.

and automation during development,

30 I 2010 I Voith Paper I twogether(p. 21-23).

Contact
Dr. Thomas Wurster
thomas.wurster@voith.com

9New plants

PM 9 and PM 10 – Successful start-ups at Yueyang Paper

Commissioning world record double feature
To commission two paper machines just two months apart is impressive. To do the whole thing inthe same building within 16 months and in a record time of just three hours from “stock on wire”
to “paper on reel”, is a world-record breaking achievement. By opting for two paper machines,
papermaker Yueyang Paper, from Hunan province in China, achieved its goal of environmentallycompatible production of writing and printing paper using as much recovered paper as possible.

Big challenge: Assembly and start-up of two paper machines in the same hall, within the time frame of two months.

In February 2008, Voith Paper won the

majority of pulp for its paper industry

parent company of Yueyang Paper,

order to supply two identical paper

has to be imported. Projects that can

had divided up the planned capacity

machines, each capable of producing

demonstrate a sparing use of resources

increase of 400,000 t/year of writing,

200,000 t/year. This raised theare therefore being promoted and also

printing and copy paper between twoquestion of why not just build a wider,receive the necessary authorizations forpaper machines with 200,000 t

faster machine that could produce therealization more quickly. The aim is tocapacity each: The premium gradessame volume of paper with lower

significantly reduce the use of virgin

requiring imported, bleached long andspecific production costs? Moreover,fibers in papermaking and to become

short fiber pulp as their raw material

the order came from China, a country

less dependent on pulp imports.

are to be produced on the PM 9. Onwith the widest, fastest and mostThis is why even at the tendering stage

the other hand the second machine,

powerful paper machines in the world.

the >>> Tiger Forest & Paper Group,

the PM 10, will produce offset andHowever, current developments in
China provide the answer to thesequestions: In recent years there has
been an increasing environmental
awareness developing in China.
Because the country is comparatively
lacking in raw supplies of wood, the10>>> Info: Tiger Forest & Paper GroupThe Tiger Forest & Paper Group is one of the top ten companies in the Chinese paper industry. The
production capacity of the Yueyang Paper Mill in Hunan province, in particular, has been expanded
enormously in recent years. The paper mill on the banks of Dongting Lake – linked to Shanghai via
the Yangtze River – had a production capacity of around 650,000 t in 2008, mostly newsprint and
LWC paper. In the same year, the decision was taken to expand the capacity of the mill by another
400,000 t per year in writing, printing and copy paper.

30 I 2010 I Voith Paper I twogether

new plants

copy papers from up to 85% deinked

Voith Paper started the fabrication of

pulp (DIP) and will be labeled

the machine components at a very

“Environmentally friendly”. The

early stage of the project and Yueyang

invitation to tender for the DIP system

Paper was able to track the excellent

was worded accordingly: Production ofprogress being made at various

500 t/day furnished from “Sorted Office

Voith sites worldwide. More than a

Paper” with a whiteness of 78-82%.

quarter of the total investment in the“We collect recovered paper here inpaper machine was pre-assembled at

China and overseas. Three years ago

Voith's Chinese works in Kunshan,

we established subsidiaries that focus

particularly the wire and press

on collecting recovered office paper.

sections, the reel, parts of the web

Our objective is to use as muchguide, and the dryer.

recovered office paper in China as
possible, in order to save costs,”

Ahead-of-schedule deliveries in more

explains Peng Zhinbin, deputy chief

than 20 shipments and unproblematicengineer and project manager at thecustoms clearance were the result of a

Hunan Tiger Forest & Paper Group.

comprehensive coordination process.
Voith Paper undertook the planning ofProject roadmap

the installation and found a way ofstarting the erection even 14 days

The kick-off meeting in Yueyang had

before schedule.

already finished before the contract
was signed in early March 2008. Since

The great challenge in this project wasthat time the project teams fromthe installation and start-up of two

Yueyang Paper and Voith Paper have

paper machines in an interval of justbeen working closely together. An

two months apart and with aimportant factor at the start of theclearance of less than 10 m between

project was the pre-engineering. Thethem in the same paper machine

PM layout and the dynamic calculation

production hall. The prompt andand structural analysis of the building

cooperative response to problems

were concluded in a very short period

during the installation and start-upof time. This meant that Yueyang Paper

phase was the result of the

could start on the foundations andpartnership of mutual trust between

sub-structures on the scheduled date.

Voith Paper and Yueyang Paper.

Contract signing (from left to right): Ming Ming
Liu, Voith Paper Asia; Dr. Annette Schavan,
Federal Minister of Education and Research inGermany; Dequan Chen, representative of theChinese Government; Wu Jialin, Tiger Forest &Paper Group; Zhongquan Zhang, China National
Technical Imp. & Exp. Corp.
Project background:
According to information from the China
Paper Association, in 2008, 14 million
tons of uncoated writing and printing
paper were produced in China and13.8 million tons were consumed. Imports
and exports amounted to 390,000 tons
and 540,000 tons, according to theChinese General Customs Authority.
“The market for uncoated writing andprinting paper appears to have found acertain balance. Although there is toughcompetition, the market lacks a highquality and at the same time inexpensive
range of products. Most products are
sold at high prices but do not offer
reliable product quality,” stated Wu Jialin,
Chairman of the Tiger Forest & Paper
Group, the parent company of Yueyang
Paper, as the reason for deciding toinvest in this segment.

Included in the delivery of the PM 9 & PM 10: complete paper machine along with basic and detail engineering, automation package withmachine control system and quality control system, clothing and QualiFlex press sleeves.

DuoFormer D

MasterJet

TopDuoRun

Tandem NipcoFlex

30 I 2010 I Voith Paper I twogether

CombiDuoRun

Wire width: 5,850 mm
Design speed: 1,400 m/min

SpeedSizer

MasterReel

EcoSoft11

new plants

100
80
Start-up PM 9

60

20
0
100
80
60
40
20
0

Start-up PM 10

Time efficiency [%]

40

Aug.

Sept.
Oct.
Month 2009

Nov.

Just a few weeks after start-up, both machines attained
outstanding time efficiency.

Wu Jialin congratulates start-up supervisor Dr. Martin Zimmermann on the
successful commissioning.

“We took only 16 months until the commissioning of the PM 10 – possibly theshortest time ever for the completion of such an extensive project in China.”
Wu Jialin, Chairman of the Tiger Forest & Paper GroupWu Jialin, Chairman of the Tiger

The availability and runability of theand a good specific volume. As a

Forest & Paper Group, the parent

machines are also pretty impressive:

result, the PM 9 will predominantly

company of Yueyang Paper, is equally

In November, the PM 9 achieved aprocess premium quality copy paper

proud of the way the project wastime efficiency (without downtimes)(for photocopiers and laser printers)

executed: “We took only 16 monthsof 92.7%, while the PM 10 evenand high-quality, uncoated writing,until the commissioning of thereached a level of 96.3%. On average

printing and offset papers. “We hope

PM 10 – possibly the shortest time

the PM 10 experienced just 0.9 webthat our production can replace someever for the completion of such an

breaks per day. The project wasof the imports and that in the near

extensive project in China.” Allcompleted successfully with the final

future we will even be able to export,"

measures taken and adjustments

acceptance in May 2010.

says Wu Jialin with some pride.

Quality and sustainability

On the other hand the paper produced

necessary during start-up of thePM 10 could then be adopted for
the PM 9. The start-up of the PM 9

by the PM 10, almost exclusively

went off even more smoothly than

So what is the current situation withoffset papers for the Chinese market,

that of the identical PM 10. There were

the paper quality produced by the two

fully meets the demands for a productjust three hours between “stock on

machines, and to what extent are thefabricated from recovered fibers. Duewire” and “paper on reel” – a record-customer’s objectives being achieved,

to the high recovered paper content

breaking commissioning time!

particularly for DIP-based paper? The

the finished paper will bear the label

PM 9 produces offset and copy papers“Environmentally friendly”. The DIP

from 25% long fiber and 75% shortfacility supplies a furnish with afiber pulp. The quality meets thewhiteness of around 80% and is

Both paper machines achieved their

expectations demanded of a premium

deliberately distancing itself frommaximum operating speeds of 1,300

product in every respect: first-rate

the use of virgin fiber pulp. The DIP

m/min within a few weeks of start-up.

formation, very low roughness values

content in the raw material mix is

Project outcomes

12

30 I 2010 I Voith Paper I twogether

new plants

around 75-80% and is limited by theadmissible number of dirt specks.
Over the long term, Yueyang Paper
wants to completely dispense with
virgin fiber pulp for the PM 10.
“Our long-term perspective is to use
only deinked paper. We hope toachieve this goal within the next two
years,” explains Wu Jialin.

Project Manager Peng Zhibin, Yueyang Paper (2nd from left), and Gerhard Buhmann,
Voith Paper (6th from left), with the successful management and project team of the twocompanies.

Compared with the PM 9, the paper
produced by the PM 10 has aand environmentally compatible

whiteness level that is around 15%

papermaking are the savings ofless, and a somewhat lower specific

160,000 t/y virgin fibers andvolume at the same roughness.

the efficient use of paper fibers

However, Yueyang Paper does not

as a resource.

want its recycled paper to competewith the virgin fiber paper. The paper

It may well be that these endeavors

from both machines is deliberately

are not yet appreciated by all

targeted at different customer groups

consumers and that paper that isand applications.

slightly less white will have to struggle
for acceptance on the market.

The somewhat lower selling price for

But in the medium and long term,

the “environmentally friendly” paper

the courageous and pioneeringfrom the PM 10 – compared with the

stance taken by Yueyang Paper will

premium grades produced by thebear fruit. Virgin fibers and recycled

PM 9 – is also offset by lower raw

papers need one another – so there

material costs. What is moreis no reason why they cannot

important with a view to sustainableco-exist.

Location
China
Beijing
Yueyang
Yueyang Paper

Shanghai

The city of Yueyang is located at the mouthof the Yangtze River at Dongting Lake insouthern China and is connected to
Shanghai via the Yangtze River. The areaaround Dongting Lake is rich in raw
materials for the paper industry.

Contact
Gerhard Buhmanngerhard.buhmann@voith.com“We trust each other and enjoyed our cooperation
during the project…”
Shao Qichao, Vice General Manager & Vice Chief Engineer of
Yueyang Paper Co., Ltd.
“The project staff of both parties, regardless of whether they are senior executives, project managers, or experts
in design, logistics, installation and start-up, have a wealth of experience. We trust each other and enjoyed ourcooperation during the project. Within one week of start-up, both machines went into normal production andproduced salable paper. And after two months, both machines reached the design operation speed, andpaper quality meets contractually agreed specifications. This is one of the most successful projects of the
Tiger Forest & Paper Group.”

30 I 2010 I Voith Paper I twogether

13rebuilds

New shoe press solves raw material problems at Alberta Newsprint“Wild Rose” defies the Mountain Pine Beetle
Thanks to the new NipcoFlex shoe press installed at the Alberta Newsprint Company (ANC) in
Whitecourt, Canada, the company is now able to increasingly use pulp from trees infested with
the Mountain Pine Beetle. The shoe press was successfully started up in 2009 on PM 1,
the so-called “Wild Rose”. The rebuild has also led to increases in productivity and enhanced
paper quality.

British Columbia

Alberta

Prince Rupert

Alberta Newsprint

Area affected byMountain Pine Beetle
in Western Canada

Prince George
Williams Lake

Total area of population
Strongest infestation
0 100 200 km

Kamloops
NelsonVancouverInfested forest areas.

Population area of Mountain Pine Beetle
in Western Canada.

In the early 2000’s, an outbreak ofPapermaking implications

the Mountain Pine Beetle occurred

A tiny organism causes massive
damage.

To ensure continued efficientperformance of the paperin British Columbia. Its impact on

ANC expects the fiber supply tomachine and maintain paper

the eco-system, as well as thecontain greater amounts of Mountainquality, ANC entered into a

economic impact has already been

Pine Beetle affected trees either

research program with a number

felt throughout the region. A morethose killed recently, with excessiveof partners committed to help

recent meteorological event

pitch content or those left standing

determine the best path forward.

coincided with the beetle’s shortdead and dry producing a weakermigration period and carried thepulp with poor brightness andBesides ANC, contributors

beetle over the Rocky Mountains

optical properties. Additionally, theincluded, Alberta Forestry Researchand into ANC’s wood basket. In

beetle leaves a fungus behind which

Institute (AFRI), Alberta Research

the past, cold winters caused

causes a blue stain on the inside

Council (ARC), FP Innovations,

beetle winter kill rates in the orderperimeter of the tree, which also

Innoventures Canada, Nationalof 97% and kept the infestation inhappens to be the main portion of

Research Council Canada (NCR)

check. Recent mild winters havethe log that is converted by theand Voith Paper. All looked forincreased the survival numbers andlumber mill to wood chips andinnovative methods to manage

the insect population has thus

subsequently supplied to paper

the inferior wood supply.

exploded.

mills.

14

30 I 2010 I Voith Paper I twogetherrebuilds

Vor Umbau

Property

Rebuild
improvements

Comments

Press solids

40-46 %

6 % gain (absolut)

Reel speed

9 % increasenon affected wood by the
Mountain Pine Beetle

Steam usage

up to 20 % reduction

Web breaks

12-60 % reduction

dependent on location

Tensile5 % increasenormalized to 1,400 m/min

TEA*

8 % increasenormalized to 1,400 m/min“Wild Rose” before rebuild …

Vor Umbau… after rebuild.

Nach Umbau* TEA = Tensile Energy Absorption

The installation of a NipcoFlex shoe press has considerably increased productivity and paper quality.

Successful with new shoepress

Nach Umbau

In order to compensate for thedetails of the press were evaluatedweight value added grades. Machine

early during the engineering phasespeed has increased since thein anticipation of this criticalinstallation of the NipcoFlex shoe

application.

press and “Wild Rose” PM 1 recently

expected loss of sheet strength onachieved its mill speed record of

the paper machine, especially at the

ANC’s high quality newsprint sheet

weakest point, the first open draw, a

has long been well regarded in thedecision was made to install aindustry. Significant additional

NipcoFlex shoe press at the 3rd nip.

improvements to the paper

Location

The improved press solids andmachine operation and paper

Canadareduced draw would ensure highest

quality have been achieved andpaper machine operating efficiencies

documented with the installation ofand compensate for the weaker

the NipcoFlex shoe press. The

furnish. It also makes certain that theoperating window has been

sheet’s dry strength properties such

expanded, allowing increased use

as tensile and TEA are maximized forof Mountain Pine Beetle affectedsuperior press room runability.

fibers, as well, future growthWhitecourt is located along the Yellowhead

Special consideration of all design

potential assured to lower basis

Trail, Western Canada’s most famous settler

1,600 m/min.

Whitecourt, Alberta
Alberta Newsprint
Company
Edmonton

Ottawatrail from the 19th century. The town has
approx. 10,000 inhabitants and is situated in“Voith Paper was atremendous partner…”
Mike Putzke, Mill Manager,

Alberta Newsprint Co.

“Voith Paper was a tremendous partner to ANC in helping us utilize

the western part of the province of Alberta,
about 200 km north-west of Edmonton.
Forestry, oil and gas industries as well as
tourism are the cornerstones of Whitecourt’s
economy.

Contact
Mark Young
mark.young@voith.com

Mountain Pine Beetle attacked trees. The shoe press installation andstart-up was flawless.”

30 I 2010 I Voith Paper I twogether

15rebuilds

For the first time, Voith Drives for packaging paper machine

Nettingsdorfer relies on energy efficiency
Drive units, steam units and vacuum units are the systems which require the most energy in apaper machine. The biggest consumer is the dryer section. Approximately half of the total energy isexpended there: a good reason for Smurfit Kappa Nettingsdorfer to decide in favor of energy-efficientdrives in this area.

Fall 2009 saw for the first time theNettingsdorfer decided in favor of thelasting increase in respectively

entire dryer section of a packaging

new drives as its previous equipment

safeguarding of drive availability.

paper machine equipped withwas technically outdated. Thus theMoreover, the new solution was toVoith Drives. The pioneering site isavailability of spare parts, for example,

meet the current technical state of the>>> Smurfit Kappa’s Nettingsdorfer

could no longer be ensured.

art, which means being gearless. A

mill located in Austria. All 35 drives ofFurthermore, the old drives were being

speed reserve, high energy efficiency

the dryer section in the PM 6 wereoperated far beyond their designand low maintenance costs were further

rebuilt.

capacity. The aim of the rebuild was a

key arguments for Nettingsdorfer.

The Voith Drive is an integrated drive that replaces the traditional arrangement of cardan shaft, gears, coupling and motor.

