1

Dear Customer, dear Reader,
The twogether issue No 15 in front of you clearly represents Voith Paper Technology’s
wide spectrum of products and services it offers to the pulp and paper industry as wellas its truly global representation.
You will read about the fastest, widest and most productive commodity-grade paper
machines of Voith origin as well as such special items as the production of bank note
papers. The success of these installations is augmented by our competence in the fieldof Fiber Systems, Automation, Finishing, Roll Service and Roll Cover technology andlast, but not least, the clothing expertise of Voith Fabrics.

Hans Müller

The synergies between Voith Paper and Voith Fabrics are well in place and appreciatedby our customers. We are in the process of moving our Voith Fabrics headquartersfrom Raleigh, North Carolina, USA to Southern Germany. We are convinced that thismove will further strengthen the positions of Voith Fabrics and Voith Paper (Voith
Paper Technology) in the marketplace. In the past business year we successfully integrated Jagenberg’s paper technology activities, the recycling and dewatering divisionof Kvaerner Pulping and Finckh into the Voith Group of companies.
Our focus will now be even more directed towards research and development and the
expected growth resulting from new products and services.
Our overall performance in the past business year 2001/02 was quite satisfactory inall business results except for order intake. The overall business environment andspecifically that of the pulp and paper industry left its mark. However, the first fourmonths of our new business year (starting October 1st, 2002) showed a remarkable
recovery in orders received for the current business year and we are quite certainthat we will reach our planned order intake.
With the acquisition phase virtually completed and with the formation of the new
Automation Division Voith Paper Technology now offers products and services thatare second to none in completeness.
On behalf of all Voith employees serving the pulp and paper industry I wish you an
enjoyable read.

Hans Müller,
on behalf of the Voith Paper Technology team2

Startup highlights in 2001/2002

Fiber Systems
Stock preparation systems andsub-systems for graphic papers
UPM-Kymmene, Kaipola,
Finland.
Papierfabrik August Koehler,
Kehl, Germany.
Linde, Malchin, Germany.
Sappi Alfeld, Alfeld, Germany.
Steinbeis Temming Papier,Glückstadt, Germany.
Papeteries Matussière et Forest,
Voreppe, France.
Madison Paper, Alsip, USA.
Steyrermühl, Steyrermühl,
Austria.
Norske Skog Parenco, Renkum,
Netherlands.
Rhein Papier, Hürth, Germany.
Khanna Paper Mills, Amritsar,
India.
Abitibi-Consolidated,
Baie Comeau, Canada.
Ponderay Newsprint, Usk,
USA.
Great Lakes Pulp & Fiber,
Menominee, USA.
Marusumi Paper, Ohe,
Japan.
Stock preparation systems
and sub-systems for board andpackaging papers
Knauf Danogips Inlands
Kartongbruk, Lilla Edet,
Sweden.
Papeteries de Gascogne,
Mimizan, France.

Moritz J. Weig, Mayen,
Germany.
Yuen Foong Yu Paper, Hsin Wu,
Taiwan.
Stora Enso Packaging Board,
Kaukopää, Finland.
St. Regis Paper, Watchet,Great Britain.
Hans Kolb Papierfabrik,
Kaufbeuren, Germany.
Pactiv Molded Fibre, Griffith,
USA.
Potlatch Corp., Lewiston, USA.
Weyerhaeuser, Springfield, USA.
Weyerhaeuser, Plymouth, USA.
Portucel, Viana do Castelo,
Portugal.
Solvay, NY, USA.
Norampac, ON, Canada.
Inland Paperboard, CA, USA.
Newark America, MA, USA.
Industria Papeis da Bahia,
Bahia, Brazil.
Ibema-Cia Brasileira de Papel,
Ibema, Brazil.
Rigesa Celulose Papel e
Embalagens, São Paulo, Brazil.
Productora de Papeles Propal,
Cali, Colombia.
Fernandez Industria de Papel,
São Paulo, Brazil.
Papeles Cordillera/CMPC,
Puente Alto, Chile.
Santa Clara Ind. de Papelão,Paraná, Brazil.
Klabin Correia Pinto/Celucat,
Santa Catarina, Brazil.
Oji Paper, Fuji, Japan.
Daishowa Paper, Yoshinaga,
Japan.

Stock preparation systems andsub-systems for tissue papers
Ssangyong Paper, Chochiwon,
South Corea.
Metsä Tissue, Mariestad,
Sweden.
Georgia-Pacific, Muskogee, USA.

Paper machines
Graphic papers
SCA Graphic Laakirchen,
Austria.
Rhein Papier, Hürth, Germany.
Board and packaging papers
Shandong Rizhao Wood Pulp,
China.
Lee&Man Paper, China.
Ibema-Cia Brasileira de Papel/
Ibema, Turvo, Brazil.
Papeles Cordillera/CPMC,
Puente Alto, Chile.
Newark America/Fitchburg GBM &Fitchburg LBM, USA.
TissueCopamex Industria, Monterrey,
Mexico.
Mili Distribuidora de Papeis MP4,Três Barras, Brazil.
Dewatering machine
Aracruz Celulose, Aracruz,
Brazil.
Installation and rebuilds
Kübler & Niethammer Papierfabrik, Kriebstein, Germany.

Neu Kaliss Spezialpapier,Germany.
Sappi Austria Produktions-GmbH& Co.KG, Austria.
Koehler Kehl GmbH, Germany.
Papierfabrik Palm, Eltmann,
Germany.
Tamil Nadu Newsprint & Papers,
India.
AO Solikamskbumprom,
Russia.
Torraspapel, Motril, Spain.
UPM Kymmene Kaukas,
Lappeenranta, Finland.
Madison Paper Company,
Alsip, USA.
M-real, Biberist, Switzerland.
Stora Enso North America,
Duluth, USA.
Fritz Peters, Gelsenkirchen,
Germany.
Ripasa Celulose e Papel,
PM1, PM2, Limeira, Brazil.
Cartiere Burgo, Tolmezzo, Italy.
Cartiera di Villorba, Italy.
Cartiera di Carmignanao,
Italy.
Kappa Herzberger Papierfabrik,
Germany.
Mayr-Melnhof Karton, Austria.
St. Regis, New Taplow,
United Kingdom.
Stora Enso, Tainionkoski,
Finland.
M-real, Äänekoski, Finland.
Peters Papierfabriken,
Gelsenkirchen, Germany.
Mondialcarta, Lucca, Italy.
Papelera del Principado/Paprinsa,
Mollerusa (Lérida), Spain.

3

MeadWestvaco, Evadale BM5,
USA.
Longview Fibre, Longview BM11,
USA.
Inland Container, New
Johnsonville BM1, USA.
Tembord, Temiscaming BM1, USA.
Weyerhaeuser, Hawesville, USA.
Indústria de Comércio de Papeis ePlástico/Citroplast; São Paulo,
Brazil.
Papel, Caixas e Embalagens;Amazonas, Brazil.
Oji Paper, Saga PM5, Japan.
Japan Paper Board, Soka PM2,
Japan.
Fiberteq, Danville IL, USA.
Nanping Paper, Fujian, China.
Steinbeis Temming Papier,Glückstadt, Germany.
Zanders Feinpapiere,
Bergisch-Gladbach, Germany.
VPH Veiligheitspapierfabriek,
Ugchelen, Netherlands.
Hokuetsu Paper, Niigata PM8,Japan.
Oji Paper, Tomioka PM9, Japan.
Chuetsu Pulp & Paper, Sendai
PM6, Japan.
Nippon Paper, Ishinomaki PM6,
Japan.
Celulose Nip-Brasileira, Cenibra,
Belo Oriente, Brazil.
Klabin Riocell, Guaíba, Brazil.
Mili PM3, Três Barras, Brazil.
Melhoramentos Papeis PM7,
Caieiras, Brazil.
Klabin Kimberly PM4,
Mogi das Cruzes, Brazil.
Irving Tissue, Toronto, Canada.

Riau Andalan, Kerinci,
Indonesia.
Productora de Papeles, Propal
PM1, PM3, Cali, Colombia.
Cia Suzano de Papel e Celulose,
Suzano, Brazil.
Coating technology
Shandong Chenming Paper
Holdings, Shouguang, China.
Koehler Kehl, Germany.
Kübler & Niethammer
Papierfabrik, Kriebstein,
Germany.
Torraspapel, Motril, Spain.
Madison Paper Company, Alsip,
USA.
Neu Kaliss Spezialpapier,Germany.
Sappi, Lanaken, Belgium.
Cartiera di Toscolano, Italy.
Bowater, Covington/TN, USA.
Fabrika Kartona, Umka, Serbia.
Reno de Medici, Magenta, Italy.
Arjo-Wiggins, Bessé-sur-Braye,
France.
Smurfit Carton y Papel de Mexico,
Cerro Gordo, Mexico.
M-real, Äänekoski, Finland.
Madeireira Miguel Forte, Paraná,
Brazil.
Steinbeis Temming Papier,Glückstadt, Germany.
Nippon Paper, Iwakuni KC3,
Japan.
Hokuetsu Paper, Nagaoka CM6,
Japan.
Oji Paper Thailand, Thailand CM1,
Thailand.
Mitsubishi Paper, Japan.

Votorantim Celulose e Papel,
Jacarei, Brazil.
Ripasa, Limeira, Brazil.
Ledesma, Jujuy, Argentina.
Winding technology– Sirius
SCA Graphic Laakirchen,
Austria.
Rhein Papier, Hürth, Germany.
Stora Enso North America,
Duluth, USA.
Shandong Chenming Paper
Holdings, Shouguang, China.
Madison Paper Company, Alsip,
USA.
Rigesa Celulose Papel e Embalagens, Três Barras, Brazil.

FinishingJanus Concept
SCA Graphic Laakirchen,
Austria.
Shandong Chenming Paper,
China.
Ecosoft calender
Rhein Papier, Hürth, Germany.
Ningxia Meili Paper, China (2).
Cartiere Miliani Fabriano, Italy.
Nanping Paper, China (2).
Hebei Jiteng Paper, China.
Ripasa Cellulose e Papel,
Brazil.
Neusiedler, Ruzomberok,
Slovakia.
Calenders
Kishu Paper, Osaka CM1, Japan.

Shandong Chenming Paper,
China.
Maanshan Shan Ying Paper
Making, China.
Jingxing Paper Group, China.
Lee & Man Paper, China.
Twister / Roll Handling
Steinbeis Temming Papier,Germany.
Axel Springer Verlag,
Germany.
SCA Graphic Laakirchen,
Austria.
Roto Smeets Deventer,
Neth0erlands.
Norske Skogindustrier,Norway.
Shandong Chenming Paper,
China.
Roll cutting machines
Shandong, Rizhao, China.
Kombinat Goznak,
Krasnokamsk, Russia.
Vipapa Videm Krsko,
Slovenia.
SCA Graphic Laakirchen,
Austria.
Papierfabriken Cham Tenero,
Switzerland.
Lee & Man Paper, China.
Oji Paper, Japan (2).
SCA Containerboard,
Germany.
Hengan Paper, China.
Rhein Papier, Hürth,Germany (3).
Torraspapel, Motril,
Spain.

4

Recent large orders

Fiber Systems

Stock preparation systems andsub-systems for graphic papers
UPM-Kymmene, Shotton,
Great Britain.
Pan Asia Paper Thailand,
Singburi, Thailand.
UPM-Kymmene Papier,Schongau, Germany.
Zanders Feinpapiere, Bergisch
Gladbach, Germany.
Daehan Paper, Cheongju,
South Corea.
Papierfabrik Albbruck, Albbruck,
Germany.
Cartiere Sarego Valchiampo,
Sarego, Italy.
Hindustan Newsprint, Kerala,
India.
Sepoong Corp., Kunsan,
South Corea.
Daishowa Paper, Iwanuma,
Japan.
Papeteries Matussière et Forest,
Turckheim, France.
UPM-Kymmene, Kajaani,
Finland.
SCA Graphic Sundsvall, Ortviken,
Sweden.
Minfeng Paper Mill, Jiaxing,
China.
Gaspesia Pulp and Paper,
Chandler, Canada.
Marusumi Paper, Ohe,
Japan.

Stock preparation systems
and sub-systems for board andpackaging papers
Thai Kraft, Wangsala,Thailand.
Wuxi Long Chen Paper,
Jiangsu, China.
Cartiera di Cadidavid,
Ca’ di David, Italy.
Propapier, Burg,
Germany.
Brødrene Hartmann, Tondern,Denmark.
Kappa Kraftliner Lövholmens
Bruk, Lövholmen, Sweden.
Cartiera Giorgione, Castelfranco
Veneto, Italy.
Shandong Bohui Industrial,
Bohui, China.
PCA, Tomahawk, USA.
Saica, Zaragoza, Spain.
Papelera de la Alqueria, Alqueria
de Aznar, Spain.
Indústria de Comércio de Papeis ePlástico/Citroplast, São Paulo,
Brazil.
Adami Madeiras, Santa Catarina,
Brazil.
Rigesa Celulose Papel e
Embalagens, São Paulo,
Brazil.
Oji Paper, Fuji, Japan.
Daishowa Paper, Yoshinaga,
Japan.
Marusumi Paper, Kawanoe,
Japan.
Daishowa Paper, Iwanuma,
Japan.

Stock preparation systems andsub-systems for tissue papers
Georgia Pacific Nederland, Cuijk,
Netherlands.
SCA Hygiene Products,
Lilla Edet, Sweden.
Kimberly-Clark, Chester, USA.
SCA Tissue North America,
Barton, USA.

Paper machines
Graphic papers
Shandong Huatai Paper, China.
Security Papers, Karachi,
Pakistan.
Sichuan Jinfeng Paper, Sichuan,
China.
Minfeng Special Paper, Jiaxing,
China.
Board and packaging papers
Shandong Bohui Industry,
Huantai, China.
TissueSCA Tissue North America,
Barton, USA.
Wepa Papierfabrik P. Krengel,
Kriebethal, Germany.
Installation and rebuilds
UPM Kymmene, Rauma, Finland.
Neusiedler, Ruzemberok,
Slovakia.
Stora Enso, Veitsiluoto, Finland.
Shotton Paper Company,
United Kingdom.

Holmen Paper, Braviken,
Sweden.
Papierfabrik Palm, Eltmann,
Germany.
Tamil Nadu Newsprint & Papers,
India.
AO Solikamskbumprom,
Russia.
Norske Skogindustrier, Saubrugs,
Norway.
SCA Graphic Sundsvall, Ortviken,
Sweden.
Sappi, Ehingen, Germany.
Stora Enso, Kabel, Germany.
Haindl Papier, Schwedt,
Germany.
Hansol, Corea.
Mundanjiang Henfeng Paper
Group, China.
Neusiedler Ybbstal, Kematen,
Austria.
Torraspapel, Motril, Spain.
Neusiedler Szolnok Papirgyar,
Dunaujvaros, Hungary.
Cartiere Sarego Valchiampo,
Italy.
Kaysersberg Packaging,
France.
W. Hamburger, Pitten, Austria.
Sappi Tugela, South Africa.
Mondialcarta, Lucca, Italy.
Cartiera di Cadidavid, Italy.
Cartiera di Ferrara, Italy.
Cartiera di Tolentino, Italy.
Papelera de la Alqueria, Alqueria
de Aznar(Alicante), Spain.
Assi Domain, Frövi,
Sweden.

5

Kartonfabrik Buchmann, Rinnthal,
Germany.
Indústria de Comércio de Papeis ePlástico/Citroplast; São Paulo,
Brazil.
Adami Madeiras, Santa Catarina,
Brazil.
Papel Caixas e Embalagens/PCE,
Amazonas, Brazil.
Korea Export Packaging, Osan,
Corea.
Oji Paper, Saga, Japan.
Japan PaperBoard, Soka, Japan.
Oji Board, Nayoro PM3, Japan.
Koa Kogyo, Fuji PM6, Japan.
Papresa, Renteria, Spain.
Zanders Feinpapiere,
Bergisch-Gladbach, Germany.
Papirnica Vevce, Ljubljana,
Slovenia.
Condat, Le Lardin, France.
Owens Corning Veil, Apeldoorn,
Netherlands.
Trierenberg, Wattens, Austria.
Papierfabrik Schoeller & Hoesch,Gernsbach, Germany.
Radece Papir, Radecde,
Slovenia.
VPH Veiligheitspapierfabriek,
Ugchelen, Netherlands.
Crane, Tumba, Sweden.
Papierfabrik Louisenthal, Gmund,
Germany.
Zhejiang Papermaking ResearchInstitute, Hangzhou, China.
Nippon Paper, Komatsujima PM1,
Japan.
Kishu Paper, Kishu PM7, Japan.

