twogether
Paper Technology Journal

27

En route on the seas: recovered paper I Interview with Carlos
Aguiar, CEO Aracruz I Successful start-up of PM 1 in Khon Kaen

27 I 2008 I Voith Paper I twogether

2Contents

4	En route on the seas:
recovered paper.

14	Interview with Carlos Aguiar,
CEO Aracruz Celulose, Brasilien.

18 The new PM 1 in Khon Kaen,
Thailand, is setting quality standards.

ReportProducts

Research & Developement

4 En route on the seas:

40 Quality improvement with lower

64	DuoFormer Base II – a step towards

recovered paper
11 Largest and most up-to-date
deinking plant in the world in Lynn
12 “Lufthansa-Magazin” printed on
LEIPA paper
14 Interview with Carlos Aguiar,
CEO Aracruz Celulose

energy consumption – MultiFoilRotor and C-bar screen basket
42		 NipcoFlex shoe presses andQualiFlex press sleeves for optimal
dewatering
45		 Reliable tail transfer with the
TailBlade system
46		 Gecko start and end gluing that

New Plants
18		 The new PM 1 in Khon Kaen issetting quality standards
22 Klabin celebrates PM 9 firstanniversary

Rebuilds

inspires49		 New approach in doctor blade
technology

28 New MasterJet headbox at
Manistique Papers
30		 Single NipcoFlex with PrintFlex
SP3 Planar in use in Docelles
32		 Increase in performance by
upgrade of the forming section
35		 UPM Schwedt success story

increases production and saves energy
70	Improving the drying process using
PrintTech LFC with Linx technology
72	Energy-saving pulping concept
for recovered paper fibers –IntensaPulper IP-R
73	New solutions in stock preparation
at the Fiber Systems Technology
Center51		 Rolls – top-level precision53		 Forming fabric MultiForm HC,
the new standard for demandingNews

positions75	Guess where the paper comes from55		 OnC VeriCheck57 – convenient
upgrade option

24 IP Pensacola – uniquecollaboration

the future
68	New polyurethane roll cover SolarSoft

for the latest children's bestseller
76	Carbon-neutral printing of
twogether magazine

Service57 Energy audits reveal savings
potential
60 The virtual winder – training
simulator used successfully
62 NipSense and NipMaster for
optimized dewatering

76	Blended Learning with Norske Skog
77	Voith Paper Environmental Solutions
wins coveted environmental award
77	Mondi and Voith Paper –“adventure day twogether”
78	Voith Siemens Hydro – state-of-theart hydro power laboratory
79 News from the Voith Group37		 Interview with Steffen Deszpot,
UPM Schwedt

2

27 I 2008 I Voith Paper I twogether

EDITORIAL

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

Dear customer, dear reader,

Just a few decades ago, the boldest

cing energy, water and fiber con-futurologist would certainly not have

sumption without compromisingdared to suggest that anyone would

quality. We received the coveted

talk about recovered paper as a

British environmental prize, thevaluable commodity. In our cover“Green Apple Award” in the House

story, we highlight the impressiveof Commons, for these achievements

details of the global trade in the raw(pg. 77).

material of recovered paper.
The engineers at Voith Paper neverVoith Paper has been active in thecease to constantly improve theirworld markets for many decades.

own products. The energy savings

The interview with Carlos Aguiarwith a Mini NipcoFlex shoe press(pg. 14), CEO of Aracruz Celulose S.A.

amount to around 65,000 kilowatt

in Brazil, the world’s largest manufac-

hours per day (pg. 42). In the end,

turer of bleached eucalyptus pulp,

our energy audits offer all customers

illustrates how deeply involved wethe opportunity to accurately identify

are in the field. I would like to takeand calculate the savings potential inthis opportunity to thank Mr. Aguiar

their own paper mill. Read more

for agreeing to the interview and forabout this on page 57.

his open and very honest answers toour – at times – critical questions.

On behalf of Voith Paper, I would like

They demonstrate our customers’

to thank you for the confidence you

understanding for the necessary

have shown in us in 2008. We wish

ecological measures and prove thatyou and your families a happy, festive

the industry is also ready with anseason and a successful year in 2009.

answer and to put words into action.
The answers from Voith Paperare clearer than ever. We researchand develop new products andmachinery, with the aim of conserving
resources and systematically redu-

27 I 2008 I Voith Paper I twogether

On behalf of the Voith Paper team3

Report4

27 I 2008 I Voith Paper I twogether

ReportEn route on the seas:

recovered paper
27 I 2008 I Voith Paper I twogether

5Report

Recovered paper – very special waste.

The Californians found it to be a successful export. Municipalities and private
waste disposal companies argue about it in Germany. Swiss townships
finance communal projects such as kindergartens with it. France, Spain, Italy
and Great Britain have increased their collection rates enormously in the last
few years in order to participate in the growth of this commodity. Recovered
paper, formerly a waste material, has advanced to become a material with ahigh world market price. And like other high-value raw materials, this one
also has to travel around the world.

6

27 I 2008 I Voith Paper I twogether

REPORT

Once again, globalization sends its

a long-term pattern requires noregards: Sparsely wooded countries

clairvoyant abilities.

Definition

nations need more paper than everContinuous increase in demandin the course of their economic deve-

for recovered paper

Return rate and notrecycling rate

like China, India and other Far East

lopment, be it packaging, sanitary or
printing paper. Since domestic raw

Today, China is already the second-materials are scarce goods and fresh

largest paper producer in the world

pulp from abroad is expensive, they

after the USA. In 2007, according toare securing recovered paper foran estimate from market observers,

themselves where it is separately

the country imported more than 20

collected: in Europe and North

million tons of recovered paper – in

America.

1996, it was only a good 3 million
tons. Further growth of its paper pro-Transport can be organized inexpen-

duction and thus also of its need forsively. The compacted recovered

recycled paper is estimated to be at

paper bales travel to the Far East as

least 10 percent per year. A similar si-

inexpensive return cargo on freight

tuation is expected in India. In theships that carry more and more com-meantime, a world market for recove-puters, monitors and entertainment

red paper has developed. Its volume

electronics from Asia to the Westernis estimated to be 35 million tons

industrial nations. In some ways, the(2007). For comparison: in Germany,

material thus returns to its source:in the past year around 15.5 million

The Association of Chinese Package

tons of recovered paper was

Manufacturers estimates that in 2005

collected; in Europe, it was aroundaround 20 million paper and card-

56 million tons.

board packages were exported to
the whole world, of that eight to nine

However, with consumption of 15.8

million to Europe. And the forecast

million tons, Germany is a net impor-that this commodity flow will become

ter and is thus contributing to the

27 I 2008 I Voith Paper I twogether

Recovered paper recycling was the forerunner of an organized recycling economy,
but is distinguished from materials suchas steel, aluminum or glass by the factthat not all used paper can be recycled.
Sanitary paper, for example, is notrecycled. Books are also not a typical“recycling product.”
For that reason, with paper one doesn’t
speak of the recycling rate, as with othermaterials, but instead of the utilization
rate. It indicates the ratio of the amount ofutilized recovered paper to the amount of
new paper that the paper industry of acountry produces. The fact that theutilization rate of Lithuania in 2006 was
119 is not a typographical error. The
paper industry there produces primarily
packaging paper that is almost exclusively
made from recovered paper. Since significantly more recovered paper is requiredfor production than ultimately leaves theplants as new products, the utilization
rate exceeds the 100 percent mark. In
Finland and Sweden, this value is 5 and17 percent, respectively.
A second important indicator is therecovered paper return rate. Due to theaforesaid sanitary paper alone, it cannever be one hundred percent. It depends
on the consumer buying habits of acountry and – quite fundamentally – on
the collecting discipline of the populace
and the effectiveness of the respective
collection system. With a return rate of
75 percent, the Germans are world
champions in the collection of recovered
paper. With values of over 70 percent, theAustrians and the Dutch also doing well.
Without a doubt, there is still room toimprove in North America. The return
rate here is currently “only” a bit over
50 percent. The recovered paper return
rate in China is still comparatively low.
It is indicated as being 34 percent andis thus significantly below the value of73 percent stated for Japan.

7ReportA brief cultural history

Germany:highly organized
In Germany, recovered paper disposal isorganized to a high degree. The return
rate is correspondingly high: Three quarters of the paper consumption of roughly
21 million tons was put back into circulation in 2007. Private collection systems
exist in parallel with the municipal andregional systems. In contrast to the situation in Sweden, for example, the paperindustry has not developed any of its own
activities.
The rising recovered paper price has awakened new interest. Since a lot of money
is involved, collecting brings forth strange
fruit – it is somewhere between popularsport and professional profit seeking. In
some cities and regions, a regular battle israging for the new asset, especially between private and municipal waste
management providers, but also between
competing private companies – in somecities, residents found up to four of thespecial blue recovered paper bins at theirfront door overnight. In other places,
resourceful citizens disposed of public
collection containers on their own initiativein order to supplement their householdmoney with the sales proceeds (five cents
per kilo).

A precious item in every office: the waste paper basket.

global shortage. This is not without

two places can recovered paper coll-consequences. In 2002, the munici-

ection still be increased. In printing

palities sometimes had to pay the

shops, cardboard packaging plants

waste disposal companies more thanand other processing operations,

110 euros for each ton of recovered

systematic recycling has been thepaper hauled away, regardless of thedaily routine for quite some time.

Many of the municipal and regional operations consider themselves to be victims ofthis development. They see themselves as
being deprived of an important income
source that – according to their arguments– should contribute to lowering disposal
fees.

sales proceeds that could be realized.

The same holds for the “unpackers,”

But two to three years later, the situa-

particularly commercial enterprises intion turned around: increased raw

which colossal amounts of packaging

material and energy prices and thematerial accumulate, and for the

globally rising demand suddenly

publishing houses and commercial

made commercial paper out ofpress enterprises that have their

By contrast, the disposal groups want to
use the opportunities the market is offering them. With the blue bin at the front
door, they want to mobilize the last reserves by accommodating consumers who
previously had to bundle their newspapers
or carry them to a public paper container.

recovered paper. From that time

returns recycled.

on, prices have been rising and havealmost doubled just since 2006.

The recovered paper reserves in

Presently, a ton of sorted recovered

Germany are thus only around 5 per-paper fetches 70 to 90 euro.

cent of the paper consumed. Around75 percent is already collected, while

Offices and households foranother 20 percent is not available for

improving waste paper collection

recycling. This includes, for example,
technical paper, which is used in

8

It thus becomes attractive to worm

electronic components, transformers

out every last bit from households

or in automotive engineering, or

and offices. Because only at thesesanitary paper. The additional effort

27 I 2008 I Voith Paper I twogether

REPORT

via “urban mining” – the buzzword isnoticeable savings in energy con-already circulating – to mobilize thesumption. The production of paper

last 5 percent is worthwhile, if at all,from recovered paper uses only about

only at the current price level.

a third the amount of energy that isrequired for production of new paper

Waste paper as a low-costfrom wood (fresh fiber paper). Water

raw material

consumption is only 15 percent,and water contamination only about

The paper industry is watching the

5 percent. But the rising prices put

development with mixed feelings. For

the energy-intensive industry underreasons of cost alone, it is keen on

additional pressure.

using as much recovered paper as
possible. The recycling material is

It seems as if the game with recove-cheaper than fresh pulp, and not justred paper in this country is largely

as raw material. Using it also brings

exhausted. The German paper

A brief cultural history

Sweden: the paperindustry does the collecting
Sweden is in the top group when it comes torecycling recovered paper. Of the 559,000 t
of paper disposed of in 2007, 85 percent of it
was collected and reprocessed. Despite thehigh return rate, Sweden still imports around
400,000 t of recovered paper annually. In
Sweden, the paper industry itself has takenover the task of collection. For this purpose,the big companies of the industry, Holmen,
Stora Enso and SCA, founded Pressretur AB.
Later, M-real also joined the system. Pressretur has made agreements with the 290
municipalities in Sweden. According to theagreements, the municipalities obligated thehomeowners to set up collection containers.
In addition, there are 5,800 public recycling
stations. Three transport companies are
exclusively commissioned with the collectionof recovered paper. Processing is done in 31
sorting stations. From there, it is delivered toseven paper mills in containers or in the formof bales weighing up to 1,000 kg. This system costs the owners of Pressretur annually
37 to 43 million euros. Pressretur makes no
profit. The Swedish system is thus supervised primarily by the municipalities that inturn are monitored by the Office for Environmental Protection.

Switzerland: tied bundles
The Swiss are proud of their recovered paper
collection system. In the Alpine republic, they
are convinced that in no other country arenewspapers, magazines and (brown) cardboard packages collected in such good quality as in Switzerland. That is due to collection
logistics oriented to need. Thus, light-coloredrecovered paper is predominantly bundled
separately. Only in regions where the recovered paper is used as raw material in a cardboard plant are light-colored and brown
grades collected together (in a bin). A framework agreement with the paper industry guarantees the municipalities minimum prices forthe recovered paper. The municipal collections can thus work in a cost-covering
fashion. At the same time, it is left up to themunicipalities to conclude contracts on thebasis of market prices and to achieve surpluses that they can use for municipal projects. But then they have to take the risk offalling prices into account.

27 I 2008 I Voith Paper I twogether

9Reportproducers in the meantime financea good two thirds (utilization rate:

A brief cultural history

68 percent) of their production withrecovered paper. Most newspapers

China: recovered paper urgently sought

today are printed on paper thatconsists of 100 percent recycled
fiber material. Most sanitary paper
likewise has high portions of recovered paper. Even paper of higher
value, e.g., for magazine printing,increasingly contains recycled fibers.
Deinking – prerequisite for useof recovered paper
The technique dates back over
200 years ago when rags – theChina has no municipally organized collecting, sorting or recycling programs. Nonetheless, recycling of newspapers, magazines, cardboard and paperboard – and also
iron, non-ferrous metals, glass and plastic - functions optimally. The raw materialvalue in the “junk goods” alone ensures that largely everything used finds its way
back into the resource circulation system. Recovered paper is a prime example
here. Thus in front of supermarkets and electronics shops, cardboard transport containers are neatly folded and bundled in stacks, in order to then be transported on
bicycle racks or the loading platforms of all sorts of vehicles to the privately organized acceptance points.
Even light-colored graphic paper is collected, but is sometimes more heavily contaminated, so that like brown packaging paper it is usually “only” suitable for production of cardboard and paperboard – and utilized primarily by smaller operations. Big
paper manufacturers like Huatai in Shangdong Province import recovered paper(deinked paper) from North America and Europe. The quantities and qualities theyrequire are not to be found in China itself.

classic textile paper raw material –became scarce. In 1774, the Göttingen professor Justus Claprothpublished “An invention to make newpaper from printed paper and wash
out the printing ink completely.”
As “deinking,” his process is to thisday the basis for utilization ofrecovered paper.

California: higher prices for cleaner paper
The return rate for paper in the USA is currently at 51.6 percent, in any case significantly more than the 31 percent in 1997. But large quantities of recovered paper
still end up in the garbage dumps – in 2004, 8.4 million tons just in California. It istrue that 95 percent of all California households have joined the state recycling
system. But in many places the paper still ends up in the same bin with yogurt
containers, plastic bottles and cans. In Los Angeles, there has been a recycling
system with waste separation since 2002. Utilization takes place partly in municipal, partly in independent operations. There has been a change of attitude toward
recovered paper – and in no small part because of economic considerations.
“Recovered paper is number 1 among the export goods on the US west coast,”
says Jared Blumenfeld, director of San Francisco’s environmental agency. For thatreason, San Francisco is investing in new garbage trucks. The first 180 trucks in the
fleet compress the contents of the recycling bins separately so that glass doesn’t
break and the paper isn’t contaminated. The city hopes to recover the additionalcosts for these garbage trucks – it can demand very high prices for its clean paper.

India: recycling for survival

Collection of waste paper is alreadypracticed in many countries.

10

Glass bottles, plastic canisters, the remains of newspapers – in India, approximately 1.5 million people earn their livelihood by collecting and selling on potential
recyclables. For many, it is the last hope before starvation. As a rule, the municipal
councils are responsible for disposal of household waste. But as overflowing containers and unofficial garbage dumps indicate in large numbers, the municipal
waste disposal systems are not very effective. Megacities like Delhi, Mumbai and
Chennai have transferred parts of their waste disposal to private companies.
The system of the garbage collectors works better. They recycle about 20 percent
of domestic waste. They sell their “booty” pre-sorted to middlemen who further
sort the garbage and pass it on via other dealers to recycling operations. Largescale consumers such as hotels, plants and offices deliver their potential recyclables directly to middlemen or processors.
Entire branches of industry, such as the steel industry or paper production, largely
rely on recycled raw materials. According to information from the Board of Trade,
India imported around 1.7 million tons of recovered paper in the 2005/06 fiscal
years. Since the paper industry is achieving two-digit growth rates, its hunger forrecovered paper will substantially increase in the future.

27 I 2008 I Voith Paper I twogether

REPORT

New paper mill in England featuring the world’s largest drumpulper

Largest and most up-to-date deinking plant in the world
Voith Paper is currently building a new paper mill for the papermaker Palm. Starting Autumn 2009,
newsprint paper will be produced at the mill in King's Lynn, England. With its pulping capacity of
2,000 bdt/d (bone dry tons per day), recovered paper will be the world's largest deinking line.

The flotation deinking process wasdeveloped in stock preparation atVoith Paper as far back as the late
1950s. Voith supplied the first flotation
machine for the production of tissuecrêpe paper in July 1959. Since thenVoith has delivered more than 1,000
flotation machines all over the world.
The deinking process step has
become part and parcel of recovered
paper treatment for high-quality
writing and printing papers.
The use of recovered paper places
high demands on the recycling of
Schematic diagram of Lynn PM 7 deinking line.

residual material, as 500 t of waste
are produced in Lynn from a furnish of

In Britain the recovered paper situa-in the world. Following pulping, the2,000 bdt/d recovered paper. After thetion differs to that in Germany: there

recovered paper is screened in several

flotation and circuit-water cleaning

is a surplus of recovered paper that is

steps to remove coarse and finestages about 400 t of it occur in theexported in large quantities. At thecontaminants.

form of sludge. Residual material rep-same time there is a deficit of news-

resents a valuable energy and material

print paper, which has to be imported

The screening is followed by thesource. While screened coarse rejects

from North America, Scandinavia andflotation, the key to every deinking

such as iron and metal parts can beCentral and Eastern Europe. For Palm

system. At 70 m, Voith Paper’s

re-used directly, combustible residues

the British market is very promising.

EcoCell flotation machine will be theare transferred for energy recovery or

The new paper machine Lynn PM 7,

longest flotation line in the world. In

the generation of power. This results indesigned for a maximum annual ton-

the flotation machine the air entrained

profitable utilization instead of expen-

nage of 400,000 t, will be the largest

into the stock with the EcoCell diffusor

sive waste disposal.

paper machine for newsprint paper inremoves the printing inks that have

Europe.

separated during the pulping of therecovered paper.