16

rebuilds

The customer is fully satisfied

How much energy can be savedwith the Voith Drive concept

depends on the respective drive

selected – regardless of whether

position. On average it is 5% withit’s a question of accessibility,

the installation, as compared to aavailability or controllability ofwheel housing, but noticeably larger

the equipment. Voith Paper alsosavings are also possible. Voith

got good grades as a partner.

Drives are also better for the“Highly competent during theenvironment. As there is no central

entire project,” is the summary

oil lubrication, there is no risk of oilof Siegfried Hochrathner, Project

leaks. Tempering of the motors

Manager and Manager of Electricalis done with water.

Maintenance at Nettingsdorfer.
Assembly of the drives is possible
The Voith Paper drive concept ison the drive or tender side. However,

especially suitable for rebuilds

installation on the tender side hasof paper machines. The direct

advantages for the entire system:

drives do not require a foundation

expensive rebuild of the steam andand their installation therefore

condensate system is no longer

saves space. In addition, the use

needed and the total rebuild timeof Voith Drives reduces energy

is shorter than that of conventional

consumption, due to the drive

drives. Downtime costs are thus

system’s higher efficiency. This

reduced.

is facilitated by doing without
Paper mill Nettingsdorfer is a company
with long-standing tradition.

mechanical components, suchas wheel housings in the dryer
section and additional external

Location

A special feature in the use ofgears, cardan shafts, couplings

Austria

Voith Drives on the PM 6 was theand lubrication units. At the samevery high temperature range attime, the noise level in the machine

the installation position. It canhall is also reduced. The costs

climb to around 100 °C at theand the maintenance outlay are

upper cylinders. For that reason,

therefore lowered. In addition,

the motors are protected with an

fewer components also mean

Nettingsdorf is a district in the town ofinsulation hood made of glass

fewer spare parts that

Ansfelden, which is 180 km west offiber reinforced plastic.

have to be stored.

Vienna in the northern part of Austria.

ViennaAnsfelden
Nettingsdorfer
Paper Mill
AG & Co KG

Industrialization of the agrarian area around>>> Info: Paper mill Nettingsdorfer
The Nettingsdorfer paper mill, which is part of the Irish company Smurfit Kappa, has a long
tradition. Nowadays it is one of the leading producers of corrugating base papers in Europe.
Annually, Nettingsdorfer releases about 400,000 tons of high-quality kraftliner and 20,000 tonsof test liner onto the market, with 85% of production being exported. The main markets are inCentral and Eastern Europe.
Nettingsdorfer is an integrated paper mill – Austrian conifer, log wood and sawmill leftovers areused as the main raw materials.

Ansfelden began with the founding of thepaper mill in 1851. Even today it is oneof the town’s biggest employers.
Contact
Johann Schneider
johann.schneider@voith.com

The PM 6 was built by Voith in 1984. The fourdrinier machine has a working width of 7.4 m andthe maximum production speed is 1,100 m/min. The basis weight range is 115-300 g/m².

30 I 2010 I Voith Paper I twogether

17rebuilds

Proven R2S technology eliminates sediments and increases performance

Easy conversion of high-performance anaerobic reactors
The purification rate of anaerobic reactors can drop significantly over time. The reason for this areusually deposits of heavy, inactive granular sludge. They are found especially when waste water witha high calcium content is purified. The new Up2S conversion kit allows the rebuild of conventional
high-performance anaerobic reactors with the proven R2S technology. Sediments can thus be quickly
and easily removed during ongoing operation and low-performance reactors can be put back on
course.
By means of a tangential
flow guide, the sedimentthat develops gathers in thecenter of the cone and canbe removed easily duringongoing operation.

By using thermography,
the heat profile can bevisualized:
blue: cold zones= deposits of sediments
white/orange: warm zones= active reactor volume

18

rebuilds

Anaerobic reactors in the paper

turbulence occur which can lead tostage downstream increases andindustry are frequently used as high-biomass washing out of the reactor

can lead to an overload. As aperformance reactors. Among otherwith the treated water. Furthermore,consequence COD values in thereasons and due to restricted space

an uneven supply of the biomass

effluent deteriorated or formation

areas, they are usually between 20 mwith substrate, triggered by a lackof bulking sludge might beand 30 m high. Reactors usuallyof mixing and partly plugged

observed.

have a flat bottom tank. Depending

distribution system, lowers theon the manufacturer, reactors may

COD degradation capacity.

have internals for improvement of

Up2S conversion kit – the easy
and efficient solution

fluidization. The risk of deposits is

Areas in which sediments haveespecially high with this type ofsettled will not be flushed andAt this point, the patented concept

reactor. Calcareous waste water

consequently cool down. Theof the R2S anaerobic reactor formay quickly lead to a reduction inskilled operator assesses thethe discharge of sediment offers atreatment efficiency, since the lime

condition of the anaerobic reactor

reliable solution. In order to makeprecipitates accumulate in the formby observing the temperature drop

the advantages of the R2Sof sediments on the bottom of the(cold spots) on the tank shell. Bytechnology available for existing

reactor. Thus the amount of available

using thermography, the heat profile

high-performance anaerobic

active biomass in the reactor needed

can be visualized. After emptying

reactors, Voith Paper has successfully

for COD (chemical oxygen demand)

the reactor, it becomes clear thatlaunched the Up2S conversion kit.

degradation decreases; the active

sediment deposits can block thereactor volume decreases and the

distribution system of an anaerobic

Components of the Up2S conversion

COD removal efficiency of thereactor to a large extent. In such akit:anaerobic reactor drops.

case, the COD load to the anaerobic• Segmented, cone-shaped reactor

reactor needs to be reduced so that
In addition, often channels form

the remaining active biomass willin the accumulations of sediment.

not be damaged irreversibly. The

At these channels areas of high

COD load to the activated sludge

bottom• Cone flushing line
• Heavy sludge drain line
• Innovative inlet distribution system

Segmented cone-shaped reactor bottom.

30 I 2010 I Voith Paper I twogether

19rebuilds

system. For example the distribution

while reusing the temporarily storedlines may be cleaned easily during

granulated anaerobic sludge that had

ongoing operation.

a high portion of lime.

Successful in operation

Meanwhile, the converted anaerobic
reactor has been in operation for

Due to heavy lime precipitates

more than half a year. The new inlet

and, as a consequence, reduced

distribution system works very evenly

treatment efficiency of the existing

and the periodic removal of sedimentanaerobic reactors, the SCA

has become part of the normal

Aschaffenburg paper mill in

operation. Inspection with an infrared

Germany decided to convert one

camera shows that the convertedof its three anaerobic reactors toreactor is in good condition. The area

R2S technology. The positive

beneath the cone is not flowed

experience with the R2S anaerobic

through and thus cold. Above the

The conversion is carried out by anreactor that has been successfullycone, the light coloring shows

experienced team underoperated for more than two years

optimal mixing of the sludge bed.

consideration of the operationalat the sister plant in Lucca, Italy,needs of the paper mill.

also had a positive influence on

The entire anaerobic process stage

this decision.

profits from the stable operation of

The converted reactor at SCA Aschaffenburg, Germany (center).

Technological concept

the reactor converted to R2S

By means of a tangential flow, theThe reactor to be converted wastechnology, since it ensures reliablesediments that develop gather in thecompletely emptied and theoperation with high degradation

center of the cone. A special process

installed distribution system wasefficiency.

concept allows to separate pellets

removed through an opening in thewith active biomass in a better way

tank. Then the cone-shaped reactor

Locationfrom sediments. Thus sediments withbottom and the new distribution

Germanya very high portion of ash can besystem were installed in the tank.

discharged. Draining of the sediment

After successful rebuild, thetakes place during ongoing operation.

anaerobic reactor was refilled with

BerlinAschaffenburg,
SCA Aschaffenburg

sludge and started up. Immediately
Another special feature is the rugged

thereafter, the reactor readily

and reliable intake distribution

attained high treatment efficiency
The university town of Aschaffenburg, withapproximately 70,000 inhabitants, is well-

Rebuilt

Not rebuilt

known as the gateway to the Spessart region.
King Ludwig I. of Bavaria (1786-1868)
nicknamed the town the “Bavarian Nice”,
because of its mild climate.

Contact
Axel Gommel
axel.gommel@voith.com
Inspection with an infrared camera shows that the rebuilt reactor is in good condition.
The area beneath the cone is not flushed and thus cold. Above the cone, the lightcoloring shows optimal mixing of the sludge bed.

20

30 I 2010 I Voith Paper I twogether

products

CycloMech: an attractive retrofitting solution for
the approach flow system

Mechanical white water
deaeration requires
little space
Air in the white water of a paper machine can have
many negative consequences — beginning withformation errors in the finished product all the way
to deposits on the rolls and a break in the paper
web. Without a deaeration machine, controllingthese consequences has traditionally required costly
chemicals. But the new CycloMech from Voith Paper
offers an efficient, space-saving alternative.

Model of the CycloMech.

21

products

Smurfit Kappa's paper mill in Zülpich,

which is based on the centrifugal

The Zülpich mill uses only recovered

Germany, which manufactures

principle, and rotated. By means ofpaper for paper manufacturing. It is,

corrugated cardboard base paper,

the centrifugal forces, the lighter air

therefore, especially susceptible tohas operated the CycloMech on agathers in the center of the housing.

microorganisms whose growth istrial basis for the last year and a half.

From there, it is pumped out withaccelerated by air in the white water.

Workers at the paper mill are more

the aid of a vacuum – a quick,

Slime and agglomerates form thatthan satisfied with the results:

reliable method of deaeration.

contaminate the paper machine and“With the same quality of our end

clothing. Although the doctor blades

product, we were able to save almost

Quick retrofittingin the dryer section ensure that a

20% of the retention agents and overlarge part of the contamination is

25% of the anti-foaming chemicals,”

However, the decisive argument

removed, they, too, must be regularly

reports Holger Scheben, process

for the CycloMech is its spacecleaned or replaced. Before

engineer for PM 6 at Smurfit Kappa

advantage: with its compact

installation of the CycloMech, doctor

Zülpich.

dimensions, it can even be retrofitted,

maintenance was part of the daily

without a problem, while a paper

work cycle in Zülpich.

Also, because the CycloMech

machine remains in production. With

improves system cleanliness, muchconventional mechanical deaeration

Since installing the small mechanicalless maintenance and cleaningmachines, based on the deculator

deaeration system, the interval

are necessary. This has enabledprinciple, retrofits are possible only

between doctor cleaning cycles

production increases between

at great expense: for physicalhas tripled. Specifically, this means

1% and 1.5%.

reasons, the vessel must be placeda production increase of about

on the mill roof. Associated retrofit

4,500 tons of paper per year.

The way the CycloMech functions

costs can also be enormous —“Lessening the need for cleaningis the key to achieving such aespecially given the structural

also improves work safety, sinceconsistently good balance. Whiteprecondition that the roof must

maintenance on the blades is work

water is channeled into thebe designed to withstand a weightthat is not completely without

mechanical deaeration system,of more than 10 tons.

danger,” explains Holger Scheben.

With the installation of CycloMech retention agents anddeaeration chemicals can be saved.

Clear improvement of mechanical characteristics throughpartial flow deaeration with the CycloMech.

100%

60%

40%

20%

Basis weight: 100 g/m2
Without CycloMech

6

+ 15%

With CycloMech

5
4
3
2

+ 13%

1

0%

0

Free/dissolved
air

22

Without CycloMech
With CycloMech
Breaking length [km]Savings

Savings

Savings

80%

7

Retention agent

Anti-foaming
chemicals

Machine direction

Cross direction

30 I 2010 I Voith Paper I twogether

products

Clear advantage compared towell with other process chemicals.

chemical deaeration

A variety of problems can ensue.
The residual deaeration chemicals,

Thorough deaeration of the whitefor example, can impair thewater in the approach flow systemeffectiveness of retention agents.

of a paper machine has a decisive
influence on operating costs.

Last, but not least, the CycloMech

Contaminants such as micro-stickies,

is independent of the paper

can attach to free air bubbles andproduction cycle. This means thatlead to deposits on rolls and clothing.

production can continue during

If this contamination is not eliminated,maintenance work on the deaerator.

a break in the paper web generally

No stoppage costs arise. Size,

results. Moreover, reducing air

efficiency, and easy integration into

content supports optimal dewatering

the existing production chain makeand minimizes formation errors – andCycloMech an attractive component

improved sheet formation meansof any paper machine.

improved paper quality.
Holger Scheben agrees:
As a mechanical deaeration system,“In my opinion, the CycloMech is a

the CycloMech is a cleaner, moremust for every paper machine thatuser-friendly alternative to chemical

produces light packaging paper up

systems. Such systems add

to 120 g/m².”

expensive chemicals to dissolve
air bubbles in the white water.
The chemical agents are stillmeasurably present in the finishedpaper, and they do not interact

The CycloMech at Smurfit Kappa Zülpich
Papier, Germany.

Air bubbles in the headbox flows displace fibers: CycloMech reduces these air bubbles,in turn enhancing sheet formation and strength properties.

On focus: CycloMech
ProSafety
ProEnvironment

Fiber

ProRunability
ProQuality
ProSpace
150 µmØ 170 µm

Section: approach flow system
150 µmAir bubble
Ø 300 µm

Paper grade: board & packaging

Ø 30 µm

Contact
Dr. Martin Störzer
martin.stoerzer@voith.com

Ø 100 µm
Wire

30 I 2010 I Voith Paper I twogether

Open area23

Products

MasterJet Pro combines optimum paper quality with maximum energy efficiency

A new milestone in headbox development
It has been 99 years since Voith filed a patent for the first “high-pressure” headbox. At that time it wasa major step in being able to develop faster paper machines. Now, in 2010, we see the advent of thelatest generation of MasterJet headboxes featuring a whole new innovation: the MasterJet Pro.
It combines, for the first time, optimum paper quality with maximum energy efficiency.

24

Products

First references
First installations of the new MasterJet Pro are alreadyoperating successfully, while others are on the order books.
Graphical paper grades
The first three MasterJet Pro headboxes for graphicalpapers will start up in 2011. The MasterJet Pro will be installed on hybrid and gap formers.
Board and packaging papers
The first installation for packaging papers has been
operating successfully since the end of 2009. Anotherfive MasterJet Pro headboxes will follow in 2011.
TissueOne MasterJet Pro is already in operation for tissue grades.
Another headbox will be installed in 2010 followed by afurther seven in 2011. The MasterJet Pro will be used forsingle and two-ply applications.

25

Stilling chamber

Conventional headbox

Turbulence
generator
NozzleEffect in paper

With the MasterJet Pro, the dilution water is fed directly into the stilling chamber (no mixing
chamber). The ink dispensing effect in the paper is thus improved.

55%

100%

MixingchamberSamedeflocculating
effectMasterJet Pro

Cross flow
headerPressure loss due tolayout and design

MasterJet Pro

Energy forjet acceleration

Conventional headbox

Operating costs

Products

Reference:
Width 6 m;
1,200 m/min;
Stock flow
60,000 l/min;
0.06 €/kWh

Less operating costs thanks to MasterJet Pro.

The core innovation of the newfluctuations with steep gradients,

consisting of metering element,

MasterJet Pro generation is the

such as those that occur in edge

valve, linear drive unit and control.

completely redesigned ModuleJetzones due to reflexions and edge

The unit’s hydraulic system concept isdilution technology. The mostwaves, can be corrected far more

tailored perfectly to the new dilution

important improvement is that theeffectively.

principle and thus ensures maximum

dilution water is fed directly to thecontrol capability with high accuracy.

stilling chamber using injectors, with

The new dosing principle allows

The fast, state-of-the-art actuation of

the dilution water distributed evenly

for larger ModuleJet spacing where

the linear drives via an ethernet

over the entire height of the channel.

quality requirements are less impor-interface and components designed

This dosing method improves thetant. This means for example thatto the superior IP 67 protection classaccuracy of the control response in

the profile quality of a conventional

guarantee reliable operation even in

the web by over 50% comparedsystem today can be achieved evenchallenging environments.

with conventional systems, whilewith 100 mm spacing. The reduced

maintaining the balancing function of

number of valves and actuators also

Turbulence generator andthe stilling chamber. This means that

results in lower investment costs.

jet quality

an injector spacing of 50 mm allows

In addition, optimization of the new

optimum CD basis weight profiles

ModuleJet system’s hydraulics means

The MasterJet Pro’s turbulence

and fiber orientation to be achieved.

that the pressure losses that occur

generator adopts the proven basic

In particular, local basis weight

are substantially reduced.

design of its predecessor. However,

100

0

0

25
50
75
100
Total flow quantity [thousand l/min]

adaptation to paper grades, to takeaccount of the increasing variation in

50

Energy cost savings with MasterJet Pro.