Papeles Norske Skog Bio Bio
PM1, Concepción, Chile.
Bahia Sul Celulose, Mucuri,
Brazil.
Votorantim Celulose e Papel PM2,
Jacareí, Brazil.
Votorantim Celulose e Papel,
Piracicaba, Brazil.
Cia. Suzano de Papel e Celulose
PM8, Suzano, Brazil.
PCE – Papel, Caixas e Embalagem,
Manaus, Brazil.
Adami, Caçador, Brazil.
Citroplast Ind. E Com de Papéis e
Plásticos, Andradina, Brazil.
Amcor Cartonboard, Petrie,
Australia.
Cia. Suzano de Papel e Celulose
PM6, Suzano, Brazil.
Riau Andalan PD2, Kerinci,
Indonesia.
Papeles Industriales, Santiago,
Chile.
Klabin Kimberly PM4,
Mogi das Cruzes, Brazil.
Coating technology
Usine de Condat, Le Lardin,
France.
Tamil Nadu Newsprint & Papers,
India.
Mundanjiang Henfeng Paper
Group, China.
Hansol, Corea.
Torraspapel, Motril,
Spain.
Minfeng PM 21, China.
Jinfeng PM 3, China.

Shandong Bohui Industry,
Huantai, China.
Mitsubishi Paper, Japan.

NipcoFlex calender
Stora Enso, Baienfurt,
Germany.

Winding technology– Sirius
Shandong Huatai Paper, China.
Neusiedler, Ruzemberok,
Slovakia.
Stora Enso, Veitsiluoto, Finland.
Papresa, Renteria, Spain.
W. Hamburger, Pitten, Austria.

Calenders
Cartiera di Carbonera, Italy.
Kishu Paper, Osaka CM1, Japan.
Minfeng Special Paper, China.
Bowater, Catawba, USA.
Ibema-Cia Brasileira Papel,
Brazil.
Shandong Bohui Industrial,
China.
Chung Loong, China.
Huacai, China.

FinishingJanus Concept
Bowater, Catawba, USA.

Twister / Roll Handling
Shandong Huatai Paper, China.

Ecosoft calender
Ibema-Cia Brasileira Papel,
Brazil.
Ripasa Cellulose e Papel,
Brazil.
Shandong Huatai Paper, China.
Shandong Bohui Industrial,
China.
Papeteries des Vosges, France.
Minfeng Special Paper, China.
Shenzhen Wander Color Printing& Packaging, China.
GAP Insaat Yatirim ve Disticaret,
Turkmenistan.
Stora Enso, Kemi, Finland.
Neusiedler, Ruzomberok,
Slovakia.
Stora Enso Magazine Paper,
Kotka, Finland.

Roll cutting machines
Ripasa Cellulose e Papel,
Brazil.
Chung Loong, China.
Gojo Paper Manufacturing, Japan.
Stora Enso, Kemi, Finland.
Shandong Bohui Industrial,
China.
Sichuan Jinfeng Innovation
Industry, China.
Smurfit Nanterre, France.
W. Hamburger, Austria.
Minfeng Special Paper, China.
Neusiedler, Ruzomberok,
Slovakia.
GAP Insaat Yatirim ve Disticaret,
Turkmenistan.
Cartiere del Polesine, Italy.
Shandong Huatai Paper, China (2).

6An impressive demonstrationof innovativetechnology competenceInternational Customer Conference Graphic Papers, September 4 to 6, 2002 in Salzburg, Austria

Almost 700 paper industry decision-makers from195 companies in 38 countries met in Salzburg for this 3-day
science dialogue – aptly entitled “Process & Progress”– to learn more about Voith Paper’s process competence.
Ingo Schmid
Corporate Marketingingo.schmid@voith.com

7

S c i e n c e

D i a l o g

4.9.2002
Wednesday, 4.9.2002

The symposium started on September 4
with an international press conference. In
dialogues with press representatives,
members of the Voith Paper management
discussed current projects, opportunities
and risks in the future growth market
of China. The focus was also on Voith
Paper’s latest innovations.
After this press conference, the symposium was officially opened by Voith
Board member Dr. Hans-Peter Sollinger.
In the foyer of Salzburg’s new congress
center, guests were then able to whettheir appetites at the Voith Paper Innovation show, where experts and engineers

were on hand for answering all theirquestions.
As a fitting conclusion to such an striking
demonstration of Voith Paper innovationcompetence, the evening closed with afestive dinner and musical entertainment.

85.9.2002

Thursday, 5.9.2002
The impressive series of papers highlighting this event was introduced by
Board Chairman Hans Müller. In his address, Hans Müller focused again on thetransformation undergone by Voith Paper
from a purely machine-building company
into a comprehensive supplier for all paper industry processes.
Accordingly, the central theme of this
symposium was the One Platform
Concept, whereby Voith Paper offers
comprehensive customized solutions for
all paper grades. The following challenges in the paper industry gave rise tothis concept:● Increasing use of recycled fibers withsteadily declining quality● Rising production speeds● Higher fillers content● Lower basis weights● Ever-increasing demands on paper
quality● Integration of offline processes in thepaper machine● Higher productivity● Lower production costs.

9

S c i e n c e

D i a l o g

The One Platform Concept enables optimally custom made solutions for all customer needs, ensuring the highest productivity in every case thanks to dependable well-proven modules. This concept
covers the entire papermaking process,from stock preparation to finished product, and is applicable to all paper grades(including board and packaging papers).
With the One Platform Concept, Voith
Paper can supply the most productive
and cost-effective production line for any
paper grade.
Each of the symposium presentations focused on the individual benefits of thisconcept. The primary need in Newsprint production, for example, is costeffectiveness. For optimal production
economy not only are cost-effective machinery and equipment necessary, butalso low operating costs, high availability
and runnability, and outstanding process
stability. As impressively demonstrated
by this presentation on the One Platform
Concept for newsprint, Voith provides solutions meeting all these requirements.
The presentation dealing with SC papers
focused above all on printability, whilethat on LWC papers underlined the aspects of quality and cost-effectiveness.
As explained in the One Platform Concept
presentation for Woodfree papers,
the main requirements in this case arehigh quality and high production speeds.
With regard to Specialty papers, therespective presentation emphasized that
due to their enormous variety, the primary need here is for flexible machine concepts.

The audio-visual perfection of thesepresentations was rounded off by two
customer contributions, in which SCA
Graphic Laakirchen and Rhein
Papier documented the process competence of Voith Paper. As conclusively
demonstrated by the outstanding startups in Laakirchen and Hürth recently,
Voith’s One Platform Concept brings decisive advantages for the paper industry.
The round of presentations was summed
up by Dr. Hans-Peter Sollinger. He pointed out once again that all the activities
and development efforts of Voith Paper
are focused on maximum benefit for ourcustomers – the paper industry – withwhom close ongoing teamwork is vitalfor long-term success.
The grand finale on Thursday evening
was a gala banquet held in Schloss Hellbrunn, preceded by a reception in the imposing palace courtyard. In this uniquefestive atmosphere, appropriate for thecity of Mozart, guests were able to makecloser contacts, customer relations were
deepened, and valuable experiences wereinterchanged. The evening was highlighted musically by stars from the Salzburg
Festival, and visually by the spectacular
illuminated fountains.

10

6.9.2002
Friday 6.9.2002

On Friday morning the symposium participants boarded a historical steam train in
Salzburg main station for a nonstop trip
to the SCA Graphic Laakirchen millin Laakirchen. Here they were shownaround the world’s most advanced production line for SC grades. Entirely consisting of Voith Paper modules and components according to the One Platform
Concept, this line holds the record forshortest startup time. Fascinated by suchan impressive high-tech plant, whichgave rise to some very enthusiastic discussions accordingly, our guests thenreturned in style to Salzburg on their
special train for last goodbyes before departing.

The success of this unique event is reflected not only by extremely positive
feedback from our customers, with numerous letters of thanks and praise, butalso by the outstanding press reports.
Voith Paper has impressively demonstrated to the best of paper industry decisionmakers, that the One Platform Concept integrates unsurpassed technological competence with a matchless spirit ofinnovation.

For the seminar papers and other documentation, please contact:
info.voithpaper@voith.com

11High Tech for China –Highranking guests from the Middle Kingdom at Voith
During the international Voith Paper customer conference in Salzburg, Austria, in September 4 - 6, 2002, Voith Paper was pleased to welcome
650 participants. These representatives from 195 companies and 38 countries were a worldwide gathering of clients with unique technical competence. After the German-speaking group of customers, China, with its about
60 delegates, was the nation sending most representatives. This broughthome to the international specialists the continuously growing importanceof the Chinese paper industry and its constantly growing importance on
Markus Wild
Paper Machines Graphic
markus.wild@voith.com

the international scale. Highest-ranking representatives and functionaries
were able to convince themselves that Voith is a partner with whom tobuild up and expand the paper industry using state of the art technology.
The Chinese companies represented included (in alphabetical order):Chenming Group
CNTIC (China National
Technical Import & Export
Corporation)
Foshan Huafeng Paper
Gold-East/Dagang
Guangzhou Paper
Hengfeng/Mudanjiang Paper
Huatai Group
Jincheng Paper
Jinfeng/Chengdu
Nanping Paper
Ningxia Meili Mill
Qiqihar
Tianjin Global Paper

The visit to SCA Graphic Laakirchen, Austria, at the end of the customer conference was another highlight(visitors were transported by a historicaltrain from Salzburg right to the middle of
the SCA company premises, where a walkthrough the presently most modern andpowerful SCA-Plus machine in Laakirchen
started); at the same time, it was the
beginning of a series of visits of theChinese delegation.
Among others, these included a visit toVoith Fabrics in Frankenmarkt, Austria,
the Voith headquarters in Heidenheim, thecompany Lang Papier in Ettringen, Rhein
Papier in Hürth and the Kehl works ofKoehler, all located in Germany. A schedule which allowed visits to four of themost important reference plants withinjust one week.
We would like to take this occasion toexpressly thank the high-ranking andtechnically competent representatives ofthese companies, who made it possible
for the first time that such a large delegation from China was granted access totheir mills and the Voith-supplied machines.

12

Lang Papier,EttringenThis fact is all the more important as
these are the most modern Voith machines of the now famous and extremely
successful One Platform Concept, producing a variety of products, such as SC
paper (SCA and Lang Papier), newsprint(Rhein Papier) and coated thermopapers(Koehler) at the relevant mills.
On the following weekend, the exclusive
program of visits for our Chinese guests
began.
The Saturday began with the trip to
Frankenmarkt to our Voith Fabrics plant.
Here, the visitors were able to see with
their own eyes the most modern technology used and the absolute technical competence during their impressive walkthrough the plant.

After a bus trip through the AustrianBavarian foothills of the Alps to Munich,Sunday’s highlight was the visit to theroyal Hirschgarten. Under a picture-bookwhite-blue sky, our visitors were able toenjoy a piece of Bavarian lifestyle during
a hearty lunch and good German beer.
The weekend found its completion with asuccessful dinner in Heidenheim.
The week, with its interesting program ofvisits, was started by Hans Müller on
Monday morning with his introduction tovery interesting presentations on the subjects Voith – Engineered reliability, Voith
Fiber Systems – Know how for the Chinese Market and Voith Paper Investments
in China. In addition, the sale of the200th ModuleJet was celebrated with apresent for Mr. Li, Shandong Huatai
Paper Industry Co Ltd (Fig. top left).
After lively technical discussions with thepresenters, Dr. Sollinger, Dr. Pfalzer and
Mr. Gather, the delegation visited theworkshops and the R & D center ofVoith.
On Tuesday, the connection between thetheories presented and practice was to beestablished. The first reference plant,
shown to us full of pride by Mr. Murtola(production manager, Lang Papier Ettringen), was the PM 5 in Ettringen, thefastest line for online-SC papers in theworld. Mr. Murtola first gave an overview
of the Myllikoski group and the mill in
Ettringen, then he gave the visitors a tourof the new DIP plant and the PM 5.

13

Hürth PM 1
Start up

August Koehler,
Kehl

To round off the day, and as a stop on
the way to the next reference mill, we
visited Neuschwanstein castle with ourguests.
Wednesday began with the visit to thelatest newsprint mill in the world at
Rhein Papier in Hürth, which, like
Lang Papier, also belongs to the Myllikoski group. We were welcomed by Mrs.
Murtola (plant manager) and Mr. Schmidt(project manager). After a brief introduction, we could see the DIP plant and
the PM.
The PM was started up with the world
record speed of 1,560 m/min and has, inthe meantime, already been producing at
a speed of 1,912 m/min for short periodsof time. Part of this noteworthy successis due to a totally new kind of collaboration between the supplier and customer,
which includes a service agreement for
maintenance. It is the goal to unify thecore competence of the paper manufacturer with the core competence of theplant supplier, making use of synergy
effects in order to ensure a high overall
efficiency and high economic efficiencyof the operation.

to visit the new PM for thermopapers
with Mr. Boschert (division manager). At
this mill, a PM and offline coater produce
thermopapers. Nine months after startup
and intensive cooperation between thecompanies Köhler and Voith Paper, theline is already producing above design
speed at 1,460 m/min.

After the visit to Rhein Papier, a boat tripon the Rhine brought us closer to ournext highlight of this reference trip, and it
also allowed us to hold discussions andhave dinner together.

This was the successful end to a weekthat was consistently interesting both forthe guests and Voith due to the numerous intensive discussions and the positive feedback, and which left lasting impressions. With the assurance of anothermeeting in the near future and good cooperation, we said farewell to our guests
at the Frankfurt airport.

This further highlight was a visit to thecompany August Koehler in Kehl,
where on Thursday morning we were able

14

Norske Skog Parenco –more than happy with their new F0I 6
stock preparation line
Just what Parenco wanted: finished stock in only 14 days.
In December 2000 Parenco BV (at that time fully owned by Haindl
Papier) awarded Voith Paper Fiber Systems the engineering contract for a new stock preparation line (F0I 6, Flotatie Ontinking)at their Renkum mill in the Netherlands. The scope of supply also
included various existing system rebuilds as well as all key
components.
Andreas Heilig
Fiber Systems
andreas.heilig@voith.com

Fiber Systems

15

Fig. 1: 3-dimensional computer simulationof the new FOI 6 stock preparation line.
Fig. 2: The Norske Skog Parenco mill in
Renkum, Netherlands.

2

lem-free commissionings in Augsburg andKymmene. To gain approval of this trans-

Steyrermühl, thanks to Voith’s precisionaction by the anti-trust authorities, how-engineering.

ever, the Parenco mill had to be sold off
to Norske Skog of Norway in order to

In addition to a higher production capaci-comply with market competition law re-ty, the customer’s objective with this pro-

quirements.

ject was to increase the use of recovered1

paper furnish whilst maintaining or im-

Since anti-trust board approval was notproving product quality. The outdated

given until the end of 2001, the curious

FOI 2 stock preparation line was shutsituation arose that in the meantime UPM

down after successfully commissioning

people were working for their competitor

the FOI 6 line.

Norske Skog.

Haindl’s project team of engineers from

Notwithstanding these rather challenging

the Parenco mill and from the central en-

circumstances, Voith, in close teamwork

After the design and installation of twogineering department in Augsburg proved

with the Parenco and Haindl technolo-

new stock preparation lines/rebuilds at

itself very well, making ideal use of thegists, designed a modern two-loop stock

the Augsburg and Steyrermühl mills, thisexperience gained in Augsburg and Steyr-preparation system, including water clari-

was the third large order Voith had re-ermühl for meeting the specific require-

fication, rejects handling and sludge

ceived from Haindl within a very shortments of Parenco.

treatment.