Voith Paper's TwinDrum pulping tech-At 5 to 500 micrometers, printing ink

nology will be used in stock prepara-

particles are so fine that mechanicaltion. In future it will be able to pro-screening is impossible. They accu-

cess 2,000 bdt/d recovered paper,

mulate on the air bubbles and are

giving it the highest pulping capacity

discharged as foam.

27 I 2008 I Voith Paper I twogether

Contact
Bernhard Müller
b.mueller@voith.com

11

ReportLEIPA: High quality magazine paper from secondary fibers

Recycled paper from Berlin			 used as raw material for “Lufthansa Magazin”
The production of magazine paper from recycled fibers has failed until now mainly because of the poor
quality of the end product. LEIPA Georg Leinfelder GmbH, with mills in Schrobenhausen and Schwedt,
Germany, faced this huge technological challenge together with Voith. And succeeded. Since July
2004, the PM 4 in the Schwedt mill has produced first-class LWC paper from up to 100% secondary
fiber pulp. Since January this year, Lufthansa AG is one of the well-known customers of the recycled
product with its magazines “Lufthansa Exclusive” and “Lufthansa Magazin.”
With a print run of 310,000 copies,

in vain for an excellent-quality maga-

Forerunner role in ecologicalthe Lufthansa in-flight magazine iszine paper with high recovered paper

magazine production

provided for guests of the airline in thecontent. Only the recycled paper that

airplanes and airport lounges. Since

is produced by LEIPA in Schwedt met

The Lufthansa magazine has been

one copy is generally read by several

the high requirements. The concept ofprinted on LWC paper by LEIPA sincepassengers, the glossy magazine

producing high-quality LWC paper

January 2008. Up to 1,000 km of pa-

reaches around 1.4 million people in 16

from up to 100% deinked recovered

per run through the printing machinecountries each month. For a long time,

paper fiber, on a fast running online

for one issue. The IKEA magazine in

the Lufthansa editorial team searchedmachine is a one of a kind worldwide.

Turkey, Israel and Belgium, the Rus-

12

27 I 2008 I Voith Paper I twogether

REPORT

The Lufthansa magazine is printed onhigh-quality LWC paper from LEIPA in
Schwedt, Germany.
The recovered paper is made from up
to 100% secondary fibers and meetsthe highest requirements.

sian “Newsweek” and the “Victoria’s

year. Both the customer and the pa-

coating to supercalendering take

Secret” catalogue from the USA arepermaker can be satisfied with the end

place online at production speeds ofalso produced from LWC paper byproduct. Three years ago, coatedup to 1,800 meters per minute.

LEIPA. After 27 months of close cooper-

magazine papers by LEIPA, consisting

ation with Voith Paper in the projectof up to 100% secondary fibers, was

To achieve better product quality,

and implementation phase, LEIPA

certified as meeting the Forest Stew-

LEIPA assigned responsibility forput the PM 4 into operation four years

ardship Council (FSC) guidelines.

the complete production process ofago. Back then, the paper machine

LEIPA thus received official confirma-

the PM 4 to Voith Paper in 2003 in

led the way in ecological magazinetion that their production is especiallyaccordance with the Process Lineproduction and it continues to do soenvironmentally friendly.

Package concept. Voith supplied thetoday. It was the first to successfully

entire process line, starting with baleproduce coated magazine paper

The recovered paper that is recycleddewiring to stock preparation and thegrades with such high recoveredin Schwedt comes mainly from house-

paper machine through to the roll

paper content while retaining a quality

hold collections in the greater Berlin,

packaging machine. Even after thelevel in all relevant properties that is

Brandenburg and Mecklenburg-West-PM 4 was put into operation inequal to primary fiber products.

ern Pomerania area. Approximately

July 2004, Voith remained involved

800,000 metric tons of recovered pa-

in the project through classic and on-

Magazine paper made from up to

per are processed in the mill eachgoing system partnerships. What is

100% secondary fibers

year. With a wire width of 8,900 mm,

still a very successful reference paper

the PM 4 can produce a basis weightmachine today is the result of the

A total of 300,000 metric tons of LWC

range between 39 and 60 g/m². All

continued, close cooperation between

paper are produced on the PM 4 eachprocesses from precalendering toVoith and LEIPA.

27 I 2008 I Voith Paper I twogether

13

INTERVIEW

The plantations use degraded land only, which are areas thathave already been destroyed, either by railway construction,
sawmills or the farming of other agricultural crops.

Interview with Carlos Aguiar, CEO Aracruz Celulose

Transparency brings critics to silence
The Brazilian company, Aracruz Celulose S.A., is the world’s largest producer of bleached eucalyptus
pulp. The Group cultivates around 286,000 hectares of its own eucalyptus plantations, interspersedwith around 170,000 hectares of native forest reserves, in the states of Espírito Santo, Bahia, Rio
Grande do Sul and Minas Gerais. The wood is processed in plants in the first three of the above locations. With a workforce of 12,000, made up of 2,500 of its own permanent staff plus 9,500 temporary
workers, Aracruz posted a turnover equivalent to 1.88 (2006: 1.68) billion US dollars in 2007.
“twogether” conducted an interview with the CEO Carlos Aguiar.
twogether: The pulp industry world-tion was another. There has also

forest ecosystems in the world.

wide is coming in for a lot of criticism,

been substantial progress in our ef-

How do you counter these charges?

despite the fact that erstwhile sins

forts to reduce energy consumption

such as elemental chlorine bleachingand produce power in our own plants.

Aguiar: First of all, let’s deal withhave long been a thing of the past for

One project at our plant in Rio Grande

the second issue: this accusation is

the majority of producers. What is

do Sul aims to supply almost twice as

totally unfounded. Our plantations use

your point of view?

much power to the public grid than is– and will always use – degraded land

used by the plant itself.

only, which are areas that have alreadyAguiar: We endeavor to continuously

been destroyed, either by railway

improve our processes in both envi-

twogether: The international media

construction, sawmills or the farming

ronmental and economic terms. As

is keen to level two charges at yourof other agricultural crops. And oursoon as new opportunities for impro-

company: one, the misappropriation

special “mosaic planting” method –vement are discovered, we are alsoof land tracts, which you were forced

our plantations in Espirito Santo areprepared to invest in them, in orderto return to the Tupinkim and Guarani

interspersed with remnants of theto benefit from the advances in our

Indians in 2007, and two, the accusa-

former Atlantic Forest – ensures aindustry. Chlorine-free bleaching wastion that you are cultivating planta-large variety of species. Studies prove

one such development and the dra-tions on land that was once consi-that since 1989 more than 125,000

stic reduction of our water consump-dered one of the most species-richbirds and 559 different species of

14

27 I 2008 I Voith Paper I twogether

INTERVIEW

animals have been observed in our

However, the problem has been resol-

national paper industry with an im-

forests. Regarding the question ofved: in order to avoid further conflict

portant raw material. Yet Aracruz

indigenous land: on the basis of

we have concluded an agreement tois often criticized for its high export

documents going back to 1860 wehand over the 11,000 disputed hec-

quota and thus its contribution to

can prove that not one of the lands

tares to the Indian tribes. We also

globalization. Is the criticism that

acquired by Aracruz has ever belon-

have a court ruling to the effect that

Aracruz is sacrificing native forests on

ged to the Indians. Anthropological

the surrounding area is not indigenous.

behalf of foreign industry justified?

studies also prove that in the past

This will allow us to prevent further

there were never any Tupinikim or Gu-

manipulation by these Indian tribes.

aranis living in that region. The Tupini-

Aguiar: It is not for nothing that wehave been listed on the Dow Jones

kim came from Bahia, the Guaranis

twogether: As the market leader for

Sustainability Index for four consecuti-

from Paraguay or Rio Grande do Sul.

eucalyptus pulp you supply the inter-ve years. In addition, we belong to thesustainable business index of theBrazilian stock exchange Bovespa.
This shows that we are using advanced practices. Because we are particularly visible as the global leader in
eucalyptus production it is obviousthat we come in for most of the criticism, perhaps also because our critics
hope that changes made by the leading companies will have a knock-on
effect for the rest of the industry. In
addition, Aracruz, like most pulp
producers, works in regions in which
there continues to be a lot of social
inequality. Although we have contributed a lot to the development ofthese regions, no one can expect one
company to single-handedly solve all
the social problems and dilemmas
faced by the community. So even

“We endeavor tocontinuously improve
our processes in both
environmental andeconomic terms.”
Carlos Aguiar, CEO, Aracruz Celulose S.A.

though it is unfair, it is understandable
that the biggest company in a region
will be criticized for these problems.
twogether: Do you see any ways ofresolving this image problem?
Aguiar: Yes, I have to say that the situation has already improved. Aracruz
is trying to be more and more transparent, and this helps to graduallydampen some of the criticism.
Our strength is that we listen to our

27 I 2008 I Voith Paper I twogether

15

INTERVIEW

Studies prove that since 1989 more than 125,000 birds and 559 different species of animals have been observed in the Aracruz forests.

personnel. By telling us what they

twogether: Are these predominantly

power in these regions. Not to menti-

think about what Aracruz is doing theyeconomic benefits?

on the CO2 effect: planted forests
absorb large amounts of greenhouse

help us to improve the company, make16

it more competitive and work for the

Aguiar: We can demonstrate econo-gas. For every ton of CO2 emitted bybenefit of the community.

mic, social and ecological benefits.

our factories, three tons are absorbed

One of the major environmental bene-

by our forests. This is one of thetwogether: Plantations can make afits is the opportunity to protect andreasons why huge eucalyptus planta-

significant contribution to supplying

even expand native forests. Brazilian

tions have been established in coun-

the global economy with fiber without

legislation requires that for every

tries such as India and China.

having to destroy indigenous forests.

two hectares of planted eucalyptus

Why is it that the advantages of thisforests, one hectare of native forest

twogether: Plantations are often

kind of cultivation receive so little

has to be preserved or planted. Our

described disparagingly as “green

recognition?

forestry partners program, involving

deserts.” Is the accusation that they

3,900 farmers with a total of 96,000

contribute to a reduction of bio-

Aguiar: Here too, there has been

hectares, also prevents the cutting

diversity justified?

some improvement. In Brazil and other

down of native forests for private use,parts of the world there are a consi-

i.e. for firewood, charcoal or fuel. This

Aguiar: What is better – an area of

derable number of NGOs (Non-Go-

is because the farmers receive for

pastureland that is not capable ofvernment Organizations, editor’s note),their own use a specific percentage

sustaining even a minimum amount of

which are starting to recognize thatof the plantation wood they produce.

flora and fauna, or a planted forest

plantations are a strategic solution to

In fact, the sustainable planting ofwith at least 500 different species inmeet the increasing demand for wood.

eucalyptus trees on depleted soil

it? When we intersperse native forest

There is an increasing awareness thatprovides an alternative source ofwith the planted forest we create

the systematic planting of forests has

wood for various purposes, and gives

ecological corridors. “Green desert”

numerous beneficial effects.

us the opportunity to retain rural man-is a derogatory term without any

27 I 2008 I Voith Paper I twogether

INTERVIEW

scientific basis. The planted forest

Castello Branco (1964 –1967, editor’s

the pulp and paper industry in bothprotects the soil from erosion, pro-note) 71 million hectares of Brazilian

economic and ecological terms, we

tects the watersheds and improves

soil have been earmarked for agricul-

are still not using any genetically mo-soil quality. Fourteen years of planta-

tural reform. Soy beans take up 21

dified plants. This is in compliancetion work show us that eucalyptus

million hectares, corn 3 million andwith Brazilian legislation, with major

trees help to recuperate degenerated

sugar cane 6.6 million. The sum total

debate on the subject still ongoing.

soils, by increasing the amount of or-of Brazil’s planted forests is only

Instead of discussing rigid positions,ganic material and retaining humidity.

5.5 million hectares, of which only

we can move forward constructively,

2 million are for pulp and paper. The

analyze the risks and discuss thetwogether: Land is very much inrest is destined for lumber, chip-measures necessary to keep thesedemand. Conservationists, theboard, fuel, charcoal and other uses.

risks to a minimum. The cultivation

regional population, indigenousThanks to 5.5 million hectares ofof genetically modified corn and soy

peoples and various sectors ofplantation we enjoy almost 2 million

has already been approved in Brazil.

industry are competing fiercely withhectares of preserved native forest.

The issue of approval for planted

one another for the land available.

forests has not yet been resolved.

How do you see the position of thetwogether: There is worldwide dis-As soon as the Brazilian legislature

pulp and paper industry among these

agreement as to whether the benefits

follows the lead of the scientificconflicting interests?

or risks predominate in the develop-

debate and gives the go-ahead, wement and cultivation of genetically

can initiate some trials in this area.

Aguiar: Brazil’s pasturelands today

modified plants. Are you alreadyBecause, of course, in the long term,

account for an area of 220 million

working with genetically modified

Aracruz has to keep in step withhectares. Without the least obligation

eucalyptus plants?

technological progress.

soil degradation and erosion.

Aguiar: Although we believe that this~ Aguiar, thank you
twogether: Senor

Since the time of the government oftechnology can be of great benefit tofor talking to us!

to protect native forests this causes

The sustainable planting of eucalyptus trees on depleted soil
provides an alternative source of wood for various purposes.

“One of the major environmental
benefits is the opportunity to protect
and even expand native forests.”
Carlos Aguiar, CEO, Aracruz Celulose S.A.

27 I 2008 I Voith Paper I twogether

17new plants

Khon Kaen PM 1
Paper grades:	Woodfree writing and printing
papers, Copy papers
Production capacity (gross):
730 t/24h (based on 80 g/m²)
Wire width:
5,850 mmMax. paper width on reel:
5,280 mm
Design speed:
1,500 m/min
Max. operating speed:
1,300 m/min
Raw material:		
Bleached short fiber pulp
80 - 100%
Bleached long fiber pulp
0 - 20%Filler10 - 20%
The result of the joint efforts by PPPC and Voith: a paper machine with state-of-the-art technology.

The new PM 1 in Khon Kaen is setting quality standards

Top in every aspect
The new paper machine of Thai papermaker Phoenix Pulp and Paper Co. Ltd. (PPPC) – a subsidiaryof the Siam Cement Group (SCG) - went into operation just in time for the 2008 New Year Festival in
Thailand. It became clear very early on that the quality of the paper produced is setting new standards.
Furthermore, all guarantees could be successfully confirmed just five months after startup.

Already during the inquiry process forcosts. The location for the new paper

duce bleached eucalyptus pulp there

this major project, PPPC asked for themachine was to be at Khon Kaen,for years. The objective of the invest-

best technology available to ensure

approximately 500 km northeast fromment was to process the pulp into highthe highest quality and efficiency,

Bangkok in the heart of Thailand.

quality writing, printing and copy paper

while keeping to optimum investment

PPPC has operated a factory to pro-directly on site. With the new produc-

Layout Khon Kaen PM 1.

18

27 I 2008 I Voith Paper I twogether

New plants

A good partnership from left to right: Egdar Roman,
Voith Assembly Manager; Amnuay Ponpued, Khon
Kaen Mill Director; Terasak Chamikorn, Managing
Director; Surat Khoonrugsa, Paper Production
Manager Khon Kaen PM 1; Dr. Martin Zimmermann,
Voith Chief Commissioning Engineer.

tion line, the capacity of these papers

the various Voith Paper locations inand storage areas were sodden,

should increase by 200,000 metric

Europe and China. Numerous draw-

trucks got stuck and containers over-tons per year and SCG Paper willings, foundation plans and piping

turned. The difficult conditions led to

become the leading producer ofdiagrams were generated from thedelays with construction. However,graphic papers in Thailand.

3D mill model. Chests, structural

thanks to the huge efforts of all thecomponents and pipes could be pre-staff working on the building site, we

The Voith Paper delivery includes the

fabricated to a great extent thanks tomanaged to avoid missing the dead-approach flow, the complete paper

the extremely effective 3D planning.

line,” explains Voith Project Manager

machine with auxiliary components,

Hubert Eger.

MCS, CD profile control systems andMonsoon rain hinders

The project teams from PPPC, Voith

the winder. There was a tight time

construction

Paper and C.L. International worked

frame for the design and engineering

extremely well together throughout

work but this all went to schedule.

The construction and assembly

the entire project. Surasak Amawat,

The individual sections and compo-

teams had to battle unusually heavy

project manager from PPPC, thanked

nents were preassembled in time atmonsoon rain in August 2007. “Roads

Voith Paper for the good partnership.

27 I 2008 I Voith Paper I twogether

19new plants

36
No. of measurements

8
6
4
2

Khon Kaen PM 1

32

10
Khon Kaen PM 1

No. of measurements

12

28
24
20
16
12
8
4

0
1,0

1,4

1,8

2,2

2,6

3,0

3,4

3,8

4,2

4,6

5,0

0

0,0 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 2,0 2,2 2,4 2,6 2,8 3,0Variation coefficient MD [%]Variation coefficient CD [%]Fig. 1: Benchmark basis weight MD profile.

Fig. 2: Benchmark basis weight CD profile.

“We chose Voith as the main supplier for this project				
because we are confident in the quality of machineryand services. … We are very happy with our PM 1.”
Terasak Chamikorn, Managing Director Khon Kaen

Customer training as a factor

papermakers supported the Khon

increased to 1,200 m/min within afor success

Kaen team. Surasak Amawat is

few short weeks. In the case ofconvinced that these comprehensive

120 g/m² offset paper, 816 metric t/dIn order to ensure the success of the

training measures contributed signifi-

were produced three weeks after

project in the long term, the custom-

cantly to the success of the project,

startup, 12% above the design

er’s employees received intensive

especially to the smooth startup andspecification.

training. A comprehensive training

effective optimization.

program for the customer’s future

Outstanding paper quality inoperating and maintenance staff wasPaper on the reel just in time

set up and run by Chief Commission-for the “Songkran” Festival

ing Engineer Dr. Martin Zimmermann.

every respect
It was already clear soon after the

In addition to theoretical instruction,

To the customer’s great delight,

startup of the paper machine that thepractical training modules were also

the first paper was wound onto theambitious quality targets had been

completed during the shop assembly

MasterReel just a few hours before

met. The quality control system

at Voith in Heidenheim and visits“Songkran,” the Thai New Yeardisplayed an absolutely even crosswere made to a suitable reference

Festival on 12 April 2008. Sellable

profile for basis weight, caliper andmill over several days. During thefrom the outset, as mill director,

moisture content. The Tapio analysis

startup, a group of experts from

Amnuay Ponpued emphasizes.

in the Voith Paper laboratory confirms

various disciplines and experienced

The starting speed of 1,000 m/min

this: the variation coefficients of basis

20

27 I 2008 I Voith Paper I twogether

New plants

16
12
10
8

Khon Kaen PM 1

No. of measurements

14

6
4
2
0
1,0

1,5

2,0

2,5

3,0

3,5

4,0

4,5

5,0

Variation coefficient residual [%]Fig. 3: Benchmark basis weight residual deviation.