26

Integrated solution

WFC

TissueEnergy cost saving[thousand euros/year]

Outlet width: 6 m
Power costs: 0.06 €/kWh150

Testliner

there is now an even more systematic
200

125

The new ModuleJet dilution system

raw material composition and customer-

is controlled by the OnQ ModuleJet

specific quality requirements. The design

CD actuator. Close cooperationof the turbulence elements and tube

between the development disciplines

geometry therefore allows for grade-of mechanical and process

specific and energy-efficient dimension-engineering and automation has

ing in each case, ensuring a broad-produced a mechatronic module

ranging and stable operating window.

30 I 2010 I Voith Paper I twogether

Products

Fourdrinier

Gap

TissueMasterJet Pro headbox family.

Cutting-edge concept

The degree of turbulence is further

flows at the cross distributors. The

adjusted in the nozzle area using

result is that the entire volumetriclamellas. Patented lamella geometries

flow to the headbox is reduced by

The MasterJet Pro is a modular headbox

and materials guarantee quality

up to 10% – without impairing theconcept combining optimum paper

and reliability. To meet special

quality or stability of the process.

quality with maximum energy efficiency.

requirements for sheet symmetry

This has already been confirmed withThis is made possible through a range

and flatness the new ParaSliceextensive testing on production andof innovations complemented by provennozzle geometry is used. Numerous

pilot plants. In combination thesecomponents. This unique combination

installations on copy paper machines

measures lead to headbox pumpof experience and innovation marks

bear impressive testimony to thepower consumption being reduced

the new MasterJet Pro out as a cutting-positive effect of the ParaSliceby between 15 to 25%, depending onedge headbox design.

design. (A detailed description

the respective headbox configuration

appeared in twogether Magazine

and machine speed.

issue no. 29).

On focus: MasterJet Pro
ProSafety

A further systematic step towards

ProEnvironment

simplifying operation and

ProRunability

maintenance is the absence of a

ProQuality

Many of the pioneering innovations

heating chamber system, andProSpeed

give a substantial reduction inconsequently the entire heating

ProSpace

operating costs, mainly reflected inloop, in all headbox models. This

reduced power consumption by thedesign principle has already been

Section: wire section

headbox pump. For example, byimplemented in more than 200

Paper grade: all

optimizing the hydraulics of theheadboxes to date. Compared withheadbox system, including LC andthe complicated system of deflection

HC flow routing, pressure loss could

compensation using heating

be reduced by up to 30%. A further

chambers and loops, the patented

innovation, facilitated by the design

design principle ensures thatof the MasterJet Pro’s flow system, isdeflection due to temperature

the complete absence of recirculation

drops do not occur at all.

Less operating costs

30 I 2010 I Voith Paper I twogether

Contact
Thomas Ruehl
thomas.ruehl@voith.com

27

Products

Northern Tissue Group as pioneer for new developed shoe press

First NipcoFlex T successfully started up
Ten years after the first shoe press worldwide was installed at the Northern Tissue Group (NTG) mill,
the group has decided once again to be the first tissue producer to install the new Voith NipcoFlex T
shoe press. The NipcoFlex T is the latest development of shoe press technology for tissue andimproves product quality and plant efficiency.

The first Voith TissueFlex shoe press
was launched on the market approx.
ten years ago. At that time the main• How can the efficiency of the plant
be increased?

such as steam pressure, which in turnchanges the operating temperature and• Where can energy be saved?

thus the deformation of the Yankee
heads and shell. A shoe press for a tissue

focus was on the product features ofbulk and softness in order to differ in

These questions were the focus for themachine must therefore be designed toquality from the standard Dry Crepeproduct development of the new

be very flexible across the full width ofmachines.

NipcoFlex T shoe press.

the nip. This is a prerequisite forDuring the last few years competition

Technological challenge

generating a uniform linear load in thepress nip so that a homogeneous CD
moisture profile can be achieved.

has become distinctly tougher even in
the tissue sector so that in addition to

The press nip of a tissue machine

However, a rigid pressure shoe inquality characteristics, questions ofdiffers fundamentally from the press nip

machine direction is essential so thatenergy saving and increase inof a paper machine. The reason for that

we achieve the desired high dryness.

efficiency have gained in importance.

is the Yankee dryer which is not like theDue to very strong competition and theconventional mating roll of a press.

NipcoFlex T for maximum
productivity

need to reduce costs, many production
managers are confronted on a daily

Besides the known parameters such as

basis with the following questions:linear load, the Yankee dryer is subject

The mentioned technological challenges• How can the fiber input be reduced?

to additional varying factors of influence

were successfully implemented into

“It was a pleasure to work with Voith during the project
phase and especially during the start-up and optimization
phases. After this close cooperation we consider theVoith Paper team as a partner.
With the NipcoFlex T shoe press we are able to dramaticallyincrease the energy efficiency and runability of tissue
production at NTG, even more so than expected. This
technology is setting the bench mark for minimum energy
consumption and highest quality.”
				

28

Steve Mulcahy, Mill Manager NTG

Nip pressure [MPa]Products

4.0
3.5+ 15 mm

Line load = 90 kN/m
Slope =
-15 to +15 mm

2.5+ 10 mm

2.0+ 5 mm
No slope- 5 mm- 10 mm- 15 mmWith the NipcoFlex T,various pressure profiles
can be created andchanged during production
via the process control
system for maximum dry
content and no rewetting.

3.0

1.5
1.0
0.5
0.0

-40

-20
0
Nip length [mm]10

Conventionalpress nip

The challenge
The uneven Yankee deformation
is influenced by:- line load
- temperature profile- steam pressure- centrifugal force- stiffness of the cylinder covers

low

The flexibility of the NipcoFlex T allows setting of variouspressure profiles.

highDeformation of the Yankee by the line load sets high requirements
for the NipcoFlex T.

NipcoFlex T succeeds

the design of the new NipcoFlex T

the control room so there are noshoe press. In order to ensure

production downtimes for adjusting

maximum operational reliability withthe shoe position. Maximum

In addition to the first installation for

the first installation, Voith Paper has

flexibility for the optimum setting

the Northern Tissue Group, thesubjected the new NipcoFlex T to awith regard to dryness, bulk andNipcoFlex T will be installed in two

thorough test plan. The innovation

softness is achieved at the samenew tissue machines. These machines

was tested technically not only in thetime.

will have a paper width of 5,550 mm

shoe press test rig but was also

and will be installed in China.

tested technologically for quality

The first installation wascharacteristics such as bulk andstarted up successfully

dryness at Voith’s tissue pilot plant in

In 1999, Voith Paper established shoepress technology for tissue as the first

The first NipcoFlex T was success-supplier worldwide. Since then it has

fully started up at the Northernbeen the market leader in the sector of

All the results gained from these

Tissue Group in Lancaster, UK intissue shoe presses with twelve

rigorous tests confirmed that the

April 2010. As was already the caseinstallations in operation.

NipcoFlex T has substantial

on the Voith pilot plant, the start-up

advantages for the manufacture of

was without any problems. The after

tissue:press dryness was immediately

Sao Paulo, Brazil.

increased by more than 5% directly

On focus: NipcoFlex T• With the NipcoFlex T, maximum

after the start-up with unchanged

ProEnvironment

drynesses of up to 48% can bebulk. The objectives of the new

ProRunability

achieved. This means that when

NipcoFlex T have already been

ProQuality

compared to a conventional suction

exceeded during this first

ProSpeedroll press, approximately 20-25%

installation:

drying energy can be saved.

• The NipcoFlex T stands out due
to its extremely uniform nip,

Section: press section• The drying energy was reduced bymore than 20%.

which results in a high operating• The flexible shoe ensures a very

efficiency. Disturbing phenomena

good CD moisture profile andsuch as edge lifting are now a thing

optimum runability.

of the past.

• The effective shoe position can be
adjusted during production from30 I 2010 I Voith Paper I twogether

Paper grade: tissue
Contact
Dietmar Sporer
dietmar.sporer@voith.com• The flexible shoe adjusting device
permits optimization of bulk anddryness during production.

29

Products

AS G2 – the new generation of seamed press fabrics

Press section performanceincreased
To meet the demands of machines worldwide, seamed press fabric improvements are an ongoing effort.
The fabric has to guarantee safe and fast installation, high dewatering capability and no negative effecton sheet properties. The AS G2 line of press fabrics builds upon new and existing components andmeets these demands.

The aim of the improvements is toare due in large part to the new

Further benefits withhave a >>> seamed product line,

Enhanced Needling System (ENS),

components

capable of producing paper over awhich is a global standard. The im-

broad range of pulp to tissue ma-

proved needling combined with seam

AS G2 fabrics can be designed tochines, regardless of press section

zone components and reinforcement

incorporate the latest technologies

type. AS G2 fabrics provide:

agents improve flap wear resulting inVoith Paper has to offer to meettransparency of the seam, allowing

the requirements of most press

AS G2 fabrics to be utilized on suchapplications. Components proven toa variety of applications.

provide benefits to the papermaker• Safest and easiest installation• Increased durability and stability• Improved batt fiber entanglement• Reduced seam marking• Better and more controlled water
handling• Steady state performance• Energy efficiency tailored to theapplicationin terms of energy savings, sheet
With varied batt fiber selections,

property improvement, reduced

base structures, and technology

fiber usage, faster start-up, vibration

components, dewatering can beelimination and improved fabric life

controlled based on the application.

can be part of the package.

For slower speeds and grades notconducive to nip dewatering, orVector technology

where pans and doctor blades are30

The roundness and straightness of theinsufficient, an AS G2 fabric can be

Vector technology is a proven corner-

seam loops, coupled with installation

designed appropriately. Results onstone of many Voith Paper press

assists tailored to the position, make

VPM 6 pilot machine in the Paper

fabric designs, endless, non-woven

AS G2 fast and consistent to seam on

Technology Center (PTC) in Heiden-and seamed. In conjunction withthe paper machine. The increased

heim, as well as in the field, show

AS G2 seam zone enhancements, flap

durability and reduced seam marking

this dewatering versatility.

integrity is unparallel in the industry

30 I 2010 I Voith Paper I twogether

Products

Illustration of the Vector technology (left) and the E-Flex technology (right).

and provides excellent seam mark>>> Info: Seam felts

reduction potential. The non-woven,machine direction orientation of
Vector provides excellent cleanability,
compaction resistance and highdewatering rates over the lifetime of

Seamed press fabrics had their beginning in the 1980’s as an answer to difficult press
fabric installations. For many years, papermakers were accepting some of the growing pains.
They were content with the ability to install a seam felt faster on a machine than an endlessversion. As technology improved and the applications broadened, fabric suppliers began expanding efforts to supply seamed products for most all paper grades and press configurations.
As years passed, it was realized that seamed fabrics offered more than just speed ininstallation. Papermakers soon realized other key benefits:

the fabric. The versatility of Vector
as a component allows the useof AS G2 fabrics in a very wide rangeof board and graphics applications,both coated and uncoated.

• Safety (less fatigue/strain, less man hours, less downtime)• Versatility in applications (weave patterns, yarn types and fibers)• Steady state performance (less compaction, less filling, better durability)
These factors lead to a rapid increase in seam growth in North America, and introduction
in other regions globally, where seams perhaps had not been considered before.

E-FlexThe special polymer matrix known
as E-Flex, which uses a combinationof polymer particles to optimize thefabric structure, along with G2 technology, yields a fabric with many

In 2005, Voith Paper first introduced AST (Advanced Seam Technology) in North America,
and the “Tool Box” approach to making a better seamed fabric. The key to AST was Vector
technology, coupled with varying weave patterns and fabric treatments to enhance an alreadyproven product line. With continued growth in the seam market overall and further expansion
into shoe presses, lighter weight graphical grades and tissue/toweling, the need for further
improvement kept its rapid pace. In 2009, AS G2 was introduced in North America as thesecond generation of Advanced Seam Technology, now it is available worldwide.

benefits to the customer.

-0.6%

8

Peel back [mm]AS G2 seam technology

6

Average of non-G2
weight change per
day = - 0.33%-0.5%

Old seam technology

-0.4%
4

-0.3%
-0.2%

2
-0.1%
0

0

5

10 15 20

25 30 35 40 45

50 55 60 65 70 75

No. of pulls
AS G2 residual seam durability compared to old seamtechnology.

30 I 2010 I Voith Paper I twogether

79% less avg.
weight loss

-0.0%
AS G2

Non-G2Comparison of AS G2 versus Non-G2 seam felt on a linerboard
machine.

31

Products

AS G2 seam felt

Competitive felt

flow channels created by the rollside structure.

• Low MD flow resistance• High, steady state dewatering
rates

Comparison of two used press felts. Both were 47 days on a B&P machine(2000 pli, LNP press).

Functional needs based on theVoith Paper is equipped with two

demands of the position can easily

polyurethane offerings that are

be met:both available in AS G2 designs.

• Increased press solids• Improvements in bulk
• Lower vacuum levels• Vibration dampening/elimination

The polyurethane Spectra layer

On focus: AS G2 seamed fabrics

is proven to dampen vibration on

ProSafety

start-up and dewatering)a variety of applications worldwide,• Z-direction flow resistance

ProRunability

most notably high speed graphic,

ProQuality

latter press positions.

ProSpeed• Pore size distribution (for enhanced(for nip dewatering)• Surface optimization (for improved

HT (Hybrid Technology) is Voith

printability and potential energy

Paper’s latest elastomer compo-

Section: press sectionsavings)

nent, and is a special yarn, encap-

Paper grade: all• Fabric resilience (paper and rollside to reduce abrasion)

sulated in polyurethane, applied
to the roll side of the press fabric.

Contact

First introduced for vibration
Elastomer technology

Cory Stagg
cory.stagg@voith.com

improvement, much like Spectra,
HT has shown excellent results

Being the pioneer in elastomer

in both graphic and board applica-

technology for press fabrics,

tions based upon machine direction“Press performance while running Voith Paper
AS G2 seam felts is very good …”
Jeff McKee, Paper Machine Process Owner,
Domtar Columbus mill, Mississippi, USA“Voith Paper AS G2 seam felts are definitely a plus for our machine here at Domtar Columbus. Delivery,
packaging, seaming, and start-up are all non-issues. Press performance while running Voith Paper AS G2
seam felts is very good, which is a must-have attribute for making a top quality product as well as producing
budget tons.”

32

30 I 2010 I Voith Paper I twogether

products

Innovative measuring technology for the former

OnQ FormingSens opens up new perspectives
Changes in the forming section have a far-reaching impact on paper moisture andconsequently on the entire paper manufacturing process. Now, for the first time
ever, it has been possible to develop an online sensor that determines the water
weight in the former in a reliable, reproducible and consistent manner.

OnQ FormingSens: small tool, big impact.

33

Products

An important parameter in the former

cooperation from the very start

Simple process in a complex

is the volume of water, which can be

between Voith Paper’s processenvironment

modified using foils, vacuum or wet

technologists, fabric specialists andsuction devices. Until now, determining

automation engineers. This meant,

The OnQ FormingSens is a sensor

the water weight or dry content in thefor example, that initial tests ofthat enables accurate measurement

former was almost exclusively theworking models (pre-prototypes)of water weight in the former bydomain of hand-held measuring

and prototypes could be carriedmeans of high-frequency microwave

instruments. These provide dataout beforehand on the former test

technology. In the process, the natural

sporadically and therefore constituterig and pilot facilities VPM 5 andfrequency of a resonator speciallymerely a snapshot of the processes

VPM 6 at the Paper Technology

fabricated for this application istaking place in the former. However,Center in Heidenheim under realistic

measured. The natural frequency ofprocess conditions such as vacuum

machine conditions. This not onlya system capable of oscillating, andsettings or the condition of thesubstantially reduced developmentthat includes water molecules, is theforming fabrics change constantly

time but also played a key role infrequency with which the system

and affect the entire downstream

enabling a reliable and fully

can vibrate once set in motion. This

paper manufacturing process. Thisfunctioning product without ‘teething

complex process can be comparedis why the water weight has to betroubles’ to be installed prior towith playing the guitar. The vibration

measured continuously to ensure

the first trial run at the customer’sof the string produces a sound in theconsistently favorable former settings.

premises. In addition, endurance

resonance chamber (soundbox) oftests on the pilot machines and in

the guitar. Depending on its thickness,

The OnQ FormingSens now provides

the field have demonstrated thateach string has a different natural

additional leverage for determining

the low-wear, low-abrasion ceramicfrequency. The thicker the string, thewater weight online and for optimizing

sensor surface does not affectdeeper the sound, at the same string

the former. When developing theeither the forming fabric or thetension.