When the project got underway at the end

Voith’s

Key reasons for winning this repeat or-of May 2001, contracts were alreadybasic and detailed engineering both for

der were the extremely short and prob-

signed for the sale of Haindl to UPM-

the stock preparation process and for the

space of time.
engineering

contract

covered

16

4
5

3

Fig. 3: EcoCell preand post-flotation.
Fig. 4: IC and LC
slotted screening.
Fig. 5: EcoDirect
disperger.

automation technology and covered the● 2-stage hole screening and heavy-

Thanks to our colleagues from the Voith

following scope of supply:

weight cleaning, comprising HC clean-facility in Vaassen, we had no communi-● Engineering of the new FOI 6 deinking

ing, MultiSorter, Combisorter andcation problems in holding our training

LC cleaningfor operator and maintenance personnelline● 2-stage EcoCell pre-flotation (Fig. 3)

in the dutch language. The erection work

water systems and cooling circuits inwith five primary and three secondary

was also carried out in close teamwork

the existing FOI 4 and FOI 5 deinking

cells, including two deaeration cy-

with our Netherlands colleagues.

lines, analogue with the new FOI 6 line

clones for installation in the foam tank

● Engineering of a new MC stock storage● 3-stage IC slotted screening (0.25 mm

The Voith Paper joint-venture partner

C-bar technology), comprising Multi-

Meri, Munich, was responsible for instal-

Sorters in the first two stages and thelation and commissioning of an existing

proven MiniSorter as final stage

Deltapurge, which had been taken out of(Fig. 4)

service some time ago. Installed on the● Standardization and optimization of thesystem● Engineering of a new central millwide
system for sludge treatment● Optimization of existing additive
systems and planning of new ones

● 4-stage LC slotted screening withroof of the new FOI 6 building, it has a

0.2 mm C-bar technology, comprisingwater clarification capacity of 25,000● Millwide system analysis, including

MultiSorters in the first three stagesl/min. Meri also supplied the new rejects

balancing of stock, water, thermal

and likewise a MiniSorter as final stage

handling and disposal system designed

energy and COD, as well as simulation(Fig. 4)for all three stock preparation lines, in-(such as soap preparation)of future production conditions● Development of a millwide processwater management concept.
Voith also supplied the following key● The recently developed EcoDirect
disperger (Fig. 5) with direct heatingcluding magnetic separator, shredder andcompactor.

and preceding equalizing screw● 2-stage EcoCell post-flotation withAs previously at the UPM-Haindl mills

quality-relevant stock preparation sub-five primary and two secondary cells

in Augsburg and Steyrermühl, Voith’ssystems:

including deaeration cyclone.

patented

AP2000(Advanced

Process

Fiber Systems

17

6

7

Fig. 6: AP 2000
concept with mixing
pumps.
Fig. 7: Screw presses
and disc filter.

2000) engineering concept was imple-

The new FOI 6 stock preparation line, inplier was able to prefabricate a great deal

mented here (Fig. 6). Since lack of space

combination with various rebuilds (FOI 4 /of the pipework based on the precisionprecluded the installation of a conven-

FOI 5 / PM 1 / PM 2) as well as measuresisometrics provided by Voith Paper.

tional system with chests, the compact

derived from the results of the systemand operationally cost-effective AP2000

analysis (not forgetting the new water

Early in the engineering work, Norske

concept, with its virtually closed-loop de-management philosophy!) have helped

Skog Parenco engineers were able to also

sign and high degree of automation, wasParenco move further towards becoming

use the 3-D computer simulation to checkselected here.

one of the leading deinking plants indesign accessibility, as well as mainte-

terms of efficiency and runnability.

nance-friendly and operational reliability.

the papermaker can now group start the

The high degree of automation has not

A significant factor for the successful

entire line in only ten minutes, and shut it

only simplified operation and increased

commissioning, particularly of the modi-

down in about twenty minutes, including

reliability, but has also ensured meeting

fied existing systems, was the exemplary

flushing. Another welcome highlight for

Parenco’s requirement for a central con-tie-in work. In close teamwork with pro-the plant operator is certainly the produc-

trol room for all three stock preparation

duction management, even the shortest

tion control system, which enables thelines.

shutdown times were fully used for con-With the new stock preparation concept,

necting the complex pipework and forrequired production to be precisely set

adjustment of software, etc.

with a single command. The millwide wa-

Collision checks were continuously madeter management concept and its accom-

during the planning phase, using Voith’s

panying control system also proved ex-

3-D computer simulation system. Thanks

One of the main reasons, however, fortremely welcome. With this system, theto this and by using it during installation

this picture-book deinking line start-up

water volume throughout the mill is auto-of the pipework, costly and time-consum-

was the several weeks of software tests

matically maintained constant for various

ing alterations were largely avoided dur-

carried out prior to commissioning. Every

production conditions.

ing erection. In addition, the piping sup-single function of the 1,400 control cir-

18

Harald Fichtl
Walter Rummler
Ben Kortekaas
Norske Skog
Parenco

We hold Voith’s comprehensive

new FOI 6 line. We therefore attachedsystem competence in highgreat importance to carrying out a mill-esteemwide system analysis. Based on thisRenkum can look back on a very long

analysis and the millwide water manage-

tradition of paper production, dating

ment concept proposed by Voith we canfrom the original mill in 1720. The mill

now increase our product quality andas it stands today was founded in 1912.

operating reliability for various operating
conditions by maintaining a higher con-

The two paper machines at Norske

stancy in quality and process, whilst still

Skog Parenco today produce standard

complying with the strict limits set by

and improved newsprint with basis

the various authorities. All at minimum

weights from 45 to 56 g/m 2. Annual

investment costs.

gross production is around 500,000 t.

Fig. 8: The new MC stock storage towers.

Voith not only had to design a new stock
We mainly use recovered paper as ourcuits was simulated and thoroughly test-

preparation line for us, but they also had

raw material. This consists of a mixture

ed during this time.

to integrate it into a complex existingof ONP and OMG which is prepared instructure with limited fresh water re-three deinking lines. The overall recov-

Despite the tight schedule and very de-sources and restricted effluent volumes –ered paper content is 75%, and we add

manding requirements, the commission-

all without affecting the flexibility of our

25% TMP. It is interesting to note thating team was thus able to deliver high-furnish recipe.

grade stock to the new MC storage sys-

until well into the eighties, the ratio of
deinked stock to TMP was exactly theAlong with the specific know-how of our

opposite.

former colleagues in the Augsburg central engineering department and our own

tem only two weeks after beginning thestart-up phase in July 2002 (Fig. 8).
With this modern technology, Norske

With an overall investment of 65 million

Norske Skog Parenco technologists andEuro, we are systematically pursueing

production people, Voith’s complete

our quality strategy. The new FOI 6 line

system competence has provided us withhas, of course, increased our flotation

an outstanding concept for efficiency andstock capacity and this opens up future

quality enhancement. With the measurespossibilities for the furnish mix. This

we have implemented together with Voith,

investment certainly has further poten-

we can look to our mid-term objective oftial for cost savings and quality im-

becoming one of the world’s most effi-

provements.

cient recovered paper preparation plants.

Our existing water system would have

We sincerely thank Voith for the excellent

been inadequate for the additional

cooperation, and wish them all the best

We wish Norske Skog all the very best for

production capacity after installing thefor the future, too.

the future – and not only in Renkum!

Skog Parenco have passed another important milestone in their long and impressive recycling track record. Voith isproud to be a partner in this development, but we also take this as a commitment. A commitment to continue contributing towards the economic successof

Norske Skog Parenco, and to thestrengthening of our partnership.

19

1

New DIP 5 for 600 t/24 h finished stock
at Pan Asia Paper, Jeon Ju, Korea –just 10 months from contract signing to start-up“As you make your bed, so you must lie in it.” This German
proverb perfectly describes Pan Asia Paper’s mill in Jeon Ju (Chonju)
in the South West of Korea. Green lawns and fountains (Fig. 1) withshady groups of seats do not necessarily suggest that you have justpassed the entrance gate to a highly efficient paper mill. This pleasant environment obviously strongly motivates the people working
here since the visitor will find the paper manufacturing plant just as
Leo Engelmann

well-looked-after as the green areas.

Fiber Systems
leo.engelmann@voith.com

This impression is underlined when theVice President of Production, Young-Jae
Kim, states that the employees are thegreatest asset for efficient production.
Founded in 1965 under the name of Saehan Paper Co. Ltd., the mill has been amember of the Pan Asia Paper Groupsince 1999. Pan Asia Paper is a cooperation between Norske Skog, Norway andAbitibi-Consolidated, Canada, with its
head office in Singapore.
Further production plants are in Chongwon, Korea, in Thailand and in China.

Fig. 1: Pan Asia Paper in Jeon Ju(Chonju), Korea.

In 2001, seven paper machines produced
1,007 million tons of paper in Jeon Ju.
Together with the Chongwon mill, Pan

Asia Paper covers more than 50% of thenewsprint demand in Korea. Approximately 25 % of the production is exported.
The main raw material for the paper machines is provided by 5 deinking lines forthe preparation of recovered paper, together with 2 TMP plants.
This makes Pan Asia Paper in Jeon Ju thepaper mill with the world’s highest capacity for the production and processingof DIP stock.
An interesting point worth mentioning
here is that in 1995 the Korean government awarded Pan Asia Paper, Jeon Ju, aprize for environmentally-friendly paper
production.

20

Fig. 2: Protector System.
Fig. 3: Hole and slot screening (foreground) andpart of the EcoCell deinking system (background).
2

For the most recent of the 5 deinking
plants in Jeon Ju, DIP 5, which started
up in July 2001, Voith Paper was awarded the contract for delivery of the key
plant components and machines in August 2000.
A long-standing partnership developed
during the time the orders for the DIP 3
and DIP 4 plants were being processed
and this provided valuable experience forthe smooth cooperation on the DIP 5 project.
The plant is designed for 600 t / 24 h offinished stock and fully reflects the latest
state of technology. The furnish today
consists of approximately 70% Korean
ONP, 20% European ONP and approximately 10% American OMG.

DIP 5 deinking line
The Protector system (Fig. 2) immediately following pulping ensures highly efficient removal of contaminants such as
glass, paperclips and sand so that today,
after more than 12 months’ operation,

Young-Jae Kim

Kyoung-Yong Lim

Vice President Production,
Pan Asia Paper, Jeon Ju

Production Manager DIP 5,
Pan Asia Paper, Jeon Ju“Cooperation based on partnership isthe basis for a successful project.”“In the production line from DIP topaper machine, quality and productivity
is improved by direct feedback fromthe paper machine as ‘customer’.”Fiber Systems

21

Fig. 4: Disc disperger.
Fig. 5: In grateful recognition of the excellent
cooperation and satisfaction with the achieved
results, Pan Asia presented Feridun Dormischian,representing Voith Paper Fiber Systems, with acommemorative plaque.
3

there is no basket wear worth mentioning
in the subsequent 3-stage MultiSorterand MiniSorter hole screening system(Fig. 3).
The production manager of the new DIP
5, Kyoung-Yong Lim, emphasized the excellent results achieved with the EcoCell
Flotations I and II (Fig. 3), consisting ofa total of 11 primary and 3 secondary
cells as well as 2 deaeration cyclones.
The DIP 5 plant is up to 5 % more efficient than the previous plants in removing printing inks whilst at the same time
the use of chemical additives has beensignificantly reduced.
The configuration of 6 primary and 2 secondary cells in Flotation I and 5 primaryand 1 secondary cell in Flotation II
achieves a brightness of between 70 and
72 ° ISO as needed on PM 5 for therequired particularly bright paper grades.
Flotation I is followed by 3-stage LC slot
screening (Fig. 3) with MultiScreens and
MiniSorter (all with 0.15 mm C-bar screenbaskets), and a disc disperger (Fig. 4).

4

For heating and thickening a SpeedHeater,
two disc filters and a Thune screw press
were supplied by Voith Paper AS, Tranby,
Norway (the former Kvaerner Recycling
and Dewatering Division).
The screw conveyers between the process
stages were delivered by the Voith subsidiary B+G Fördertechnik, Euskirchen
and Voith’s joint venture partner Merisupplied two Sediphant machines and agravity table for reject handling andsludge treatment.
Apart from the process machines themselves, the Pan Asia Paper project team
were able to smoothly integrate Voith’sengineering requirements into the overallplanning.
Here, too, the experience gained fromprevious joint projects had a positive influence. It was therefore no problem at
all for Pan Asia Paper’s experienced planning department to take over the process,control and instrumentation details prepared by Voith and integrate them into
the overall system planning.

5

All interfaces were clearly defined in detail and agreed by the specialists fromboth companies during the project meetings held in Jeon Ju. The reward forthese meticulous preliminary discussions
was a record erection and start-up time.
The machines were installed by local
companies, supported by erection specialists from Ravensburg and Tranby.
Punctual deliveries, excellent preparatory
work by the construction company andthe competence of the erection companies meant that the time schedule for thecomplete plant could be met exactly.
The preparatory work by all parties involved was so thorough that the plant
was able to start up production, supported by Voith’s commissioning engineer,in July 2001, approximately 10 months
after contract signing.
Pan Asia Paper is fully satisfied with the
new DIP 5 plant’s production performance in terms of quality and quantity of
the finished stock as well as overall
runnability of the deinking plant (Fig. 5).

22

1

Khanna Paper
joins the top ten paper producers in India

Saurabh Khanna
Technical Director,
Khanna Paper Mills

Not far away from the magnificent Golden
Temple (Fig. 1) in the city of Amritsar(Punjab), the unassuming Chairman of
Khanna Paper Mills , B. M. Khanna, runs
a highly successful operation, supported
by his two sons Rahul and Saurabh. The
start-up in March 2002 of a new Voith
200 t/24 h deinking plant, the largest todate in India, has firmly put the mill up
among the top ten in paper production inIndia.
From a very modest 500 kg/24h of board
in 1964, Khanna today produces around
300 t / 24 h of both board and writing andprinting papers. With the new installation, Khanna has also become the first
paper mill in India to produce their highquality writings and printings from 100 %deinked woodfree recovered paper.

Alfred Kettl
Fiber Systems
alfred.kettl@voith.com

Designed according to the latest state of
the art technology and automation, thedeinking plant comprises the following
main process equipment:● High consistency pulping, followedby high density cleaning and hole
screening.
● EcoCell pre- and post-flotation for
efficient ink removal (Fig. 2).
● Fine cleaning with the new generationof EcoMizer cleaners and fine screening with narrow slot widths of 0.15 mm,
using proven C-bar baskets.
● The desired high final stock brightness
is ensured by peroxide bleaching in the
recently developed EcoReact HC
bleaching tower as well as by hydrosulfite bleaching.
The whole stock preparation plant is controlled by only one plant operator using a
DCS system.
The project was carried out in close cooperation between Khanna Paper, Voith
Paper Fiber Systems in Ravensburg,
Germany and Voith Paper Technology(India), based in Calcutta. The latter is a
joint venture between Voith and Larsen &Toubro.
2

200 t / 24 h deinking plant catapults the mill into the big league“In Voith Paper we have found atrustworthy, competent and reliable
partner for the present and future
projects.”
Saurabh Khanna, Technical Director,
Khanna Paper Mills.

23

1Hürth PM 1 –the world’s most modern newsprint line breaks
new records
Thomas Schaible
Paper Machines Graphic
thomas.schaible@voith.com

This entire project and commissioning impressively shows what canbe achieved through an optimal combination of meticulous planning, innovativetechnology, and competent personnel both on the side of the supplier and thecustomer. Bernhard Schmidt, Rhein Papier GmbH project manager, sums up the
Hürth PM 1 project execution and results as follows: “In the record time of only
12 months from construction start to first paper on the Sirius reel, we completAndreas Köhler
Paper Machines Graphic
andreas koehler@voith.com

ed an exceptional project together with Voith. Hürth PM 1 is certainly one of thegreatest successes in our entire company history”.
The customer

Joachim Huber
Fiber Systems
joachim.huber@voith.com

Rhein Papier GmbH is a new subsidiaryof the Myllykoski Corporation, which was
founded more than a century ago. Myllykoski is present in all key paper markets around the world, and specializes incoated and uncoated graphic printing
grades. About three million tons of paper
are produced annually on 19 machines in
the nine Myllykoski mills.

The decision for this modern newsprintline was made in December 2000 in viewof the serious shortage of newsprint atthat time – a good many publishers andprinters had great difficulty during 2000
with paper supplies. Successful negotiations were held with potential paper customers even prior to this decision.
On April 27, 2001 – after hardly 4 months
of intensive project work – the contract

24

2

was signed with Voith Paper for the delivery of a complete new production line
for newsprint, from stock preparation toslitter/winder.
Decisive for the award of this contract
was above all Voith Paper’s comprehensive know-how in graphic paper production from 100 % recovered paper.
The location near Cologne, Germany, wasselected, since most large consumers arein the vicinity of the new production line,
which is the only major secondary fiber
processing plant of this size in the region.

Project summary
After deciding on the location in May
2001, detailed project planning started
immediately, in order to comply with thevery tight time schedule:
Construction work started in July, and asof November Voith’s representatives were

continuously on site. The erection phasebegan in December 2001, and to ensureongoing compliance with the schedule,
up to 900 erectors were required at peaktimes. Production start-up was planned
for August 1, 2002, but this goal wasreached considerably earlier.
On July 4, 2002 Voith Paper and Rhein
Papier celebrated the first paper at the
Sirius reel.

Hürth PM 1 plant manager Anne Murtola
was very enthusiastic about the smooth
start-up of this paper machine:“We beat the start-up deadline by almosta month – and even at the world record
start-up speed of 1,560 m/min. That was
the crowning achievement of this outstanding project team!”.
Not long afterwards, Hürth PM 1 alreadyproduced paper to market quality standards.