The Khon Kaen team with the first full drum.

weight and caliper for CD, MD andquickly increased to the maximum

We chose Voith as the main supplier

residual deviation are among the best

operating speed of 1,300 m/min –for this project because we are confi-

ever measured. This is illustrated

a top speed for machines with hybrid

dent in the quality of machinery andimpressively by the histograms informer for wood-free grades. Further-services. Many thanks to your teamFig. 1- 3. Thanks to ModulePro in themore, five months after startup, thefor your cooperation and support.

warranty test runs were successfully

We are very happy with our PM 1.”

dryer section, excellent 2-ơ-values ofless than 0.2% were achieved forcompleted first off for all reference

the moisture cross profile on the reel

grades. “Top quality and productivity

Tongchai Soha, Process Engineering

too. It is not only the profiles that arevalues - and at record speeds!”

Manager at SCG Paper, sums up it up

convincing; the paper from the Khon

Voith Commissioning Engineer, Martin

briefly and succinctly: “This machine

Kaen PM 1 also leads the way in

Zimmermann sums up proudly.

is top notch in every aspect.”technological parameters. With
80 g/m² copy paper, an Ambertec

As a result of the smooth startup,

formation index of 0.32 √g/m² and a

the Final Acceptance Certificate

bulk of 1.4 cm³/g was achieved.

(FAC) was already signed after a

The rough two-sidedness is withinrecord-breaking six months after the± 10% in the entire roughness range

machine was put into operation.

from 70 to 220 ml/min Bendtsen.
These exceptionally good values

Amnuay Ponpued, the Khon Kaen

confirm the technological total

Mill Director is happy with the hugeconcept of the PM 1.

success of the project:Contact
Peter Mirsberger
peter.mirsberger@voith.com“We are setting new standards with
Greatest level of customer sat-the quality of our copy and offset

isfaction

papers and are very well placed in
the competitive landscape.”

The starting curve of the machine isManaging Director, Terasak Cha-also a top performer. For 60 andmikorn is also extremely pleased:

70 g/m² offset papers, the speed“I have known Voith for a long time.

27 I 2008 I Voith Paper I twogether

Hubert Eger
hubert.eger@voith.com

21

new plants

Klabin celebrates PM 9 first anniversary

A masterpiece has been delivered
With a yearly production capacity of 350,000 tons, Klabin today has
the largest virgin fiber board machine in Brazil. The PM 9 is specifically developed to produce Liquid Packaging Board (LPB), Folding Box
Board (FBB) and Carrier Board. The machine was installed in theMonte Alegre mill in Telêmaco Borba (federal state of Paraná) and isalready in full operation.

Almost 400 days have passed since

proved not to be the best solution. As

Brazil’s major producer and exporter

Klabin has been a long-term supplierof paper and cardboard completed

to Tetra Pak in a 25-year partnership,

one of the most important projects

the realization of the MA-1100 project

undertaken by the company in thatwas seen as necessary in order tocountry – the MA-1100 – and started

support the foreseen growing market

up its core component, the PM 9.

demand, as only few companies‘MA’ stands for Monte Alegre andaround the world have the technology‘1100’ for the 1.1 million tons capac-

to supply LPB.

ity of the paper mill. Project planningbegan around 2003. Voith Paper ex-

A tight space and a tight schedule

perts initially suggested a few alternatives to improve LPB production,

One of the major challenges of thesuch as rebuilding the PM 4 andMA-1100 project was to find space

PM 6, which, after several studies,in the Monte Alegre mill. The site is

One of the several groups visiting the paper machine during the opening ceremony.

22

27 I 2008 I Voith Paper I twogether

New plants

The red cable car hovers above Rio Tibagi.
Employees have an incomparable view to
the Monte Alegre.

Official opening. Council of Administration of Klabin, Mr. Roberto Requião(Governor of the state of Paraná) and Mr. Miguel Jorge (Minister of Development,
Industry and Exterior Trade Department for Brazil).

located between the Harmonia andparts of the project, from the

Tibagi rivers, and the mill is built on a

civil construction supervision to thesteep hill, which made it very difficult

start-up itself, involving 40 direct

to find space for a 250-meter-longsuppliers and almost 400 indirect

paper machine and its building. The

vendors. Voith Paper Brazil set up

solution was to move the sheeting planta project management “war room”

and to build the new machine room onin the company’s headquarters inthat site. About 60,000 truckloads ofSão Paulo, where weekly meetingsmaterial had to be moved to the site.

were held to monitor and control thesituation in all areas involved.

Customer Comment
Francisco C. Razzolini
Project, Industrial
Technology & Purchasing Director“We at Klabin felt really comfortable withthe final design that we achieved for theThis was not the only challenge:
achieving the agreed deadline was

On October 15th, 2007, Klabin and

PM 9 with the help of Voith’s profession-

crucial for Klabin and Voith. Acquisi-

Voith started up the PM 9 exactly atals. With the trials we did and all the ref-tion of the PM 9 was approved by

8 pm, producing its first paper parent

erences we searched, we felt very confi-

Klabin on April 21st, 2006, and Voithreel, which was celebrated at the milldent of Voith’s qualifications to build thishad the mission to build the machine

and also throughout the company inparticular machine. They have a large

and start it up within 17 months.

Brazil. The machine is now operatingpresence in Brazil, with a large, qualified

at full production. Klabin’s engineers

body of technicians. Voith delivered a

In order to speed up the process,believe that soon the PM 9 will surpass

masterpiece.”

Voith invested in pre-engineering andthe level of production foreseen for it.
Infoboxresearch before the project acceptance, defining all the items that wererequired for the sucess of the project
before the official start. The ProcessLine Package acquired by Klabin from
Voith was also of great help. Voith

Contact
Hilton Pinto
hilton.pinto@voith.com

With the Process Line Package (PLP), Klabinacquired the complete stock preparation
system, the approach flow system, board
machine, winder, roll transport and wrapping
systems, ancillary equipment, the electricalequipment as well as installation and start-up.

became responsible for all technical27 I 2008 I Voith Paper I twogether

23

REBUILDs

A unique collaboration leads to the industry’s new benchmark

IP Pensacola:
That’s the way to do it“We all win, or we all lose.” Is there a better way to put together
the spirit of a common project of great magnitude? In this case,the challenge was raised by International Paper’s Pensacola mill.
But how to get there – let the story begin…
PM 5 produces lightweight kraftliner with aquality exceeding all expectations.

It’s nearly impossible to find anyone

two production areas: uncoated

The IP Pensacola rebuild, however,

who doesn’t know International

papers and industrial/consumer

was anything but typical. Just a few

Paper based in Memphis, Tennessee,

packaging.

months after the first project meeting,USA. IP is a major player: the largest
forest company in the world. It has

IP chose Voith Paper to carry out theFull involvement in every level

been the premier producer of paper

project for the PM 5. Voith Paper waschosen to be not only the supplier,and board since the acquisition

A typical paper machine project in-

but also a real partner in a mega-of Weyerhaeuser containerboard,

volves meetings after meetings, quo-scale initiative.

packaging and recycling business.

tations and updates, test runs, visits

Today, IP operates 23 pulp, paper

to reference sites, and the list goesFirst, IP and Voith Paper signed aand packaging mills in North America

on. The possible suppliers competepre-engineering contract, which wasand one in Mexico. In 2007, thehead-to-head, and in the end, one ofsoon followed by an order for the PM 5

company delivered more thanthem wins the deal.

rebuild. In time, IP realized the benefits

12 million tons of paper to themarket.

of a single source supplier and brought
The numerous discussions involving

in other Voith Paper divisions – such

purchaser and supplier might some-as Fabrics, Fiber Systems and Rolls –However, the North American paper

times run hot, since the opinions areto the project. Consequently, Voith Pa-

industry has gone through hard times,

not always the same. Naturally,

per became IP’s all-inclusive supplier.

and the changing market demands

everybody plays for his own team

Right in the beginning, an in-depth

leave no one unaffected. Streamlining

following their own targets; it takesalignment session was organized forthe business had become essential.

time to come to an agreement satis-the core project team to show theFor IP, this means concentrating on

fying all participants.

correct way. During the project ex-

24

27 I 2008 I Voith Paper I twogether

REBUILDs

Machine description of PM 5
Wire width:
Production:
Product:
Basis weight range:
Design speed:
Start-up:

9,640 mm (380 inches)
500,000 short t/year
high-quality kraftliner from virgin fiber
112 - 176 g/m² (23 – 36 lbs/MSF)
1,128 m/min (3,700 feet/min)
September 22, 2007

Main scope
Supplied by all divisions of Voith Paper, Board and Packaging, as the leading partner• Three pressure screens, HydroMix and upgrade of existing equipment• TopFormer F, two MasterJet F headboxes, ModuleJet dilution water control• DuoCentri NipcoFlex shoe press• Dryer section upgrade• New roll covers and coatings• Complete upgrade of existing winder• Several quality enhancement tools for lightweight grades,
like DuoShake unit and EdgeModule for headbox• Control and automation package with engineering services• PM clothing including QualiFlex press sleeves

ecution, frequent meetings took placeof modern communication tools, thethose alterations is relatively low.

where everyone whose job function

seven-hour time difference wasEven though FEL requires more time

was affected by the PM 5 conversion

working for the project!

and money in the beginning, thesewas included. IP involved all different
levels. The whole staff was fully

costs are minor compared to the exFEL as project structure

engaged in order to be able to iden-penses and efforts saved in not having
to make changes at a later stage.

tify with the new product. Complete

IP chose Front-End Loading for the

training across the machine was pro-handling of project development.

IP is experienced in the FEL field, andvided to everybody.

FEL is a systematic stage gate

Voith Paper is no greenhorn, either.

concept to develop major capital

Together, the companies had alreadyOn top of that, every three months,

projects, where the customer, thecompleted one project, using the FEL

a stakeholders’ meeting was con-engineering company and theconcept with success.

ducted, keeping the top management

supplier work all together as oneof IP and key suppliers involved andteam.

fully informed.

The Pensacola FEL project consistedof five phases. The first one was

Front-End Loading includes roughthe execution of a complete business

Even the distance over the Atlanticplanning and design already in theanalysis. Four aspects were always

did not create problems during theearly stage of a project lifecycle.

top of mind in all stages – strategy,

project execution. Additionally to

There is a solid rationale for thiscost reduction, regulatory andface-to-face meetings, conference

approach: In the beginning, the ability

maintenance – so that all possible

calls and web meetings were used

to influence changes in design isconsequences were taken into

efficiently. Thanks to the utilization

relatively high and the cost to makeaccount.

27 I 2008 I Voith Paper I twogether

25

REBUILDs

The moment of truth: After several weeks downtime PM 5 will soon run again.

The second phase concentrated

as optimization. Moreover, the projectproperties and basis weight profiles

on technical aspects. A preliminary

did not finish with the start-up of theare at the high end of the market.

machine design was defined. The

paper machine. An evaluation

In addition, the PM 5 is, without any

partnership between IP and Voith

comparing actual performance toexaggeration, one of the world’s fast-

Paper gained momentum.

project objectives and a transfer of

est kraftliner machines.

the lessons learned during the proAfter business and technical issues,cess were also carried out.

the focus was set on an execution
analysis. Project plan, implementation

These results could not have beenachieved without the hard work of all

Quality beyond all expectations

strategies, balances – all that andteam members. The customer, theequipment supplier, the engineeringmuch more – were completed in theConverting an existing copy paper

company and the construction com-third phase. The detailed concept formachine to produce completely

pany did all their very best to achieve

the rebuild was now developed to-different grades involves many

the project targets.

gether, based on IP’s product specifi-

uncertainties. Starting from the pulp

cation and the capital investment

mill through stock preparation, allVoith Paper is convinced that Interna-

proposal took form.

machine sections and functions

tional Paper is on the same success-must be carefully inspected andful path that SAICA charted several

upgraded.

years ago. As is widely known, theAfter the go-ahead, an implementation phase followed. This fourth

Spanish SAICA was the first one tophase included permit, procurement,

In the end, the only point that matters

produce lightweight corrugating me-

construction, training and commis-

is whether the product quality meetsdium from 100% recycled fiber andsioning, for example.

the project specifications and market

is considered to be the industry’s

demands.

benchmark in the medium and test-

Finally, in the fifth phase, PM 5 start-

liner market. With its Pensacola PM 5

ed up. IP executed the go-to-market

At Pensacola, the result is moreproducing lightweight kraftliner fromplan and began the operation as wellthan positive. The achieved strength

100% virgin fiber, nothing prevents

26

27 I 2008 I Voith Paper I twogether

REBUILDs

IP from achieving the same in its

every phase of the project. IP paidPensacola produced saleable paper

own area.

constant attention to the team spirit,from the start! The rebuild of PM 5

especially in the hottest project phas-

has a fairy tale ending – the paper-

Collaboration – How to walkes. Even when the team encounteredmaker, the end customers, thethe talk

challenges with conflicting opinions,

supplier – everybody is happy.

consensus was quickly reachedThat’s the way it should be.

If one word could describe thebecause everyone was truly on thePensacola project, it would besame team and working toward a“collaboration.” The importance ofshared goal.

this word may be diminished becauseof overuse, but at Pensacola, it has

The whole team can be proud oftrue meaning. A real cooperation

the result. The 12-month ramp-up

developed between all teamcurve was cut down to one third

members, and this was evident atof the original project plan, andContact
Erwin Holzinger
erwin.holzinger@voith.com“Voith did a very good job
in this very challenging role. ”
Todd Crutcher, Investment Manager, Intenational Paper's Pensacola mill, USA

twogether: At the beginning of thetwogether: Collaboration and teamCrutcher: Pensacola is clearly aproject, you decided to choose Voith

spirit – how did you succeed to walkglobal market leader in container-

Paper to be your single source

the talk?

board production, and the machine
has remarkable capabilities.

supplier. What were your exact
expectations, and how were they

Crutcher: It wasn't easy! I give a

fulfilled?

great deal of credit to the leadership

twogether: What are your expecta-of the key groups participating in thetions concerning the market develop-

Crutcher: The close coordination ofproject: engineering, construction

ment for (lightweight) kraftliner?

all the components (e.g. equipment,

and our mill partner. The overriding

machine clothing, roll covers) needed

principle was always to drive to the

Crutcher: There is no limit to further

in the machine rebuild was an impor-best solution through clear, honest

development of lightweight kraftliner

tant factor. The supplier had to workcommunication of the issues.

from Pensacola. Our customers likewith the mill production, project engi-

Success was only measured by thethe product, and the mill teams are

neering, maintenance teams and theTeam's results. It was never okay

becoming more proficient at making

construction company to ensure thatto have a win/lose situation. I am

the optimum use of the new technol-

the finished product was perfect – inproud of this result!

ogy installed.

every way. This expectation was crucial to the success of the Pensacola

twogether: How would you describe

rebuild. Voith did a very good job in

the quality of the end product and its

this very challenging role.

current position in the global market?

27 I 2008 I Voith Paper I twogether

27

REBUILDs

New MasterJet headbox at Manistique Papers

Rebuild results in
new production record

New headbox at Manistique Papers.

In 2007, Manistique Papers invested 6 million US dollars to upgrade their facility by replacing the existing
headbox with a new MasterJet II F Dilution Control headbox. Since the start up in June of 2007, the newheadbox is fully living up to the customer’s expectations and has significantly improved sheet profiles andsheet formation.
Objective of the Rebuild

the new dilution plate technology was

and a dilution system for excellent

used. The dilution header and highcross direction weight profiles were

The existing headbox was a Voith

consistency header were placedalso included.

W headbox from 1980, originallyabove the headbox in order to fit theAfter a scheduled nine day shutdown,

designed for 3000 fpm. The W

new equipment into the restricted

the new headbox was started up on

headbox was rebuilt years ago to

space, minimizing the total installed

be able to handle a maximum operat-

cost significantly.

ing speed of 4000 fpm, however,the current operating speeds have

New MasterJet II F Dilution

exceeded this level. The objective ofControl Headbox

this rebuild was to replace the W
headbox with a new MasterJet II F

In June of 2007 Manistique Papers

Dilution Control headbox designed

replaced the old W headbox withfor the current production speeds,

a 4.2 m (163.62 inches) wide Master-and capable of operating as a gap

Jet II F Dilution headbox. The newformer headbox in a future rebuild ofstate-of-the-art headbox is equipped

the wet end.

with lamellas for best jet quality,
Edge Module to achieve optimum

Voith had a significant design chal-fiber angle, and Edge Master tolenge to fit the new headbox into thecontrol sheet edges. A PD Tank tolimited space. To resolve the problem,

reduce approach flow pulsation

28

Aerial photo of Manistique Papers.

27 I 2008 I Voith Paper I twogether

REBUILDs

Customer Comment

Further Improvements

June 20th of 2007 and salable paper

Jon Johnson

was produced the same day. The
sheet went on the reel quickly thanks

The machine draw was reduced byGeneral Manager

to all the good preparation work done

approximately 1%, mostly due toManistique Papers, Inc.

by Manistique Papers and Voith. Soon

improved sheet edge quality. The

after the start–up, the optimization

sheet fiber alignment (TSO angle)

process of the new equipment tookafter the rebuild was within ±3

place and the results were very im-

degrees and the overall machinepressive. The new headbox improved

efficiency increased.

“Manistique Papers, Inc. has been on across direction weight profiles bypath of transformation from a newsprint

50%.

mill to a 100% specialty mill for over a

Infobox
The improved weight profile also

decade. In the past, our 100% recycled

Manistique Papers Inc.

resulted in a better moisture profile

content created customer excitement, but

Manistique Papers, located in Manistique
Michigan, USA, was founded in 1920; the mill
was recently acquired by the Kramer family,
based in Northbrook, Illinois, USA. Manistique's
100% recycled specialty paper products areused for commercial and book printing, as wellas business and envelope papers. It has been
manufacturing 100% recycled uncoatedgroundwood papers since 1984.

at the reel. The mill was able toincrease the reel sheet moisture
setpoint by 1.5%, resulting in lower
dryer steam consumption and significant cost savings.
Formation Improvements

variability in basis weight and moistureprofiles created printing and converting
deficiencies.
The new MasterJet II F Dilution headbox
provides excellent sheet formation, vastly
improved weight profiles and has enabled
us to increase machine capacity with theability to optimize sheet moistures.

Lamella technology and an intensive

A production record of 500 t/d was set on

Contact

optimization of jet impingement, jet

August 22, 2007; this shattered the oldvelocity (rush/drag) and table settings

Gilles Naultgilles.nault@voith.com

resulted in an improved formation.

record set in 1995 of 481 t.
The new headbox is a key component for

Sheet formation improved by 30 tothe future of the mill and the Voith team

40% for all grades produced on thisprovided unparallel support.”

Basis Weight [g/m2 ]machine.

0

0.2

0.4

0.6

0.8 1.0

1.2

1.4

1.6

1.8 2.0

2.2

2.4

2,6

2.8 3.0 3.2

3.4

3.6

3.8

Machine Width [m]Old Headbox

New Headbox

Improved CD profiles with new headbox.

27 I 2008 I Voith Paper I twogether

29

REBUILDs

Felt change in Docelles: the bottom felt is prepared for the installation in the press section.