OnQ FormingSens there was close

paper.
The measuring process in the former
works in a similar way. The greater
the volume of water above thesensor, the lower the resonancefrequency. Therefore, the natural
frequency clearly depends on thevolume of water above the resonator.
The electronic evaluation unit usedallows this value to be measured
accurately and reliably. Automatic
temperature compensation in thesensor itself ensures that secondary
influences are also minimized.
Numerous applications withgreat benefits
The readings supplied by the
OnQ FormingSens are the basis
for numerous optimizations in the

The sensor does not leave any marks on the forming fabric or paper.

34

former. The sensor’s technical30 I 2010 I Voith Paper I twogether

products

56

23

21.4

Dry content [%]Average dry content [%]

21.7

21.1
20.8

Basis weight

21

51

19

46

17

41
36

15

20.5
0

1

2

3

4

5

0

1

Week

2

3

4

5

Week

In future papermakers will be able to monitor dry content over theentire lifetime of the forming fabric.

The mean dry content allows the ideal fabric to be selected.

features allow it to be used for all

threading process, an accurate

technology can replace the radiation

types of former and paper grades.

measurement of water weight isused in many hand-held measuring

For the first time, for example, thethe crucial key to success here too.

devices. In addition, operators using

dewatering behavior of forming fabrics

A further distinctive feature is thehand-held devices on a working

can be analyzed in depth over their

sensor's measuring accuracy.

paper machine are exposed to quite

entire service life. The measurements

Hand-held measuring devices are

considerable risks, which arefrom the OnQ FormingSens candesigned to determine the greatest

completely avoided when using thetherefore assist in analyzing thepossible volumes of water. Althoughno-maintenance OnQ FormingSens

performance of the forming fabrics

this allows for an extremely large

for continuous measurement.

used. Using the data provided, Voith

measuring range, this is always at

Paper specialists can analyze thethe expense of accuracy. If, in theperformance of the fabrics over theircase of graphical paper machines,

entire service life and determine thethe dry content at the end of formers

best choice of fabric in consultation

is to be determined to the nearestwith the customer.

0.1%, the measurement has to beable to detect differences of less

The OnQ FormingSens enables

than 1 g/m² water weight. The

the papermaker to take suitable

OnQ FormingSens is capable ofmeasures to adapt the runability of

doing this and also offers athe paper machine to the operating

sufficiently large measuring range

characteristics of the fabric. It isof 100 to 5,000 g/m². This means,no longer necessary to rely on ‘gut

for example, that the dewatering offeeling’ or indirectly measured

graphical paper machines can bevariables. If the sensor is installed atcontrolled continuously to determine

the appropriate location in machine

the optimum dry content. Thiscross direction, the threading processenhances runability and helps to savefrom former to press section following

vacuum or drive energy.

shutdowns or web breaks can also be
shortened. As the tear strength of

Last but not least, online measuring

the paper depends on the moisturetechniques improve occupational

content and largely determines thesafety. The completely safe microwave

30 I 2010 I Voith Paper I twogether

2

Dry content

Average dry content at 43 g/m 2

Basis weight [gm]22.0

On focus: OnQ FormingSens
ProSafety
ProRunability
ProQuality
ProSpeed
ProSpace
Section: former
Paper grade: all
Contact
Oliver Crasser
oliver.crasser@voith.com

Oliver Kaufmannoliver.kaufmann@voith.com

35

Products

How an IntensaPulper works
The rotor is eccentrically positioned in the vat. A doubleconed arrangement provides for a flow-optimized transition
from the tub-bottom, up its (vertical) cylindrical walls. Thus
the IntensaPulper achieves the most intensive level of mixing
in the shortest time – with low energy input.
The IntensaPulper has already been awarded several prizes.

Intensa principle – the right choice also for recovered papertransport routes are required. The

20% energy savings due toIntensaPulper IP-R

recovered paper infeed system

The slushing of pulp and recovered paper through the Intensa prin-of the stock preparation: the new

ciple has become an increasingly popular choice among paper mills.

IntensaPulper IP120-R.

for the PM 7 can process both bales
and loose paper. A de-wiring system
is also integrated. After the infeed
comes one of the core components

A current example is the Hamburger Hungaria paper mill inDunaújváros, Hungary. The new IntensaPulper IP-R (R = recovered

Its pulping energy requirements have

paper) is used there on the PM 7. It processes 100% recovered

been reduced by 20% in comparison

paper in its stock preparation and has a more effective operation,

to conventional technology, throughthanks to its new flow guide.

an optimized design based onhydrodynamic principles. The IP120-R

More than 25 IntensaPulpers fromstand out: Energy savings andin Dunaújváros consumes only 770

Voith Paper are already in use

improved stock preparation quality.

kWh of power at nominal production,
while conventional pulpers require 910

worldwide, with more installations in

36

progress for 2011. To date 16

In >>> Dunaújváros 100% recovered

kWh. Additional savings were

customers have had existing pulpers

paper from the local surroundings areachieved through a variable frequency

rebuilt to the “IntensaTechnology”

used as the raw material. Additionally,

drive which adjusts the pulper speeds

from Voith Paper. With all new systems

this helps improve the carbon footprint

according to its mode of operation. On

and rebuilds to-date, two advantagesof the end product, as only shortaverage another 150 kWh savings.

30 I 2010 I Voith Paper I twogether

Products

1a

1b

1c

1d

Fig. 1: Flow-pattern in the IntensaPulper IP-R: heavy contaminant removal (black arrows), intensive turbulence (red arrows) andlow-level turbulence zone (yellow arrows).

Precisely guided flows
In Dunaújváros, the pulper detrashingforms a chicane that serves to more

more easily and gently. Therefore,

effectively direct these heavier items

less energy is consumed through flow(see fig. 1a).

partitioning than would be required

system is equipped with a Junkomat,

for a more uniform circulation of theContaminex and a drum screen

And how is energy efficiency achieved

allowing the typical coarse rejects

during the pulping process? The

contained in recovered paper to be

configuration of the entire pulper isremoved early in the stock preparation

optimized for minimal flow losses.

area. Larger impurities can be

The upper flow guide design acts

disposed of before they are groundincreasingly as a breaker to create

down, thus minimizing wear in the

an area of more intensive surface

downstream process stages.

turbulence, so that bales are quickly
drawn under and fed to the rotor (seeentire stock volume (see fig. 1d).
>>> Info: Dunaújváros
The PM 7 at Dunaújváros is a superlative
packaging paper machine. It has been insuccessful operation since 2009. Duringcommissioning it produced its initial 90 g/m²
sheet at a record speed of 1,225 m/min.
The entire production system – from stock
preparation to reel – is built according tothe Voith Paper One Platform Concept.

But how do those particularly large

fig. 1b). Flow-turbulences are eased inand heavy impurities get drawn so

the remaining pulper areas. Paper, andquickly into the Junkomat, instead ofsheets separated from bales by theextended periods rotating around ininitial rotor contacts stay submerged

the pulper? The answer lies in the

below the surface, soaking andnew flow guide in the IntensaPulper

swelling. In the process losing their

On focus: IntensaPulper IP-R

IP120-R, which takes into accountfiber-to-fiber bond and thus allowing

ProEnvironment

the typical behavior of heavy particles

them to become more easily pulped

ProRunability

in a slurry. The combination of a(see fig. 1c). Subsequent rotor contact

ProQuality

double-cone bottom and flow guidedissolves the pre-swollen paper flakes

ProSpace

Wire width: 8,600 mm
Design speed: 1,500 m/min
Production capacity: 400,000 tons/year

Section: stock preparation
Paper grade: all recovered paper
Contact
Wolfgang Müller
wolfgang.mueller@voith.com
Fig. 2: IntensaPulper
IP-R installed in
Dunaújváros.

30 I 2010 I Voith Paper I twogether

37

Products

NDuraPlate ES convinces with its new eye-shaped perforation.

Energy savings through sophisticated screen plate designs

EyeShaped – unique perforation accelerates
the pulping process
Screen plates play a significant role in the accept quality of stock suspensions. They ensure pulp
cleanliness by filtering out impurities. The nature and design of their screen openings influences both
the duration and quality of the pulping process. With the NDuraPlate ES screen plate, a completely
new design of screen plate is now available, providing significant improvements in the areas of stockcleanliness and energy efficiency.

38

Screen plates are essential toreject separation process. They

New perforation improves

pulping operations and play amust be capable of long term

efficiency

substantial role. They ultimately

resistance to extreme dynamic

influence the operation of the paperloads, often accompanied by highSince the quality of the accept is

machine by reducing downstream

levels of abrasive wear. In order todetermined by the condition of the

impacts on stock processing

withstand such harsh conditions

screen plate, its hole design plays anequipments and thus improve the

NDuraPlate screen plates areimportant role. Until now, roundcost-effectiveness of the entire

manufactured from NDura material,

perforations were the standard, evenpaper manufacturing process.

an extremely wear-resistantwith NDuraPlate screen plates. A large

stainless steel. The service life

selection of hole geometries have

Heavy demands are made on screenof the screen plate is thus

recently been made possible throughplates during the screening andsignificantly extended.

a novel manufacturing process. Voith

30 I 2010 I Voith Paper I twogether

Products

Paper has embarked on a new pathbetter accept quality can be achieved,with the NDuraPlate ES. This defining

despite accelerated process times.

change comes through a completely
new eye-shaped perforation – hence

NDuraPlate ES screen plates can be in-

the designation ES. The results ensure

stalled in almost all Voith pulpers as wellboth improved product, and energy

as in pulpers from other manufacturers.

efficiencies during the stock

These screen plates have also provenpreparation process.

themselves in detrashing machines suchas the Contaminex CMV and Fiberizer

The eye-shaped perforation in the

T.S from Voith Paper. NDuraPlate ES

screen plate provides a working-edge

is also available in multiple layer

increase of up to 10%, thereby“Multilayer” screen plate arrangements.

achieving an overall reduction inThis technology has proven itself

pulping time requirements. This in turn

particular effective in the case of screen

enables a pulping efficiency increaseplates with high thicknesses. For theseof up to 20%, compared to other holeapplications the uppermost screen

designs on the market.

plate layer is replaceable, thus reducing
costs.

Compared to standard screen plates
the new perforation also achieves a

At a glance: Customer benefits of NDuraPlate ES

screening open-area increase of up to
10%. This enables up to 20% inincreased production, or up to 15%• Increased pulping capacity with lower specific energy consumption• Improved deflaking effect due to longer working-edges• Longer service life due to better wear-resistance

improvements in stock quality levels.
Such improvements in the accept
stream stock quality (reduced levels of
flake and rejects) has a noticeably
positive impact on the downstream
processing stages and equipments.
Accelerated pulping, improved
accept quality
A faster pulping time allows a pulper
capacity increase. Above all, thespecific energy consumption can be
reduced – this in continuous, as wellas batch operations. In both cases

Right: patented multiple layer “Multilayer”
screen plate system (under-side view).

On focus: NDuraPlate ES
ProEnvironment
ProRunability
ProQuality
Section: stock preparation
Paper grade: all
Contact
Willem Boterman
willem.boterman@voith.com

process times are improved by theability to pulp out the recovered paper
in a shorter time frame, thus raisingenergy efficiencies.

Michal Stepien
michal.stepien@voith.com

A significant difference over previous
applications is that after installation of
the new screen plate, the same or

30 I 2010 I Voith Paper I twogether

39Products

Energy-efficient systems in the approach flow section reduce costs

Success on two counts:
Energy savings and energy recovery
The approach flow system of a paper machine moves large volumes of stock. This uses a considerable
amount of pump energy that needs to be reduced and/or used more efficiently. The cleaners represent
an area of the approach flow system where energy consumption can be substantially reduced.
The axial-turbine PowerTube now offers a new system to recover energy.

VoithVac
EnergyEnergysavings

recovery

Cleaner
DuoFormer TQv
HydroMix

MultiScreen

ComMixPowerTube
4-stage

HydroMix
MultiScreen

White water
Stock

MultiScreen

PowerTube

Fig. 1: Energy savings and energy recovery in the approach flow system.

In conventional systems the stock

the diluting process into two stages.

Despite the increase in stock

suspension is diluted to the low

In the first stage the high consistency

consistency the efficiency of removal

consistency needed for sheet

stock is diluted to 2.0-2.5% up-of heavy particles (e.g. sand) is still

formation upstream of the first cleaner

stream of the inlet into the cleaner

greater than 95%. The EcoMizer

stage. At stock consistencies ofsystem. This has the effect ofsystem can be retrofitted to existing

1.2-1.4% this results in considerable

reducing the volume flow comparedcleaners.

volume flows. Depending on thewith conventional systems by up tovolume flow a large number of50%.

cleaners and pump energy isnecessary.

The accept stock is deaerated in theVoithVac and in the second stage

Voith cleaners working on thebrought to the necessary consistency

EcoMizer principle continue to allow

for sheet formation. Afterwards, theWith its new concept (Fig. 1) Voithan efficient separation of the stock

stock suspension is transferred to thePaper is pursuing a separation ofeven at high stock consistencies.

headbox via a two-stage pressure

40

30 I 2010 I Voith Paper I twogether

Products

PowerTube

Inlet
OutletFig. 2: The axial-turbine PowerTube can recover energy up to 80 kW.

screen. Thanks to the new system,

easily be re-used for energy

substantially reduced and it is subject

for example, the necessary pumpgeneration. However, in order for theto a lower degree of wear.

energy for the cleaner system of aenergy yield to be cost-effective the

10 m wide newsprint machine withvolume flows have to be available in

Depending on the size of the volume

a production speed of 1,900 m/min

sufficient quantity. The recirculation

flow the energy recovered can be up

can be reduced by around 610 kWh.

flow at the headbox, or the reject

to 80 kW. One reference installation in

Assuming 350 production days andvolume flow at the primary screen

Germany (Fig. 3) is already producing

an electricity price of 0.07 €/kWh, thisseparator, are particularly suitable for

52 kW and saves the operatingmeans that savings of 360,000 €/year

this purpose (see yellow marking incompany up to € 31,000 a year inin energy costs can be achieved.

Fig. 1).

electricity costs. As a result, theAs well as saving energy, there is also

For efficient energy recovery Voith

the option to recover energy in the

Paper developed the axial-turbine

approach flow system. Valves

PowerTube. This generates a pressure

These solutions can also be retrofitted

generally have to be used to reduce

loss in accordance with the turbine

to most plants and help to reduce

the pressure of some volume flows

characteristic and, using a generator,

energy costs.

occurring as overflow or rejects. This

converts this to electrical energy. The

pressure loss, however, can just as

load on the pressure reduction valve isnecessary investment pays for itself injust a few years.

On focus: PowerTube
ProEnvironment
ProRunability
ProQuality
ProSpace
Section: approach flow system
Paper grade: all
Contact

Fig. 3: Reference
installation of axialturbine PowerTube inGermany.

30 I 2010 I Voith Paper I twogether

Günther Kriechbaum
guenther.kriechbaum@voith.com

41

Products

Fine and nonetheless stable: PrintForm IS

Forming fabric impresses customers worldwide
A new class of structure-bound fabrics revolutionizes the market and does justice to two claims inequal measure: running performance and quality. With the PrintForm IS forming fabric and its uniquewarp ratio of 3:2, Voith Paper has been providing completely new perspectives since the productlaunch a year ago.

PrintForm IS suites a wide application fieldfrom demanding packaging grades to finegraphical papers.

42

Products

The PrintForm IS is ideally used in

PrintForm IS in the top wire andA customer in Asia was able tomachines with up to 1,500 m/min.

a fine SSB fabric from Voith Paper

harness the advantages of the highIt is used for the production ofin the bottom wire, the profile

fiber support. A competitor’s design

fine paper as well as demanding

quality was improved and thewith a 1:1 warp ratio had been in use

packaging paper. Graphic paper such

surface roughness was reduced.

on the customer’s BelBaie machine.

as LWC and ULWC was previously

The marking tendency was also

But the competitor was clearly beaten

manufactured on fine to medium-finenoticeably minimized. “We arewith the first installation of the

SSB (sheet support binder) fabrics

very satisfied with the use of the

PrintForm IS. The high dewateringor double-layer fabrics to ensure

PrintForm IS on our machine,”

performance of the PrintForm IS had

non-marking, retention, formation

says Andreas Jaeger, Assistanta positive effect on the energy

and porosity. Demanding packaging

Manager Production on the PM 4balance. The fine paper side of thepaper was produced on designs

in Walsum.

fabric led to better retention, whichallowed the customer to reduce thethat tended to be more robust so
as to ensure stability and to meet

Similarly positive experiences

use of retention aid. A clear successrunning time expectations but withprompted a customer in North

with regard to paper quality andlower fiber support. That has

America to choose PrintForm IS as

cost-efficiency.

fundamentally changed with theits standard clothing. On the BelBaie

use of PrintForm IS. Now it ismachine with a wire width of 8.5 m

Up until now, such results had only

possible to work on paper quality

and a speed of 1,200 m/min, wood-

been possible with trade-offs inwith the aid of forming fabrics

free coated and uncoated paper isrunning time expectations for the

without limitations on the running

produced within a base weight range

fabric. The PrintForm IS convinced

performance.

of 75-104 g/m². By using thea customer in North America of the

PrintForm IS, the running time wascontrary. Due to the addition ofnoticeably increased and the fabricabrasive fillers, the customer had

Enthusiastic customers

showed outstanding dewatering

been having problems for years

LWC and ULWC paper is produced

performance. In comparison to awith short fabric running times ofon the Norske Skog PM 4 incompetitor’s SSB design, PrintForm

on average of only 50 days on the

Walsum, Germany. The Voith PM

IS increased the running time from

DuoFormer D machine for production

with a DuoFormer CF and a wire

55 days to 87 days. The downtimeof newsprint with a wire width ofwidth of 8.10 m runs at a speed

and the costs were thus reduced

7.4 m. In September 2009, Voithof 1,350 m/min. By using theand efficiency increased.