At that time, the production line was in
the initial optimization phase – and after
only six weeks another record had beenbroken: the machine was briefly run up toa speed of 1,912 m/min. Never before
had this happened so soon after commissioning, and the machine clearly has thepotential for continuous production at
speeds exceeding 1,900 m/min.
The key reasons for the success of thisproject can be summarized as follows:● Innovative technologies● Single-source delivery● A forward-looking and quality-oriented
maintenance concept● Excellent time management.
Voith Paper’s “One Platform Concept”
systematically developed over the last
five years was implemented here for the
first time with nearly all its modules.
Hürth PM 1 comprises a ModuleJet headbox, DuoFormer TQv, a tandem NipcoFlex
press section, TopDuoRun dryer section,

25
Fig. 1: Rhein Papier GmbH, Hürth, Germany.
Fig. 2: PM 1 former section.
Fig. 3: Dry end with Sirius reel.

Technical data
End product

Newsprint made of 100% recovered paper furnish

Average production speed

1,800 m/min

Maximum production speed

2,000 m/min

Design speed

2,200 m/min

Wire width

8,900 mm

Web width

8,150 mm

Production

280,000 tonnes per year3

softnip calender and Sirius reel. Apartfrom the actual paper machine including
quality control system, Voith also supplied all the stock preparation machines,
as well as all the fabrics from Voith
Fabrics.
The unusually short construction time of
only 12 months is the fastest worldwide
for this kind of production line so far.
A unique maintenance concept has been
implemented with Hürth PM 1 for the
first time in Europe – Myllykoski closed
a service contract with Voith covering
the entire maintenance of the mill’s machinery.
Routine on-site maintenance is done by
the customer’s personnel, while for allcomplex service and repair work a qualified VIS team (Voith Industrial Services)
is on call. This outsourcing concept originated from Rhein Papier's need to concentrate on its core competence of paper
technology and production.

To shorten commissioning time and ensure optimal start-up, comprehensive onsite training courses were held for thecustomer’s personnel. Furthermore, Voith
provided Rhein Papier with two project
managers throughout the realization period. After intensive support during theerection and commissioning phases, ourexperts are currently on site for consulting and support with optimization.

and cost-effective production line forstandard newsprint – without exceeding
the budget and without compromising
any quality standards. To ensure optimal
results, previous project experience andresulting synergies were to be integrated.
The commissioning target was to break
the world start-up curve record for thistype of production line, and, in the longterm, to attain a stable operating speedof 1,800 m/min.

Teamwork with the customer
Both sides were delighted with thissmooth teamwork. Thanks to the customer’s efficient and highly qualified
team, who tackled this tight schedulevery professionally, no delays of any kindoccurred.

Prior target settings
The ambitious goal set for this project
was to build the world’s most modern

Today, all these goals have already beenreached. Only three months after startup, Hürth PM 1 was producing paper tothe very highest quality standards. As
confirmed by end customers, excellent
printing results were already attainedwith the first paper deliveries.
As for the targeted speed of 1,800 m/min,this was already exceeded at the beginning of 2003.

26

DAF 1

Fig. 4:
Deinking line,
2-loop system.

Paper machine

LC screening

DAF 3

Separator

Rejects
handling

HW cleaner

Storage

Disc filter II

Flotation II

Disperging

Screw press

Disc filter I

Flotation I

PM Loop

Loop II
LC screening // 0.15

Dump tower

MC screening ø 1.0

HD cleaner

Drum pulper

Loop I

Saveall
PM
spray
water

Sludgehandling
DAF 2

Fig. 5: B+G raw
material handlingequipment.

Stock preparation
The Hürth PM 1 stock preparation line
(Fig. 4), delivering 880 t/24 h oven-dry
finished stock from 100% recovered paper, also reflects the overall project philosophy. Only by combining well-provencomponents, modules and process
stages with system innovations and close
teamwork can such a fast and successfulcommissioning be realized.
Voith supplied all the key stock preparation equipment, from drum pulper charging to thickening, storage, rejects andeffluent treatment, as well as broke pulping.
Recovered paper furnish
charging
The B+G Fördertechnik charging system
for mixed furnish from 40 to 60% ONP
and OMG handles loose paper as well as
bales. The scope of delivery comprised
the entire conveying system including
bale dewiring and breaking as well as levelling drum (Fig. 5). Bale feed can be up
to 70% of total charge, and in this connection a performance check shortly aftercommissioning showed a bale dewiring
efficiency of more than 98%.
TwinDrum drum pulper system
Immediately after commissioning the
TwinDrum (Fig. 6), the enormous potential of this pulping system in terms ofthroughput and finished stock quality
was apparent. Production capacity withmaximum drum charge is around 1,700 t/
24 h air-dry.
The Voith TwinDrum uses separate rotating pulping and screening drums (withdisplacement body inside the pulping drum),connected via a transfer station. This enables selective optimization of pulping
and screening to suit the respective furnish (for more details, see twogether 9).
Pulping and screening results with the
TwinDrum are far superior to conventional drum pulpers with regard to deflaking,gentle fiber treatment and avoidance ofcontaminant size reduction. The screen
drum rejects are practically free of fibers
thanks to intensive washing and screening, thus reducing overall fiber losses instock preparation.

Cleaning and screening
To prevent deposits and stringing, thedrum screen accepts tank is tapered
down. At this point the stock is alreadycoarse screened using 8 mm holes.
The stock then passes through six highconsistency cleaners with intermittent
rejects discharge.
The 3-stage forward-flow MC coarse
screening system comprises three MultiSorters in the first two stages followed
by a MiniSorter as final stage – all withbaskets with contoured 1.0 mm holes.
The practically flake-free stock quality
demanded by this fine perforation is ensured by the efficient TwinDrum pulper
system. Hole screening accepts are
pumped to the two storage towers, which
operate free of deposits.

Flotation I and II
The Hürth PM 1 flotation system was, up
to the time of commissioning, the largest
EcoCell line ever delivered by Voith, witha finished stock capacity of 880 t/24 hoven-dry (Fig. 7). It includes a pre-flota-

Paper Machines

27
Fig. 10: Anne Murtola, mill manager
Rhein Papier GmbH with Roland Rauch,project manager Voith Paper Fiber
Systems.

Fig. 8: EcoDirect
disperger.

Fig. 6: TwinDrum
pulper system.

Fig. 7: EcoCell
deinking line.

tion stage with six primary and six secondary cells delivering the accepts forward, and a post-flotation stage with five
primary and three secondary cells.

Fine screening
Pre-flotation is followed by an effective
4-stage LC slotted fine screening stage
with 0.15 mm C-bar technology. Stages
3 and 4 are both in tandem layout andenable efficient stickies removal. This has
an extremely favourable effect on paper
machine runnability.

Disperging
For efficient dirt speck reduction, stickies
disintegration and deinking, the nextstage is disperging (Fig. 8) with two EcoDirect dispergers.
Steam is injected directly into the housing of this new disperger type, so that noprior heating screw is required. The highstock consistency required for disperging(up to 30%) is ensured by the preceding
thickening stage I with disc filter and twoscrew presses.

Fig. 9: Broke pulper.

Disperging is followed by post-flotation,
thickening stage II, and finally by storageof the finished stock.

Effluent and rejects handling
The Voith Paper joint-venture partner
meri supplied all the rejects handlingequipment including channel rake, magnetic separator, shredder and compactor.
Rejects from the cleaners are handled bya Sedimator, while the coarse screening
rejects are handled via Elephant filter andcompactor for disposal. Meri also supplied the entire effluent treatment plant,
comprising three Deltapurge machines.
Sludge is dewatered by two gravity tables, plus Elephant filter and sludge
presses. Effluent is pre-cleaned by Elephant filter and microflotation before
passing to the effluent plant.

Other equipment
Voith also supplied all the broke pulpers
for the paper machine and the two slitterwinders (Fig. 9).

What does this project say
about Voith?
This project has once again demonstrated
Voith’s innovation competence, not only
in developing new concepts, but also incarrying them out efficiently.
Voith concentrated, as always, on customer needs and developed solutions optimally meeting them through:● complete system delivery● uniform standards● clear interfaces with other suppliers● taking over machine servicing andmaintenance, thus enabling thecustomer to focus on his core
activities of production and end
product marketing.

World records broken
by Hürth PM 1
● Production start-up only 12 months
after beginning site work
● Start-up speed of 1,560 m/min● Production speed of 1,912 m/min only
six weeks after commissioning.

28

Laakirchen PM 11 –State-of-the-art production line for SCA-Plus
grades; a challenge for LWC paper
In September 2000 SCA Graphic Laakirchen ordered a newpaper machine from Voith Paper, complete with offline Janus MK 2
calender, to produce high-grade SC-papers for offset and rotogravureKarl-Heinz Bühner
Paper Machines Graphic
karl-heinz.buehner@voith.com

printing. The commissioning of this new line in May 2002 was particularly successful – numerous quality parameters very soon exceeded
all expectations.

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

29

Technical data of PM 11
1

Wire width

9,650 mm

Finished sheet width

8,700 mm

Design speed

2,000 m/min

Planned annual output
Phase 1240,000 tons
Phase 2360,000 tons
Basis weight38-65 g/m 2

Paper grades:

SCA-Plus, offset androtogravure printing papers

Production start-up

May 2002

Fig. 1: Laakirchen PM 11.
Fig. 2: Schematic layout of Laakirchen PM 11.

After forty years of excellent service, theold Laakirchen SCA PM 3, delivered byVoith in 1962, was ready for its wellearned retirement, and duly replaced by
PM 11 after commissioning.
This new Voith paper machine 11 wasstarted up well before the deadline. It
went on line five weeks earlier thanplanned, and very soon proved its potential for meeting the required quality standards. Due to limited availability of stock,its operating speed is restricted to 1,300
m/min during the initial phase.

The great success of this project is attributable to the intensive cooperation
between SCA and Voith, with clearly
defined responsibilities down to the lastdetail, and precise control thanks to interface protocol reporting.
Thanks to primary target-setting by Voith
for the key mechanical and plant engineering partners, the paper machine was
rapidly integrated into the overall process
on a systematic and well-proven basis.
Professional project management ensured full compliance with the erection
and installation schedule.

Special attention was paid to acceptancetesting of individual prefabricated components at the various production locations. Functional trials were done in advance on the units and control systems.
A comprehensive test schedule wasdrawn up to ensure compliance of all thePM 11 components with specific requirements.
The production line commissioning was
systematically organized right down to
the last detail. As shown by the results,
this guaranteed smooth and trouble-freestartup of the entire line.

2

30

Fig. 3: Stock preparation.
Fig. 4: Wet end: tandem NipcoFlex press.
Fig. 5: Dry end: TopDuoRun and Sirius reel.
Fig. 6: Paper machine efficiency development.
Fig. 7: Janus MK 2.
Fig. 8: VariTop slitter-winder.
4

3

Based on the One Platform Concept, thisproduction line includes the following
components:● ModuleJet headbox● DuoFormer TQv● Tandem NipcoFlex press● TopDuoRun dryer section● Sirius winder● Offline Janus MK 2 calender● VariTop slitter-winder● Roll transport system● Twister roll packaging machine.

directions, and absolute surface equality
on both sides of the sheet, ensuresmooth running in the printing press
without any folding – which also helps toenhance printing efficiency”, says Wolfgang Kühnel, manager technical customer service at SCA Graphic Laakirchen.
“Thanks to close teamwork with PM 11
manufacturer Voith Paper and our SCA
Graphic Research department in Sweden,
we arrived at an intelligent combinationof numerous production factors ranging
from the design concept and furnish
composition to the finished product”.

Concept
Goals set for SCA Laakirchen
Sheet formation and subsequent drainage
in the press section of this new paper
machine take place under fully controlled
conditions. The result is uniform productquality in every respect.
“The unprecedented profile uniformity
both in the machine and cross-machine

The construction permit for this project
was already applied for in 1991. Primaryobjective was to replace the old PM 3,
dating back to 1962, setting the following
implementation goals:● Investment costs not to exceed Euro
225 million.

● Production capacity increase to484,000 tons p.a.
● Paper product quality as least as goodas with Laakirchen PM 10, and significantly better than with Laakirchen
PM 3.
● Project completion time 21 months.
● State-of-the-art but well proventechnology.

Development target
The future-oriented key concept for thisnew paper machine was “convertible”,
since the current quality gaps between
SCA and LWC grades will probably cease
to exist before long. This assumption
decisively influenced the entire paper
machine concept.
Production tonnage increase and thepaper machine operating speed of
1,800 m/min apply both to the SCA andthe LWC alternatives. The question as to31

5

The PM 11 concept embodies the development potential for producing SCA-Plus
paper of the highest quality. If LWC quality standards can than be reached closing
the gap between the two grades, a quantum leap will have been reached with asingle machine concept at the highest operating speed.

throughout the entire project makes thisdevelopment possible. All concerned are
well aware of the great challenge involved, and even the most difficult problems are being tackled systematicallywith a view to long-term solutions.

90

Efficiency %the final concept was to be answered 6
during the development of PM 11, forwhich intensive research work started
prior to commissioning and will continue
for some time to come.

80

70

60
May June July Aug Sept Oct Nov
Production month
2002

Partnership type cooperation between thepaper machine operator and supplier
7

At the present time, six months after
start-up, the success of this approachhas been confirmed. The new Voith Paper
line with EcoCell flotation, paper machine, Janus calender, slitter-winder, rolltransport and Twister packaging machines not only produces outstandingly
high quality rotogravure and offset printing grades, but also sets a milestone withthe specially developed Grapho Nova
8

32

9

grade for high quality printing press
papers.
Mark
Lunabba
Chairman of
the Board
SCA Graphic
Laakirchen

Not even a year after startup, we canalready report extremely successful
operating results. Our ambitious production targets have been exceeded,
and from the quality point of view,PM 11 represents a new epoch.
This success has certainly not beenachieved by chance, and is not only
attributable to the joint know-how ofboth partners in this project: Voith
Paper in paper machinery and SCA inprinting papers. Decisive in my opinion
for these outstanding results is the
exemplary teamwork and open cooperation between our two companies.

Voith Paper congratulates SCA Graphic
Laakirchen on this impressive new production line, and shares their pride inwhat has been achieved so far. The enthusiastic feedback from our customers,
after viewing this new line following the 10
recent symposium in Salzburg, impressively confirms again Voith Paper’s competence in comprehensive customer andproduct-oriented solutions.

Company overview
SCA Graphic Laakirchen is one of Austria’s longest-established paper mills.
Founded in 1867, the company was takenover in 1963 by Wilfried Heinzel andexpanded. In 1988 it was acquired by
Svenska Cellulosa Aktiebolaget (SCA) of
Sweden. With 550 employees, SCA
Graphic Laakirchen turnover for 2001 totalled 233 million Euro. Production in
Laakirchen exclusively consists of supercalendered (SC) rotogravure and offset
printing papers.

Fig. 9: SCA Graphic Laakirchen.
Fig. 10: PM 11 inauguration with the SCA team.

33

1

Picturebook start-up of the new Voith line
for coated fine papers at Shandong Chenming
Paper – 4 months ahead of schedule

Klaus Meier
Paper Machines Graphic
klaus.meier@voith.com

In December 2000 Shandong Chenming Paper Holdings
Ltd. ordered from Voith Paper a four-station offline coater and two
Janus MK 2 calenders including reel transport system for their
Shouguang mill in China.

Chenming, a Chinese paper industry
leader for some years now, is entering
the market for coated fine-grade papers
Albrecht Weberwith this new line. Over the next three toPaper Machines Graphic
albrecht.weber@voith.com

five years the Shandong Chenming Paper
Group will be expanding its gross annual
production of all commercial grades from
400,000 to more than 1,000,000 mtpy.
Efficient sales logistics systems alreadyexist in a good many of China’s medium
to large industrial centers, and export
business with Asian and American markets is currently being expanded. A fur-Johannes Linzen

ther step in this direction has now been

Finishingjohannes.linzen@voith.com

taken with a completely new greenfield
paper mill, using exclusively virgin fibre
furnish with the highest brightness.

2

34

3

Figs. 1 and 2: Shandong Chenming Paper Holdings Ltd., Shouguang mill.
Fig. 3: 4-station offline coater with two Janus MK 2 calenders and reel transport system.
Fig. 4 and 5: 4-station offline coater.