Single NipcoFlex with PrintFlex SP3 Planar in use in Docelles

An unbeatable teamIn the summer of 2006, the PM 1 of the Finnish paper maker UPM
Kymmene was rebuilt by Voith Paper in the French mill at Docelles.
Especially for UPM Kymmene Docelles, Voith Paper developed afelt, which guarantees high dryness with a consistently goodmachine run. In October of 2008, a speed record was achieved on
the PM 1 with the Print-Flex SP3 Planar fabrics.

30

27 I 2008 I Voith Paper I twogether

REBUILDs

In October 2008, the PM 1 in Do-

Single NipcoFlex press from Voith

develop a product, which ensured

celles operated at 1215 m/min during

installed in 2006.

high dewatering from the beginningthe production of the envelope pa-

while at the same time guaranteeing

per “UPM Poste.” A few days earlier,

Challenge: high dewatering

consistent properties throughout the

felts of the PrintFlex SP3 Planar

right from the beginning

operating time. After numerous tests

type were mounted at both press

and test runs on the VPM 6 in thepositions in the press section of

The installation of the Single Nipco-

Voith Paper Technology Center inthe paper machine, combining

Flex press in 2006 was part of a

Heidenheim, Germany, the combina-

the proven Planar concept withrebuilding phase in the mill intion of Planar and Spectra technolo-

the Spectra elastomer technology.

Docelles. UPM Kymmene had decid-

gies finally developed. The innovative

Planar technology is a unique

ed to further improve the paper

PrintFlex SP3 Planar felts and themodular non-woven concept. Indi-

quality of its copy and envelope

Single NipcoFlex press operatevidually twined threads are placed

paper, and to increase the produc-

outstandingly in Docelles, which isnext to one another in a layer,tion. In order to meet this challenge,

also underscored by the speed

without being connected by other

Voith Paper recommended the Single

record.

threads.

NipcoFlex concept in Docelles. The
press became the core of the rebuild.

Thanks to the lack of crossing

It is one of the most space-saving

points, they provide the greatest

press sections and suitable for wood-

possible contact surface to thefree, uncoated grades. In addition

paper web and are thus clearly

to the new press, hot air dryers andsuperior to woven structures. For

products such as the Voith Drive andexample, a maximum production

ProRelease+ stabilizers were installed.

performance can be achieved thanks
to fewer sheet marks, faster runs,

Voith Paper Automation was in-and consistently high dewatering.

volved with the installation of an
OnQ EnviroScan and an OnV Felt-

Spectra technology is a non-woven,

View in the rebuild project. Bothnon-textile elastomer, which can

products were implemented for thebe highly compressed and provides

measurement of moisture during thea long-lasting reset force. The

paper production process. While the

combination of Planar and Spectra

Felt View measures felt moisture,operates optimally on sophisticatedpermeability, and felt temperaturepress positions where high dewater-in the press, the EnviroScan deter-ing performance and a compensa-

mines the moisture and temperaturetion of the vibrations are required.

of the web.

Thanks to the Spectra elastomer,
disturbances and irregularities in

The PM 1 in Docelles was only

the press are compensated. Sinceable to set its speed record after

February 2008, PrintFlex SP3 Planar

the Single NipcoFlex press had been

has been used as top and bottom

covered with the PrintFlex SP3 Planar

felt. PrintFlex SP3 Planar is a three-on all positions. The felts used are thelayered felt and consists of two

key element of the Single NipcoFlex

Planar layers and one Spectrapress section. For the Voith Paper’s

layer. It is the ideal fabric for the

research team , it was a challenge to

27 I 2008 I Voith Paper I twogether

InfoboxCooperation for over 30 years
The cooperation between Voith and the
UPM Kymmene Docelles mill began in the
1970s. As part of major rebuilds at the time,
Voith provided the press section, which was
followed in the 1980s by the rebuild of thedryer section.
Shortly before the turn of the century, a
DuoFormer D was installed to improve quality.
In 2005, Voith Paper received the contractfrom UPM Kymmene for the rebuild of thePM 1 in Docelles.

Contact
Christophe Le Morzadec
christophe.lemorzadec@voith.com

Sebastien Vanhove
sebastien.vanhove@voith.com

31

REBUILDs

The PM 4 at UPM Steyrermühl was rebuilt to the modern DuoFormer CVB design.

Increase in performance by upgrade of the forming section with loadable forming blades

Small outlay – big effect
The PM 7 at UPM in Schongau (Germany) and the PM 4 at UPM
in Steyrermühl (Austria) were equipped with counterblade
technology through rebuild of existing DuoFormers CV to themodern DuoFormer CVB concept. The paper quality was thereby
improved and the dewatering capacity increased. Both machines
have the fastest blade formers by far and with average speeds ofaround 1750 m/min are among the ten fastest newsprint machines
in the world.

PM 7 UPM
PM 4 UPM
Schongau
Steyrermühl
			Startup

1989

1990

Wire width

9,200 mm9,650 mmGradenewsprint

newsprint

FurnishDIP+TMP

Basis weight

40-49 g/m

DIP+TMP240-49 g/m2

Fig. 1: Basic data for the PM 7 UPM Schongau and the PM 4 UPM Steyrermühl.

32

27 I 2008 I Voith Paper I twogether

REBUILDs

The production of graphic paper

as the industry standard. Meanwhile,is used solely as the initial dewatering

grades with gap formers has its origin

gap formers for new graphic paper

element. It is designed as a separate

in the blade former. From 1988 tomachines are designed exclusively

element for the DuoFormer CB or,

1994, Voith built numerous successful

with flexible counterblades. This

alternatively, as the first section of

DuoFormer CF and CV blade former

key technology also finds broad

the subsequent forming suction box

models.

application in rebuild concepts forfor the DuoFormer CVB. The mostexisting formers. In particular, thesuitable concept in each case is the

The early blade former concepts

numerous existing blade formers offer

result of the overall evaluation ofwere impressive due to their gooda big market potential. Apart from aqualitative requirements and theformation, but at the same time

few exceptions, these machines wereexisting machine parts.

showed certain deficiencies in reten-

originally not equipped with loadable

tion characteristics. In addition, there

counterblades.

Both rebuild concepts were devel-

were other optimization issues typicaloped, tested and optimized by meansof the model, such as the sensitivity

Rebuild concepts forof intensive test runs on the Voithof jet impingement and cross profiles

blade formers

pilot machines. The deficiencies ofand also the sheet symmetry.

the early blade former concepts wereIn order to meet the most varied

thereby eliminated. Essential successAt the beginning of the nineties, thecustomer requirements, two rebuild

factors were, among other things,

blade former lost more and moreconcepts with counterblade technol-

optimized geometries for jet impinge-

importance. With the introduction ofogy for blade formers were devel-

ment and wire support, modern wire

combined roll-blade gap formers andoped: the DuoFormer CB and thedesign and the defined sequence ofthe flexible loadable counterblades,

DuoFormer CVB. Both concepts build

dewatering pulses.

the trend developed unequivocallyon the long experience of Voith gap

toward more modern concepts suchformer technology. They are

Rebuild of PM 7, UPM Schongau

as the DuoFormer CFD.

tailored both to Voith blade formers

and PM 4, UPM Steyrermühl

and to BelBaie formers.
Key component: loadable
forming blades

Both machines were started up barely
The arrangement of the dewatering

twenty years ago and produce mainly

elements follows the proven concept

standard newsprint. The PM 7 at

Since being launched by Voith, thisof the DuoFormer TQv. No forming

UPM in Schongau was rebuilt intechnology has become establishedroll but rather a curved blade shoe2006. The PM 4 at UPM in Steyrer-

DuoFormer CVB

DuoFormer CB

Fig. 2: Rebuild concepts for blade former with counter blade technology.

27 I 2008 I Voith Paper I twogether

33

REBUILDs

Optical Formation

Formation CD Profile Deviation

Bone Dry CD Profile Deviation

- 40%
+ 20%
- 70%

BeforeAfter

BeforeAfter

BeforeAfter

Fig. 3: The PM 4 at UPM in Steyrermühl – improvement in quality through rebuild from DuoFormer CV to CVB.

Perfect Fit rebuild concepts

mühl followed in 2007. Both formers

duction speeds. They are thus thein their original DuoFormer CV design

fastest blade formers in the world andwere rebuilt to the DuoFormer CVB

are among the ten fastest newsprint

The blade former rebuild concepts

concept. Essentially, the blade geom-

formers generally. The diagrams

described supplement the alreadyetry of the forming suction box wasabove show some quality improve-numerous solutions designed formodified and at the opposite side ament results of the PM 4 at UPM

other types of forming sections suchforming box with three loadable form-

Steyrermuehl. Along with the clearly

as hybrid formers or roll-blade gap

ing blades was installed.

reduced cross profile deviations, theformers. These concepts also offer

formation, in particular was improved

the most cost-efficient solution for

In combination with additional modifi-

by a good 20%. The good blade

meeting the customers’ targets. As acations on other machine sections,symmetry was achieved, dewatering

rule, loadable forming blade technol-

both machines increased their speed

capacity and thus process stability

ogy is used as the core element here,by ca. 100 m/min following the re-of the former was also increased attoo, in order to be able to meet typi-build. Today, both machines are in thethe same time by the installation ofcal customer targets such as quality

range of 1,750 m/min average pro-counterblades.

improvement and speed increase.

Fig. 4: Overview of rebuild concepts for graphic gap formers.
Duo TQb

Duo TQm

Roll-Blade

Duo TQv

Contact
Bernd Güldenberg
bernd.gueldenberg@voith.com

Blade

Duo CB34

Duo CVB

Duo CBhThomas Rühl
thomas.ruehl@voith.com

27 I 2008 I Voith Paper I twogether

REBUILDs

Between meadows and forests, up to 305,000 t/a of newsprint paper are produced on the PM 11 at the UPM mill in Schwedt, Germany.
(Image source: UPM Schwedt).

UPM Schwedt success story

A new lease on life: fit for the future in three days
The times are changing and we are changing with them – those responsible at UPM Schwedt, Germany,
took this old saying literally and decided to bring their 12-year-old quality control system (QCS) up to thelatest state-of-the-art system.
UPM Schwedt is not settling for

could be integrated into the new

cross profile controls were automatedhalf-way measures. The mill, which issystem supplied by Voith Paper

with the Profilmatic. In order toin the immediate vicinity of the Ger-

Automation. The existing isolated

achieve the highest possible unifor-

man-Polish national park, is setting

applications were integrated into themity of paper quality, several machine

standards in the areas of environment,

QCS software, so that UPM Schwedt

direction controls were also installedsafety and quality management.

is now profiting from a continuous,

that, among other things, also contain

Nothing less than “best available

uniform platform.

a program for automatic grade

technology” was set as the goal forchange.

the PM 11 paper machine, so

In the process, an upgrade for themodernization of the existing QCS

existing Profilmatic software, which

Furthermore, UPM Schwedt opted

was the obvious thing to do.

was already used on the headbox atfor a soft-/hardware update of

the OnQ ModuleJet dilution water

OnV TechnologyMonitoring. This

In doing so, it was important that thecontrol was also carried out. In thesystem monitors all critical machine

already installed automation products

course of standardization, all othercomponents and immediately sounds

27 I 2008 I Voith Paper I twogether

35

REBUILDs

Continuous quality control system from the headbox to the reel: OnQ ModuleJet, OnQ EnviroScan and OnQ Scanner.

		 “Along with the new hardware landscape,						
now fit for the future, the now uniform
platform was for us, above all, a great leap forward.”
Steffen Deszpot, Manager Mill Service & Energy, UPM Schwedt

an alarm if there are vibrations of felts

dryer section was checked andThose responsible at UPM Schwedt

or rolls. Furthermore, it is in a position

worn-out parts replaced. The project

were also satisfied with that andto detect short-wave fluctuations of

was topped off by delivery of an

Steffen Deszpot, responsible for thequality parameters – such as basis

OnView information system with a

PM 11 technology, is convinced:

weight or moisture – and assign themhigh-power database. It is integrated

to the machine parts that are causing

into the new QCS. Via OnView, easy

“Along with the new hardwarethem.

access to historical as well as current

landscape, now fit for the future,

data is possible that can be clearly

the now uniform platform was for us,

In addition, the other QCS hardware

visualized with various tools andabove all, a great leap forward.”

was also reconditioned and replacedthus analyzed.

when necessary. Thus, the scanner in

36

front of the reel was replaced by a

The extensive modernization was

Voith OnQ Scanner, which is equipped

carried out within three days. The

with sensors for basis weight, mois-

aim of increasing the uniformity of theture and thickness. The previous ash

paper produced was achieved. This

point measurement was integrated

illustrates the significant improvement

into the scanner. The existingof the 2sigma values of all important

OnQ EnviroScan that measures thequality parameters. Furthermore, Voith

moisture and temperature of the paper

Paper Automation guarantees

web directly at the beginning of thea technical availability of 99.8%.

Contact
Holger Loockholger.loock@voith.com

27 I 2008 I Voith Paper I twogether

REBUILDs“It’s clear:professionals wereat work here …”

During a visit to the UPM mill in Schwedt, Germany, Steffen Deszpot, Manager Mill Service & Energy, tooktime out for a conversation. The topic was the modernization of the quality control system (QCS) on the
PM 11. The 35-year-old has worked at the mill for seven years and has had a storybook career. Since lastyear he has taken over the responsibilities of Technical Director and has jointly overseen the QCS project.
twogether: Mr. Deszpot, what were

twogether: Without a doubt, youthat Voith will upgrade the Schwedt

the reasons behind the modernization

solicited several proposals. What ulti-

service center and we thus profit fromof the PM 11?

mately tipped the scales for Voith Pa-

quick access times and an expanded

per Automation?

spare parts storage.

incomplete hard- and software support

Deszpot: Voith’s proposal offered

twogether: UPM and Voith employ-

for the previous QCS. We simply didn’t

what was technically the best and mostees worked hand-in-hand on the

Deszpot: The crucial factor was the

get any more spare parts, or only at high innovative solution. It satisfied our de-project. How would you describe thisprices. In the current situation on thesire to integrate existing automation

joint teamwork?

paper market, however, you just can’t

components into the new QCS. Thereafford that. A market leader, like we are,were indeed less expensive proposals,

Deszpot: The teamwork was very

who wants to stay that way in the future

but I can defend Voith’s somewhat

good! The project support was beyond

can only do it with modern technology.

higher price without misgivings, sincedispute. Voith started up with a vigor-

For that reason, along with good,

I’ve gotten quality for it. Furthermore,ous, experienced group here, and you

uniform paper quality, high technical

we also wanted Voith’s automation forhave to praise the responsible project

availability was also an aim of the proj-a Voith machine in order to have as few

managers on both sides. They worked

ect. It was clear to us: if you want todiscussions about interfaces as pos-

together closely and in a structured

be one step ahead, you have to invest.

sible. In addition, it was important to us

fashion and really delivered a super job.

“A market leader, like we are, who wants to stay					that way in the future can only do it		 with modern technology.” Steffen Deszpot
27 I 2008 I Voith Paper I twogether

37

REBUILDs

Because of that, the final implementa-

What do you think are the mosttoring possibilities than were available

tion of the project took only threeimportant advantages?

to us previously, was a clear leap

days.

forward. Nowadays, such a system
Deszpot: The PM 11 already had ais indispensable in order to keep antwogether: One of Voith’s claims israther high degree of automation be-eye on the machine. Proactive mainte-

to offer our customers custom-madeforehand, but the system had grown

nance thus becomes possible andsolutions ...

slowly and featured a motley hard-malfunctions can be eliminated before

and software mix. Everything wasthey cause problems.

Deszpot: ... and that was done, too.

operable, but there was no well-Since we have our own programmers

rounded concept. That has changed

However, one of the most importantand developers at the plant, over the

now! Existing isolated applications

advantages for us is also the reliable

years some of UPM Schwedt’s own

were integrated and all QCS products

spare parts supply for the QCS thatsolutions emerged that we didn’t want

have now been brought together on ais now ensured. In this way, we saveto lose. They were responsive to thesecommon platform. The daily workon procurement costs and the mainte-

special requests and even attended toroutine has thus become clearer,nance costs are also at a reasonabledetails such as font sizes and so forthi.e., in very concrete terms, we havelevel.

on the control panel displays.

also been able to say goodbye tosome monitors in the control room.

twogether: How do things look with

twogether: The new system has

Furthermore, the new Voith technology

the paper quality? Have your expecta-

been running now for almost a year.

monitoring, offering many more moni-tions been met here?

		 “Voith started up with a vigorous,							experienced group here.” Steffen Deszpot

38

27 I 2008 I Voith Paper I twogether

REBUILDs

		 “Nowadays, such a system is indispensable					
in order to keep an eye on the machine.” Steffen Deszpot
Deszpot: Our aim was to get a uni-

have a higher smoothness of running

twogether: Mr. Deszpot, when you

form, suitable, i.e., for us controllable

and thus also an easing of the ma-look back on the project today, what

paper quality both in machine directionchine’s web break characteristics.

do you remember in particular?

and also in cross direction. Our

That’s difficult to express in figures,customers, the printing houses, should

but in my assessment the number ofDeszpot: Many companies canhave exactly the same basis weight

breaks has decreased. Due to theimplement the technology today.

at the beginning of the roll as at theconstant quality, the paper runs

However, a project is carried out by

end and of course also a clean profile

through the machine in a superior

the people who work on it. And in thisover the entire width. The moderniza-

way not only with the printers, butcase all have really done a very goodtion certainly helped us in this. The

also with us.

job! It was clear from the very begin-2sigma values of oven-dry tons,

ning: professionals were at work there.

moisture, thickness and ash are clearly

twogether: Have you also had

I can thus say with a good conscience

better. Furthermore, thanks to the

feedback from your customers in thisthat I would do it again in exactly the

new grade change program, we canregard?

same way.

weight to the next, so that the differ-

Deszpot: Yes, complaints regarding

twogether: Many thanks for theence in cutting of rolls declines. In

quality are declining and our paper

candid conversation!

addition, the more uniform paper

has a very good reputation with thequality contributes to the fact that we

printing houses.

change more quickly from one basis

The PM 11 of UPM in Schwedt.

27 I 2008 I Voith Paper I twogether

39

PRODUCTS

A perfectly matched team: MultiFoil rotor and C-bar screen basket

Quality improvement with lower energy consumption
Save energy wherever possible: a goal high on the priority list of many paper makers. Utilizing the rightcombination of rotor and screen basket in the screening machine can save up to 30% on energy costs.
The MultiFoil rotor and C-bar screen basket from Voith Paper have proven themselves to be an especiallysuccessful duo. Moreover, a newly developed narrow bar basket allows for further improvements in quality.

C-bar S

C-bar QA perfectly matched team: MultiFoil rotor and C-bar screen basket.