Paper installed the PrintForm IS

Warp yarn ratio 1:1

PrintForm IS – A unique SSB design

Paper side warp
PrintForm IS

Machine side warp
Warp yarn ratio 3:2
Paper side warp

Performance

Paper qualityt Excellent drainaget Good dryness
t Clean runningt Stablet Excellent lifet No sheet marking
t Good profiles
t Good formationt Improved porosity

30 I 2010 I Voith Paper I twogether

Machine side warp
The new warp ratio of PrintForm IS sets
the basement of a unique SSB Design:an optimal combination of runability andpaper quality.

43

Products

Advantages of PrintForm IS as
compared to SSB

80
70

50

20
10

Competition II

30

PrintForm IS 2. trial

PrintForm IS 1. trial

40

Competition I

Running time [days]

60

0

While conventional SSB (sheet support binder)
forming fabric concepts with a warp ratio of 1:1(yarns in machine direction) reach their limits,
PrintForm IS offers new possibilities. The special
feature is a completely new arrangement of warp
yarns to one another. Instead of a 1:1 ratio, thewarp yarns are in a paper to machine side ratioof 3:2. Through this combination, the fine top sideof the fabric for fiber support can be united witha stable bottom side for better service life andstability (see a detailed article on PrintForm IS in
twogether, issue 29, page 51-53).

Running time of PrintForm IS is significant higher than comparable products.

forming fabric for the first time in thecustomer in Finland to test thebottom wire. A record running time

PrintForm IS fabric on a hybridof 67 days was thus achieved.

former. Book paper in a base weight
range of 60-90 g/m² is produced

Immediately thereafter, the second

there at a speed of 1,380 m/min.

installation was done at this position.

The high dewatering performance,

The result was even better: a running

good formation and higher running

time of clearly more than 80 days.

time prompted the customer to rely

Cost savings came about due toon the PrintForm IS design. The

lower fabric consumption andclothing times and downtimes

fewer downtimes. For this reason

were noticeably reduced. Highand also with improved formation,

fabric stability ensures goodthe customer chose Voith Paper as

profiles and outstanding runningits standard supplier.

characteristics. Due to the highOn focus: PrintForm IS
ProEnvironment
ProRunability
ProQuality
ProSpeed
Section: former
Paper grade: graphic paper, high qualityboard & packaging paper
Contact
Verena Wittverena.witt@voith.com

dewatering performance of theHigh demands for quality andfabric, the power could also berunning performance also moved a

reduced.

“We are very satisfied by using the PrintForm IS.”
Andreas Jaeger, Assistant Manager Production, Norske Skog Walsum“By using the PrintForm IS in the top wire and a fine SSB fabric from Voith Paper in the bottom wire, the profile
quality was improved and the surface roughness was reduced. The marking tendency was also noticeably
minimized. We are very satisfied by using the PrintForm IS.”44

30 I 2010 I Voith Paper I twogether

Products

SolarMax: ingenious combination of a suction roll cover and a press felt

Higher dry content – less energy– improved quality
Production costs can significantly be reduced with improved press section
dewatering. A 1% increase in dry content out of the press section can leadto energy savings of up to 4% in the dryer section. The quality of the rollcovers and felts used is the most important factor to ensure high-performance
dewatering. For that reason, Voith Paper now relies on a combination, so far
unique, of high-performance felt and especially efficient roll cover.

The perfect interaction of roll and felt is determine for the maximum
dewatering performance.

45

Products

The new SolarMax product combination, consisting of the structurally optimized E-Flex felt (left) and the polyurethane suction roll cover
SolarFlow (right), has great dewatering potential.

SolarMax is the key to improved

material characteristics. These include

are more difficult to evacuate in

dewatering in the press section.

greater elasticity, mechanical strength,comparison to grooves. The

Two recent products from Voith

increased temperature resistance andremaining water in the blind drilled

Paper form the foundation of thisenhanced hydrolytic stability.

holes is carried back to the nip,significantly reducing its actual

dewatering solution: the SolarFlow
high-performance roll cover and theBlind drilled holes becoming

storage capacity. This can result in

E-Flex structurally optimized press

obsolete

reduced dewatering efficiency witha higher flow resistance, resulting in

felt which can effectively bridge theroll cover grooves due to its polymer

The surface pattern of a standard

increased hydraulic pressure andnetwork structure on the roll side.

suction roll cover can consist of

re-wetting. In certain circumstances,

Each product is already individually

three elements which support thethis also leads to a visible mark in the

distinguished by increased

dewatering of the paper web: suction

end product referred to as shadow

dewatering characteristics. Together,holes, grooves and blind drilled holes.

marking, which noticeably reduces

they make a formidable team for

Blind drilled holes or grooves havethe quality of the paper.

fast-running paper machines.

typically been used in addition to thesuction holes to further increase cover

The SolarMax solution utilizes the

The primary advancement is instorage volume. The properties of thehighly developed polyurethane

the aggressive surface structure ofcover material limited the dimensions

material found in the SolarFlow

the suction roll cover. With a novelof the grooves. Therefore, high watersuction roll covers. Voith engineers

groove concept, blind drilled holes

load applications sometimes required

succeeded in developing a new

can be completely eliminatedincreased void volume from blind

polyurethane functional layer thatin some applications. Increased

drilled holes in addition to grooves

withstands the highest pressure andgroove depth and narrow land widths

in the surface structure.

abrasion conditions while maintaininga high level of resistance to chemical

provide a roll cover surface with more46

efficient water storage capacity thanBlind holes can have negative effects

attack. The stability of this innovative

any other roll cover on the market.

on paper quality especially on paper

functional layer allows for aggressive

The increased void volume of thegrades which are critical for marking

groove patterns. The covers used ingrooves is possible due to improved

respectively on fast-running machines.

the SolarMax solution utilize groove

polyurethane which features a denser

Blind drilled holes are typically adepths of up to 3.0 mm with amolecular structure with optimized

less efficient surface pattern as theyminimal space between grooves of

30 I 2010 I Voith Paper I twogether

Products

1.8 mm. The additional dewatering

unimpeded flow of water to thecapacity from these aggressive

channels of the roll cover can begroove patterns can eliminate theensured over the lifetime of the felt.

need for the less efficient blind drilled

With its extremely stable structure,

holes. This reduces the danger of

E-Flex itself bridges the grooves ofhydraulic pressure build-up andthe roll cover used without resulting

minimizes shadow marking in thein any markings in the paper web.

SolarMax impresses with its perfectcoordination of roll cover and press felt.

paper.
Convincing results were obtained
Dewatering performancewith the SolarMax dewatering

fully utilized

solution on the pilot paper machineat the PTC. Sheet solids in the press

Successes in practiceAt the Paper Technology Center

section were improved in some cases(PTC), the new suction roll coverby as much as 1%. In addition, theSolarMax is already being used bywith a maximized grooved surface

increased water storage capacity ofcustomers. Although the new rollpattern was combined with a wide

the felt and roll cover allowed for atogether with cover and press felt

variety of felts in order to find the

reduction of uhle box vacuum,

are still in the adjustment phase,

optimal match. The best results forincreasing nip dewatering and leading

the dry content has been increased

paper machines with high speeds

to additional energy savings.

by 0.5% and dewatering performance

were obtained with the E-Flex press

SolarMax is the ideal solution to fully

has also increased. This vividly

felts. Thanks to the polymer network

optimize the dewatering performance

demonstrates the importance ofstructure of the felt, pressureof the suction press roll. The

perfect interaction of roll and felt fortransmission is distributed uniformly

maximum groove void volume of thesatisfactory dewatering performance.

over the entire surface of the web,suction roll cover in combination withthus facilitating uniform pressing

the uniform surface structure of theand dewatering. In addition, theE-Flex felt insures high sheet solids

polymer coating prevents the felt

even at high speeds while obtaining

from compacting too rapidly. The

optimal paper quality.

On focus: SolarMax
ProRunability
ProQuality

The polymer network structure of E-Flex provides for uniform pressure distribution in the nip.

ProSpeed
Section: press section
Paper grade: g raphic paper,
board & packaging paper
Contact
Peter Mödl
peter.moedl@voith.com

Michael Weinzettl
michael.weinzettl@voith.com

30 I 2010 I Voith Paper I twogether

47

Products

Cost-efficient package for SCA Barton

Integrated automation replaces insular solutions
SCA’s tissue plant in Barton, Alabama, needed an automation package that could be integrated
seamlessly into existing systems. Voith Paper succeeded in defining a solution that exactly matchedthis requirement.

The tissue plant, situated in the stateof Alabama in the USA, needed an
automation package for both its new
de-inking facility and its PM 14, a
5.50 m wide tissue machine withcrescent former that came on streamin October 2008. As well as a cost
analysis taking account of the entire
life cycle of the new PM 14, SCA
Barton attached particular importance to the seamless integrationof the automation package into
the existing system topography at
its facilities.
Specific objective for award
of contract
For SCA, one factor was crucial
when it came to awarding the orderfor the automation package for the
new PM 14: an integrated solution
with a uniform user interface and –as much as possible – common
technical and maintenance-specificcomponents. The system should befully integrated without superfluousinterfaces.
The solution should be based on only
one platform, including process,quality, motor and drive control.

SCA Barton was looking for a fully
integrated automation solution – andfound it with Voith Paper.

48

30 I 2010 I Voith Paper I twogether

Products

At the same time, the focus for SCA

had already worked on jointly

Barton was on achieving a balance

developing control function blocks,

between technical and economic

controller faceplates and user inter-benefits. The most important aspectfaces a year before the SCA Barton

was the option of in-house servicing.

project. Voith Paper therefore

The company specified that every-

achieved its objective of supplying

thing had to be capable of being

the customer not with “automation

maintained in-house. SCA Barton

islands” but with integrated solutions

did not want to rely on externalwith a standardized user interface.

assistance, as it has sufficient knowhow within the company and has

In addition, the scope of supply

previously had the experience that

includes a modern quality control

external servicing can rapidly

system. The scanner for theescalate costs.

PM 14 is equipped with a basis
weight sensor and a 4-channel infra-

Integrated solution wins

red moisture sensor. The basis weightthe contract

sensor offers a high measuring speed
and a good signal-to-noise ratio, as

The scanner impresses with its
reliability and ease of maintenance.

The decision in favor of Voith Paper

it dispenses with the energy-absorb-

Automation as the system integrator

ing windows used in conventional

in charge of the project was taken

ionization chambers. Any axis shift

following a comprehensive technicalof the sensors or the effects of sheet

to separate the measuring heads

evaluation and a visit to Voith’s Paper

flutter are automatically identified

and insert a new sensor module.

Technology Center (PTC) in Heiden-and corrected.

The whole process takes only a few

heim, Germany. SCA Barton saw

minutes. This is a major precondition

the advantages of collaborating

The 4-channel moisture sensor

with an automation supplier with theguarantees accurate measurement

experience and process know-how

at four defined wavelengths, even in

Mark Phiscator, Vice President of

to control tissue manufacture andthe event of uneven formation andEngineering and Maintenance at SCA

de-inking processes to optimum

moisture. Dust build-up, a particularly

Barton, rated the benefits of theeffect.

critical issue in tissue manufacturing,system as follows: “In our view theis prevented by a range of measures

Voith Paper Automation OnQ System

At SCA Barton the automation

including the use of purging air andwas reliable and can be repaired

system developed by Voith Paper

antistatic components. In addition,quickly if necessary, meeting ouris based on Rockwell hardware.

the DynaComp function counteracts

original objectives for in-house

For SCA, the decision to work withdirt or deposits on the measuringservicing capability. The measuringa Rockwell platform made bothwindows. This allows consistently

accuracy of the QCS is among thetechnical and economic sense. The

high measuring accuracy to be

best available on the market and it

paper mill already had hundreds ofachieved and means that fewer

is the most cost-effective solution

Rockwell controllers installed in its

standardization periods are neces-over the long term.”

PM 12 and downstream processing

sary.

facilities.

for cost-effective in-house servicing.

FAT in Appleton
SCA was particularly impressed by

The cooperation between Voith Paper

the option to replace sensor modules

To guarantee a smooth commission-

Automation and Rockwell came asin next to no time without any

ing process all components of theno surprise, as the two companies

special tools. All that is necessary

automation solution were tested

30 I 2010 I Voith Paper I twogether

49Products

View of control room:
Visualization of processcontrol system for thede-inking facility.

beforehand in a three weeks factoryat SCA, expressing his satisfaction

machine exceeded SCA Barton’s

acceptance test (FAT) at Voith Paper’s

about the ease of contact with the

expectations. The production speed

Appleton site in Wisconsin, USA.

company.

of the tissue machine, which mostly
produces napkins, was already at

The tests covered the system communication, controls, interlocks andSimple transition to new

over 95% of the paper mill's target

enable devices as well as operator

systemvalues.

control functions. During the process
all necessary adjustments were

The new automation system simpli-

made. During the system acceptancefied the changeover for operating

inspection the user interface for

personnel, some of whom had

ProSafety

the Rockwell drives was then alsopreviously worked on the existing

ProEnvironment

integrated into the operator control

PM 12 at the Barton paper mill. The

ProRunability

system.

aim was to take over the operating

ProQuality

philosophy of the PM 12 as far as

ProSpeed

On focus: OnQ Quality Control System

The attention shown to even minor

possible, or to further improve it

details paid off, and led to a smoothwhere still necessary. Voith Paper

Section: total paper machine

start-up. SCA Barton was very

therefore designed the PM 14 user

Paper grade: allsatisfied with both project execution

interface in such a way that existing

and the work of those involved inoperating and diagnostic processes

the project. “Whenever there was aand data display were retained andproblem I only had to call one person

optimized.

Contact
Tom Orella
tom.orella@voith.com– and that was Tom Orella, the Voith

50

Paper Automation project manager,”

By the summer of 2009, the firstsays Tim Fulmer, electrical engineer

conclusions could be drawn: the30 I 2010 I Voith Paper I twogether

Products

Journalist visits Voith Paper Automation

A day at the Neuwied				
production facility
Paper machines – the first thing that springs to mind when you hear
the name Voith Paper. But would you associate it with automation
technology? Mark Rushton, editor of the trade publication “Pulp &Paper International” (PPI), was in a similar position. So, with his
curiosity aroused, he went to have a look for himself.

Just a few minutes after landing atwith the fact that the company is also

Germany’s Cologne-Bonn airport, I ama supplier of automation technology.

sitting in my rental car and entering a

Seeking more information about astreet name and place I have nevernon-contacting caliper sensor they

heard of before into my GPS:

recently launched, I contacted theCarl-Borgward-Straße – Neuwied.

company to learn more about theright place, as you can see the Voith

The Voith Paper Automation sitein Neuwied, Germany.

sensor and was immediately invitedcompany logo on the production

Until now I have been in much theto come to Germany to visit thehalls from a long distance away. I

same situation regarding Voith Paper

company and find out for myself.

find myself in front of the Center of
Products and Manufacturing for

Automation, the automation supplierthat I am planning to visit in person

Impressive dimensions

quality measuring technology atnine o’clock in the morning.

today. I was familiar with Voith Paper
as a leading manufacturer of paper

After a one-hour drive, my GPS

machines. However, I was less familiar

had obviously brought me to the

Richard Windheuser, responsible
for both the Neuwied facility andinternational sales at Voith Paper
Automation, personally welcomesme at the door. My tour throughadministration, production, R&D
and the testing area begins right away.
“Everything you see here has to dowith the development and productionof sensors, which as a component of
the comprehensive QCS have become
the centerpiece of our automation
systems,” says Windheuser. After the
takeover of Windheuser’s former
company “LSC Process- und Laborsysteme GmbH” by Voith Paper
Automation in 2007 the development

Richard Windheuser wears two professional hats: He is responsible for the Neuwied
production facility and he heads the international sales of Voith Paper Automation.

and production sector at this location
was extended by 700 m2 due tothe high capacity utilization.