Technical data
Coating line

Janus MK 2 calender

Product range

wood-free coatedMaximum operating speed
fine papers,
coated label printing papers

1,000 m/min

Basis weight90-250 g/m 2(final, after
calendering)

Design speed

1,100 m/min

Coating stations

4 for double coating or
2 for single coating

Trimmed web width

4,555 mm

Maximum operating speed 1,400 m/min

Max. line load

300 N/mm

Design speed

1,500 m/min

Surface temperature
Flexitherm rolls

120°C

Maximum web width

4,635 mm

Project goals

Coating line

To reach the ambitious production target

This coating line is fed from a continuous– 250,000 mtpy. of A-grade coated paper

unwind with automatic flying splice. The– the customer formulated the following

four coating units incorporate modern

requirements:

Dynamic Coaters with JetFlow-F applica-● Modern technology with the latest

tors and two Profilmatic C cross-profile

innovations.

control systems. Each drying section● Fastest possible implementation.

comprises a gas-heated infra-red dryer● Start-up at high operating speed, andand three steam-heated air dryers. The

fast compliance with guaranteed

first two coating stations can be by-product quality.

passed to enable either single or double● Domestic market leadership in wood-coated paper production. Four pull stacks

free coated and calendered grades, andfor tension control (two of which felted)

greater access to export markets.

and the two sheet edge controllers

35

4

ensure a safe web run. The coating line iscompleted by a Sirius reel equipped with
Eco Change water-jet cutter for turn-up
to minimize broke.

Janus MK 2 calenders
The two offline Janus MK 2 calenders are
10-roll units with flying splice unwind
and reel. Loading is inline by roll carts.
Two plastic covered Nipco rolls in top
and bottom positions generate the necessary line load and enable zoned profile
control. Adequate heat transfer is ensured by the four independently controlled thermo-rolls in positions 2, 4, 7
and 9. A separate thermal system is provided for the plastic covered intermediaterolls. User-friendly operation and maintenance is facilitated by a mobile inner
platform and two mobile external stairways. The two cooling rolls reduce thetemperature of this sensitive high-grade
product prior to reeling.

5

36

Fig. 6: Production capacity.
Fig. 7: Overall line efficiency.

7

8000

80

6000
4000
2000

100

Actual capacity
Efficiency [%]6

Production capacity [t/week]

Fig. 8 and 9: Janus MK 2 calender.

Design capacity
3 daysShut-down0
32 34
Start upStart up
6. August
61.9

82.6

AugustSeptember
2002

87.7

60
40
20
0

36

38 40 42
Calendar week

44

46

Systematic automation concept

October

Project implementation

8

for the entire line
The PCS 7 process and quality control

The success of this project was foundedsystem for the coating line and the two

on efficient detailed planning at all levels

calenders comprises various intercom-

right from the start. This already beganmunicating networked systems. Incorpo-

by preparing everyone involved in the

rated in the coating line are five scan-

project for the new concept and the dif-ners, two automated cross-profile con-ferent approach required accordingly.

trollers, and a RollMaster winding hard-

Enormously helpful thereby was theness controller on the Sirius reel. All

intensive ongoing communication – notrelevant quality and production data are

only by paperwork but also in the form of

One of the main reasons for this picture-processed by a database server for report

regular project meetings on site. Valuablebook start-up was the early start made on

downloading throughout the mill via In-

support was provided in this respect bycustomer staff training, differentiating

ternet browser.

the experienced staff of Voith China.

thereby between mechanical and electri-

Two Caltronic machine direction profile

The resulting greater flexibility ensured

and maintenance personnel. After basic

gloss controllers on the calenders arethat all the customer’s additional needs

theoretical instruction, practical training

linked with two scanners. Here again,

were taken into account without delay. In

was done on the actual production line.

each calender is equipped with a PCS 7

fact with such harmonic teamwork be-

This was followed up by an in-depth re-process controller with integrated quality

tween customer and supplier, success

fresher course during the start-up phase.

control module. The networked databasewas programmed from the outset.

cal (instrumentation) system operatingin the coating line is incorporated in theoverall reporting system.

Thanks to comprehensive and systematic
project management at all the Voith

By early detection of abnormal machine

Paper locations involved in this project,vibrations, a Voith monitoring system

all targets were jointly met with regard towith 64 sensors ensures much greaterdelivery and erection, commissioning andoperating reliability.

operator training.

37

Chen
Hongguo
President
Shandong
Chenming
Paper
Holdings Ltd.

“I am very pleased to see the huge success, made possible that our Chenming
Paper Mill chose Voith Paper as supplierfor Coater and Calender for our PM.
This is the result of both sides’ efforts
and cooperation. Therefore, I hope Voith
Paper, the first-class supplier in theworld, and we will become permanent
partners in the future.”
9

Erection work, which commenced on time

On August 6, 2002 the coating machine

Twelve days after start-up a run-time effi-

at the beginning of February 2002, wasand first Janus calender were started up

ciency of 91 % was attained. And on day

done by the customer’s subcontractor in

at 1,000 m/min. Only eight days later the

16 the 1,000-ton milestone was passed

24-hour operation during the peak phase.

coating machine speed was increased towith a daily production of 1,123.5 metricAs a result, the contractually agreed erec-

1,200 m/min.

tons of coated art paper. On August 16,

tion time of 10 months was shortened to
4.5 months.

2002 the second Janus calender started
The goal of operating the coating ma-

up on schedule, likewise at 1,000 m/min.

chine at maximum speed of 1,400 m/min
The first operating tests began only two

two months after commissioning was

The product gloss and smoothness val-

weeks after the final site deliveries.

already reached after 23 days.

ues for double coated fine grade paper
exceeded requirements from the outset,
and are now taken as a benchmark forother lines of this kind in China.

38

Voith supplies new machinefor decorative papers to MD Papéis
MD Papéis, founded 112 years ago, located near the cityof São Paulo, Brazil, always matched tradition with modernism.
Recognized as a traditional producer of specialty papers forindustrial use, MD Papéis is once again one step ahead in thesegment of decor papers for plastic laminates.

Marcelo Nielsen
Voith São Paulo, Brazil
marcelo.nielsen@voith.com

Concentrating on present markets andequipment for stock preparation, a new

products, but with its eyes focused on

forming section, a new press section andthe future, MD Papéis invested US$

a new dryer section. The target was to en-

25 million in the new line for decor

sure the production of high quality prod-

papers, with latest generation equipment,

ucts at competitive operational costs.

aiming at high quality and production.
The future
Eduardo Gabriel

The supply

Voith São Paulo, Brazil
eduardo.gabriel@voith.com

The total MD Papéis capacity for decor
In February 2001, MD Papéis signed apapers is now sufficient to not only sup-contract with Voith Paper for the supply

ply the Brazilian market but also otherof the new production line for decor

South American markets. After the start-

papers for plastic laminates. The basic

up of the new decor paper machine, MD

scope of the project included the erection

Papéis is planning to expand its exports,of a new PM on the old MP 3 site, com-increasing its share in the worldwide

prising, among other items, the supply ofmarket from 1.5% to 5%.

Paper Machines

39

Fig. 1: The new PM for decor papers.
1
Fig. 2: Scheme of the new PM.

“Considering the present market require-segment, by tripling the current produc-ments, it is important to foresee the cus-tion capacity of decor papers, as well as

tomers’ expectations and to offer quality

incorporating special surface characteris-

papers, that meet the excellence stan-tics to the product. These targets are todards and even surpass the technical andmeet the very high demands on printabili-

economical goals”, said the MD Papéisty by the laminated flooring market,

management during the recent machine

which now shows significant increaseinspection at Voith Paper.

throughout

South

America,

RubensBambini Jr.
Business
Director of
MD Papéisfollowing

trends observed in Europe and in the
The new machine for decor papers repre-

USA.

Taking into account its future produc-sents state-of-the-art technology, and istion capacity, its strategic geographicalspecially designed to produce “world

location and, also, a very efficient team,class” decor papers, including both solid

The start-up

the core business.

color papers and base papers for printing.

MD has clearly elected decorpaper as

The machine start-up was very successful. Production of the first paper roll wason July 31st, 2002.

Partnership

The investment
The new PM 8 is designed to produce

The partnership between Voith Paper and

MD Papéis is recognized worldwide for

90 t/day of decor paper with 50-150 g/m 2

MD Papéis has resulted in the most ad-

dominating different process and productbasis weight, 2,600 mm paper width andvanced equipment for the production oftechnologies applied to several types ofat a speed of 450 m/min maximum. Withdecor papers with the same characteris-

specialty papers for industrial use. This

such characteristics, the new machine

tics as the best European papers, satisfy-

investment, in particular, aims to satisfy

will allow quality and productivity gains

ing the continuous innovation require-the present and future demands in thisthat will certainly allow to develop newments of the furniture and civil construc-markets.

tion industries.

2

40

Sirius for Duluth PM 1 –Production increase after extremely shortrebuild time
At the end of June 2001, Stora Enso in Duluth, USA, placed
an order with Voith for the exchange of the existing reel on PM 1 fora Sirius reel. The decisive factor for the placement of the order with
Voith was the technologically outstanding ranking of the Sirius incomparison to other winding systems available in the marketplace aswell as the guaranteed extremely short rebuild shutdown period.

Pre-assembly
Jörg Keppler
Paper Machines Graphic
joerg.keppler@voith.com

17.6.2002

Stora Enso, the market leader in magazine, newsprint and fine paper grades
as well as packaging board produces
633 t / day of supercalendered SCA and
SCA+ papers at the Duluth mill.
With the exchange of the reel the primary
goal is to minimize the amount of brokeat the reel. This goal was achieved by thefollowing measures:Michael Neumann
Paper Machines Graphic
michael.neumann@voith.com● Increase in the rewind diameter from2,350 to 3,300 mm. This means a 50%
reduction of wound rolls per day.
● The optimal roll structure with Sirius
technology reduces the amount of
non-usable paper to a minimum.
● Reduction of sheet breaks at rollchange by the EcoChange S system.
The expectations placed in the Sirius
were met from the very first roll. Stora
Enso Duluth expects to save costs ofalmost 5 million U.S. dollars per annum
by this investment.

A special challenge was the short delivery
time and the extremely short shutdown
period. Only 9 1/ 2 months passed between
the placement of the order and delivery.
The short project phase required considerable efforts on the part of all those involved. In parallel with the installation of
the equipment supplied by Voith, consisting of the Sirius, an automatic parent rolltransport system and the Fibron VTT3000 tail transfer system, in connection
with the enlargement of the rewind diameter, Stora Enso had to make modifications to the parent roll logistics. Besides
the rebuild of the unwinds at the supercalenders and winders, new and stronger
overhead cranes had to be installed because of the significantly higher parent
roll weight.
Working through all of these packages
within a very limited time period was
possible only thanks to the excellent
cooperation during the project and a very
pragmatic work style with short decision
paths between Stora Enso and Voith.

Paper Machines

41

22.6.2002

To be able to implement the extremely
short rebuild time, the Sirius had to beinstalled on the existing sole plates. Thiswas only possible with the very compact
layout, designed specially for this reel exchange in a few days. The type of design
is characterized not only by a minimization of the Sirius installation modules,
but also includes the useful integration of
the control components, equipped withbus technology, into the installation modules.
Before the shutdown of the PM, the Sirius was installed in line with the systemalready producing paper. Just 76 hours
after the last parent roll change at the oldreel, the Sirius was completely mounted
mechanically and electrically and the I/Ochecks concluded.
An extraordinary performance in installation was followed by a start-up that wasof world-class standard. Just 54 hours
after termination of the installation work
the PM was able to resume production

and the first parent roll of saleable SCbase paper was wound up on the Sirius.
This start-up performance can be rated
all the higher because, with General
Electrics, a drive supplier was selectedthat had until then not been able to gain
any experience with the electric drive of
the Sirius. Added to this is the fact thatthe installation of the new Fibron VTT3000 tail transfer system was also one of
the first of this kind of application. The
shutdown period planned by Stora Enso
was shortened by half a day despite thesechallenges and the very high safety standards for the installation and start-up
work in the USA.
This excellent performance with regard toproject handling, installation and start-up
is an important milestone for future reelexchange projects. The great challenge toexchange an existing reel in a few days
for a Sirius was taken up and solved par
excellence. A result that the customer andsupplier can be proud of and which has
shown that “twogether – it is possible”.

Patrick
Moore
Mill Manager
Stora Enso
North America,
DuluthDowntime – 5.5 days on a 6 day budget.
There was an excellent working relationship between Stora Enso and Voith.
The Voith commissioning crew also did
an excellent job. Pre-erection on site
was an obvious benefit in shortening
the length of the downtime. We havebeen able to make jumbo reels almost
from day one.

42

Lee&Man Paper –high speed linerboard machineon a high speed track
The new high speed linerboard machine no. 4
for Lee&Man Paper Mfg., Co., Ltd. in Dongguan / China
started up on September 22, 2002, only 12 months and
10 days after the contract coming into force! After the
first reels of paper were produced, the experts from
Lee&Man and Voith Paper are convinced that the newhigh-tech paper machine no. 4 will achieve all expectaHerbert Zapletal
Paper Machines
Board and Packaging
herbert.zapletal@voith.com

tions within a short period of time. PM 4 started up with
127 g/m2 corrugating medium at a speed of 936 m/min.

1

Erwin Holzinger
Paper Machines
Board and Packaging
erwin.holzinger@voith.com

2

Lee&Man Paper Mfg., Co., Ltd. is a privately owned, fast growing company inChina’s paper industry, located in the cityof Dongguan, approx. two hours north of
Hongkong in the province of Guangdong,
China. Founded in 1994, Lee&Man has already become a leading manufacturer ofpackaging paper in China through continuous innovation in technology and production methods.
Voith Paper signed the first contract with
Lee&Man for key components of thepaper machines no. 1 and 2 in May 1995.
PM 1 and PM 2 were supplied by our, atthat time, joint venture partner LPMC
(Liaoyang Paper Machinery Corporation).
Both machines together are producing
350 tons/day of linerboard.
The contract with Voith Paper for thepaper machine no. 4 came into force on
September 12, 2001. The new machine isdesigned for producing 1,000 tons/dayof testliner and corrugating medium in abasis weight range of 90 - 200 g/m 2.
From the early stage on, Lee&Man put
a lot of attention on a short projectschedule.

All involved project members had to takeextra steps and extra efforts during thehandling of the project to achieve the set
goals regarding the time schedule. Goodplanning of the Voith Paper project activities regarding engineering, purchasing
and manufacturing activities, was essential to deliver the equipment ahead of thecontractual delivery dates, which had already been very optimistic. On the customer side, the plant engineering and thecivil work were also completed within avery short time. Only due to the close
collaboration of the project teams from
Lee&Man and Voith Paper during the en-

43Fig. 1: PM 4 of Lee&Man Paper
Mfg., Co., Ltd. in Dongguan, China.
Fig. 2: Scheme PM 4.

tire project, including site installation andcommissioning of the plant, the first
paper was produced on September 22,
2002, two months ahead of the contractual start-up date.
By manufacturing essential components,
the Voith Paper subsidiary in Liaoyang
has also contributed decisively to theproject.

Paper machine concept
The “one platform” machine concept conforms to state-of-the-art technology.
The sheet forming section includes a
DuoFormer Base (gap former) for theback layer and middle layer and a TopFormer F with Duoformer DK for the top
layer, ensuring excellent formation andthus optimum printability on the top sideof the sheet.
The DuoFormer Base is equipped with a
two-layer MasterJet M2 headbox with theMilestone dates

2001-06-22

Signing of contract

2001-09-12

Contract coming into force

2002-06-28

Last equipment delivery

2002-08-24

Certificate of endof installation

2002-09-22

Start-up(2 months ahead ofcontractual start-up date)44

4

Production [t/d]1000 Design capacity

3

800
600
400
200
22.9.

Layout data PM 4
Product

Corrugating medium
and testliner

Basis weight

90 - 200 g/m 2

Wire width

5,980 mm

Paper width
at the reel

5,500 mm

Operatingspeed

631-1,104 m/min

Designspeed

1,250 m/min

Production
capacity

1,000 t/d grosswell proven ModuleJet dilution water system for the middle layer.
The ModuleJet system, together with theProfilmatic M control system, warrants
optimum basis weight CD profiles andallows for independent adjustment offiber orientation.
The DuoFormer Base, exclusively developed for packaging paper grades in theupper speed range, ensures optimum utilization of the fiber potential in terms ofstrength properties. Lee&Man is the first
customer in Asia utilizing the advantagesof a gap former for producing packaging
grades.

6.10.

schedule
Shut-down
10.10.
3.11.
Date

17.11.

A MasterJet F headbox is installed on the
TopFormer F. The DuoFormer DK provides top side drainage, enhancing thedrainage capacity, formation and smoothness of the top layer.
The press section is a closed tri-nip DuoCentri NipcoFlex press using the wellproven NipcoFlex technology, which provides excellent sheet dryness with
optimum strength properties. The closed
sheet transfer throughout the press section ensures excellent runnability at highoperating speeds.
The dryer section consists of 3 single-tiergroups (TopDuoRun) with DuoStabilizer

5

Paper Machines45

Fig. 3: DuoFormer.
Fig. 4: Start-up curve.
Fig. 5: Reeler TR 125.
Fig. 6: The start-up team at the first tambour.

boxes, followed by 4 conventional top
and bottom felted dryer groups. A special
feature of the dryer section is the exceptional quick ropeless tail threading system for ease of the threading process.
The tail transfer from the last dryer to thehardnip calender is handled by an automatic Fibron VTT Turbo vacuum tailthreading system. DuoCleaners for conditioning of the dryer fabrics are installedon the first and second group top dryer
fabrics and on the fourth group bottom
dryer fabric.
Following the dryer section is a two-rollhardnip calender enhancing the smoothness of the top side.
The reel is a conventional type TR 125 fora roll diameter of 3,500 mm with an automatic reel spool magazine.