As early as 2002, the MultiFoil rotor

capita consumption of about 4.000

C-bar screen baskets noticeably im-

and C-bar screen basket were in-people in Thailand.

prove the screening efficiency andstalled in several pressurized screens40

20% larger open screen area throughnarrower bars with the new C-bar Q.

product quality. The reduction rate

at the Thai Kraft Paper factory. Since

The secret to success is the optimizedof sticky content increases and thethen, the Thai paper maker is saving

screening mechanism of the two

overall fiber loss drops.

nearly 7 million kWh of electric powercomponents. The foils allow theeach year, emitting 9,143 fewer tons

MultiFoil rotor to generate adjusted

Successful retrofitting of third-

CO2 and reducing the overall fiberpressure and suction pulses, whichparty equipment

loss in the approach flow systemthus provide for constant flowfrom 0.4 to 0.1% when compared toproperties. Pulsations like those that

Voith machines have been adapted

the old screening equipment. It was

frequently occur with other types offor a long time to the high perfor-

also possible to considerably reduce

rotors are kept to a minimum. This

mance requirements of screening

the residual sticky content following

significantly reduces power consump-

systems in paper mills. Since 2000,

the screening system. The electricity

tion. Thanks to the precise apertures

over 200 non-Voith screens have alsosaving corresponds to the yearly per

and the special profile design, thebeen retrofitted with the C-bar tech-

27 I 2008 I Voith Paper I twogether

PRODUCTS

C-bar S

C-bar Q

Converted TLA 450 with MultiFoil rotor
and C-bar screen basket.

C-bar Q quality advantage: noticeably fewer impurities in the product (sample sheets
taken from the second stage of OCC long fiber screening).

nology and MultiFoil rotor from Voith

impossible to increase output.

pulp is distributed across a larger

Paper. These include, among others,

After converting to MultiFoil and C-bar

available open screening area. The

the facilities of Chinese paper makertechnology, the screen worked out-

screening efficiency increases andNine Dragons and Smurfit Kappa

standingly — even at 20% higher

contains noticeably less foreign sub-based in the city of Zülpich in Germany.

throughput.

stances in the screened stock. If thePrior to the conversion, Nine Dragons
often had to deal with fiber spinning

slot passing velocity is kept constant,
Even better screening resultson the rotor and the screen basket.
The problem was solved by equip-

the production quantity of the screen
can be increased alternatively without

The various products of the C-bar

compromising the screening quality.

ping the pressurized screen with aseries are distinguished from each

As a result, the use of the C-bar Q

C-bar screen basket and MultiFoil

other by the width of their verticallyeither improves the screening effi-rotor. Throughput was also increased

arranged bars. The more narrow theciency or increases production andfrom 950 to 1.000 m³ per hour whilebar width, the more open screening

without any compromise on quality.

power consumption was reduced byarea is available. In 2007 Voith Paper

The Spanish customer of Voith Paper

30%.

launched a new narrow bar screen

was so convinced by the C-bar Q

basket design, the C-bar Q, offeringresults that he immediately ordered

At the Smurfit Kappa mill in Zülpich,

20% more open screening area than

the same type screen baskets for ad-

there were troubles with fiber

the standard bar screen basket.

ditional screens.

spinning on the PM 6, which wasremedied by retrofitting the approach

Comparisons made at the Spanish

flow screen. At the same time,

cardboard maker U.I.P.S.A. (Union

throughput was increased by 10%

Industrial Paperlera S.A.) using thewithout any change to the total power

new C-bar Q and the standard screen

consumption. Installing a MultiFoil

basket C-bar S showed that for therotor and C-bar screen basket in thesame aperture width it was possible toPM 4 in Zülpich also resulted in a

increase the removal rate of stickies

production increase. The old screen-with the C-bar Q by 12%. The reason

ing equipment had run up against a

is a reduction of the slot passing

throughput limit, meaning that it wasvelocity because the same mass of

27 I 2008 I Voith Paper I twogether

Contact
Michael Thoma
michael.thoma@voith.com

41

PRODUCTS

Pure high technology – NipcoFlex shoe press.

NipcoFlex shoe presses and QualiFlex press sleeves for optimal dewatering

Evolution instead of revolution
The technology of the closed shoe press has been on the market for over 20 years. Nonetheless,milestones in the efficiency of paper machines are still being achieved with NipcoFlex shoe presses
and QualiFlex press sleeves through consistent development.
The technology of the closed shoe

have been successfully brought onto

classic roll nip. The NipcoP counter rollspress was already launched in a firstthe market so far.

to the shoe roll are equipped with theapplication in 1984. The advantages
that can be obtained with shoe presses

new grooved stainless steel cover,Undisputed market leadershipare not only the energy-efficient optimi-

G-Flex. In addition, QualiFlex press
sleeves are also supplied for the Nipco-zation of a production line. The rise in

The 400th NipcoFlex shoe press was

Flex shoe presses. Voith Paper is thedry content here leads to a reduction ofsold by Voith Paper to Tamil Nadu

only manufacturer that has shoe press

thermal drying energy, with the addi-

Newsprint and Paper in India. It is partand press sleeve technologies concen-

tional consumption of electrical driveof the new PM 3, which will produce

trated under one roof; thus, they can beenergy being overcompensated by far.

high quality, wood-free writing and print-

optimally coordinated with one another.

Additional advantages include, e.g.,

ing paper. The PM 3 has a wire width

longer felt running times or improvedof 6,100 mm and a maximum speed of

For Tamil Nadu, this is already therunnability of the production line due to

1,200 m/min. It will be equipped with

fourth shoe press after rebuilds of thefewer breaks. With gradual introductiona Tandem NipcoFlex press section, in

PM 1 and PM 2 in 2002. This follow-up

of shoe press technology, starting withwhich the enormous dewatering ca-order shows the confidence Tamil Nadu

packaging paper and going through all

pacity of two NipcoFlex shoe presses

has in this proven technology. With aother paper grades all the way to theis combined with the volume-conserv-

market share of 60%, Voith is the clear

shoe calender, over 400 shoe presses

ing pressing, completely without themarket leader in this segment.

42

27 I 2008 I Voith Paper I twogether

PRODUCTS

Mini NipcoFlex shoe press

enormously high power density was

solution for small and medium-sizeachieved, so that with a sheet widthmachines. As an application example,

Depending on the production line sizeof 4,500 mm a line load of up toa press rebuild of a paper machine forand required output of the shoe press,

500 kN/m can be attained.

production of wood-free paper grades

the construction kit of available modulethat is 5,000 mm wide (Fig. 2) can besizes had already been consistently

It is significant that all essential com-noted. Starting with a roll press with aexpanded in the past and oriented toponents of the NipcoFlex technology,

120 kN/m line load in the third nip, withmarket needs. Specifically in rebuild

already proven in many instances,which 45% dry content is achieved,

situations with restrictions regarding

such as pressure shoe, press system

the dry content can be increased by

space requirements or crane capacity,or hydraulic concept, were also taken

3% to 48% by using a Mini NipcoFlex

Voith was always in a position to offer

over for this new roll size in order towith a 450 kN/m line load.

the most compact shoe press rolls withoffer maximum reliability.

the highest power density.

In Fig. 3 the energy-related andAs an example, the integration of afinancial effects for 80 g/m² paper at

This construction kit is now supple-

Mini NipcoFlex press into a multiple-

1,200 m/min are shown. The higher

mented by the Mini NipcoFlex press.

roll press, as was done with the firstdryness corresponds to a saving ofHere, it’s a matter of a new shoe rollorder for a customer in Italy (Fig. 1),

115 t of steam per day or approx.

size with only 770 mm diameter.

can be cited. The Mini NipcoFlex

72,200 kWh/d less energy. But at

Despite this very small diameter, anpress is generally an ideal rebuild

the same time only ca. 4,900 kWh/dFig. 1: First Mini NipcoFlex installation (blue and yellow) in Italy.

27 I 2008 I Voith Paper I twogether

43

PRODUCTS

more electrical energy are required formaterial. Only if all three criteria are met

sleeves’ land area under load and thethe drives and hydraulic system. It thus

a press sleeve can contribute to last-required flexibility for use in shoe

becomes very clear that a shoe press isingly ensure the maximum performancepresses. The result is a void volume in

the ideal way to save large amounts ofof a production line over the entire life

the nip that is up to 20% higher. This

energy. Even taking into account thetime.

is the basic precondition for efficient

fact that a KWh of steam is more cost-

dewatering with the highest line loads.

effective than electric current, good val-

In the development of QualiFlex sleeves,With the same nominal groove geom-

ues result for the ROI. Despite extra ex-

work is continuously done on all three

etry in comparison to competitors, itpenditure for drive energy or press

areas. With the introduction of an inter-can contribute to increased and at thesleeves the paper manufacturing costs

rupted groove in the surface portfolio,same time long-lasting dewateringin the selected example can be reduced

customer needs can now be addressed

and improved dry content values.

by almost 900,000 euro per year to a

in a more individual fashion. Precisely

large extent as a result of energy sav-for systems in the transitional range be-This can be clarified on the basis ofings. And this does not yet take any ac-

tween blind-drilled and grooved sleeves,practical experiences clearly showing

count of possible additional production

this can be a way to optimize the drythat the dewatering remains constantdue to increased speed.

content without getting problems withover the long running time. This iswater spraying back. With over 100

reflected toward the end of a sleeve

QualiFlex press sleevesdifferent possibilities, QualiFlex sleeves

period with demonstrably up to 1%

thus offer the largest surface variety on

more dry content.

The performance of a shoe press is also

the market and allow individual coordi-

significantly dependent on the perfor-

nation with the requirements.

Contact

mance of the press sleeve used. The
essential factors for success here areWith optimized polyurethane grades,

the right surface selection, with grooved

there has been success in combining

sleeves maximum stability of the land

the highest abrasion resistance witharea and an especially wear-resistantextremely high stability of the grooved

49

Energy and financial effects for wood-free paper (80 g/m²)
and a working width of 5,000 mm (nearly 200 in):48
Dryness [%]

47

+ 3%

46
45
44
43
100

A

B

150

200

250

300

350

400

450

500

550

Line load 3rd Press [kN/m]
A DuoCentri II Press
B Mini NipcoFlex Press
Initial situation: 	v = 1,200 m/min
v = 1,200 m/min
Line load 70 / 80 / 120 kN/mLine load 70 / 80 / 450 kN/m
Fig. 2: Up to 3% increase in dry matter content possible.

44

Thomas Augscheller
thomas.augscheller@voith.com

Today

Mini NipcoFlex

Speed

1,200 m/min

1,200 m/min

Line load

70 / 80 / 120 kN/m

70 / 80 / 450 kN/m

Dryness

45%

48%

Steam		- 115 t/day
consumption		- 72,200 kWh/day
Electrical drive		+ 4,900 kWh/day

Sum		- 881,900 €/year

Fig. 3: Through use of the Mini NipcoFlex press,
881,900 euro can be saved annually.

27 I 2008 I Voith Paper I twogether

PRODUCTS

The TailBlade system shortens the threading time and increases threading reliability substantially.

Market leadership with ropeless transfer systems strengthened further

Reliable tail transfer with the TailBlade system
A cooperation agreement was concluded at the beginning of the year with the Finnish company,
Runtech Systems. It has to do with ropeless tail transfer for double-tier dryer sections. The TailBladetransfer system provides for reliable and fast threading.
The Voith Paper system for ropelessnozzle blows in the direction of thetail transfer that has been successfully

dryer cylinder. There it lifts the sheet

used for over 15 years was further

tail from the dryer and creates an air

Top priority during the development

developed with the company Runtech

cushion.

was given to low sensitivity to process

Systems and thus ensures market

Advantages of TailBladefluctuations such as grade changes

leadership in the coming years.

The second nozzle blows in the direc-

and speed changes. After a webtion the paper is running; it acceler-

break or restart of a paper machine,

Functioning of TailBlade systemates the paper tail and fixes it cross-the TailBlade system shortens thewise to the machine direction bythreading time and increases threading

Just like the previous threading sys-means of the suction effect at thereliability substantially. The papertem, the new system works with blow-

TailBlade. The upper air nozzles in

web can be run wide earlier and theing nozzles in order to be able to

the guide element likewise blow in thefull production starts up again quickly.

transport the sheet tail safely fromdirection of the sheet run and thus

In addition, the maintenance costs aredryer cylinder to dryer cylinder. Mini-

support a stable paper run with mini-

noticeably lowered and operational

doctors made of carbon fibers are

mal shreds.

safety at the paper machine is in-installed on the top and bottom cylin-

creased.

ders. These TailBlade units are move-

Variable designs of the TailBladeably mounted so that they can beprovide for safe and fast transfer evenattached to the dryer cylinder

with narrow space conditions, such as

during the tail threading. The core ofat group gaps or at already installed

the TailBlade transfer system consists

machine-wide doctors. The flexibilityof a carbon blade of the doctor, whichof the application is additionally shownis designed as an air nozzle and sepa-

by the possibility of upgrading the

rated into two air chambers. The firstprevious blow-air threading system.

27 I 2008 I Voith Paper I twogether

Contact
Norbert Butzke
norbert.butzke@voith.com

45

PRODUCTS

Cascades bet on hot melt for winder

Gecko start and end gluing that inspires

Fig. 1: The application unit – the heart of the Gecko.

46

27 I 2008 I Voith Paper I twogether

PRODUCTS

The operators of winders know about the significance of start andend gluing. However, until now some wishes remained unsettled.
The new Gecko system from Voith does away with the previous
disadvantages. Quality and productivity increase noticeably and, in
addition, the costs of consumables can be lowered. The Gecko is
the perfect conversion solution for all existing winders.

Start and end gluing is an important

Our solution

step within the winding process. If
the gluing process does not proceed

The new “Gecko” start and end

optimally, bothersome production

gluing is the first choice when it’s ainterruptions and badly glued spots

matter of replacing existing gluing

are the results. The former lowers theequipment. The new hot melt systemproductivity of the winder and thenot only does away with the difficul-

latter causes problems in subsequentties during the production processprocessing such as packing anddescribed above but also guarantees

transporting of the finished rolls.

a durable and resilient adhesion.

Basis

Voith’s Gecko has a strong andreliable hold – just like its little green

Until now, you could fall back on

namesake. But in contrast to thetwo alternative methods for start andliving version, the system works in

end gluing. Either cold glue is applied

contactless fashion. With several

to the paper web or adhesive strips

applicator nozzles, it sprays hot melt

are attached. These hitherto known

precisely onto the paper or board

methods often do not satisfactorily

web from below.

perform the task of gluing.

Infobox
Advantages of the new hot melt system
Gecko:• High process reliability• Suitable for all paper grades• Strong and long lasting adhesion•	No limitations in gluing-, web-, and setchange speeds• Easy maintenance•	Low operating costs with low glue
consumption•	Circulation principle avoids clotting or
hardening of the glue•	Approved for indirect contact in foodprocessing

27 I 2008 I Voith Paper I twogether

With cold gluing, the elaborate clea-

In collaboration with eight adhesivening of the applicator nozzles and tray,

manufacturers, 30 adhesives were

the dispensing of dripping water into

examined on the way to the best

the slitter section or into the mainte-possible gluing result. The Powernance area and incorrectly adhering

Tack M700 adhesive, which iscold glue hamper the smooth produc-

particularly distinguished by its

tion flow. Once the gluing process isadhesive strength and cure time,interrupted, it can no longer be proper-

was developed especially for use

ly completed. In that case, the processwith the Gecko.

must be carried out by hand. Unplanned machine standstills and additionalField report: Cascades

personnel expenses are the result. If
adhesive strips are used, complica-

After development of the new starttions can result due to cutter and sur-and end gluing, a customer wasface dust, along with the high costs forquickly found who wanted to test theconsumables and the time-intensive

Gecko under production conditions.

changeover process.

Voith found a competent partner in

47

PRODUCTS

Fig. 2: Sizing using spin-spray process.

Cascades at Arnsberg, Germany,
where coated folding box board between 180 and 450 g/m² is produced.

• reduction in the high running costsof consumables (adhesive strips)• reliable start and end gluing of
the rolls

The challenge for every retrofitting• reduction of dead times for theand every subsequent installation inwinder (increase in productivity)

an existing system is to carry out thewere all achieved to the fulltask in the shortest possible time.

satisfaction of the customer.

Customer Comment
Manfred Stemmer,
Managing Director,
Cascades Arnsberg
GmbHBest of all, during a planned standstill.

Since November 2006, the hot melt

“We were the first ones who retrofitted

system was successfully put intoa winder onto the new roll start andAfter two days of on-site preparatory

operation on four other winders in

end gluing system from Voith Paper. The

work, commissioning took place inEurope.

collaboration was excellent. Despite a

Arnsberg within only six hours intight schedule, all deadlines were met

November 2006. This lightning-fastby Voith “to the minute.” When we had

conversion is possible since thequestions, there was always a contact

Gecko is set-up and completely

person available who promptly gave
exhaustive information.

tested before delivery. The Gecko
has been working now for more than
two years without malfunction or
maintenance worth mentioning.

Contact

After several months running time, one
Johann-Günter Grilljohann-guenther.grill@voith.com

can say that it was a smooth project
without start-up problems. To end witha play on words: “Voith’s start and end

The goals of the conversion sought

gluing – perfect from start to finish!”by Cascades

48

27 I 2008 I Voith Paper I twogether

PRODUCTS

New approach in doctor blade technology

The perfect harmonization of doctor blade and roll coverRoll, cover and doctor blade must become an unbeatable trio. To achieve this, modern doctoring analysis
methods, a unique doctor service and constant innovations in doctor blade technology are all necessary.
Efficiency and runnability of a paper machine can only be increased considering these factors.
Thorough analyses of the doctoring are• Measurements of blade angles onnecessary to identify existing weak
points. In a complex doctor audit, eachworn and new doctor blades• Check of doctor efficiency anddoctoring system

machine section is investigated and• Measurements of run-in doctor
angles with micro-section andmicroscope• Profound report including summary• Optical check and evaluation of• load• oscillation• check of drive and bearing

The results gained in an audit arefunction of cover and blade• Investigations and evaluations ofevaluated and analyzed with state-analyzed.
A doctor audit contains:• Check of lubrication in operation

doctor profile in the lab

and suggestionsof-the-art methods of modern R&D

Voith Paper Rolls service expert changing a blade.

27 I 2008 I Voith Paper I twogether

49

PRODUCTS

techniques. In addition to the investi-

Success Stories

gation results, on-site inspection of
the doctor blades are subject tocover was optimized. The fibercomposite blades (SkyComp 60)

LWC machine in Austria:

profound analysis in the Voith Paper

reached a lifetime of 45 days; former
blades reached only 15 days.

labs. Technical and application know-

The doctoring situation was investi-

how is incorporated into the constantgated and analyzed as described

These results can only be achieved

monitoring of the doctor situation,

above. The operation conditions werewhen roll covers and doctor blades

which is important for the successful

optimized by the specialists fromare constantly working together.

performance of roll covers.