51

Products

In the final inspection area, where all

The automation division has its

systems are tested prior to dispatch,

headquarters in Heidenheim,

I am looking at two huge scanners

Germany, and it is represented

that have to be longer than 12 meters.

by local organizations worldwide.

Their identification plates reveal their

In recent years, the service network

destinations: Hainan PM 2 and Perlen

has also been expanded in addition

PM 7. Instinctively I tap on one of theto the product range. Even thousands

scanners. This is how you imagineof kilometers away from here, local“Made in Germany”: a modern yet

service employees can commission,robust design. As well as the hugeservice and optimize systems onscanners there are countless othersite. However, I am informed thatversions for paper machines withthis is generally not necessary.

smaller working widths, destined for“Nowadays, we can quickly andcustomers all over the globe.

easily resolve 80% of all problems
using remote support. Generally, ourpersonnel only go to our customers’

to get some more detail about this.

premises for optimizations or“The sensor has the same structure

Afterwards, in the conference room,

contractually agreed maintenanceas all our other modular sensors andI enjoyed a presentation of various facts

work.”

also features the same quick-release

A “hidden champion”

couplings. This means that it canabout the company. What is surprising
is that even during the economic andRevolutionary product:

be retrofitted to all existing Voith

financial crisis the company could be

Voith LSC QuantumSens

LSC systems,” explains Windheuser.
The first thing I notice is the large

very satisfied with its sales figures.
Since 2002, Voith Paper’s automation

The next stop on the tour is thenumber of different measuringbusiness has grown to 140 million

R&D department. There, I am shown

windows on the sensor’s surface.

euros and its workforce has increased

a new example of the development

Thomas Ischdonat, product manager

to around 460. Voith Paper Automation

expertise available: Voith LSC

for quality measuring technology,

might perhaps appear to be not so

QuantumSens. According to

explains how the sensor works:

well known, but in financial terms it

Windheuser, it is the first fully“QuantumSens has three optical

can hold its own with other,

non-contacting caliper sensor for

distance measuring devices in eachestablished vendors.

use on a paper machine. I just havesensor head to accurately determine
the position of the paper in themeasuring gap. In addition,

The modular sensor concept enables high availability.

measuring head alignment is also
monitored accurately by three highresolution eddy current sensors
plus an XY sensor.”Then, equipped with safety
glasses, I take things into my own
hands: I would like to see for myself
if it is possible to change the sensor
in next to no time. I am astounded.
With a little bit of instruction fromone of Voith’s employees, I manage
to change the sensor in 30 seconds,

52

Products

Left: Voith LSC Scanner – high quality
at lowest cost of ownership.

Right: test and integration ofa quality control system.

without even having to use a tool.

parts are becoming unavailable.

form the basis for an article in one

Windheuser grins and explains

A look at my watch shows howof the issues of PPI. However,that when developing the systemquickly time has passed, leaving aperhaps what is more important isthe engineers were principally

whirlwind of different impressions

the knowledge I have gained in theconcerned with keeping the costs

from the day. Of course, ultimately

course of this visit and a clear idea ofof the system over its lifetime as low

I still want to know what kind ofwhat lies behind the name Voith

as possible. This is why, as well as

investment a paper mill needs toPaper Automation.

offering durable hardware andmake in a new quality measuringsoftware, they consider it crucial tosystem from Voith LSC. Sales

supply systems that are easy to

manager Windheuser is now in his

maintain and service. And that also

element, as he explains: “Most paper

includes being able to replace theproducers can only keep their

sensors quickly.

systems going with an expensive
service contract. At the same time,

Expertise in all areas

they keep experiencing shutdowns
and the quality of their products

Author: Mark Rushton,
Pulp & Paper International

Location
Germany
BerlinNeuwiedVoith Paper
Automation site

On our way back to the conference

is impaired. We offer potential

room we come across a legacy

customers the option of having one

system from another supplier thatof our experts come to their plant tohas been dismantled. I am surprised

get an overview and check their

Neuwied is located about 10 km northwest

to see work being done here on

system. For most clients theof Koblenz. The city was founded insystems from other manufacturers

investment in a new QCS from Voith

1653 and emerged as one of the earliest

as well. My host explains: “We have

LSC pays off in one to four years

industrial locations in Germany. Neuwied

recently replaced this system andat the most.” There are also somehas approximately 65,000 inhabitants.

we are just removing some parts in

attractive financing models on offer

order to be able to help out ourthat have already been used forcustomers with spare parts in thecertain projects, he adds.

short term.” He adds that many paper
manufacturers repeatedly experience

At the end of the day I set off backbrief shutdowns caused by obsolete

to England. In my luggage, a stackautomation systems for which spareof paper – the written notes that will

Contact
Richard Windheuserrichard.windheuser@voith.com

53

ProduCTS

NanoPearlResin composite cover• Vibration reduction• Energy savings• Extraordinary lifetime• Saves grinding costs• Increased operational safety• High damage resistance

SkyTopDoctor blade• Optimal cleaning of thermal
coated rolls• Conditioning of the rollsurface• Long lifetime

SkyResDoctor blade•	Optimal cleaning of soft
calender rolls• Conditioning of the roll surface• Long lifetime

TerraGloss
Thermal coating• Long lifetime• Energy savings•	Positive impact on gloss
and/or smoothness•	Minimization of complex
energy adjustments

Combination of resin composite cover, thermal coating and doctor blades

Optimal interaction increases calender performance
Calender requirements are getting more and more complex. Energy savings, enhanced paper quality
and longer component life are crucial for efficient calendering. The new calender concept from
Voith Paper Fabric & Roll Systems focuses on these areas and offers significant cost benefits
through the interaction of engineered products.
Today’s rising costs for raw materials

covers and doctor materials in thesomething that could not be achieved

and energy, as well as more specificcalender, to push towards optimizing

with any of the individual products

roll cover requirements andall components in a package thatalone. The first such product package

calendering objectives, prompted

harnesses the effects of synergy.

for the calender comprises theVoith Paper to take a new path.

The systematic teaming up of covers

combination of TerraGloss and

The core concept is, instead ofand doctor blades allows calender

NanoPearl and the specifically tailored

separately developing individual

performance to be improved,

doctor blades SkyTop and SkyRes.

TerraGloss

SkyTop

NanoPearlFig. 1: Coordinated filler sizes for uniform abrasion.

54

30 I 2010 I Voith Paper I twogether

ProduCTS

RA-roughness [μm]0.30Competition 2
0.20

Competition 1

0.10

Insulating layer

TerraGloss + SkyTop

SkyTop doctor blade
0

1,000
2,000
Operational time [h]3,000Fig. 2: Consistently low surface roughness of thermal
coating due to doctoring with SkyTop.

Deploying synergies

Fig. 3: SkyTop removes the insulating layer of contamination to achieve
maximum heat transfer.

thermal properties such as heat

SkyRes blade, specially developed

conductivity and heat transfer fromfor the NanoPearl, prevents stickies

The main issues to be considered

the roll surface into the paper. The

and stripes on the roll cover. In

are wear, tribology and surface

SkyTop doctor blade was developed

addition, roll cover unevenness,

topography. The aim is to control

especially for the TerraGloss carbide

caused by irregular wear, is smoothed

wear on the roll surface in such a

coating. The adjusted particles andout (Fig. 4 and 5).

way as to maintain a consistently

fillers enable constant and intensivesmooth surface with good cleaningcleaning of the roll surface. ThisThe abrasion resistance of TerraGloss

properties. This can only be done byleads to an increase in roll lifetime.

and NanoPearl prevents contact

systematically coordinating the fillers;

In addition, a high level of heat

between the roll covers in the edge

their proportions, geometry, type andtransfer is obtained by eliminating

zone, avoiding transfer of vibrations.

particle size distribution (Fig. 1).

contamination and keeping surface

This increasingly stabilizes theconditions constant (Fig. 2 and 3).

operation, ensuring constant paper

The thermal coating TerraGlossquality and trouble-free running (Fig. 7).

features wear and corrosion resistant

Directly related to this is the filler

layers of hard materials that havedevelopment in the NanoPearl elastic

been applied with high kinetic energy.

calender cover. The evenly distributed

The increased use of nano-structured

nano-particle matrix used is crucial

Pivotal to the concept is the focus

hard materials achieves very highto very long lifetime and enables highof the covers and doctor blades onwear resistance while enhancing

surface quality to be achieved. The

specific customer benefits (Fig. 6):

Focusing on customer’s benefit

SkyRes doctor blade

NanoPearlRA-roughness [μm]

0.40
0.30
0.20

Former generation

0.10

NanoPearl + SkyRes
0Fig. 4: SkyRes prevents unevenness in the composite coverand eliminates stickies.

30 I 2010 I Voith Paper I twogether

200

400 600 800 1,000 1,200 1,400
Operational time [h]Fig. 5: Consistently low roughness of NanoPearldue to doctoring with SkyRes.

55

ProduCTS

Added value
through productcombination:
Gloss increase
Smoothness increase
Lifetime increase
Production increase
Cost savings
Energy savings

Fig. 6: When combined, the benefits of the individual products provide considerable added value.

• Increased component lifetime• Increase in specific paper

The production engineer for a

In an online multi-nip calender theEuropean paper manufacturer

lifetime of the flexible covers was

quality parameters (gloss,

confirms that the line load wasincreased from 400 to over 1,000

smoothness)

reduced from 240 kN/m to 185 kN/mhours. At the same time, by replacing(data refers to mean values). The

the existing thermal coatings withcalendering conditions in the first nip

TerraGloss, the heating energy• Reduction of the energy
required for calendering

were optimized by using TerraGloss.

required to achieve a gloss level of

The concept addresses a specificThis resulted in a reduction of the

55 in the topmost heated roll wasgoal that brings the customer a

two-sidedness. The paper mill was

reduced from 1,400 KW to 900 KW,

measurable cost benefit, either

very pleased with the combination ofequivalent to annual savings of several

reducing the number of roll changes,

NanoPearl S and TerraGloss and wastens of thousands of euros.

grinding costs, output on heatedable to realize significant reductions

rolls, raw materials used or enhancing

in calender rejects. The target values

On focus: Best Fit Calender

the paper quality.

of 225 kN/m and 120°C with the

ProSafety

same quality characteristics were

ProEnvironment

achieved. Energy savings in the form

ProRunabilityof reduced drive output were also

ProQuality

Proven in practice
The product combination has alreadyobtained. This was made possible bydemonstrated its capabilities in thethe lower line load and by reducing

Section: calendercalender several times. For example,

steam consumption in the soft

Paper grade: calendered paper

the lifetime of both – elastic covers

calender by lowering the inlet

and thermal coatings – weretemperature of the heated roll bysignificantly improved.

20°C.

(mainly graphical paper)
Contact
Thomas Leitner-Kuzmany
thomas.leitner-kuzmany@voith.com

wear onthermo rolledge
contact

reduced wear
on TerraGloss

Hasso Jungklaus
hasso.jungklaus@voith.com
wear oncomposite cover56

reduced wear
on NanoPearlFig. 7: High abrasion
resistance prevents
contact in the edge zone
and reduces vibrations.

30 I 2010 I Voith Paper I twogether

Products

New attraction at Stora Enso Fors

VariFlex − a top-class winder in action
Instead of going to the capital Stockholm, recently many papermakers have been drawn to the locationof Fors in Dalarna County, Sweden. They are attracted by the VariFlex winder, which has been in
operation there for two years in the Stora Enso board mill and delivers first-class results.
When you get hold of the products

packages to deep-freeze packages.

The 180-400 g/m² premium carton-from Stora Enso Fors you discover

Also luxury products such asboards are produced on two board

coated folding boxboard of theperfumes and high-quality cosmetics

machines. And what leaves the board

highest quality: from cigarette packs,

are willingly packaged in cartonboard

machine as a premium product also

chocolate and confectionary“fabriqué dans la Papeterie de Fors.”should not be neglected later at the

Top slitters with connecting lines for slitter dust removal system.

Technical details of the VariFlex at Stora Enso Fors
Design width:
Working speed:
Design speed:
Acceleration/deceleration rate:
Max. parent roll weight:		Max. parent roll diameter:		

4,300 mm2,500 m/min
2,800 m/min
40 m/min/s
20,000 tons
(planned for the future: 41,000 t)
2,600 mm(planned for the future: 3,800 mm)

Max. roll diameter:
2,100 mm
Roll width:150-2,500 mm
Edge trim width:15-300 mm
Slitter section: 	12 pairs of knives with connected
cut dust vacuum unit
Surface cleaning system with ionization unit and vacuum device
Fully automated set change
Start and end gluing with Gecko hot glue system
Soft function covers on the winder drums and the rider roll
Option for fully automatic reel change
Transport system for the rolls via transport conveyors

57

products

Process coordinator Per Eriksson of Stora Enso (center), as well as Günter Grill(left) and Reiner Delau (right) of Voith Paper have every reason to be pleased.

Stora Ensos production location in Fors, Sweden.

View of slitting station with empty reel spool.

end of the production line, because

wish list. The old Jagenberg VariDur

the fast automatic roll change withcoated board is not easy to produce

winder had had its day.

good roll quality and also highproduction speed was of greatand even less easy to wind. It is avery sensitive product with highThe decision was made in favor of

demands on the winder in terms of

the VariFlex winder. The basis for thismarkings, gloss spots or bulk loss.

was the technical and technologicalsignificance.
Outstanding results

discussions, laboratory experiments

58

Thus Stora Enso Fors had very clear

and especially great feedback during

For a project to be successful, it

project goals when it came time forthe reference visits. Fors was above

is important to have in-depth

a new winder for the BM 2. Alongall impressed by the optimal winding

discussions and to clarify technicalwith the required increase in capacity,

quality due to the cover technology

details in advance. In addition,

improvement of winding quality,and very good end sheet and startflexibility is sought after. The

reliability and the performance ofgluing using the Gecko gluing units.

wishes of Stora Enso Fors were

the gluing units are at the top of the

The high productivity resulting fromalways the main focus and were

30 I 2010 I Voith Paper I twogether

products

implemented wherever feasible.

The VariFlex winder is impressive from

Eriksson. The reliability of the formats

Suitable solutions were found throughboth a technical and technologicalis at a high level. Not a single roll

working together on the issues thatperspective. Its stable design prevents

produced since start-up was outside

came up during the assembly andvibrations to a large extent; the Gecko

the tolerance limits and even thestart-up phase.

start and end gluing system runs

service life of the knives is very high.

flawlessly and needs only minimal

In addition, the VariFlex is easy to

The end result is very impressive.

maintenance. In addition, the control

operate. If a disturbance occurs, theThe assessment of Stora Enso

allows adjustment of all criticalcontrol system shows the operator

process coordinator Per Eriksson

parameters at any time. The roll quality

quickly and intelligibly where thecouldn’t be better: “The VariFlex

is ideal and even matt grades can beproblem is and how it can bealways runs at the maximum speed

wound without adverse markings.

eliminated.

first day after start-up.” Eriksson

Along with good roll structure, it is

Eriksson also praised the general

would have the unit do even more,also a matter of adhering to specified

collaboration. For example, thebut the current drives don’t allow it.

tolerances such as diameter andthorough training of employees

The acceleration rate is always

especially roll width. The slitter section

played a substantial role, as VariFlex

40 m/min/s, with the top speed beingthat was further developed by Voith

is a complex unit with a very highreached very quickly.

Paper completely won over Per

level of automation. He is very happyof 2,500 m/min, and from the very

that Fors got the necessary support
and all imaginable help during thePrecise inserting of cores into
carrier roll bed.

Parent roll transport with fully automated barcodelabeling unit.

start-up phase. “Voith Paper’s expert
knowledge and determination toeliminate all malfunctions, and to help
us improve our board quality andwinding technology even further, wasand still is extraordinary,” Erikssonsays two years after the rebuild.

On focus: VariFlex
ProEnvironment
ProRunability
ProQuality
ProSpeed
ProSpace
Section: winder
Paper grade: all
Contact
Dirk Cramer
dirk.cramer@voith.com

Operating unit with roll transport visualization.