Start-up
A start-up curve is influenced by a lot offactors, some of the most important are
surely a good cooperation between the
project teams and highly motivated people working together to reach the same
goal. It is obvious that the Lee&Man production and maintenance teams with anumber of well-trained and skilled people
are extremely motivated.

capabilities of this high-tech paper machine are far beyond the expected anddesigned parameters.
The guaranteed gross production capacity of 1,000 tons/day was already reachedwithin the first two months.

As already stated, the paper machine
started up with corrugating medium of
127 g/m 2 at an impressive operating
speed of 936 m/min. The first paper was
already sold and successfully converted.

After only two months of operation, it can
be claimed that the term “high speed”
runs like a red line through the entire
project Lee&Man PM 4. Lee&Man PM 4
is a “high speed” paper machine at a“high speed” track throughout the engineering, manufacturing and installation
phase with a “high speed” commissioning and start-up phase.

Two months after the start-up, the main
grades and main basis weights had been
all successfully produced over extended
time periods. The production curve of thefirst two months leaves no doubt that theVoith Paper thanks Lee&Man for the
excellent cooperation and teamwork
throughout the project and is looking forward to a good and successful relationship of both companies in the future.

6

46

Successful rebuild of board machine 2
at Mayr-Melnhof Karton, Frohnleiten, Austria

On September 8, 2002, board machine 2 at Mayr-Melnhof’s
Reinhard Wilthaner
Paper Machines
Board and Packaging
reinhard.wilthaner@voith.com

Frohnleiten mill in Austria restarted after an outstandingly successful rebuild. The goal was to improve product quality and increase
production capacity. To this purpose, Voith Paper supplied, installed and commissioned five suction cylinders and seven FloatLip
formers including white water circuit and vacuum system, together
with a NipcoFlex press. So far, five NipcoFlex presses have been
installed by the Mayr-Melnhof group, two of them in Frohnleiten.
Thanks to the outstanding teamwork and coordination among all
the companies involved, this rebuild was completed in less than
two weeks. Even the first board produced after start-up showed a

Robert Hutterer
Paper Machines
Board and Packaging
robert.hutterer@voith.com

significantly improved quality, thus upholding the correctness of
Mayr-Melnhof’s investment decision.

1

Paper Machines

47

Fig. 1: Mayr Melnhof Karton GmbH und Co. KG,
Frohnleiten mill.

Mayr-Melnhof Karton andproduct quality, and to install a shoe

existing formers for back ply and top ply

its parent mill in Frohnleiten,press to increase production capacity.

and five formers for filler plies.

With an annual production capacity ex-

In May 2001, Voith Paper received the or-

Further Mayr-Melnhof investments for

ceeding 1.5 million tons, the Mayr-der for a FloatLip former including whitemodernizing board machine 2 include aMelnhofEurope’swater system. During a brief shutdown in

new screening system for filler plies, alargest producer of folding boxboard

October 2001, this FloatLip former for

new DCS system for the wet end, and afrom secondary fiber. The parent mill of

producing the back ply was installed andnew hall crane for the 25-ton NipcoFlex

the Mayr-Melnhof Board Division is locat-

put into operation on an existing suction

press roll. Numerous modifications anded in Frohnleiten, Austria, where twocylinder. Mayr-Melnhof were thus able tostructural measures are also scheduled,board machines are in operation.

familiarize themselves and gain operatingsuch as machine building extension withexperience with the FloatLip former priorinstallation opening, overhauling and re-

In January 1999, board machine 3 wasto the extensive rebuild planned for sum-inforcing of joists, supports, etc.

rebuilt by Voith Paper into a multi-ply

mer 2002.

Austria

Board

Divisionisfourdrinier machine with NipcoFlex press

Installation and start-up(wire width 5,000 mm, operating speed

In August 2001, Voith Paper won the or-

In order not to exceed the agreed shut-

approx. 550 m/min). The main product isder for five suction cylinders for produc-

down time, Voith Paper did preparatory

coated folding boxboard made of 100%

ing the filler plies, including four FloatLip

work during the regular shutdowns. Fur-

recycled furnish.

formers, to replace the existing cylinder

thermore, all tasks possible without shut-mould units without vacuum. The scopeting down the machine were completed

Board machine 2, a multi-ply cylinderof supply was rounded off with a whitebetween the end of July and August 25,

machine (wire width 3,200 mm, operatingwater system, a vacuum system and2002.

speed approx. 250 m/min prior to re-pneumatic controls. The previously deliv-

build), also produces coated folding

ered FloatLip former for the back ply was

During the pre-assembly phase, Mayr-

boxboard from 100% recycled furnish.

intended to be used for the filler ply after

Melnhof renewed the screening system

the rebuild in September 2002. In addi-

for filler plies, added an annex to the

Rebuild of board machine 2

tion, a double-felted NipcoFlex press wasbuilding to accommodate switch rooms

An internal analysis done by Mayr-ordered to replace the existing firstand a control center, and completed theMelnhof revealed the necessity of exten-

press, including hydraulic and electricalinfrastructure required for transport andsive modernization investments. Board

controls.

installation of the new components.

rebuilds, with some parts being more

The FloatLip former installed for the backAs soon as board machine 2 was finallythan 50 years old, could no longer keep

ply in October 2001 improved the forma-

shut down early on August 26, 2002, a

up with today’s quality and production

tion results that Mayr-Melnhof ordered

number of installation personnel started

requirements. Mayr-Melnhof, therefore,

another two FloatLip formers from Voith

dismantling the equipment to be replaced

decided to rebuild the stock preparation

at the beginning of 2002. In the end, sev-

and all basement equipment in the arealine and wet end in 2001 to improveen FloatLip formers will replace the twoof the new suction cylinders.

machine 2, which had undergone several

48

Fig. 2: NipcoFlex press.
Fig. 3: Board machine 2 after therebuild. In the foreground, thesuction cylinders for filler plies with
FloatLip formers.

Key data of board machine 22

Wire width 3,200 mm
Design speed of new equipment
400 m/minMax. operating speed 350 m/min
Main products: coated folding boxboard
350 - 500 g/m 2.
Main rebuild components
Wire section● 7 FloatLip formers● 5 suction cylinders● Splash water trays and walkways● 6 control panels and pneumatic control
system● White water circuit with:
2 white water tanks;
7 centrifugal distributors, 2 of themwith dilution water control for CD
profile optimization;
various water separators;
complete piping and hoses● Vacuum system: complete, including
piping.

In parallel, the structural work was al-

All electromechanical inspection work

ready started. For example, several floor

was completed on time on September 6,

zones had to be completely replaced, the2002, and after start-up of all the newmachine beams and chests had to be

and existing equipment, the first parent

overhauled, and new foundations had toroll of board was wound just before mid-be made. All this work was completed ac-

day on September 8.

cording to schedule in day and night
shifts around the clock.

Optimization
Thanks to the customer’s highly compe-

The machine components to be reusedtent operating personnel, saleable board

NipcoFlex press● including electrohydraulic controls.

were overhauled in Mayr-Melnhof’s repair

was already produced on the start-up

shop and modified as required. A few

day. Due to the experience gained with

Spare parts for wire and press
sections

days after shutting down the board ma-

the first FloatLip former on board ma-chine, with construction work still inchine 2, and several years of experience

progress, the first components were re-in NipcoFlex press operation on board

installed. Installation of the NipcoFlex

machine 3, the start-up was finishedpress delivered just in time started only

without any problems within a short time.

Installation, start-up andoptimization● Complete installation of wire section● Supervision of installation of
NipcoFlex press and relocating ofexisting 2nd press● Supervision of start-up andoptimization of wire and press
sections.

five days after shutdown.
Immediately after production was again
The smooth sequence of work was en-started on this machine, an optimization

sured by daily coordination meetings

program was initiated in order to fully ex-

among all partners involved and continu-

ploit the benefits of this new concept at

ous checking against a jointly preparedhigher operating speeds. By installing

installation schedule.

FloatLip former headboxes for the top ply

493

and back ply and five new suction cylin-

By carefully adjusting the entire board

This allows to selectively improve theders for the filler plies, the CD basis

machine 2 to the enhanced base board

technological properties of board andweight profile was improved by up toproperties, the product quality even at

packaging paper, thus significantly up-

50% for all grades.

significantly higher operating speeds isgrading the cylinder forming technology.

comparable to that on the advanced
Replacing the straight press with a dou-board machine 3. Although it is more

The centrifugal distributor at the begin-ble-felted NipcoFlex press has so far

than 50 years old, board machine 2 willning of the flow channel of the FloatLip

allowed the maximum operating speed toremain competitive for a long time toformer ensures uniform and homoge-

be increased by about 15%. This limit iscome.

neous distribution of the suspension

currently set by the existing machine

across the entire width, thanks to the ra-components. The higher operating speed

FloatLip former design

dially arranged hoses of equal length. Air

is reached due to a higher dryness after

and technology

and lightweight particles are continuously

the press section and an improved evapo-

The latest FloatLip former generation fea-

removed through a vent pipe on top of

ration behaviour of the base board as atures the following innovations andthe centrifugal distributor.

result of its higher porosity. The highbenefits:

bending stiffness of the folding boxboard● Top lip evenly supported over its entire

is not affected by the increased operating
speed.
Despite the higher operating speed, formation with the new FloatLip former gen-length● Uniform distribution of the suspension
across the machine width● Replaceable step diffusor inserts to

The step diffusor principle is applied to
produce

optimum

turbulence

in

the

FloatLip former. Special inserts are used
to adjust the microturbulence to the operating conditions and furnishes for eacheration is better than prior to the rebuild.

generate optimum turbulence

grade of board or packaging paper. These

Uniform formation is an important factor● Improved profile and formation

inserts can be replaced in the course of afor coated board surface quality, and thus
for good printability.

characteristics● Ease of operation and maintenance.

rebuild later on.

50

Heating chambers

Top lip
Air tubes
Sealing lip
Bottom lip
Mixing chamber

Fig. 4: FloatLip former with centrifugal
distributor (without dilution water control).

Vent pipe

Fig. 5: White water tank with centrifugal
distributor on top.
Fig. 6: The Voith rebuild team.

Dipl.-Ing.
MartinMühlhauser,
Director

5

Centrifugal distributor
4

6

Production
andtechnology,
Mayr-Melnhof
Board
Division“After the extremely successful modern-

Uniform support of the top lip by air

porting beam area or in the area of theization of our board machine 3 by Voith

tubes over its entire length, together withcentrifugal distributor.

Paper, we clearly wanted to have board

a torsion-resistant stainless steel struc-machine 2 rebuilt by the same well-ture of the supporting beam, ensures a

The nozzle area is sealed towards theproven Voith team. Although the multi-

constant slice geometry and constantcylinder mould or suction cylinder by afourdrinier concept of our board

profiles independently of the operating

quick-change sealing lip of synthetic ma-

machine 3 had proved successful, wepressure. By varying the pressures in theterial at the end of the bottom lip. Special

set ourselves the joint challenge of

air tubes, the throat gap can easily be ad-lateral seals of synthetic material arereviving the suction former technology.

justed during operation to suit the oper-

arranged at the edges to limit and seal

ating and drainage conditions.

the drainage zone between top lip andcylinder mould or suction cylinder.

And that was certainly the right way to
go! This cost-effective rebuild not only

The top lip is pivot-mounted in the slice

meets all the board quality demands ofarea. This pivot has been optimized to

To facilitate maintenance, the entire

our customers, but also matches themaintain constant the slice opening set

FloatLip former can be swung away fromperformance spectrum of a high-effi-by the limit stops, while increasing or re-the cylinder mould or suction cylinder byciency board machine.

ducing the throat gap.

means of pneumatic cylinders, thus al-

Our teamwork and mutually respected

In order to ensure a constant slice geom-know-how led to open discussion andetry even at higher stock temperatures,

flexibility during project implementation.

the FloatLip former incorporates heating

All new cylinder mould formers (with or

Under such fruitful conditions, thechambers for thermal stabilization.

without vacuum, or with top section ex-

lowing machine-wide access to the top

haust system) as well as the existing

project was bound to be a resounding
success.”

lip and throat gap.

For further profile optimization, dilution

ones can be fitted with the Voith FloatLip

water can optionally be added in the sup-former.

Paper Machines

51

Process simulation –Virtual papermaking
With growing demands on paper machine efficiency as wellas product quality, a deeper knowledge of all papermaking processes
is essential. In order to identify the effects of each machinecomponent on product characteristics, increasingly complex testingis required. However, the high costs involved often preclude carryingout enough tests to eliminate statistical error. Furthermore, somemachine sections are inaccessible to measuring devices.
Dr. Jörg Reuter
Paper Machines Graphic
joerg.reuter@voith.com

Today’s vastly more powerful computers

jects to new developments, increasingly

enable a new discipline for tackling these

sophisticated simulation models can beproblems: process simulation. Given adeveloped with spending less and lesscomputer model, extensive research cantime.

be done at comparatively low cost. For
example, the effects of varying individual

Mill operators benefit directly from simu-

input parameters can be studied, design

lation technique (Fig. 1): it enables ma-parameters and machine settings can bechine concepts to be tailored to their in-

Dr. Florian Wegmann

optimized, and a deeper knowledge candividual requirements, thus optimizing

Paper Machines Graphic
florian.wegmann@voith.com

be gained of the physical processes in-product quality. Furthermore, early simu-

volved. In fact simulation results often

lation minimizes development risks bothdeliver more detailed data than test mea-

for new installations and rebuilds. And bysurements.

knowing in advance the effects of machine settings on process stability andIn this connection Voith Paper has

product quality, commissioning times

formed a team for compiling simulation

can be significantly shortened.

models of papermaking processes. This

Fig. 1: Customer benefits of simulation
techniques.

provides other departments with valuable

As shown in Fig. 2, the simulation proce-

support in optimizing existing concepts

dure is based on the laws of physics. In

and developing new ones, as well as inpapermaking these are primarily the laws

identifying and overcoming technical lim-of thermodynamics, fluid flow and mate-itations. By applying the accumulated

rials mechanics. The mathematical simu-

know-how gained from individual pro-lation model is established by combining

1
Simulation

Quality optimization

Risk minimization

Faster commissioning

52
2

Physical laws

Mathematical model

Simulation algorithm

Fig. 2: Simulation procedures.

Computing program

Fig. 3: Aspects for further study in individual
papermaking processes.

Parameter identification

the respective equations, but only sel-as in the presses and for the various

domly is a purely analytical solution pos-coating technology methods.

sible; in most cases numerical methods● Press nip analysis is required at sev-

Model verification

have to be applied. Apart from convertingeral points in the paper machine, in-the simulation algorithm into a computercluding the press section and calender.

program, the system parameters also

● Apart from the web itself, the felts andApplication

have to be defined, for example by labo-

wires also travel through the paper

ratory measurements. Before it can betion are the flow characteristics, whilemachine at high speed. Web run

applied by the user, the simulation model

winding technology simulation helps tosimulation is therefore an important

has to be verified by comparison with

optimize the paper roll structure and rollcore competence of the simulation

test results and adapted as necessary. Inchanging procedure.

team.

other words, simulation only partially replaces research on the test-bed. Only byThe

individual

As a typical simulation project, we ana-

combining the two, an efficient R&D tool

processes are so important, that a single

commonfeaturesoflyzed the top and bottom wire speeds in a

can be developed.

simulation group for the entire paper-

former. Since the tensions in wire loop

making process is very worthwhile. Vari-sections vary widely, the wire stretch andTypical of papermaking technology is theous points in the process are governed

the speeds also vary accordingly. Ideally,

wide variety of tasks in each processby the same laws of physics, as follows:

both wires should run at the same speed

stage (Fig. 3). In the headbox, for exam-

when in direct contact with each other.

ple, simulation can provide information● The laws of materials mechan-This not only avoids shear stress in theon stock mixing efficiency with the dilu-

ics apply to nearly all process simula-web, but also minimizes wire wear in thetion water, on jet geometry and on fiber

tions. They define elasticity, viscous oredge zones.

orientation. Simulation of the drainage

plastic behaviour, and stock character-process in the former shows how theistics such as viscosity and permeabil-

The simulation model converts the vacua

ity.

on the suction elements into friction

fibers and fillers are redistributed by thevacuum elements. Particularly interesting● Fluid dynamics simulation is re-forces, using the coefficients of frictionis also a simulation of the drainage

quired above all in the approach flow

measured between bars and wires on our

mechanisms in presses, showing the ef-

section, headbox and former, as welltest facility. Fig. 4 shows the simulated

fect of various machine parameters on at-

relative speeds in the former.

tainable dry content. It also indicates theflow velocity between web and felt, which
influences the paper surface quality. The
main information derived in the drying 3
section, apart from evaporation efficiency, concerns the web run behaviour andweb shrinkage characteristics. Among thecoating information obtainable by simula-

HeadboxMixing processes
Jet geometry
Fibre orientation

Wire section
Wire run
Fibre and fillers
distribution

Presses
Drainage

53

v

Paper Machines

Fig. 4: Aspects for further study in individual
papermaking processes.