Voith Paper Rolls. With the perfect

Both components have to be

doctor blade quality, the cleaning and

Joint development of roll covers

synchronized to achieve maximum

conditioning of the cover surface wasand doctor blades

efficiency. Detailed knowledge aboutsignificantly improved. The lifetime ofcovers and doctor blades are of

the blades could be increased; de-The latest innovation in thermal coat-utmost importance and both are

posits between take-off and cleaning

ings, TerraSpeed, was the basis for

combined within Voith Paper. The

position were reduced.

the development of thermal coatedharmonization has proven to be very
successful. Permanent cooperation

doctor blades, which can be applied
Kraft paper machine in Bulgaria:

between production, application ser-in both cleaning and take-off position.
State-of-the-art manufacturing tech-

vice and R&D are the motor for inno-

Based on the results of a detailed

nologies were implemented for thevations, developments and effective

analysis of the press section, theproduction of thermal coated steel

applications of SkyLine doctor blades.

doctoring situation on the TopRock

doctors and coater blades. Besides
the high quality coating, the grinding
procedure for coater blades is of high

SkyLine team in expert talk (from left to right) Christoph Scherz (Production),
Rene Zottler (Application service), Alexander Etschmaier (R&D).

importance for the product. Verynarrow tolerances must be observed.
Tailored bevel geometries can beapplied to the coater blades (SkyCoat),on special machines in only one production step.
First successes were achieved on aboard machine. The intense cleaningof the TerraSpeed coating and thenever achieved lifetime of the
SkyTerra doctor blade proved theapproach of harmonizing roll coverand doctor blade to be right.

Contact
Dr. Georg Gobec
georg.gobec@voith.com

50

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PRODUCTS

View of a honeycomb structure.

Top-level precision

Rolls – rolling round the clock
As paper machines are increasingly becoming larger, wider and faster, it is essential for the rolls tokeep up with this development. Qualified staff, state-of-the-art technologies and advanced manufacturing processes are extremely important and a prerequisite to achieve this goal.
Every day, over 110 people are busy

around paper machine rolls. The

deviation. As the material used for

manufacturing rolls and contributing

machinery in the manufacturing hallmanufacturing rolls changes andtheir experience. Many of them haveare up to 18 m long, yet these ma-

moves during machining, it poses a

been working in manufacturing forchines are aligned for straightness

great challenge to both man anddecades and have deep knowledge

tolerance of less than 0.04 mm

machine. Almost every roll is unique

27 I 2008 I Voith Paper I twogether

51

PRODUCTS

and specially tailored to the needs of

140,000,000 holes. Placing all holes

produces a very light, yet very sturdy

the paper machine for which it is in-

one after the other in a straight line

structure. Since the electrical resis-

tended. Length, diameter, weight andwould result in a length of more thantance changes as the honeycomb isload data are exactly calculated and7,000 km, which equals the distancebuilt, a special CNC system is used todefined before production begins.

from New York to Budapest!

monitor and adjust the welding param-

Tibo

New welding robot

In 1999, the first gun-drilling machineThis year, a welding robot was ac-

are important. The Austrian roll

(Tibo 1) was installed in St. Pölten,

quired to assist the personnel infactory is certified according toAustria, for producing suction rolls.

plasma jet welding operations. The

ISO 9001/2000. This is how Voith

Tibo 2, the bigger brother to thiswelding robot achieves an extremely

keeps pace with the constantproven machine, was installed tohigh accuracy, which is essential foradvancing development of paper

handle the increasing number of suc-stainless build-up welding of suction

machines.

tion rolls. Almost 200 spindles simul-

roll heads. A very high, but very shorttaneously drill the suction holes into

energy input leads to minimum mixing

the duplex stainless steel. The Tibo 1

while resulting in excellent bonding toand Tibo 2 are the most advanced

the parent material.

eters to stay within precise tolerances.
Consistent high quality and precisionsuction roll drilling machines in theworld. For example, a continuous vi-

Honeycomb structure

Contactbration monitoring system is used todetect drill wear and vibration in order

Apart from that, honeycomb struc-to minimize and avoid breakage oftures for forming rolls and dandy rolls

drill bits. Up until now, Tibo 1 andare also manufactured. Spot-welding

Tibo 2 have drilled more thanwith an amperage of up to 5,000 A

Made to measure: Suction holes are drilled into the duplex steel by spindles.

52

Thomas Hackl
thomas.hackl@voith.com

Welding robot for plasma welding.

27 I 2008 I Voith Paper I twogether

PRODUCTS

MultiForm HC and DuoFormer Base perfectly fit together.

Forming fabric MultiForm HC, the new standard for demanding positions

Producing Board and Packaging on a new level
The new H-Series product line would not have been complete without the HC design range.
MultiForm HC is a coarse SSB weft bound design, featuring high dewatering capacity, low marking
and predictable life, fitting today’s application requirements for coarse forming fabric demanding
board and packaging positions.
The MultiForm HC is the coarsest

formation, low marking, high strength

activity, to obtain a good profile andmember out of the recently developed

values, clean running and predictablea homogeneously formed sheet.

H-Series. This design is especiallylife.

For example, in the case of multiply

created to fit Voith Paper’s DuoFormer

board, this might also enable a

Base bottom positions. In addition, theHigh forming fabric dewatering

reduction of under-top and top layer

MultiForm HC has a much wider field

capacity is required as often raw

grammages. Additionally, it is benefi-

of application. It is suited for the pro-material with high SR values arecial not only to get high amounts

duction of middle or filler ply of multi-

applied or in gap-former technology

of fines on the surface to get highboard and under ply of white top liner,huge amounts of water need to be

surface strength, but also high ply

test liner, kraft liner and grey board.

removed in a short time span. At thebonds between sheets.

same time, high mechanical retention
Forming fabric requirements

without the use of chemical additives

From the point of view of machineis preferred, even when dewatering

productivity, clean running is a very

Typically, forming fabric requirements

takes place under aggressive circum-

important issue. Flat forming fabricin relation to the above mentioned

stances. The forming fabric needs toedges, low water spraying and fiber

application fields are high dewatering

be stiff and stable, but at the same

bleeding or fiber carrying will keep

capacity, good retention, homogenous

time be able to pass on counter blade

the machine environment clean and

27 I 2008 I Voith Paper I twogether

53

PRODUCTS

ARI

400

150
140
130
120
110
100
90
80
70
60
50

350
300
250
200
150
100
MultiForm HC

Competitor 1

ARI range

FSI range

Competitor 2Competitor 3

FSI

Competitor 4

achieved. In Asia, MultiForm HC wason the gap-former at a record start-up,
producing the first paper at a speed of
1210 m/min. According to the customer,
the target dry content and sheet quality
were achieved. Based on the apparent
features, MultiForm HC is the newstandard for coarse forming fabricdemanding positions in board andpackaging. Feedback from customers
of different countries is very positive,
showing a bright future for MultiForm HC.

FSI (Fiber Support Index) and ARI (Abrasions Index) in comparison.

reduce the risk of breaks. Goodmany, our DuoFormer Base trial mach-and predictable running times enable

ine. This way, new forming concepts

long production runs, shorter andcan be tested in a non-production

less machine stops.

environment and later be transferred,
at low risk, to real production machines.

MultiForm HC Development

Trial runs with MultiForm HC wereInfoboxJulius Schulte Söhne PM 3, Germany
Paper grade: Coreboard, Speciality paper /Cardboard packaging
Basis weight: 140- 650 g/m²
Former: Fourdrinier with top dewatering unit

made in comparison with MultiForm V
MultiForm HC has been developed to– a warp bound SSB design, and Multi-

address all of the mentioned points.

Form A – a high shed Extra Weft Added

Additionally, taken into account havedesign. The new MultiForm HC showed

been the potential decrease in raw

higher initial dewatering, higher me-material quality and higher quality de-chanical retention, lower marking andmand of the customers of board andsmoother surfaces. Furthermore, thepackaging producers. A further object-

MultiForm HC ran very clean.

Customer Comment
Dirk Niedel
Production Manager at
Julius Schulte Söhne

ive is the desire to save costs byproducing lighter grades with the same

Field results“We have established that MultiForm HC

strength properties. The outcome is the
SSB technology-based MultiForm HC

Runs on production machines confirm

can be used for the whole range of our(SSB = Sheet Support Binder), combin-

the test results. In general, improved

products. Increase in machine speed anding, for example, a high Fiber Support

formation is reported as well as

production were two results we were

Index of 142 and an Abrasion Index oflowered retention aid consumption. At

able to achieve, moreover paper quality

330 within one product. In comparison,

Julius Schulte Söhne PM 3, Germany,

improved. MultiForm HC has become

out in the market there are hardly any

the production of core board was clearlystandard on PM 3 and now, moreproducts within this segment even

improved by upgrading from a triple

recently, also on our PM 2.”reaching one of these two numbers!

weft fabric to MultiForm HC. The customer reported that he was able to in-

Test runs at VPM 5 increase machine speed and production

Ravensburg

output as well as improving the relevantContact
Johan Mattijssen
johan.mattijssen@voith.com

paper parameters and the dewatering
MultiForm HC has been thoroughly ex-

capacity. Fabric life was 110 days,

amined on VPM 5, Ravensburg, Ger-

about 15% more than previously

54

27 I 2008 I Voith Paper I twogether

PRODUCTS

Convenient upgrade option

To a new S7 controller
without production loss

27 I 2008 I Voith Paper I twogether

55Products

A new control system in five steps
1. Removal of existing CPU
2. Installation of new “OnC VeriCheck57” module
3. Reading of S5 and S7 programs
4. Mixed operation with synchronization of both programs
5. Activation of S7 program
The hardware components can be subsequently
replaced at any time.

If a product is phased out, it’s time to look around as quickly as possible for something new.
It is good if the alternative also brings additional benefits: OnC VeriCheck57 allows graduated-costmodernization of existing S5 controllers without additional standstill.
After production of the SIMATIC S5

output signals are also simultaneously

gradual conversion, the costs areprogram, which is common in the pa-

processed by S7. This allows a de-staggered and the investment remains

per and pulp industry as a controller,

tailed alignment of both programs

straightforward. The extent of theis gradually phased out by the manuf-that is automatically recorded andmodernization is individually arranged

acturer, the product will no longer be

evaluated.

with the customer. In addition, due toavailable from 2015 at the latest. In

the software verification a FAT (factoryorder to make the conversion of

As soon as there are no longer any

acceptance test) becomes unneces-

existing S5 controllers to the S7 suc-irregularities between S5 and S7 andsary, saving both time and costs.

cessor version as simple as possible,

both work in completely congruent

Voith Paper Automation has develo-

fashion, one can switch over to S7

ped a solution with OnC VeriCheck57

during a planned shutdown. Thisthat is adapted to the needs ofverification of the software offers thecustomers.

highest possible reliability during
migration. In addition, a modernization

Quick, safe, gradualof the S5 controller becomes possible
without production loss.

OnC VeriCheck57 offers a gradualmigration of SIMATIC S5 to S7. In the

Keeping costs under control

process, the existing CPU (central
processing unit) is first replaced with

One of the most important advantages

a new, more high-performance V57

of modernization by means of OnC

assembly from Voith. In the next step,

VeriCheck57 is the separation ofin addition to the existing S5 thehardware and software conversion.

S7 program is also read in, so that

In contrast to other approaches, withboth run parallel in combined operati-

this solution only the CPU is replaced

on. Control of the connected hard-

and the rest of the hardware compon-

ware, such as valves, is still done at

ents such as I/O cards and PCs canthis time via S5, but all input andcontinue to be used. Through this56

Infobox SIMATIC S5/S7
The SIMATIC S5 was launched on the market
in 1979 and is among the programmable logic
controllers (PLCs). It is for controlling process
and machine functions. The program is stored
on a processor, the so-called CPU (central
processing unit).
After production of the S5 is stopped, an
upgrade to the SIMATIC S7 successor version
will be necessary to ensure the availability of
replacement parts and support by service
personnel.

Contact
Michél Lochmannmichel.lochmann@voith.com

27 I 2008 I Voith Paper I twogether

Service

Energy audits reveal savings potential

Papermaking under close “energy-scrutiny”
In recent years the costs for oil, gas and electrical power have increased at breakneck speed.
One of the biggest challenges in papermaking is therefore to reduce energy consumption, so as toensure cost-efficient production. An energy audit carried out by Voith Paper provides an analysis of
the energy consumption in paper production. It then identifies where in the production processenergy can be specifically saved and/or better utilized.

Approach Energy Audit. Savings through:Reduction of specificenergy consumption (kWh)Optimizations in the areas of:Heat recovery of dryer systems

Performance review bycomparison of situation before and after energy audit

Steam & condensate system
Preparation of process water
Refining energy
Energy consumption vacuum system
Electrical drives
Operating concepts & procedures
Overall energy balance

Fig. 1: Process focused on mass consumers.

The Voith process and product engi-

is to be investigated. The energy audit

which are to be investigated in detailneers are familiar with every step ofwith Voith Paper results in specificin phase two. The dryer including thethe papermaking process as well as

solution proposals with detailed costhood could be examined, for exam-

the latest products and solutions foranalysis for each individual situation.

ple. After all, the dryer is responsible

saving energy effectively. They work
closely with the customer to determine

for 50% of the energy used in paper
Energy audit process

the best solutions for the respective
situation.

production. Or, the actual consumption of the paper machine drive could

The energy-saving potential in thebe examined.

paper production is investigated andUsing state-of-the-art measuring tech-confirmed in three phases:

Second phase: detailed analysis

First phase: potential analysis

In this phase of the energy audit,

nology the papermaking process is
examined on site. The focus is not juston saving energy, but also on evaluat-

Voith Paper’s process engineers

ing the locations where there is poten-

First, the current process data of

calculate, compile and evaluate thetial for energy recovery or energy pro-large-scale consumers is looked atmeasured data. How much energy isduction. The customer decides whichwith the customer. The benchmark

consumed in total? Which measured

area of the paper production processleads to selecting the key focal areas

data are particularly conspicuous?

27 I 2008 I Voith Paper I twogether

57

SERVICE

The data from the customer’s paper

customer has decided for a go, Voith

mill is compared with various param-

Paper experts perform the engineering

eters: the usual standards, the stan-and implement the solutions. Efficiency

dards of Voith Paper products andmonitoring confirms the economic

future options. Specific solution pro-viability of energy savings.

Raw material:	Recovered paper,
TMP
Sheet width at reel:5,300 mm
The evaluation of measured data andposals to save, recover or produce

process data on paper machine A

energy in the production process are

Case study of an energy audit

led to the following results for the air

now worked on. A detailed report ishandling system:

sent to the customer just a few weeks

What form does an energy audit take• One option achievable in the short

after the on-site analysis. This reportin practice? Using an example, the in-term is to save steam by making

contains:

dividual steps will be shown in detail.

modifications in the steam andIn consultation with customer the aircondensate system of the produc-• A summary of the energy audit• Tables with all measuring results• Detailed analysis of the data
• Comparative studies• Solutions, options• Voith Paper’s recommendations

tion hall heating.

handling system on two paper machines with the associated steam and• There is no economically attractive mo-condensate system and hot water cy-

dification possible in the area of the heatcle (paper machine B only) have been

recovery system expanded in 1994.

determined as the area to be audited.
Measurements were recorded and thePaper machine B

prioritized according to feasibility

existing processes were investigatedand economic viability.

and analyzed from the point of view of

Output:	190,000 t/a

feasibility, the necessary investment

Product:	LWC and newsprint

cost and economic efficiency.

Main basis weight: 57 g/m²

Third phase:
Offer and implementation

Raw material:	Recovered paper,
Paper machine A

TMP

The most cost-effective solutions that

Sheet width at reel: 5,400

mm

were worked out in phase two (detail

Output:130,000 t/a

study) form the basis for an engineer-

Product:

Newsprint

ing offer to the customers. Once theMain basis weight: 45 g/m²

Customer

Idea,
Needs,
Datas

DecisionVoith

1. Potential analysis

Process
analysis,
Benchmark,Experience,
Experts

Potential
analysis
Steam &
condens.
Heat reco.
drivesVacuum

2. Detail study

Decision

Datas
collection
Measurement report
Plausibility

ReportProposal forsolutions,
Recommendations,
ROI
BudgetAt paper machine B the air handlingsystem, production hall air condition-

3. Realization

Decision

Detail quotation
Pre-Engineering,
Feasibility,

Order
Engineering
DeliveryCommissioning
After action review

Fig. 2: Energy audit phases 1–3: step-by-step to an individual solution.

58

27 I 2008 I Voith Paper I twogether

SERVICE

ing and hot water cycle were exam-

As a follow-up contract to the com-ined thoroughly. The measurements

pleted energy audit, detailed engi-

and process data show that energy

neering – including quotation for thesavings can be implemented eco-conversion of the heat recovery sys-

nomically for the air handling systemtems, ducts system and integration ofand also the hall ventilation.

waste water heat recovery in the process water cycle – was carried out for

The following solution proposals

the air handling system. Here, too, awere formulated:

ROI of less than 1.5 years could beshown. Voith Paper energy audits

Air handling systemproduce the following results:• Operating mode with lower hood

• Solutions for sustainable energy

intake air temperature• Savings of energy through expanding the heat recovery systems
and integrating a waste water heatrecovery process.
Hall ventilation / air conditioning

savings• Unlock hidden potential• Amortization period usually< 1 year• Complete customer satisfaction
Many references confirm theseresults.

• Optimizing the operating modethrough optimum use of the heatContact

recovery energy from the hall air

Raimund Rembeck
raimund.rembeck@voith.com

conditioning system thanks to Voith
EOS (Energy Optimization System),
resulting in a ROI in less than a

Infobox
The following sub-systems may be part of anenergy audit:• Hood and air handling system- Dew point measurement and hood balance- Air flows, humidity, air temperature- Insulation, leak and corrosion tests- Operating window for fan• Drying cylinder- Cross profiles and heating curves- Siphons- Evaporation calculations• Steam and condensate system- Review of concept- Assessing components (valves, pumps,
separators, pipe routing etc.)- Actual values and operating window- Evaluation of operating point• Heat recovery- Balance- Checking heat exchanger capacity- Calculating maximum load and economic
load• Hall ventilation- Balance- Air volumes, temperatures- Testing hot water cycle• Process water treatment• Energy for refiners• Energy consumption vacuum system• Electrical drives

year (details Fig. 3).

Results of case study Paper machine B
Investment energy audit
Saving optimization controls machine related air systems

ROI = 0,3 a

Investment Energy Optimization System (EOS)
Saving optimization controls hall ventilation

ROI = 0,5 a

Investment alternative hood exhaust air 3
Saving inclusive wastewater treatment plant

ROI = 1,4 a

Investment alternative hood exhaust air 1&2
Saving inclusive wastewater treatment plant

ROI = 1,3 a

Required investments
Saving potential

ROI = 0,9 a

Fig. 3: Amortization period < 1 year for a high degree ofcustomer satisfaction.

27 I 2008 I Voith Paper I twogether

Fig. 4: Solutions for sustainable energy savings.

59

SERVICE

The virtual winder is a functional and graphic computer model which is connected with the real control system.