30 I 2010 I Voith Paper I twogether

59

SERVICE

Machine audit identifies capacity reserves in Heidenau PM 4

Dresden Papier producing more than 10,000 t
extra per year
It doesn’t always have to be the big solutions that make a crucial difference to the development of apaper machine that is past its prime. This is demonstrated by Dresden Papier’s success in carrying out
sectional rebuilds at its Heidenau paper mill, in Germany. Since mid-2008, these measures have been
implemented consistently and step by step on the PM 4 in collaboration with Voith Paper. Within thescope of a machine audit, weak points were identified systematically and development steps devised.

Dresden Papier GmbH, a subsidiary of

A long-standing partnership

Dresden Papier was highly satisfied

Fortress Paper Ltd. in Canada, iswith the completed modification ofamong the leading producers of high-The decision to extend the productthe stock feed to the two sheet

quality print substrate for the wallpaper

range was the cornerstone of an

forming systems including theindustry. In 2002/2003 the company

intensive collaboration, based on a

installation of two MasterJet F/L

was faced with a shift in its market

spirit of mutual trust, between theheadboxes on the top and bottom

environment, which caused it to move

two companies Dresden Papier andwires. In this process, the insertion

away from its traditional wallpaper base

Voith Paper. Dresden Papier sawof synthetic fibers and handling

production to specialize in premiumin Voith Paper the ideal partner tocapability in the downstream

quality duplex non-woven wallpaper

resolve the diverse challenges

papermaking process were thebases. High dimensional stability, good

associated with this kind of productchallenges that had to be mastered

dry release properties, color retention,

realignment.

by working together. Subsequently,

printability and abrasion-resistance aredrying capacity downstream of thethe decisive quality features that

Between 2003 and 2007, a number

SmartCoater was extended bycharacterize these products containingof extensive rebuild measures were

installing a Voith InfraAir dryer

synthetic fibers.

already undertaken. For example,

system.

Production speed [m/min]

Production [t/y]50,00040,00035,000

400

400
300

20,000200

10,000100

Before rebuild After rebuild

60

29%

30,0000

Dresden Papier in Heidenau, Germany.

500

45,000300

0Before rebuild After rebuild

The rebuild measures after the machine audit (phases 1 and 2) resulted in aconsiderable increase in production and speed.

30 I 2010 I Voith Paper I twogether

33%

SERVICE

Machine audit for higher
productivity
Following on from these successful
rebuild measures Dresden Papiercommissioned Voith Paper to perform
a machine audit in December 2007.
The aim was to further enhance theperformance of the PM 4. The operating speed for producing the main
non-wovens was to be raised fromthe then current level of 300 m/min toa future level of 400 m/min, while atthe same time improving the quality
characteristics of the products thatwere established on the market.
PM 4 Heidenau.

The machine audit was performed inseveral stages, in order to prepare

Rebuild phases Heidenau PM 4

customized, cost-effective proposals
for optimizing the system.
First step: preliminary investigation
on siteTo gain a detailed insight the first stepis to carry out a visual inspection of
the production facility on site. This
also includes a perusal of existing

Sheet width, uncut: 3,380 mm
Product: duplex non-woven wallpapers/
duplex wallpapers
Basis weight: 65-170 g/m²
The goal of this rebuild is to optimize
product quality, energy efficiency, andrunability. Furthermore, maintenance/servicing expenditures are to be
reduced, while increasing production
capacity with a multi-phased rebuild of
the paper machine.

customer documentation by Voith
Paper specialists from a wide rangeof disciplines. The main focus of theon-site inspection is to record theactual mechanical condition ofindividual system components,
relevant operating data and visible
weak points and/or bottlenecks in
production. Based on this, there isthen a technical discussion between
Voith Paper and the customer. The
aim of this discussion is to ensurethat the operating experience andtechnological factors impacting the
product parameters from theoperator’s perspective are included

1. Rebuild phase 2008:• Engineering to provide multi-motor
drive and steam/condensate system• 2x TwinFlo refiners to expand grinding
capacity• Group separation 1st slalom group,
modification of rope carrier system in
pre-dryer section including use of
RopeRings• Partial rebuild of drying cylinder
bearing system to roller bearings• Modification of steam and condensate
system• Installation of Prevo web threading
technology• Installation of a DuoShake shaking unit
on bottom wire
• Supervision of installation, complete
assembly, and commissioning

2. Rebuild phase 2009:• Installation of another 3 TwinFlo refiners• Extending drying capacity downstreamof SmartCoater with MCB-Dryer• Converting remaining drying cylinder
bearings to roller bearings• Further performance adjustments tosteam and condensate system• TailDeflector tail threading system inthe press section to improve operator
safety• Capacity adjustment with new screen
on top wire
• Supervision of installation, complete
assembly, and commissioning
3. Rebuild phase in summer 2010:• Engineering, delivery, and installationof a new Turbair vacuum system
including heat recovery• Installation of suction couch roll fluting
including doctor system• Rebuildof ropesystemto 3 ropes
Produktion
undAufrollung
von forcoaterand end section Tapetenvlies
synthesefaserhaltigem• Capacity
adjustmentPM
with
an der Heidenau
4. new screen
on bottom wire
• Supervision of installation, complete
assembly, and commissioning
including piping construction andinstallation of control andinstrumentation technology

when developing the concept.

30 I 2010 I Voith Paper I twogether

61

Service

Dr. Ulrich Paris, Head of Operations Development
Dresden Papier (right) discussing the project with
Tobias Müller, Sales Specialty Papers Voith Paper.

Grinding with TwinFlo refiners.

Improving operator safety by installing a
TailDeflector for tail threading in the press
section.

In the case of the PM 4, theIn order to record the current

analyzed and evaluated in a second

examination of critical components

condition of the vacuum system air,step. This forms the basis for the re-for the desired speed increase

flow measurements were also takenengineering of the existing machine

extended to a whole range ofat the individual suction points. In

components with a view to futuremachine sections:addition, the dry content andproduction and quality. The necessary

associated CD moisture profiles wererebuild measures are derived from thismeasured using a transportable

and the investment requirement withscanner system in order to evaluate

budget figures included. The process

the functioning of the press section.

engineer in charge can call on Voith

A vibration status analysis provided

Paper's extensive knowledge during

important information about thethis procedure.

• Headbox• Wire section top and bottom wire
• Press section• Dryer• Yankee drying cylinder• Blade coater with non-contacting
dryingmechanical condition of the entire
machine.

• Machine calender• Reel• Web guide• Vacuum system• Electrical and mechanical multimotor drive

the PM 4 were summarized in a report
Second step: elaborating on thecontaining the following key points:“Perfect Fit” solution• Re-design of existing machine
The process data collected in thepaper mill and the findings from the• Steam and condensate system

The findings and proposals regarding

preliminary investigation are thencomponents• De-watering calculations for the two
wire sections“The machine audit by Voith Paper provided us with the ideal basis
to identify the optimization potential of the PM 4 …”
Dr. Ulrich Paris, Head of Operations Development at Dresden Papier“The machine audit by Voith Paper provided us with the ideal basis to identify the optimization potential of the
PM 4 and then implement this systematically in a series of rebuild phases. The rebuilds have allowed us toincrease annual production by more than 10,000 metric tons and achieve a leading position in our productcategory.”

62

30 I 2010 I Voith Paper I twogether

Service

SmartCoater with downstream infrared
and air drying.

• Drying simulation of pre-drying

Ventilation technology for MCB-Dryer.

find the unifying thread for futuresection, Yankee cylinder, after-dryer

development. Thus its own

section and non-contacting drying

investment program could be

downstream of coateraligned accordingly.

• Elaboration of “Perfect Fit”
solutions for the individual machine

For Dresden Papier, the audit

sections e.g. optimization ofprovided optimum planning security

threading into press and dryer

for the future optimization of thesections, enhancing product quality

PM 4 in both technological andby installing a DuoShake, improving

financial terms.

production by rebuilding the dryer
section and re-arranging the dryer

In working with Voith Paper, Dresdengroups of the steam andPapier has opted for a partner thatcondensate system, as well as

offers process expertise covering

further recommendations on

all sections of the machine andimproving machine availability

comprehensive project experience,and that at the same time assumes

Third step: presentation of audit

overall responsibility for the planned

results and prioritizing

rebuild.

The audit result is presented to

A large number of the measuresthe customer and if necessary a

proposed in the machine audit

prioritizing of the recommended

have already been implemented“Perfect Fit” solutions is performed,

successively in several rebuild stages.

to realize a step by step implementa-

It was possible to increase annualtion such as for the PM 4.

production from 35,000 t to 45,000 t.
Today, this annual production rate

Machine audit pays off

makes Dresden Papier the global

The German Marburger Tapetenfabrik,among others, processes the coatednon-woven base from the Heidenau PM 4
into high-quality wallpapers.

Contact
Tobias Müller
tobias.mueller@voith.com

market leader in this product segment.
Carrying out the machine audit gave

A further rebuild stage will take place

Dresden Papier the foundation toin the summer of 2010.

30 I 2010 I Voith Paper I twogether

63

Service

Paper Machine division’s new Customer Service Center to be central contact point“We are with our customers through the entire
lifecycle of their paper machine”
Efficient service is indispensable in the paper industry. Thus, service is a special focus for the four
divisions of Voith Paper. Services have been placed at the very heart of the management structure
two years ago. In addition, the Paper Machine division has now established a new customer service
center, and its area manager, Bernd Stibi, explains its advantages in our interview below.

twogether: Mr. Stibi, what is theprocessed much more quickly andcustomer. The Customer Service

background for the restructuring of

efficiently.

Spares & Repairs department
consolidates the spare parts businessthe service area in the Paper Machine
division?
Bernd Stibi: With past service

twogether: What specific tasks

for paper machines of all paper grades

does the customer service centerin Heidenheim.

take on?
With the third department, Millinquiries, it was sometimes difficultfor our customers to find the rightBernd Stibi: In a way it is the “face”

Services, we offer comprehensive

contact in our company. We haveto our customers. Within it, threeservices that only Voith Paper can offer

many different service experts in our

departments are responsible for all

in this form as a complete process

departments, specialized in theirservice inquiries concerning theprovider. Together with our colleagues

particular fields. Now, the newly

paper machine. For new systemin the Voith Industrial Services group

established Customer Service Center

projects, the Capital Spare Parts

division, there is also the capability tofunctions as the central contact point

Projects team puts together an

support a paper mill with all of theirfor our customers. With that setup,

optimal and cost-efficient spare parts

service and maintenance needs withcustomer inquiries can now be

package, customized for eachmore involved cooperation models.

Impact of optimization

Impact of professional
maintenanceStart-up

Customer benefits

Availability and production

Customer Service Center
Bernd Stibi

CapitalSpare Parts Projects

Customer Service
Spares & Repairs

Mill Service

Lifecycle without service

Service life
Professional service is the key to long service life and high productivity of the
production line.

64

The newly established Customer Service
Center is the central point of contact for all
service-related enquiries.

30 I 2010 I Voith Paper I twogether

Service

“With the new setup for consistent,
professional service from Voith Paper,
our customers can increase productivity
and reduce operating costs.”
 ernd Stibi, Area Manager, Customer Service Center,
B
Voith Paper, Heidenheim, Germany

twogether: Support throughout theconstantly dropping, the carefullymachine availability and paper quality

entire lifecycle of a paper machine?

targeted use of the resources

are improved.

What is meant by that?

available can ensure the cost-efficient
operation of a paper machine.

twogether: Where do you see theBernd Stibi: With the new setup forSpecifically, this means thatdifference between Voith Paper andconsistent, professional service fromprofessional service increases thethe many small service providers in

Voith Paper, our customers canefficiency of the paper machine,

the market?

increase their productivity and reduce

unplanned downtimes are reduced

operating costs. In view of the ever-and production output is increased.

Bernd Stibi: Because of our know-

increasing cost pressure in the paper

Combined with suggestions for

how as an equipment supplier andindustry, that is a considerable

process optimization, our service

service provider, we have suitableadvantage for the profitability of oursaves money for the customers:

experts in every area related to thecustomers. Although budgets for

Performance and service life of apaper machine – whether it’s formaintenance and modernization are

paper machine are extended,

maintenance, trouble-shooting,

30 I 2010 I Voith Paper I twogether

65

SERVICE“For any problem or question around their paper machine, our customers areguaranteed to find the right contact in the Customer Service Center.”												process optimization or productprojects, we put together the optimum

maintenance processes. Thus,

upgrades. For any problem or

replacement parts package and inaccording to state-of-the-art

question around their paper machine,

the process take into account thetechnology, we provide paper

our customers are guaranteed toexisting maintenance setup in themills real solutions for increasing

find the right contact in the Customer

paper mill. Our customers also get

productivity and quality.

Service Center. Therefore, we can

support for their maintenancesupport each paper producer

planning and execution and can

twogether: The close coordinationaccording to the individual needs:

be sure that critical spare partsof the individual service products

whether it’s repair or maintenanceare on site in time as required. In

with one another sounds a lot likework on an individual component

regards to spare parts, each paper

the “integrated solutions” concept.

or a comprehensive support project

mill will have its dedicated contact

for an entire production line.

person who can quickly react to any

Bernd Stibi: Correct. Integrated'questions that arise. That is of crucial

solutions also are a large part of our

twogether: Isn’t that more like theimportance, especially in emergencies.

service concept. All service areas are

standard service package of aThings have to move quickly thenclosely connected with one anotherprovider for plant engineering?

in order to keep downtimes as short

so that we can coordinate our services

as possible.

in the best possible way. The Customer
Service Center consists of experienced

Bernd Stibi: It is intended to be

66

Bernd Stibi

that. Our service portfolio extends

In addition, we offer a very special

key people for the coordination of

from replacement parts and repair

service with our audit capabilities:

services, who can access thebusiness all the way to theWith proven evaluation methods,

respective experts as required. Thisdevelopment of maintenance andwe uncover any potential for improve-way, a quick coordination of services

support concepts for the entire plant

ment in the plant’s equipment itself

is ensured and our customers get theover many years. For new system

as well as in the production andservice they expect.

30 I 2010 I Voith Paper I twogether

SERVICE

Total Press Management for press section optimization

Production increase despite cost reductions
Longer roll runtimes, more even paper profiles and fewer web breaks – this sounds like a costly rebuild.
Actually, real improvements can already be achieved with a holistic analytical approach.

With the Total Press Management,

single source. Only by optimizing

paper in Poland, has used Total Press

Voith Paper offers an optimization

the interaction of all individual

Management since September 2009

process by having all components

components can the true potential be

to optimize its PM 1 press section.

of a press section analyzed andachieved. >>> Arctic Paper Kostrzyn,

By optimizing all rolls, especially thefine-tuned to each other by athe largest manufacturer of offset

functional rolls, and by carrying out
comprehensive mechanical roll>>> Info: Arctic Paper S.A.
Arctic Paper S.A. is one of the leading European manufacturers of bulky book paper and graphic
fine paper. The group produces high-quality coated, uncoated wood-free and uncoated woodcontaining papers. The main customer groups are primarily the printing and advertising industries
and end users in the book and magazine publishing industry.
The Group’s product portfolio consists of the brands Amber, Arctic, G Print, Munken, Pamo and
L Print. Production is carried out at four different European paper mills: in Poland at Arctic Paper
Kostrzyn; in Sweden at Arctic Paper Munkedals and Arctic Paper Grycksbo, and in Germany at
Arctic Paper Mochenwangen. The total production capacity of the Group’s four paper mills is
810,000 tonnes of paper per year.
PM 1 Kostrzyn has a wire width of 5.95 m and a web width of 5.30 m. It produces high quality
uncoated woodfree offset and bulky paper with a basis weight range of 60-100 g/m2.

service, coordination of roll covers
and optimization of clothing anddoctors, the dry content can beincreased. In addition, the number of
web breaks can be minimized, andthe runtimes of rolls and clothing canbe increased. This is exactly where
the difference to other concepts on
the market comes into play.
In setting out with the Total Press
Management, thorough analysisof the press section is undertaken
first, in close cooperation with thecustomer. After recording andanalyzing all technical data, precise
assessment of the measures required
to reach the agreed goals needs to be
carried out. Initial analyses at Arctic
Paper Kostrzyn had shown that thecurrent press concept would allow
for higher dry content and longer
runtimes of rolls and press felts. This
resulted in both, cost reduction andan increase in production capacity.
Contact
Kerst Aengeneyndt
kerst.aengeneyndt@voith.com

Steffen Voit (left), Customer Service Engineer Voith Paper Weissenborn, and TomaszŁuczkowski, Rolls Workshop Supervisor at Arctic Paper Kostrzyn, in conversation.