4Fig. 5: Sheet water drainage velocity in thez-axis direction on a shoe type first press.
Fig. 6: Sheet dry content distribution
in the first press.

Another example is press drainage simu-

Dry content distribution after passing 5

lation. For that material characteristics

through the first press serves as ingoing

0.0001such as rheology as well as paper andprofile for the second press, where, as

felt permeability are required, which canshown by the dry content distribution in

be measured in the laboratory. By itera-Fig. 7, compression now extends righttive computation, the simulation program

into the sheet. No further water is re-

Web thickness

Fig. 7: Dry content in the second press.

works out a solution complying both withmoved from the outer layers except nearDarcy’s law and mass retention for thethe nip centre, since only in this zone iswater and air phases.

the pressure higher than that attained in
the first press.

0-0.0001
-0.2

-0.1
0
0.1
Machine direction

0.2

6

Simulation results are shown in the fol-

0.54
0.5
0.46
0.42
0.38
0.34
0.3
0.26
0.22
0.18

It becomes apparent from both examples

shows water flow velocity in the z-axis

that simulations may provide more in-direction as the web passes through thesight than could be obtained from mea-

first press. Drainage is at first restricted

surements. Once the numerical results

Web thickness

0.0001lowing for a tandem shoe press. Fig. 5

to the two paper surfaces, but extends

have been validated against data mea-

-0.0001

deeper on the way through the nip. As

sured at experimental paper machines,

seen at the outer contour of the cross-the computer programs can be run inex-

section, the web expands elastically again

pensively to study the effects of extensive

to some extent after leaving the press.

parameter variations.

The respective dry content is shown in

Based on current and future projects, theFig. 6. On the paper surface quite highVoith Paper simulation group is going tovalues are already attained after leavingbuild up expertise in the modelling of athe press nip, while the water content inwide range of sub-processes. In the longthe center remains relatively high.

term, the individual models will be combined to form a complete model of the0.01
0.00750.005
0.00250-0.0025-0.005-0.0075
-0.01

0

-0.2

0.2

6x10 -5
Web thickness

7

-0.1
0
0.1
Machine direction

0.54
0.5
0.46
0.42
0.38
0.34
0.3
0.26
0.22
0.18

0

-6x10 -5
-0.2

-0.1
0
0.1
Machine direction

0.2

entire papermaking process.

Dry section
Heat flow
Web runShrinkage

Coating unit
Sizing flow
Contact vibrations

Winding technology
Paper roll structure
Reel change

54

1

Alsip PM 1 –conversion from newsprint to LWC
Madison Paper Company, Alsip is located 16 miles southwestof downtown Chicago, in the Village of Alsip, Illinois. The facility is
strategically located to serve a huge Midwest customer base. The millis one mile east of the I-294 North-South Toll way, adjacent to the
Calumet Sag Waterway, a commercial shipping channel, and is servedby the local railroad. Madison Paper Company, Alsip is owned 100 %by the Myllykoski Corporation of Helsinki, Finland.
Mary Ann Mokry
Paper Machines Graphic
Voith Paper, Appleton, USA
maryann.mokry@voith.com

The mill was originally built by The Field

enable the mill to produce brighter,

Corporation to supply newsprint pro-stronger, and cleaner 100% recycled pa-

duced from 100% recycled fiber to theirper, which would be suitable for businessnewspaper,

Sun-Times.

papers such as forms, envelopes andConstruction of the mill, known as FSC,

tablets; commercial printing papers suchcommenced in 1966 and was completed

as inserts; book papers, and newsprint.

theChicagoin 1968. In 1987, the mill was purchasedby an Australian industrial conglomerate.

On June 8, 2000, Madison Paper Compa-

Klaus Winkels

Until 1989, newsprint represented 100%ny, Alsip purchased the assets of theFinishingklaus.winkels@voith.com

of the mills output. In 1993, senior man-facility and immediately launched anagement of FSC purchased the assets ofaggressive strategic initiative to convert

the facility and began an investment to

the facility to LWC printing papers.

Paper Machines

2

55

Fig. 1: Madison
Paper Company, Alsip,
Illinois, USA.
Fig. 2: SpeedCoater.

Technical Concept

SpeedCoaterof the Paper Machinefits over the more conventional two blade
coating station method. These benefits

The film coater system consists of a 0

include significantly lower capital invest-

Based on the positive experience with

degree inclined SpeedCoater with an up-

ment costs and reduced space require-

Voith Paper at the Myllykoski mill at Langward web run that applies coating to bothments. Higher machine productivity is

Papier, Ettringen, Voith Paper was asked

sides of the paper simultaneously. The

another benefit of a SpeedCoater.

to conduct a feasibility study for produc-

coating application system includes aing Light Weight Coated paper (LWC)

blade beam applicator nozzle with meter-with high recycled fiber content. Exten-

ing rods for each roll. After the Speed-

sive testing at the Voith Technology Cen-

Coater, the web moves through the web

ters during February 2000 indicated thatstabilizer and air turn, both of which are

The Janus MK 2 calender consists ofthis ambitious goal could be achieved

re-located existing equipment, and theneight rolls and is capable of calenderingwith Voith Paper process technology. As

through a new two-zone air flotation dry-

paper grades ranging from newsprinta result, Madison Paper Company, Alsip

er. Voith Paper also provided new paper

through high quality LWC. The calenderpurchased an on-line SpeedCoater, Janusrolls and spreader rolls for the web run.

has a width of 242 inches, and is de-

MK 2 Calender, and Sirius Reel in Sep-

Janus MK 2 Calendersigned for a maximum line load of 2,700

tember 2000 for the re-build of the dry

Production of LWC paper grades with the

PLI (475 N/mm). The Thermo Rolls are

end of their PM 1.

SpeedCoater provides considerable bene-

designed to operate with a maximum sur-

56

3

face temperature of 300 °F (150 °C), andcalender with no pull stack between the

Flip Tray Transfer Device to the Speed-

are equipped with the high performancetwo systems. This Sirius reel is one of

Coater and two distinct rope threading

CeraCal type cover. In order to achieve

four in North America. This type of reelsystems – one for the SpeedCoater andthe highest LWC quality targets underprovides precise and sensitive nip load

the other for the after dryer section. The

high calender loads, Safir S type covers

and sheet tension control by moving theJanus MK 2 calender / Sirius reel systemwere selected for the Nipcorect rolls andSenso-Roll (reel drum) throughout theconsists of a Fibron TT 3000 vacuum

Intermediate soft rolls.

winding process. The winding process isconveyor to thread the tail to the calen-

further optimized for build up of excellent

der, and a rope system through the cal-Along with the fixed platform system andparent roll density with the highly effec-

ender and Sirius reel. This rope threading

movable stairs located on the side of thetive continuous center torque control.

system is the first of its kind due to thefact that there is no pull stack between

Janus MK 2 calender for maintenance access, this calender is also equipped with

Lastly, the EcoChange S integral compo-

the Janus MK 2 calender and the Sirius

the first movable inner platform that is

nent of the Sirius reel sheet separating

reel. The Sirius reel is equipped with adesigned to enhance access to significant

device minimizes paper loss during turnsmall pressure roll to assist in the tailcontrol

up of the parent roll.

threading process.

andmechanicalmaintenancepoints.
Tail Threading System

Fiber Systems

Sirius Reel

Tail threading systems were also sup-As part of the overall project to re-build

The Sirius reel winding system was in-plied by Voith Paper. The SpeedCoater/

their PM 1, Madison Paper Company,

stalled immediately after the Janus MK 2

after dryer system consists of a Fibron

Alsip completely re-built their deinking

Paper Machines

57

Kevin J.
KuligaPresident ofMadison Paper
Company / Alsip
Fig. 3: Janus MK 2.
Fig. 4: Sirius.
4“I offer my personal thanks to all who
have contributed to this most demanding
and exciting project. With the support ofVoith and Myllykoski Group marketing,technical, engineering, and operating
specialists from our companies in the
US, Finland, Switzerland, and Germany,
all of the LWC product quality targets
have been met or exceeded. Our productis being very well received in today’s
most competitive market.”plant. Voith Paper provided six primaryin kraft softwood. The material handling

In January 2002, the Madison Paper PM 1

and two secondary pre-flotation EcoCells

system consists of transfer conveyors,

machine, resumed operation, successful-for the removal of ink before bleaching.

a down-ender conveyor, and manual de-ly producing first newsprint and then SCC

Post-flotation, also EcoCell, was a fivewiring equipment.

paper.

Delivery of all of this equipment to the

LWC production commenced on February

Madison Paper Company, Alsip job site23, 2002.

Voith Paper also supplied a complete per-was handled in a unique manner. Due tocoated paper, Madison Paper Company

oxide bleaching system. The system con-the geographically close distance be-

has been receiving positive comments

sists of the new EcoDirect disperger withtween Alsip and the Voith Appleton oper-from their customers regarding the quali-

direct heating, the transport screw con-ation (around 220 miles), Madison Paper

ty of their LWC sheet.

veyor system to HC bleaching and theCompany accepted Voith’s proposal fornew“Just in Time” delivery of many of the

The present operating speed of the paper

various components.

machine is 2,750 feet per minute. Current

primary and a single secondary cell
design.

EcoReact HC bleaching tower, thefirst of its kind in North America.

Shortly after production of

LWC production is 125,000 tons/year.
At the same time two coarse screens

The Voith site personnel, in coordination

were re-furbished.

with the general contractor, customer,

The coated basis weight ranges from 38#

and Voith Appleton shipping personnel,

to 50# per 3,300 ft 2 (56 to 74 g/m 2) with

For the PM 1 stock preparation, a stacked-

arranged for the delivery of the necessary

a gloss target of 50 Gradner. The LWC

bale material handling system and a kraft

components to the job site just in time

furnish contains 80% DIP (deinked) fiber.

pulper were installed for handling bought-

for installation.

58

1

Small and sophisticated –Production lines for banknotes
and security paper
There are only about thirty producersof banknote paper

worldwide, most of them state-owned companies. Their total annual output
is very low at around 140,000 ton – comparable to that of a single newsprint
machine over four or five months. However, this is a question of supply anddemand. Every country naturally wants to have a stable currency, with alimited circulation of durable legal tender. That is why banknotes are not insteeply rising demand and play such a small role in global paper production
Wolfgang NeußSpecial-purpose paper machines
wolfgang.neuss@voith.com– but only quantitatively!
Qualitatively, however, banknote produc-machinery. Voith Paper is clearly thetion is one of the most highly esteemed

global market leader in this sector, bothtraditions in the art of papermaking. Duewith regard to design and construction.

to the necessarily secret ingredients andprocesses involved, the alchemistic mys-

Indeed, banknote paper production lines

tery formerly attached to papermaking

are one of the best references for Voith

still exists here to some extent.

Paper’s know-how in meeting the mostdemanding customer requirements. They

The skills and perfectionism required foralso reflect our reputation for total relia-

manufacturing these special-purpose pa-

bility when confidential matters are atpers apply even more to the production

stake.

Paper Machines

59

Fig. 1: Banknote paper machine for Pakistan.
Fig. 1: Worldwide banknote production.
Fig. 1: Contract signing with Security Paper Ltd.
in Pakistan.
2

3

America 19%
Asia 12%China 19%

Europe 50%

Market situation

Banknotes are to be produced here inEuropean market for banknote paper ma-compliance with today's internationalchinery has experienced an upswing over

There are only about thirty producers ofquality and security standards. The new

the last few years. Many experts regard

banknote paper worldwide, most of themmachine will be installed next to the first

the new Euro banknotes as the world's

state-owned companies. Their total annu-

one commissioned in 1969, which willsafest from the forgery point of view.

al output is very low at around 140,000

then be used mainly for passport andton. As shown in Fig. 2, the greatest

identity card production.

world market share of banknote paper

Making paper according to these high security standards, increasingly double-ply

production is still in Europe. However,This new machine centers around a cylin-

technology is used, where Voith Paper isAsia is clearly a growth market with highder mouldformer concept, newly devel-

the market leader. In nearly all Europe’s

potential for banknote paper machinery.

oped by Voith Paper two years ago, com-banknote paper machines, the second

bining modern headbox technology withlayer is produced by a specially devel-

The Chinese market is deliberately em-

the latest innovations in step diffuser andoped shortformer (Figs. 4 and 5). Six ofphasized in this diagram. Over the last

dilution water control systems. The sec-

these are already in service in Europe

fifteen years, ten new production lines forond cover layer embedding the security

alone, and a seventh is just about to bebanknote paper have been installed inthread is produced in a shortformer, andcommissioned.

China. For nine of these, Voith Paper

the machine also incorporates a 2x2 Eco-either supplied the entire machinery orsoft calender. Apart from the paper ma-

the main production components.

chine as a whole, the scope of supply

A sophisticated andalso includes most of the stock prepara-

flexible technology

Banknote paper machines and equipmenttion line, as well as a winder and a cross-are developed and built at the Voith Paper

cutter.

Düren plant, where vast experience hasWith few exceptions, banknote paper is
produced on synchronous cylinder mould-

been accumulated in this discipline. In

Market upswing with theformer machines – the only technology

June 2001, the Düren team received an-

new Euro currency

enabling a multitone watermark. As men-other order from Asia, this time placed bytioned, Voith Paper has developed for

Security Paper Ltd. for a new production

With the advent of Euro currency andthis purpose a new cylinder mouldformer

line in Pakistan (Figs. 1 and 3).

respective innovation requirements, thecombining modern headbox technology

60

4

5

with the latest step diffuser and dilution

speed range of 20 - 90 m/min. Voith

Depending on face value, European bank-water control innovations. This state-of-Paper’s shortformer and cylinder mould-

notes last ten months to five years before

the-art system is already well-proven on

former technology with expansion cylin-

they are taken out of circulation. During

several banknote paper lines.

der are playing an important role in com-their life, they change hands millions ofbating banknote forgery more efficiently

times and are folded many thousands ofin the future.

times. They frequently go through the

A key component of this new cylinder
mould concept is the expansion cylinder

washing machine, are heated, damaged(Fig 6), which holds several modules inSpecial materials forand ironed out again. To withstand suchtension. In one of these modules, thespecial needs

treatment, a special kind of furnish is re-watermark for the respective banknote

quired, which is why banknote papers

paper is embossed. Since banknotes ofRequirements such as forgery preventiondifferent sizes in various currencies are

and extreme durability put banknote pa-

generally produced on the same machine,

per production in a class of its own. In

Only for security paper not exposed tofrequent wire changing is necessary. To

this age of sophisticated copying sys-

such treatment is bleached chemical pulp

facilitate wire mounting and removal, ten-tems and clever forgers operating world-

used instead of the much costlier cotton.

sioning and release, an expansion cylin-

wide, a good deal of technical sophistica-

This kind of paper is used, for example,

der was developed with an ingenious

tion is required to keep each banknote anfor passports, identity cards, credit cards,

mechanism enabling its diameter to beinimitable original.

checks, securities certificates, postage

enlarged or reduced by up to 30 mm –contain up to 90 % cotton (Fig. 7).

stamps and the like.

while fully maintaining geometrical preci-

Security features start with watermarks

sion and concentricity.

and security threads incorporated in theSome people seem to think that bank-paper, together with embossed surfaces

notes will stand up to anything – even

Banknote paper machines have a web

and holograms. The printing process

lighting a cigar. However, we have not yet

width up to 2,800 mm, with an operatingadds further features, some of which are

attained such techno-

visible to the naked eye while others canlogical heights...

6

only be detected with special equipment.
Formerly, when security measures were
not so extensive, numerous amazingly
good forgeries came into circulation.
Since then, however, nobody has eversucceeded in forging modern banknote
paper without detection – one to zero for
papermakers, and of course for paper
machine manufacturers as well!

Figs. 4 and 5:
The Voith Paper shortformer.
Fig. 6: The expansion cylinderdeveloped by Voith Paper.
Fig. 7: Cotton, the primary raw material
used for banknote paper production.