The virtual winder facilitates the real work in reality

Training simulator used successfully
Steep start-up curves with new machines mean hard cash for the operating company. Of course, theoperating team can only achieve such picture-perfect starts when it is familiar with the machine fromthe outset. The Voith training simulator now sees to that for the first time. All technical workflows canbe already run through in advance independently of the real system.
In contrast to the paper machine thatout and the next parent reel is inserted.

electrically. The PLC (programmable log-

continuously produces with constant

The beginning of the paper web must

ic controller) coordinates all technical

speed, a winder works discontinuously.

be brought to the inserted core set.

workflows. Precision and dynamics of

The parent roll is accelerated to operat-

Depending on the machine type, thisthe drives are the decisive precondition

ing speed and decelerated in sufficientis done manually or automatically. Withfor the productivity of the machine andtime before reaching the finished rolla modern winder, practically all pro-for the quality of the cut rolls.

diameter. The cut finished rolls are end-

cesses can be automated. This increas-

glued and discharged. A new core set is

es not only productivity but also work

supplied and the start glue is applied.

safety. But the multitude of automatic

The next operational cycle begins. Aftermovement courses also involves highIn the ideal case, a fully automatic wind-approx. 5 wound sets the parent reel iscontrol complexity. Movements are car-er cuts one roll set after the other with-unwound. The empty reel spool is lifted

ried out pneumatically, hydraulically andout intervention of the operator. But in

60

The reality

27 I 2008 I Voith Paper I twogether

SERVICE

and diagnose malfunctions. For safety

is prepared with a special program

reasons, many areas of the machineand converted to the VRML format.

are fenced in and not directly visible toAfterward, courses of movement can

the operator. The comprehensive diag-

be defined. The simulation program

nostic functions and locking displays

activates the animations. Camera

are important aids for the operator inpositions integrated into the graphics

order to ensure smooth operation of theallow viewing of all courses ofmachine.

movement. The zoom function canenlarge every detail.

In order to prepare oneself for the demanding tasks, nowadays usually only

With the simulator, the entire process

the real machine is available. With on-

workflow of a winder can be repre-

the-job training, the necessary moves

sented in real time, in slow motion or

are learned and experience is acquired.

in time lapse. Error situations andParadoxically, this lasts all the longer

malfunctions can be activated andthe more the machine works without

repeated as often as needed. And the

malfunctions. Training in eliminating

best thing is: nothing really breaks

malfunctions is best done when practi-

down and the bothersome cleaningcally solving problems. But how shouldup after a web break is easily taken

this accumulation of faulty automatic

care of with the press of a button.

workflows be achieved in reality, and
who wants to do it anyhow? The virtual

Summary

reality, malfunctions in the process

winder is a genuine alternative here.

workflow are unavoidable. Paper is a

Based on so-called hardware-in-the-The virtual winder is a functional andsensitive product. Initial tears, breaks,

loop simulation in connection withgraphic computer model that is con-holes, imperfections or contamination

animated 3-D design graphics, it is anected to the real controller. A training

by the glue lead to technologicallyperfect training simulator.

simulator is thus available to thecontingent malfunctions. Damaged ordisplaced sensors and actuators areoperator with which all technical workThe training simulator

causes for technical interruptions in theflows can be run through. The use of
the original design data and the origi-

automatic system cycle. The winder is

The initial basis is a functional comput-

nal controller ensure that the virtualno easy challenge for the operator. The

er model of the winder. This program

winder behaves in an absolutely realis-

complex workflows are secured against

simulates the entire sensor and actua-

tic fashion. Secure mastery of com-

one another in a complex manner. The

tor system in functionality and dynam-

plex workflows can be practiced on

number of inputs and outputs pro-ics. Connected to the simulation PC are

the simulator without danger andcessed in the software are even larger

the PLC, the operator workstation andwithout interfering with production.

than in the case of a paper machine. At

the terminals. The original software ofThat is the best precondition for highthe same time, 80% of the programmed

the machine is installed on these de-productivity of the real winder.

functions are necessary to cover thevices. No software adaptations for thenumerous special cases after a mal-simulation workflow are undertaken.

function and to get back into automaticThis ensures that the virtual winder be-mode. A multitude of screen pages are

haves exactly like its real counterpart,

available to the operator on the opera-

down to the very last detail. The 3-D

tor monitors and terminals, so that he/

design data is the basis for visualization

she can configure the automatic modeof the technical workflows. This data

27 I 2008 I Voith Paper I twogether

Contact
Volker Schölzke
volker.schoetzke@voith.com

61

SERVICE

NipSense and NipMaster for optimized dewatering

Perfect Team play in the Nip
In times of rising energy costs and resource shortages, the identification of saving potentials in apaper machine becomes more and more important. The biggest saving capacity certainly can be foundin the press section. But which measures can be taken? Trials are expensive and time consuming.
NipMaster can help.

Screenshot of
NipMaster.

NipMaster is a software tool whichmore and more important. NipMastermodels and analyzes roll covers. In-

helps to quickly identify potentials

stead of expensive trials and failures,and implement steps to improve theRoll covers and felts are equally im-

the modeling of roll covers becomesmachine efficiency.

portant for the dewatering of the nip.

Felts integrated into NipMasterUsing data from NipSense, NipMaster creates a video that enables one to observe the nip closing precisely.

62

27 I 2008 I Voith Paper I twogether

SERVICE

Pull-in of NipSense mat.

In cooperation with Voith Papera polyurethane cover is installed. The

A nip allowing a uniform moisture

Fabrics the behavior of the clothing inresults showed a clear increase incross profile is of crucial importance;

the nip was tested. The efficiency ofdewatering capacity. The paper mill

not only for optimized dewatering,new felts was compared to used ones.

decided to install SolarFlow. The

which leads to energy savings in the

The results of these tests, like changes

effective outcome was an increase ofdrying process, but also for optimum

in compressibility, thickness anddryness of 1% after the 4th press andpaper quality. NipMaster andvoid volume were integrated into theelimination of shadow marking.

NipSense ensure this.

NipMaster, enabling the tool to calculate nip width and nip loads with and

NipSense

without felt. The calculation is basedon complex material models – thisBut just a software is not enough.

is unique within the industry. The

Besides the analysis of moisture crossevaluation of the dewatering capacity

profile and conditioning of felts andis defined by the available void vol-covers, it is also important to know

ume in the covers and felts. Here,the real nip conditions. Theory and

it is important to analyze the capacity

practice are combined by NipSense,

when the covers and felts havethe electronic nip measurement fromreached their life end.

Voith Paper Rolls. The measured data
can be easily analyzed with NipMaster.

More than 500 nip positions world-

The software translates the data into

wide have been calculated anda video showing the nip closure proce-

optimized with NipMaster thus far.

dure. The dewatering efficiency can

The experienced outcomes enrich the

only be increased with a proper closureknow-how data base of Voith Paperof the nip. NipSense already identified

constantly.

weaknesses in nip conditions:

For example, the improvements on an• Identification of unaligned nip

LWC machine:

closure and definition of correction

A steel suction roll was installed on themeasuresmachine. NipMaster calculated how thedewatering situation would change if

27 I 2008 I Voith Paper I twogether

Contact
Dr. Michel Beltzung
michel.beltzung@voith.com

Alois Mohralois.mohr@voith.com• Adjustments of nipco rolls• Check of crown calculations

63

RESEARCH AND DEVELOPMENT

One of 40 gap formers for board and packaging papers running worldwide - DuoFormer Base at Jass Schwarza.

How to make a successful concept even better

DuoFormer Base II – a step towards the future
Increasingly lighter basis weights, higher machine speeds and ever decreasing raw material quality –these are the three challenges many papermakers are facing today. To cope with this situation, the new
DuoFormer Base gapformer in its second generation has been developed.
Putting the more than 40 Voith Paper

specific output have been reached.

ing in more contaminants and conse-

gap formers used in the board andNow, why should anyone want toquently poorer dewatering properties

packaging industry all over the worldchange this tried and tested con-of the fibres.

together, results in an impressive

cept?

amount of operating experience.

Apart from that, the demand for lightThe answer is quite simple: Changes

er papers without raising the speed

The benefits of the gap former con-in the market require an adaptation

leads to a reduction in tonnage. A

cept have been proven in a large

to the present situation. The share ofcloser look at the gap formers sold sonumber of production lines. Several

recycled paper used as raw material

far reveals a clear trend: Ever increas-

records with regard to speed andwill even increase in the future, result-ing machine speeds and decreasing

64

27 I 2008 I Voith Paper I twogether

RESEARCH AND DEVELOPMENT

basis weights. In order to follow thisThe Voith Paper engineers focusedlored to the technological needs. Dur-trend the target of the further devel-on optimal accessibility during opera-

ing normal operation, start/stop se-

opment was to adapt the concept.

tion, simple maintenance and excel-

quences allow easy and quick han-lent clean design. The clean designdling. While doing service and mainte-features specific advantages: Lowernance work, the focus is onbuild-up of mist by showers, for in-occupational and machine safety.

Ambitious development goals
Various customer suggestions result-stance, and less deposits. Therefore,

ed in the corners of further develop-

operational disturbances caused by

The control loops are easy to operate

ment. Besides higher drainage ca-

web breaks can be reduced.

thanks to the visual display system,

pacity, operating stability, clean

offering different views for the analysis
and diagnosis of failures and alarms.

to a high-grade integration of the au-

With OnC LoopSpy, the operator has

attributes like process stability eventomation system. The proven OnCon-a very powerful tool, helping him towith varying raw material quality,

trol process control system based on

diagnose and visualize online theexcellent technological values over a

the Siemens PCS-7 platform wascause of any alarm or failed switching

wide speed range, reproducibility ofadapted to satisfy the special require-

operation directly on the screen, thus

technological parameters and easyments of the paper industry. The en-considerably increasing control trans-

grade changes were equally ensured.

tire visual display system is process-parency.

The operating window also needed tooriented and quickly gives the opera-

meet present and future demands for

tor a current overview at any time.

The settings of the former have signifi-

light basis weights.

The subordinate machine logic is tai-cant influence on paper properties.

2,000

300

1,600

250

1,200

200

800

150

400

100

0

Basis Weight [g/m²]

Great importance has been attachedvestment costs were improved. Other

Design Speed [m/min]design and the reduction of the in-50
2000 2001

2002

2004

2005

2006

2007

2008

2009

Year
Gap former

Gap former with additional fourdrinier wire

Trend in Speed

Design Speed of the corresponding PM

Fourdrinier paper machines with low operating speed and high basis weight range are decreasing.
The trend clearly goes towards higher speeds and lower basis weight - the domain of the gap former.

27 I 2008 I Voith Paper I twogether

65

RESEARCH AND DEVELOPMENT

With OnV VirtualSensors it is possible

fect on drainage capacity. Increased

Due to an optimized web guidance

to predict parameters like strengthroll drainage positively influences the

combined with good web run(for example SCTCD). This enables

strength values required for packag-

stability, a lower design height ofan optimization of the former settings

ing papers. The blade section has

the former was the result.

at an early stage.

been shortened, thereby ensuring
good formation and gentle handling

HiVac instead of suction

Secrets of dewateringof the moist web.

couch roll

As is commonly known, the major

The drainage at the forming roll is

The high-vacuum box (HiVac) has

part of drainage takes place in the in-mainly determined by four parame-

been successfully used in graphic

let area. Therefore, forming roll andters: the wire tension; the open vol-paper machines for many years.

jet channel request special attention.

ume of the roll shell, the suction zone

Adapting it for packaging papers

length, as well as the vacuum level in

was therefore nothing but a logical

Decisive concept changes in thethe suction zone. EvoFlow F with its

consequence. For light and medi-

twin-wire area are a higher forming

shrunk-on wire and honeycomb de-um-weight paper grades, the HiVacroll wrap angle, a shortened blade

sign, is the market leader when it

is used as the last dewatering ele-

section, reduced vacuum zones, as

comes to void volume due to thement instead of a suction couch roll.

well as a modified water flow.

highest open volume available. For

It improves the drainage capacity,

better wearing protection, the forming

eliminates the maintenance re-Practical experiences have shownroll can be coated with CeraForm ce-quired for a suction roll, reduces

that a larger wrap angle on the Evo-ramics. In this case, the shrunk-on

investment costs and provides an

Flow F forming roll has a positive ef-

wire is not required.

energy saving potential for

The use of the DuoFormer Base II permits up to 200 m/min higher speeds at the same basis weights.

200

Basis Weight [g/m²]

180
160
140
120
100

DuoFormer Base
TL, CM references
DuoFormer Base

80
60
600

800

1,000

1,200

1,400

1,600

DuoFormer Base II

1,800

2,000

Machine Speed [m/min]

66

27 I 2008 I Voith Paper I twogether

RESEARCH AND DEVELOPMENT

Forming roll EvoFlow F and forming wire MultiForm – concentrated Voith Paper know-how for the new DuoFormer Base II.

vacuum depending on the box’s

Choosing the right forming wire

the good clean design as well as

length.

application starts with understanding

the bundling of know-how in thethe customers needs with regard toareas of forming roll and wire design

The HiVac can increase dryness

paper quality, drainage capacity andare self-evident. Optimally matchingafter the wire section by a higher

runnability. A balance is achieved bycomponents are required to achieve

percentage compared to the solution

selecting a wire design suited to thesuperior paper quality and machineusing a suction couch roll. The

requirements. Using abrasion-resis-

performance – no matter what chal-amount of water in the web before

tant materials helps to ensure maxi-

lenges the future may hold.

the pick-up roll is lowered by

mum wire lifetime while maintaining

more than 10%, thus reducing

a high paper quality.

the water absorption in the pick-up
felt.

With MultiForm, Voith Paper Fabrics
developed a complete product

Understanding the process

portfolio to meet the customers'

leads to successrequirements.

To get the most out of the gap

The results of constant product-

former, a thorough understanding

related development of formingof the whole process is required. In

wires were quite logically integrated

particular the wires play an important

into the further development of therole, and requirements are diverse:

DuoFormer Base II.

High initial drainage capacity,

Contact

excellent fiber support, smooth

Each detail in the new concept

and trouble-free operation and run-perfectly fits together.

Wolfgang Schwarz
w.schwarz@voith.com

nability, optimal wire stability, as
well as long service lives, just to

Excellent dewatering conditions

mention a few.

(dewatering shoe, water guidance),

27 I 2008 I Voith Paper I twogether

67

RESEARCH AND DEVELOPMENT

New polyurethane roll cover increases production and saves energy

SolarSoft – the magic word for perfect tissue
Rubber roll covers in tissue manufacturing are notorious for after hardening and heat development.
SolarSoft, a polyurethane roll cover developed for tissue, minimizes these issues, while providing
potential for energy savings and production gains.

Possible surface design of SolarSoft.

Due to material limitations, rubber rolland on the fastest machine:

Longer run periods – SCA incovers are problematic in tissue

2050 m/min (6700 fpm). Hence Voith

Ortmann, Austria

manufacturing. One of the mostPaper is pursuing a two-part-strategy

common problems is after hardening

to meet the ever increasing demands

A SolarSoft cover has been installedof the rubber. Typically a rubber coverof the tissue industry. On one hand,in SCA Ortmann’s PM 9 machine

will after harden 20 to 40% over its

the current rubber roll covers will

since October 2007. An inspection inlife. This hardening changes thecontinue to be improved.

September 2008 noted that the sur-performance of the roll. Anotherface still looks nearly new after elevenunfavorable characteristic is heat

On the other, a new polyurethane

months of operation. Historically,

generation due to rubber’s dynamicroll cover has been developed

rubber covers at this mill had to be re-properties. Heat generation results in

especially for tissue. Polyurethane

moved after eight months in operation.

excessive cover temperatures, which

mitigates the hardening, heat genera-

can reduce cover life or require inter-tion, and wear resistance issues

No internal cooling – WEPA in

nal water cooling of the roll.

associated with rubber. Polyurethane

Müschede, Germany

also offers advantages in dewatering
Despite these limitations, rubber

and reduced variability formerly

Stephan Frank, Plant Manager ofcovers are still often used in theunachievable with rubber. The

WEPA Müschede stated the following:tissue industry. In North America,

result of this development effort is“Until now the pressure roll was

Voith’s T-Master II runs on the largest

SolarSoft – its successes argue forcovered with rubber covers, therefore

machines – up to 7.6 m (300 in) wide,

itself:water cooling was absolutely neces-

68

27 I 2008 I Voith Paper I twogether

RESEARCH AND DEVELOPMENT

sary. Some time ago the water cooling

was converted to SolarSoft withcover. The end result is significant

failed and the rubber cover was de-additional blind drilling (31.7% open

raw material savings as well as anstroyed within a few hours. The mainte-area). This change immediately al-

improved environmental impact.

nance costs for the cooling were

lowed a machine speed increase invery high. Now SolarSoft has been inexcess of 100 m/min, using standard

operation without cooling for several

machine settings. The Mill Processmonths. During the next planned down-

Leader said, “This change looks to betime, the cooling will be permanently re-a major move forward for this mill,

moved. This saves us time and money.”giving us a potential increase in pro-

Infobox:duction up to 5 tons per day. The roll
Rubber, being a weaker material iswas changed from the standard rub-limited to a maximum open area of ap-

ber cover without changing anythingprox. 30%. The stronger polyurethane

else on the paper machine; we restart-

allows the maximum open area to

ed without any problems and immedi-

increase over 40%. Polyurethane

ately saw a speed increase in excess

covers can also be grooved more ef-of 100 m/min. We see no reason now,

fectively than rubber, which provides

given some continued experience,

another way void volume can be

why the spare roll cover should not be

increased to customize the cover.

replaced with the same Voith Solar

Increasing the surface open area andpolyurethane cover.”SolarSoft Benefits:• Better dewatering through increased variety
of surface designs and excellent dynamic
properties• Better tissue quality through tailor madesurface designs• Longer lifetime of the cover through very
good wear resistance• Higher tissue quality through constant nip
conditions during operation• High level of operating safety and machine
availability through outstanding strength andelasticity• Optimized safety through minimizing thesubsequent damages in particular injuries ofindividuals

void volume provides opportunities toincrease dewatering at the press. In-

Saving raw materials throughcreased dewatering has three potential

optimized dewatering

advantages; production increases, reduced energy consumption, or poten-

Another example of a dewatering

tial to increase the use of recycled ma-

advantage is from a tissue mill interial. All of these opportunities reduce

North America. Initial installation of

cost while minimizing the environmen-

SolarSoft achieved three production

tal impact of the operation.

records because the cover dewateredContact
Dr. Benno Baderbenno.bader@voith.com

better. Since then, the mill has been
Increase in production throughable to increase the recycled paper

speed increasecontent considerably without signifi-

Joseph Oyler
joseph.oyler@voith.com

cantly reducing the production rate.
A standard rubber covered suction

This is something that had beenpressure roll with 19.8% open area

impossible with the previous rubber

50
40
30
20
10
0

Rubber 35 P&J

SolarSoft 35 P&J

Tear strength

27 I 2008 I Voith Paper I twogether

Relative wear resistance

40

60
Hardness [P&J]

Die C Tear [N/mm]

70

SolarSoft

35
30

Gummi

25
20

1

Hardness change

14
Days

90

360

2,0
1,5
1,0
0,5
0,0

RubberSolarSoft

Wear resistance69

RESEARCH AND DEVELOPMENT

Contaminated and cleaned Dryer Fabric. Contamination on the surface is effectevly removed with the DuoCleaner Express.