30 I 2010 I Voith Paper I twogether

67

SERVICE

Arctic Paper Kostrzyn counts on Total Press Management“Increase in efficiency starts for us
at the press section”

Voith Paper started the new Total Press Management at the PM 1 ofthe paper producer Arctic Paper Kostrzyn in Poland. Total Press
Management is designed to optimize the press section by providing
a beneficial influence on the overall performance of the paper
machine. In a collective interview, a team of Kostrzyn talked about
the background and first experiences.

The team of Arctic Paper Kostrzyn during the interview in Heidenheim, Germany (from left to right): Roman Kamiński, Dominik Darski,
Piotr Sobków and Marcin Burzyński.

68

30 I 2010 I Voith Paper I twogether

SERVICE

twogether: Growing domestic

Roman Kamiński: We had already

Piotr Sobków, Maintenanceconsumption and increasing paper

invested in infrastructure in our mill inEngineer PM 1: Voith has alreadyexports to Western Europe are

Kostrzyn, for example, in the powershown us some initial success withrevealing one fact: compared toplant, water preparation, waste water

their efforts which have not involved

other countries the Polish paper

treatment and we will be more

major investments. Fine-tuning ofindustry has the enviable ability tocompetitive in this area in the future.

all of the press section components

increase production. What do you

However, we needed more capacity

has identified a lot of previously

think about this development?

on PM 1 and in order to achieve thisundetected potential, for example thewe have to tap the full potential. This

pick-up roll run time has doubled. The

Roman Kamiński, Technicalmeans shortening machine downtime

crucial factor for this was mechanical

Director: The consumption per

by extending the shut-down to shut-roll service carried out at the Service

head in Poland is about 90 kg anddown paper machines operation,

Center Weissenborn, Germany.

shows an increasing tendency. Arctic

extending equipment diagnostics andPaper holds a strong market position

minimizing sheet breaks.

not just in Poland but also in other

Marcin Burzyński, Production
Manager PM 1, adds: Due toEuropean countries like Germany,

twogether: You decided to go forthe close teamwork and transfer ofAustria, France and UK. This positive

Total Press Management. Why?

know-how, we have already achieved

development brought us to ourgood results – like less and shortertarget to increase paper production

Dominik Darski, Production

at Arctic Paper Kostrzyn in the near

Director: At the moment our largest

future. The production has been

unused potential is in the press

twogether: How far did you get withquintupled since 1995 from 47,000 t

section. Therefore, we need additional

the implementation of Total Press

to ca. 275,000 t planned for thisproduct technology, as well as theManagement?

year. In order to achieve thisknow-how of Voith Paper. Besides,

ambition, we decided to go for the

we've known Voith Paper throughRoman Kamiński: Total Press

new Total Press Management fromyears of trusted cooperation and weManagement is an ongoing process

Voith Paper.

are aware of their knowledge

and offers multiple synergies andthroughout the whole machine.

improvement options. Further steam

twogether: You expected to see

downtime.

and energy savings are still on our

production increase and cost

twogether: What positive effects haveagenda. Having said that, we’ve

reduction from Voith Paper – what

you been able to detect – even thoughstarted long-term cooperation inviting

were the reasons behind these

the implementation of Total Press

Voith Paper for the PM 1 press section

demands?

Management happened just recently?

project.

30 I 2010 I Voith Paper I twogether

69

RESEARCH & DEVELOPMENT

AquaPress excels thanks to its special surface structure

New polyurethane cover for press rolls
In summer 2010, Voith Paper is launching the efficient AquaPress polyurethane cover for pressrolls into the market. Thanks to its innovative WebNet technology and a sophisticated groove
concept, it provides optimal dewatering and better paper quality.

Roll covers for press rolls, by theiris more elastic than standard

minimum width of 2.0 mm between

very nature, have to offer morepolyurethane roll covers.

grooves, AquaPress covers canefficient dewatering than covers

meet the dewatering requirements

for suction rolls. Since there is no

Deep grooves, higher drainageof most press applications. Deeper

vacuum applied to press rolls, thecapacitygrooves provide additional covercombination of the roll cover and felt
are the key factors in dewatering.

storage capacity and allow for
These improved material

increased water removal incharacteristics allow for innovative

demanding positions. In addition,

The new >>> AquaPress roll coversurface patterns. The depth andthe excellent hydrolytic behavior ofmeets this core requirement with its

width of the dewatering channels

the AquaPress polyurethane means

special surface structure. The

can be enlarged without impairing

the cover absorbs far less water.

AquaPress technology is primarily

the stability of the product. WithThe material does not swell, whicha result of two Voith Paper develop-

a maximum groove depth between

results in reduced wear and longer

ments: an innovative polyurethane

2.0 and 2.5 mm and an allowablerunning times of up to 12 months.

functional layer and the new WebNet
bonding technology. The functional
layer has a dense molecular structurewith improved material characteristics.
It has enhanced mechanical strength,
outstanding hydrolytic behavior and70>>> Info: AquaPress
Starting in summer 2010, AquaPress will be available in the market and will complete the seriesof high-performance roll covers from Voith Paper. The rest of the series consists of the SolarPressand G2000 covers for press rolls, SolarFlow and AquaFlow for suction rolls and the SolarMax rollcover-felt combination.

30 I 2010 I Voith Paper I twogether

RESEARCH & DEVELOPMENT

Continuous
operationaltemperature on
the cover surface

Hardness

Primary applications

AquaFlow

75 °C

5, 10, 15, 20,
25, 30 and 35
P&J

SolarFlow

80 °C

AquaPress

Groove dimensions
Groove width

Web width

Groove depth

Suction roll

0.5-0.9 mm

2.0-2.5 mm

2.0-2.3 mm

Roll cover for all
current applications

5, 10, 15, 20,
25, 30 and 35
P&J

Suction roll

0.4-0.9 mm

1.8-2.5 mm

2.5-3.0 mm

Premium roll coverfor high demanded
applications

75 °C

5, 10, 15, 20,
25, 30 and 35
P&J

Press rolls, smoothing pressrolls, counter rolls in double
felted shoe presses

0.5-0.9 mm

2.0-2.5 mm

2.0-2.5 mm

Roll cover for all
current applications

SolarPress

80 °C

5, 10, 15, 20,
25, 30 and 35
P&J

Press rolls, smoothing pressrolls, counter rolls in double
felted shoe presses

0.4-0.9 mm

1.8-2.5 mm

2.5-3.0 mm

Premium roll coverfor high demanded
applications

G 2000

85 °C

4 P&J

Press rolls and counter rolls indouble felted shoe presses
Steel roll replacement

0.4-0.9 mm

1.8-2.5 mm

2.5-3.0 mm

Premium roll coverfor high demanded
applications

The right cover for each application: Voith Paper offers different polyurethane roll covers for the press section.

AquaPress is available in threeblind-drilled holes with the newly

WebNet is based on the

different surface designs:

developed groove structures.

interpenetrated network technology

grooved, blind-drilled or aused in aircraft and automobile

combination of grooved and blind-

WebNet technology as theconstruction. The close cross-linking

drilled. AquaPress can therefore be

successor to AST

of polymers in the bonding layer

adapted to meet the dewateringresults in improved temperature

demands of the customer’s

The WebNet layer is an additional

resistance and increased stability

application. It is also worth noting

innovative component of AquaPress.

of the roll cover against chemicalthat in some applications a highWebNet has an enhanced three-damage and high mechanical stress.

void volume grooved surface patterndimensional cross-linking of polymers

may be used instead of grooved

and provides an improved bondand blind-drilled. These patterns canbetween the polyurethane functional

provide improved dewatering andlayer and the base layer. WebNet

eliminate the potential for nip flooding

is an evolutionary advancement ofand shadow marking. AquaPress

the AST bonding layer developed

compensates for the capacity of the

by Voith Paper in the 1990s.

Contact
Michael Weinzettl
michael.weinzettl@voith.com

The grooved AquaPress rollcover (left) stands out due tothe new WebNet technology(right).

30 I 2010 I Voith Paper I twogether

71

News

Still topical after 30 issues“twogether” magazine celebrates its anniversary

1
In 1996, the first issue of twogether was published.

In 2000, a Chinese edition was added.

The magazine was given a new look in 2006.

Over time, the main thematic focus has become cost-effective and resource saving products.

72

30 I 2010 I Voith Paper I twogether

News
news

In 1995, two machine and equipment manufacturers, Voith and Sulzer, merged their paper engineering
divisions to form the new Voith Sulzer Papiertechnik. The first issue of their joint customer magazine“twogether” appeared a year later. And the name of the magazine? It alludes to the fact that twoformer competitors became one.
The merger between Voith andHowever, the magazine also

Reflecting the times, the customer

Sulzer in the paper engineering

informed its readership about

magazine has also focused on cost-

sector was also the main topic inchanges within Voith Paper itself.

effective products that save resources.

the first issue of twogether in 1996.

In 2005, twogether reported on

Following issue No. 24 in 2007, which

Markets and opportunities werethe changeover at the company’s

was devoted to the subject of energy

explored and new, jointly developed

helm: Hans Müller retired and his

efficiency, the magazine has covered

systems and projects presented.

successor Dr. Hans-Peter Sollinger

core issues such as sustainable for-In the following 14 years, twogether

was welcomed. Along with the

estry, water savings, recovered paper

repeatedly focused on current

change at the top, the Voith Paperand the handling of rejects. Thesedevelopments and advances

customer magazine was also

areas will also continue to be of im-in the paper industry, from thegiven a “facelift” to create a new

portance to Voith Paper in the future,

numerous speed records achieved

look.

as they offer enormous potential for

as a result of revolutionary tech-

reducing costs for its customers.

nologies to product innovations

The opening of the Voith Paper

breaking new ground for theTechnology Center in 2006 was a

The customers have always taken

paper sector.

milestone in the history of the division

center-stage in the magazine. And

and was therefore the main topic in

so it has been quite some time

When Voith became majority

the magazine’s 22nd issue. The

since twogether just stood forshareholder in the joint venture inmagazine described the unique

Voith and Sulzer; it has come tothe year 2000 and the corporate

testing opportunities offered by the

represent the close and successful

division was renamed Voith Paper,

PTC to customers from the paper

cooperation between Voith Paper

twogether remained on board as

industry.

and its customers.

the company’s customer magazine.
For many readers from the pulp andpaper industry, the magazine hadalready become a firmly establishedand much appreciated information
source.
China, facelift & resources

The customers have always taken center-stage in themagazine. And that is why today, twogether represents theclose cooperation between customers and Voith Paper.
Right up to the present day,twogether has been distinguished

Changes in the paper industry wereby the topicality of its reporting

also reflected in twogether’s

on developments and researchdevelopment: Initially the magazine

outcomes within the paper industry.

appeared in English and German

Mainly because Voith Paper, as

only, but in 2000, a Chinese version

one of the largest paper machine

was added to take account of the

manufacturers in the world, has

growing significance of the Asianexpert know-how in all areas of themarket for the paper industry.

papermaking process.

30 I 2010 I Voith Paper I twogether

73

NEWS

Survey results: twogether hits the markDear readers,
It is rare for a readership poll to

information that is important to them.

the magazine. We were very

receive as much response as we got

Therefore, as we have done in theglad to hear that a great many ofwith our survey about twogether

past, we consulted our readers

you believed the magazine hadmagazine. More than 500 randomly

directly in March of this year. Over a

improved in terms of content andselected readers provided feedback

period of ten days, an independent

design in recent years. This is greaton the quality and design of ourmarket research institute contacted

confirmation for us that we are on

customer magazine. We would

readers all over the world. It was an

the right track.

like to sincerely thank all the

exciting time for us, as we wereparticipants for their views andnaturally very eager to find out what

At the same time, you provided verysuggestions.

they think about twogether

valuable suggestions on what we

magazine.

could still refine and improve in the

As an editor of such a multifaceted

future. Constructive feedback likemagazine like twogether you keep

Now that the results have been

this from our readers is very

asking yourself the same questions:interpreted our sense of anticipation

important to us. We now know, forIs this topic interesting not just forhas given way to delight. We haveexample, that some of you wouldme but mainly for our readers? Is it

received a lot of praise andlike information to be more detailed

well structured and understandable?

affirmation of our endeavors and thein some places. We will try toDoes it strike the right chord andmajority of readers are satisfied withaccommodate this by providing

does it also give our customers

our magazine just as it is. There wasadditional “technical detail” boxes.

something useful for their daily

particular interest in articles about

In addition, we will strive to achieve

work? After all, twogether is surely

new technologies and developments,

a balance of topics, so that there

not supposed to be for us, it’s forwhile many readers appreciated theis something for everyone. In the

our readers – and should containhigh information value provided infuture, you will be able to read more
about rebuild projects in particular.
Thanks to your frank and honest

Changes in the editorial teamSince the end of 2007, twogether magazine
has been published under the leadership ofStefanie Gerstenlauer. With great dedication
she has driven forward the focus on high-quality,
topical articles. After five issues in charge she
went on parental leave at the beginning of thisyear.
Starting with this issue, Julia Bachmeier will
be editor-in-chief of twogether. She brings withher five years experience in marketing at Voith
Paper and will now assume responsibility forthis magazine that has become an establishedfeature of the paper industry.

74

feedback we can design forthcoming
issues so that they are informative,
exciting and entertaining for ourreaders and ensure that our articles
continue to hit the mark.
As thanks for taking part in thesurvey we gave away three prizes
to participants. Congratulations to
the lucky winners from France, USA
and Greece.

Your twogether editorial team

30 I 2010 I Voith Paper I twogether

Voith industrial services I News

Expert engineering services on demandContract engineering as a growth market
Voith Industrial Services is one of the leading global providers of technical services. By merging its
three existing engineering companies it has established a strong new company – Voith Engineering
Services. This business division specializes in engineering services for the aerospace, rail and roadvehicle and process industries.
Components for aircraft, locomotives

offers staffing services for engineers

years, primarily in the automotive

and cars – that sounds like quite

from all sectors.

and rail sectors. In 2008, anotherengineering service company wasa challenge, given the different
requirements involved. Voith“The market for contract engineering

added: the North German EADS-Engineering Services succeeds by

has expanded in recent years. We

supplier CeBeNetwork, a specialist

pooling specialists with different

view this as a very promising sector

in the development of aircraft

areas of expertise, enabling it tofor us and have therefore pooled

components. An engineering company

support a range of industries andour expertise,” says Markus Glaser-

providing studies, analyses andprovide engineering services on

Gallion, member of the management

facilities planning for the process

demand.

board of Voith Industrial Services

industries had also been part of Voithand responsible for the new businessIndustrial Services for quite some

As well as the development andunit with its workforce of aroundtime. “We have the know-how, theproduction of components, this also

550. Customers benefit from aexperience and the capability toincludes planning sophisticatedhigh level of planning reliability

provide optimum support to our

new facilities and entire industrial

and cost certainty, efficient project

customers and to lead the field insites. In addition, it offers the

management and innovative

contract engineering,” states Glaser-

performance of various surveys

concepts for their products andGallion with conviction.

and process analyses. For the

production.

process industry in particular, andthis includes the chemical, petro-

The foundation for the new businesschemical and energy-producing

division was also created throughsectors, professionally executed

recent acquisitions: In 2006, thesafety analyses and risk assessments

company acquired the East German

are extremely important. However,firm Hörmann Engineering that has

Voith Engineering Services also

made a name for itself in recent

Contact
Julia Schreiber
julia.schreiber@voith.com

Engineering of Voith
Industrial Services
supports the planningof production facilities
from the ground up.

75

Voith Paper

Published by:Voith Paper Holding GmbH & Co. KG

News magazine for the international
clientele, partners and friends ofVoith Paper.

Editor:Julia Bachmeier
Corporate Marketing
Voith Paper Holding GmbH & Co. KG
St. Poeltener Strasse 43
89522 Heidenheim, Germany“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.

NEW:
The twogether customer magazine is
now available online as a FlipBook tobrowse!
www.voithpaper.com/twogether

twogether.voithpaper@voith.com
www.voithpaper.com

Technical editors:
Oliver Berger
Jürgen FrankElisabeth Marton
Helena Pirttilahti-Feichtinger
Anja Zittlow

Design, layout and typesetting:Beate Hornischer
Corporate Marketing
Voith Paper Holding GmbH & Co. KG

Images:p. 6 iStockphoto.com
p. 9 iStockphoto.com
p. 38 Fotolia.dep. 63 Marburg Wallcoverings
p. 72 iStockphoto.com
Other images: Voith Paper archive

Paper:The recycled paper RecySatin of thismagazine consists of 80% recycled fiber
and was produced on a Voith Papermachine.

July 2010, issue 30

Ident-No. 105120
Copyright 07/2010: No part of thispublication may be reproduced or copied
by any means whatsoever without theexpress permission of the editor.

2

30 I 2010 I Voith Paper I twogether