7

61

1

Advanced roll covers
and services in China
Facilities open April 2003!
Voith is a company with both, global scope and regional
focus. At Voith the word commitment comes to life in tangible form
– through modern facilities that make a meaningful impact on themarkets they serve. Voith operates more than 25 service centersaround the world. Each is strategically located to provide criticalservice support to local and regional markets.
Robert Kietaibl
Voith Paper Service Chinarobert.kietaibl@voith.com

Fig. 1: Voith Paper
Service Center, Kunshan,
Jiangsu Province, China.
Headquarters for Voith
Paper Service, in China,
5,400 m 2 manufacturing space,
80-ton lifting capacity.

The market for paper and packaging materials in China continues to grow rapidly.
With this growth comes demand for improved operations and product quality.
China’s importance to the pulp and paperindustry has since long been recognizedby Voith Paper, and Voith Paper is now
investing into two service center in
China.

represent a critical resource to meetthese dramatically increasing needs. The
technical services available at these centers create exceptional opportunities forpaper producers throughout the region.
Voith Paper Service’s two newest facilities offer Northeast Asia (China, Japan,
Korea, Taiwan) greater opportunities forincreased profitability and growth.

Voith’s two new service centers locatedin Kunshan near Shanghai, Jiangsu Province and DongYing, Shandong Province

Voith Paper Service China broke groundin Kunshan, in August 2002 and Dong
Ying in September 2002 and will start up

62

Fig. 2: Ground Breaking Ceremony Kunshan.
Fig. 3: Mr. Li Jian Hua and Mr. Kietaibl.
Fig. 4: Ground Breaking Ceremony Dong Ying.
2

3

4

commercial production in April 2003.
More than 150 guests from the local authorities in Kunshan City, led by the secretary of the party Mr. Lei Zhang fromDong Ying City, led by the secretary of
the party Mr. Shi Jun and from Guangrao
City, led by the secretary of the party Mr.
Tian Zhenyu, were attending these groundbreaking ceremonies. From Voith’s corporate board Dr. Hans Peter Sollinger wasattending.
Especially at the Ground Breaking Ceremony at Dong Ying, where Voith is build5

Fig. 5: Voith Paper
Service Center, Dong
Ying, Shandong
Province, China.
1,200 m 2,
60-ton lifting capacity.

ing a mechanical service center next tothe paper mill Huatai, Mr. Li Jian Hua,
President of Huatai Group, expressed thegreat importance of having local accessto Voith’s advanced roll covers and services. Previously, papermakers in Northeast Asia often had to send their rolls forservice to Europe or the US, a processthat took several months due to the longshipping distances. Now, the paper millsin the region will have access to the same
service and expertise in Northeast Asia,
saving both time and money.

Voith’s new Kunshan and Dong Ying service centers offer extraordinary capabilities. These facilities reflect Voith’s extensive experience in servicing the pulp andpaper industry. Every facet of their design and operation is engineered to give
you the highest level of quality and service available in Northeast Asia.
The new Voith facilities in China are fully
equipped with latest state-of-the-art
equipment for producing roll covers,
crane systems, lathes, grinders, drillingService

63

Lessebo
Manchester
Hawkesbury
Portland Neenah
Springfield
Belmont Farmington

West Monroe

Vaassen
Weißenborn
Düren
Laakirchen
Heidenheim
Ravensburg Wimpassing

Dong Ying
KunshanSalisbury
Austell

Jakarta
MucuriSão Paulo
Ponta Grossa
Buenos
Aires

Fig. 6: Voith Paper Service
locations world wide.

and balancing machines and all the modern technology necessary to ensure fast
turnaround of the highest quality products and services. Rolls with a length of
15 meter and 2 meter in diameter can behandled on all manufacturing equipment.
The China service centers are well-staffedwith technicians who receive specialized
training not only on site, but in Europe
and North America, as well. As a result,
you can be sure of expert workmanship,provided by experienced people well-prepared to meet any challenge.
And while Voith is a worldwide leader inthe production of papermaking equipment, our expertise extends well beyond
servicing our own equipment and rolls.
Voith professionals provide expert service for any equipment and any roll usedin the market.

Voith Roll Covers● Rubber● Polyurethane● Composite

Voith Roll Maintenance
Services● Suction roll disassembly, internals
inspection and repairs● Variable crown roll disassembly,pressure testing and repairs● Bearing inspection and replacement● Journal repairs and head fits
● Cooling system inspection, repairs,
and replacement● Precision grinding● Balancing● Drilling covers

Access for paper makers to combined
and concentrated resources in Kunshan
as Voith Paper Service China and Voith
Fabrics Kunshan operating out of thesame location, our technicians of bothdivisions cooperate very close for ourcustomers advantage.
With the continued growth of the Chinese
market, Voith Fabrics is making investments to further develop Kunshan as astate-of-the-art forming fabrics operation. The complexity of dewatering technology can be discussed on site and tailor made solutions for each application
will be developed between our customers, Voith Fabrics and Voith Paper
Service.
Feel free to contact us at any time under
our general email address for Voith Paper
Service China:
service.paper-china@voith.com

64

1

EnduraClean –a functional surface for paper machinecomponents
Surfaces of many components in paper machines are,nowadays, engineered to meet specific requirements to improvetheir functionality and performance. Covers and coatings are
frequently applied on OEM components and offered to the industry
as service products.

Sjaak Nelkert
Servicesjaak.nelkert@voith.com

EnduraClean is a new surface coating

down. Multiple rolls or dryers can besystem (cover) tailored to provide a

coated simultaneously to minimize theunique combination of anti-adhesion andtotal processing time.

wear resistance. It has been specificallydeveloped for any paper machine roll or
drying cylinder suffering from excessive

On Site Grinding

build-up of foreign particles (debris)
and/or from build-up of deposits.

Prior to the application of the EnduraClean coating system and depending on

2

Lead-in dryers and any rolls or drying

the condition of the roll or dryer, it might

cylinders following coaters and size

be necessary to re-condition the surfacepresses are prime candidates for thisof the component by grinding. Rolls or

coating system. The surface characteris-drying cylinders which have been doc-

tics of the coating significantly reduces

tored heavily to remove deposits, are of-the sticking tendency and also allows

ten grooved or damaged.

doctoring to easily remove any accumulation of foreign particle build-up.

The Cylinder Service Group operates various types of grinders to re-condition dry-

The EnduraClean surface coating system

ing cylinders in the machine. For safety

is being applied on-site, in the machinereasons,

and during a scheduled machine shut-remotely controlled, incorporate dust

allgrinding

machinesareService

65

Fig. 1: Sintering of Teflon coating.
Fig. 2: EnduraClean surface.
Fig. 3: Grinder.
Fig. 4: HVOF Spraying.
Fig. 5: Schematic coating system.

extraction systems and will restore theThermal Spraying

surface to dryer cans. Disadvantages ofrequired cylinder shape and surface, fast

A High Velocity Oxygen Fuel (HVOF)

the sleeves are the inability to doctor

and efficiently.

spray system is used to apply an ultra-

these surfaces and the high risk towards

dense base coat. This coat is thin, dense

accidental damage.

Dryer to dryer diameter tolerances (groupand consists of extreme hard carbides intolerances) for cylinders running in drivea tough binder, with an overall coating

Ultra-hard carbide, ceramic and metal

trains, are always maintained.

hardness of HV 1,000 (approximately

based thermal sprayed coatings are wide-

70 HRc). A very thin “adhesion” layer ofly used to provide extreme wear and cor-the same material is applied on top ofrosion resistant surfaces on press rolls,

this base layer. This adhesion layer func-

calender rolls, Yankee dryers, windertions as wear resistant matrix for therolls, and doctor blades.

EnduraClean Coating System
The on-site coating system consists of:

Teflon ® compound.

● Sand blasted bond surface

Sintered Teflonsion resistant and non-stick properties in● Thermal sprayed, corrosion and wear

The top layer, and the actual functional

one unique coating system. It will protect

surface consists of a sintered Teflon ®

the surface, prevents sticking and thus

● Thermal sprayed adhesion layer

type compound. This compound is im-improves the performance of the dryer or● Sintered Teflon ® surface layer.

pregnated into the wear resistant thermalroll for years to come.

EnduraClean combines the wear/corro-

resistant base coating

sprayed surface. Sintering on-site is done
Sand Blasting

using infrared propane heaters in a con-

The EnduraClean coating system has

Prior to applying the thermal sprayedtrolled heating and cooling sequence.

found wide acceptance in paper machines, as numerous dryers and rolls

coatings, the surface must be properly
prepared. Sand blasting has a dual func-

EnduraClean Characteristics

have been coated on site since its intro-

tion; it cleans the surface from contami-

Non-Stick properties of PTFE (polytetra-

duction. This service product is offered,nants and it increases the specific sur-fluoroethylene) and other derivatives areworld-wide, through the Voith Cylinder

face area, which assures bonding of thewell known. For years, Teflon ® sleeves

Service Group.

thermal sprayed coating system.

have been used to provide a non-stick

3

4

Teflon Compound

CarbideBase Material

5

66

The Vector press fabricbreakthrough –smooth paper, smooth production, smooth
printing: smoothing the way to higher profits
with Vector tri-axial composite press fabrics
The paper industry needs press fabric enhancementsthat provide better void volume retention, higher after press solids(dryness) and a smoother sheet finish. Voith Fabrics respondedwith the Vector solution, a tri-axial, non-woven concept. This is thefirst stage of a multi-platform system of pressing advancementsfrom Voith.

Featuresfabric technology, level one of Voith’s● Non-woven, tri-axial polyamide

new Surface Improvement Platform, is

structure● Improves batt bonding

not only smoothing out the sheet but alsosmoothing out production bottlenecks.

● Smooth “non-knuckle” pressing
surface

Smoothness gains add up to higher prof-● Increases resistance to compaction

itability through improved quality and

Tom Coulter● Reduces hydraulic flow resistancefiber savings; a reduction in calendering

Voith Fabrics
tom.coulter@voith.com

Applications

caliper. Perhaps the biggest benefit of all● Finish-critical positions

happens beyond the paper mill on de-● High water handling requirements

manding printing presses – where more

● Compaction resistance is criticalconsistent printability on both sides of● Safer, faster installation (seamed)

the sheet occurs.

Results

In a quest to improve on the age-old● Reduces seam wear

sheet roughness issue, Voith Paper Tech-● Eliminates seam marknology’s R & D explored the concept of● Improves sheet smoothness

building a laminated construction utiliz-● Increases sheet dryness

ing non-woven technology to improve

Eric Arseneault
Voith Fabrics
eric.arseneault@voith.com

requirements translates into higher sheet

overall sheet quality. The idea worked so
Even when papermakers do everything

well that what we now call Vector has be-right, producing equal smoothness oncome the reference for optimum smooth-both sides of the sheet is a formidable

ness in press fabric technology (Fig. 1).

task. The challenge to eliminate two sidFig. 1:
Vector 3.

edness is even greater on high-speed ma-

Composite Tri-Axial Designchines. The introduction of Vector’ press

Voith Fabrics utilizes a unique manufac-

Fabrics

67

Fig. 2: Suction box fabric dewatering vacuum
levels.
Fig. 3: Vector – improved sheet quality (left);
Standard 3-layer (right).
Fig. 4: Sheet quality – 40% improvement.
Fig. 5: Vector seam provides significant
improvement in seam integrity.
Vector 62 days (left);
Standard seam 55 days (right).
2

3Suction Box Vacuum

460

EmvicoVacuum Level

Standard Construction

Vector

40

20

0

10

20
30
Fabric Life

40

50

0
VectorSTD 3-Layer

turing process to produce a truly com-free pressing). The proprietary pressing

Case Studies: Graphic Paper

posite fabric.

surface, exclusive to Vector, is the lead-

Producer Smooths the Top-side

ing design concept in the press fabric
The non-woven element defining the Vec-

An SC paper manufacturer wanted to im-industry today.

prove top-side sheet smoothness in order

tor system is made of tri-axially oriented
microfilaments. The Vector layer provides

Figs. 3 and 4 illustrate the improvement

to further improve two-sidedness num-a uniform open structure that significant-in sheet quality obtained using the Vector

bers. Improved two sidedness yields bet-

ly improves dewatering over extended

technology on a machine producing high-ter printing results and therefore higher

periods.

quality board.

impact for advertisers and catalog producers.

In addition to machine direction (MD)

Whether the fabric’s construction isand cross-machine direction (CMD) open

seamed or endless, the benefits are simi-

The modern high-speed machine is pro-water removal channels, the tri-axial

lar. Improved sheet finish and dewatering

ducing high-quality SC paper; the press

system provides superior z-direction flow

capabilities are maintained throughout

section is a tri-nip configuration includ-

properties in demanding press nips. In

the entire life of the fabric. Regarding

ing a shoe press on the 3rd press posi-

combination with the open channels, theseamed fabrics, the additional advan-

tion.

Vector offers z-direction resilience which

tages of superior flap durability and elim-

yields higher permeability control overination of seam mark are also provided

Following the initial investigation, Voith

the life of the fabric. Field results confirm(Fig. 5).

Fabrics elected to target the shoe press

that suction box fabric dewatering vacu-

position (3rd press) as the best opportu-

um levels increase at a much lower ratenity for providing two-sidedness im-

when

provements. It is well known that thecompared

to

other

structures

long dwell time and unique pressure(Fig. 2).

pulse of the shoe press has the effect ofIn terms of surface uniformity, the Vector

creating a two-sided sheet (felted top/

technology has enhanced micro / macroceramic roll bottom).

scale surface characteristics (knuckle5

68

Fig. 6: Basis weight standard copy.
Fig. 7: Tandem NipcoFlex press configuration.
6

Design A

Design A1

VectorDesign B

7

After having defined the objectives with

3 points (Sheffield) leading to a reduction

the Vector 3 for the 2nd Top and Bottom.

mill personnel, the Vector technology

in calendering requirements.

Vector was selected because of its outstanding water handling. The tri-axial

was selected as the best design for sheetsmoothness improvements.

Because of tighter control of sheet

Vector technology was engineered to

caliper, the mill was able to reduce theirmaximize void volume, decrease water

The Vector 3 press fabric was installedbasis weight (Fig. 6). According to Scottflow resistance and improve z-direction

on the shoe press position and provided

Beckett, PM 2 production manager, based

resilience.

better sheet smoothness. On average, theon their production rate, this represents

top-side PPS figures were improved bysignificant savings in fiber costs. Addi-

With the Vectors installed, Visy’s produc-

16 percent when compared to Voith Fab-tional trial work is currently under way.

tion team was able to run at maximum
press load for the life of the fabrics. The

rics’ standard design and by 18 percent
when compared to the competitor’s con-

Smoother Production – Taking a

Vector 4 Pickup and Bottom eliminatedstruction.

Load Off The Press Section

sheet following/picking and improved
weir flows by 15 percent. Visy was able

In addition to significant improvements in

Visy Recycle Inc. in Staten Island, N.Y.

to increase the speed of the machine on

sheet smoothness, the Vector press fab-wanted to improve the water handlingthe lightweight grades by over 30 m/min.

ric resisted compaction and filling betterand efficiency of their press section. His-

The machine set a daily production

than previous designs. Suction box de-torically, the 1st press nip load had to berecord and a monthly production record

watering remained high throughout the

reduced at mid-life of the pickup and bot-while the Vector fabrics were running.

period of operation (110 g/m 2 vs. 20 g/m 2

tom fabrics. Running at maximum press

The Vector technology has now become

moisture drop at suction box) indicatingload during the complete life of the fab-the standard design for this press sec-

a high level of water-handling capability.

rics led to sheet following and picking intion.

the 1st press. The reduction in loading
Vector technology has now become thereduced the press efficiency and lowered

The Vector’s principal assets are its abili-

standard design for the 3rd press posi-

production.

ty to improve dewatering and maintain
openness throughout its life.

tion and is also being evaluated on otherpositions in this mill.
Considerable Fiber Savings
Seeking to increase effective press fabric

Their PM 14 is a modern machine producing 120 g/m 2 - 200 g/m 2 corrugating

In addition, the Vector’s sheet improve-medium at 950 m/min; the press section

ment results have established it as theis a Tandem NipcoFlex shoe press config-

foundation of Voith’s newly launcheduration (Fig. 7).

Surface Improvement Platform.

performance, wood-free copy paper producer Weyerhaeuser, Dryden, Ontario,

Voith Fabrics had not previously been a

Canada, tried the Vector tri-axial compos-

supplier to the machine. After a thoroughite on their shoe press position (3rdanalysis of the press operation, Voith

press). The press fabric ran for 65 days

Fabrics

and on average increased smoothness by(Fig. 8) for the Pickup and Bottom andrecommended

theVector4

Fig. 8:Vector 4.