Making a huge difference in the dryer section

Improving the drying process using		
PrintTech LFC with Linx technology
PrintTech LFC spiral dryer fabric with Linx technology combines into
one fabric the advantages of different designs such as easy to clean
and high abrasion resistance.
Higher machine speeds and increas-

In PrintTech LFC, the X-shaped

ing use of recycled fiber are placing

stuffers have a special design.

greater demands on low permeability

They work together with the spiraldryer fabrics for fabric cleanliness,structure to ensure that high pressure

better overall wear resistance,

cleaning water jets are deflected.

improved tail threading and reduced

Thereby, the surface scabs arebreak frequency.

removed effectively.

Fabric Cleanliness

The cleaning effect of different
fabric designs has been tested on a

70

To maintain a clean fabric in thestate-of-the-art Pilot Cleaner test rig

early dryer sections has always been

at Voith Paper facility in St. Pölten,

a priority for papermakers. Besides

Austria. Test samples were cleaned

helping to achieve high sheet quality

with high pressure jets at 350 bar forand maximum heat transfer, a clean

4 seconds. The test results confirmed

fabric also ensures good trans-

PrintTech LFC with Linx Technology is

mission of under-pressure for effective

the easiest to keep clean. During

sheet control and less sheet breaks.

continuous dryer fabric cleaning, it

Fabrics are often removed prematurely

is possible that too much water isdue to heavy contamination.

carried on the surface of the fabric

27 I 2008 I Voith Paper I twogether

RESEARCH AND DEVELOPMENT

causing re-wetting of the web andis 250% stronger than most woven

wear or sometimes, a combination ofcreating other paper quality issues.

designs and has 40% more material

both. By choosing PrintTech LFC

The tests also prove that the higher

to resist wear.

with Linx Technology, and combining

the surface void volume, the greater

it with a good cleaning system,

the risk of re-wetting.

Successful on the machine

Linx technology produces a spiral

On a high speed graphic paper

fabric changes translate to economic

fabric with the lowest surface void

machine in Asia, the average fabricbenefits, less machine downtime,

volume among all the spiral designs

life on the 2nd dryer section had

higher production and lower

in the market. Working together

reduced from 95 days to 40 days

operational costs.

with modern cleaning systems,

due to abnormal roll side seam wearsuch as Voith’s DuoCleaner Express,

caused by pitted roll surfaces.

these problems could easily beovercome. Longer life and fewer

PrintTech LFC with Linx Technology

The above benefits together withachieving reduced break frequency

consistently delivers a cleaner fabricDue to its superior wear resistance,

and improved sheet quality leads towith lowest re-wetting to meet the

PrintTech LFC with Linx Technology

happier faces in the paper mill.

expectation of papermakers.

improved the life by 68% and was

In conclusion, PrintTech LFC withremoved safely at a scheduled

Linx Technology can truly make a

Better overall wear resistancemachine shut after 160 days. Thishuge difference in the drying section.

translates to a potential fabric cost
A further concern is reduced life andsavings of thousands USD per year.

damage caused by abnormal wear.

The customer was extremely pleased
and rewarded Voith Paper Fabrics

For normal woven designs, the seamwith repeat orders.

area, being the weakest link of thefabric, will experience quicker wear

Summary

Contact
Jiew Poh Liew
jiew_poh.liew@voith.com

and fail prematurely, with potentiallyhigh risk of damage to the machine.

Many dryer fabrics have short lives

PrintTech LFC with Linx Technology

due to either contamination or fabric

The structure of the PrintTech LFC is optimized with specially designed filler yarns.

27 I 2008 I Voith Paper I twogether

71

RESEARCH AND DEVELOPMENT“We are very satisfied with the
exceptional performance of theIntensaPulper and also plan toequip other production lines
with this pulper.”Akihiro Yamamori (left) and Mitsuaki Fujimoto (right),
Oji Paperboard, Oita Mill, Japan.

Energy-saving pulping concept for recovered paper fibers

Success for IntensaPulper IP-R in Japan
Voith IHI Paper Technology has received the “Sasaki Prize” from Japan TAPPI for the new IntensaPulper.
The new pulping concept is catching on outstandingly in Japan: eight new IntensaPulpers were ordered in
the last 18 months and another four pulpers were converted to IntensaTechnology.
The IntensaPulper IP-R is based on

The first model was installed in Janu-

IntensaPulper, which was character-the IntensaPulper IP-V which wasary of 2007 at Oji Paperboard in Oita,

ized as great progress for the paper

designed for pulping virgin fibers.

where it replaced a conventional LC

industry. “Actually, no one in Japan

With the IP-R model it is now also

pulper. Its eccentric vat has a volume

could imagine that there could be an

possible to pulp recovered paper.

of 50 m³. With an actual input power

even more efficient and better LC

In comparison to conventional LC

of 420 kW, this IntensaPulper is forpulper than the hitherto commercially(low-consistency) pulpers, substantial

pulping Japanese OCC (JOCC). It isavailable pulper,” says Masakazu

structural changes were implemented.

distinguished by its high capacity andEguchi, Manager of Stock Prepara-

On one hand, the rotor in the vat wasan improved pulping action. In thetion Engineering department, Voith IHI

eccentrically placed; on the otherproduction quantity of up to 850 t/d

Paper Technology in Japan. “But

hand, the transition from the bottom(air-dried), there are only half as many

now the IntensaPulper is the non plusof the pulper to the cylindrical wall

flakes today as before the installation

ultra.” Already more that 20 Inten-

takes place in a flow-optimized fash-of the IntensaPulper IP-R. Since

saPulpers IP-V and IP-R have been

ion with a double-cone bottom (wethe first startup, seven other Intensa-

ordered worldwide from Voith Paper.

reported on the new development in

Pulpers were ordered in Japan andthe last issue of twogether magazine).

four pulpers were retrofitted.

Conversion with profit

guide elements in the pulper vat, an

After the new pulping concept was

Existing LC pulpers can be upgradedenergy saving of up to 25% is thereby

awarded the “Palme de l’Innovation”

to the current state-of-the-art with so-achieved.

in October 2007 at the ATIP trade faircalled IntensaTechnology. An “Intensa-

in Grenoble, France, an official dis-Technology conversion set” consists

tinction in Japan also did not fail toof a flow geometry adaptation in the

Together with optimization of the flow

Progress for the Paper Industry

72

materialize: in May 2008, Voith IHI

vat and a simple rotor conversion or

In Japan, the IntensaPulper IP-R was

received the “Sasaki Award” fromexchange that accompanies a speed

a success from the very beginning.

Japan TAPPI for development of thecorrection, depending on the system.

27 I 2008 I Voith Paper I twogether

RESEARCH AND DEVELOPMENT

The Japanese Sasaki-prize certificate.

The new IntensaPulper IP-R.

The effect of these measures is impres-(air-dried) had previously been pulped

sive. “In a specific case, we optimized

at this facility. After the conversion witha Hydrapulper in a Japanese paper

IntensaTechnology, the power input isplant in such a way that the specificonly 420 kW, although the productionenergy requirement was reduced byquantity was increased to 750 t/d. Two50%,” according to Masakazu Eguchi.

other Japanese facilities that process

With an actual input power of 560 kW,

JOCC as raw material were likewise

450 tons of recovered paper per day

successfully converted.

Contact
Naoyuki Iwashige
naoyuki.iwashige@voith.ihi.co.jp

Customer trials at the Voith Paper FTC in Ravensburg

The birthplace of new solutions in stock preparation
The Voith Paper Fiber Systems Technology Center (FTC) in Ravensburg focuses entirely on stock
preparation – which influences the complete paper manufacturing process. At the FTC, Voith Paper
develops customized process and system solutions that often set benchmarks for the future.
“We always had problems withthen worked out a highly efficient

ration. “Quality, costs and sustainability

contaminants in our stock preparation

screening system that has effectively

are always the primary criteria inline that caused papermaking irregu-

banned this problem ever since. At the

papermaking,“ points out FTC trial

larities,” explains Christopher Kaess-heart of the FTC is a highly versatileengineer Yvonne Waibel, “Which is

berger, head of stock preparation attrial facility where stock preparation

why many of our trials are aimed at us-

Rieger Paper, Trostberg.

processes for all paper grades can be

ing lower-cost raw materials while in-reproduced under realistic production

creasing yield and reducing overall

Voith specialists came to the rescue

conditions. This is complemented by aprocess energy costs.” More impor-by thoroughly testing and analyzingstate-of-the-art paper analysis labora-

tantly, in every case is to complying

his stock preparation system withtory. The Voith FTC not only solves

with quality requirements, at the same

several simulation trials in the FTC. In

customer problems, but also works

time minimizing investment and oper-

teamwork with the customer, theyout superior solutions in stock prepa-

ating costs.

27 I 2008 I Voith Paper I twogether

73

RESEARCH AND DEVELOPMENT

The worldwide network of Voith Paper Technology Centers.

Flexibility à la carte

TwinFlo refiner with energy-saving Pluralis filling.

available to them whether or not theyBrazil flow into the FTC activities. This

take advantage of the FTC trial facili-

network also enables stock, prepared

Our FTC team experts show how pro-ties.” Voith customers frequently use

in the FTC, to undergo further trials on

cess risks can be minimized both forthis fully equipped paper laboratory

one of the Voith paper machine test

rebuilds and new installations. “Thatfor analyzing samples from their own

facilities. Apart from the board andhelps our customers to reach decisions

stock preparation lines.

packaging paper machine also locatedon plant modernization and investment

Customer trials at the FTC incorporate

in Ravensburg, these include, for ex-

in future-oriented technologies,” says

the latest Voith Paper product develop-

ample, the graphical paper machine

Armin Volk, European sales manager

ments. For example: the new energy-

test facility at the Paper Technology

of Voith Paper Fiber Systems. The FTC

saving Pluralis refiner fillings, or theCenter (PTC) in Heidenheim. Our cus-

is so flexible that not only individualenergy-efficient IntensaPulper.

tomers therefore profit from the net-machines and subsystems can betested, but also complete systems.

worked synergy of Voith development
A worldwide network

findings worldwide.

Depending on scope, trials generally
take one to four days.

The FTC belongs to the global networkof Voith Paper technology centers that

“It is important to us that our custom-

cooperate as a worldwide team. All theers get the individual support theylatest findings at our Heidenheim andexpect,“ explains Armin Volk, “That is

Krefeld trial centers in Germany,

why our laboratory services are also

Motomiya in Japan, and São Paulo in

Contact
Harald Hessharald.hess@voith.com“We were very impressed by
the comprehensiveness of
this test facility, the conclusive
test results, and the professional competence of Voith
Paper’s test engineers.”
Christopher Kaessberger, stock preparation line
manager at Rieger paper mill in Trostberg, Germany

74

27 I 2008 I Voith Paper I twogether

News

Guess where the paper comes from for the latest children’s bestsellers

The Voith connection to “Inkheart” and “Skogland”
Books have always been a big favorite with children and teenagers alike. The same still holds true today.
In 2007 alone 15.4 percent of all sales in the publishing sector were books for children and teenagers.
And although the content of the current, most popular children’s books could not be more diverse, they all
have one thing in common: the paper they are printed on comes from a Voith paper machine.

The origins of the paper for the latest

and since then it has been producing

bestseller lists for children’s andedition of the children’s classic “Thepredominantly book paper in combina-

adolescent fiction. And – almost

Curse of the Darkling Mill” (publishedtion with another paper machine.

no surprise by now – the paper forin German as “Krabat”) can also be“Inkheart” also comes from thetraced back to a Voith paper machine.

The paper from Munkedals seems to

The big-screen version of “Krabat”

enjoy great popularity for use in books

just stormed the movie charts. For

for children and adolescents. For

The paper for “Das kleine Herz/The

its publisher, Thienemann, this re-example, the paper for the centenary

Little Heart” by Wolfgang Joop, on thepresented a welcome opportunity

edition of the timeless children’sother hand, comes from Uetersen in

to commission a new edition of theclassic “Pippi Longstocking,” and fornorthern Germany. This is where paper

book. The wood-free, FSC-certified

Kirsten Boie’s latest “Skogland” novel,

producer Stora Enso’s two paper

paper for the 269-page novel origi-

were also supplied by this Swedishmachines produce various papers

nates from Munkedals, one of a total

papermaker. Along with Cornelia

including the wood-free, glossy, dou-of three production sites belonging toFunke’s “Inkheart,” a political fantasy

ble coated book paper of the kind

the Swedish papermaker Arctic Paper.

novel for children, the novel “Verrat inused for “The Little Heart.” Both theVoith Paper’s PM 5 was installed at the

Skogland” (“Treachery in Skogland”)

PM 1 and PM 2 in Uetersen originate

Munkedals paper mill back in 1953,

was ranked right at the top of thefrom Voith and were installed in 1950.

27 I 2008 I Voith Paper I twogether

Voith paper machine in Munkedals.

75

NEWS

Carbon-neutral printing of twogether magazine

Protecting the environment
concerns us all

A certificate declares that the printed product is allowed to bear the logo “CO2-Offset
Printing” with ID. This means that it is madecarbon-neutral.

Climate change is omnipresent. Morecore of this initiative is the calculationand more consumers are making aand reduction of greenhouse gas

conscious decision to purchaseemissions, which includes all CO2

products made using ecological andemissions produced directly or indi-sustainable processes. Carbon-neutral

rectly by printing. A CO2 balance isprinting, too, is gaining interest in thethen created for the printed product,

public eye. The printing and media

and the amount of CO2 generated isindustry is striving to achieve a long-

offset by climate protection projects.

term reduction in CO2 emissions
through a climate initiative, in which
Voith Paper is also involved. At the

Ident-No. 080271

Conveying knowledge on press technology – anywhere in the world

Customer-oriented blended learning with Norske Skog
cost advantages for blended learning. In
principle, the number of participants is

Customer Comment
John Hofmans

unlimited, and learning is location-

Specialist Paper,

independent.

NS Technical Support

This results in less absenteeism and& Development

eliminates travel times and costs. In
cooperation with the global paper
manufacturer Norske Skog, Voith Paper
organized a blended learning event for
the first time ever – for multiple loca-“NS Academy, Norske Skog's internal

tions simultaneously and perfectly tai-training program, found a perfect partner

lored to company-specific requirements.

in Voith. The training material as well as

Participants from 25 different Norske

the lecturer have been highly appreciated

Skog locations – spanning the globe

by the participants. Thanks for this great“Blended Learning” describes teachingfrom Europe to Thailand to Brazil – werecooperation.”concepts in which a didactically usefulconnected in real time via the Internet

link between traditional “classroom

and followed the presentations given bylearning” and PC- and Internet-based

the Voith technologists in Heidenheim,

learning is made. It combines theGermany. Equipped with headsets,advantages of onsite instruction andthe technologists conveyed theire-learning. A cost-benefit analysis ofknowledge on press technology andblended learning and a previous onsite

communicated directly with participants

seminar with the same contents yields

throughout the world.

Dr. Georg Kleiser and Axel von Noorden,
responsible for the Norske Skog customer
training, conveyed their knowledge throughout the world.

76

Contact
Axel von Noorden
axel.vonnoorden@voith.com

27 I 2008 I Voith Paper I twogether

News

Voith Paper Environmental Solutions wins coveted environmental award

Green Apple Award for reduced water use

Jan Telensky (right), owner of the ressort
AquaCity, Poprad, Slovakia and leadsponsor of the Green Apple Awards handed
over the coveted environmental award to
Werner Geßler (left), General manager of VPES.

The shortage of water is increasingly“Green Organization” awards thisbecoming a problem. Therefore, theprize, which is regarded as one ofindustry must find ways to conserve

the most prestigious environmental

water. Voith Paper Environmental So-

awards in the U.K. The judges award

lutions (VPES) is developing products

prizes to companies, local authorities

and technologies that reduce the use

and individuals in 25 categories forof water in paper production.

sustainable projects and products.

And it did not take long to garner

Werner Geßler, General manager ofthe first accolade for this resolute

VPES, accepted the Green Apple

commitment to the environment:Award for the “European Company”

on November 10, 2008 VPES received

category at an official ceremony held

the renowned Green Apple Award.

in the House of Commons, the British

Every year the independent British

parliament building in London.

Mondi and Voith Paper go head to head in rafting competition“adventure day twogether”
At the end of August Voith Paper

victor. It negotiated the challenging

full of sporting challenges andinvited Mondi SCP and Mondi

whitewater course in the shortest

many private conversations andPackaging Ruzomberok fromtime. Apart from the rafting, a quad

“shop talk” there was plenty of

Slovakia to an “adventure day

bike course, and archery provided

opportunity to strengthen andtwogether 2008” at the Slovakian

some variety in the day’s entertain-

develop our interpersonal relation-

whitewater slalom park at Liptovsky

ment. In the course of this day

ships.

Mikulas. 45 participants registered
for the event, which was attended
by over 70 people representing
all paper machines in Ruzomberok.
In the rafting competition each team
was made up of employees from aPM. Eight customer teams and aVoith team then competed against
one another. Of course the competition got very heated and the capsizing of some of the rafts was partand parcel of the action. There were
five rafting rounds, two for training
purposes and three competitive
courses. In the end the “Kalamita”
from Mondi’s PM 18 was the proud

27 I 2008 I Voith Paper I twogether

Mondi and Voith “twogether” after a successful day of rafting.

77

NEWS

Voith Siemens Hydro

Over 20 million Euros invested in				 state-of-the-art hydro power laboratory
Voith Siemens Hydro Power Generation, together with its customers, partners and employees,
celebrated the 100th anniversary of its hydraulic laboratory, the Brunnenmühle, in mid-November.
“Going Beyond – 100 Years Brunnenmühle” was the claim that expressed clear leadership over time inhydro power technology as pushed by Voith Siemens Hydro.
The festivities opened up with a

as a new additional office building

above the Brunnenmühle, this lab

hydro symposium, focusing on solu-

with an overall investment of more

became Germany’s first pumped

tions and opportunities provided bythan 20 million Euros. After 18 months

storage plant with an exceptionalhydro power in the face of currentof work, visitors saw the extension

100 meters of head for testing of

global growth and booming energy

and enhancement of hydraulic test

turbines. Back then and today, latest

demand. On top of that, views of therigs and new high-performancetechnologies, methods and tools

latest development in hydro power

computers for flow simulation in

were the basis for development inand ocean energies, the increasing

hydraulic, magnetic, and electricalthe Brunnenmühle – making it theimportance of sustainability, reliability

fields of hydro units.

world’s most modern and high-and environmentally-friendly solutions

performing model testing institutions

were key points of the presentations.

Friedrich Voith had already started

The official 100th anniversary of the

100 years ago in order to investigate

Brunnenmühle was celebrated withthe behavior of hydro machines.

an opening ceremony held in Heiden-

He acquired the Heidenheim Brunnen-

heim on Friday, November 14. Of

mühle mill and turned it into a hydrocourse there was a birthday gift: aturbine testing laboratory. With his

newly equipped laboratory as wellconstruction of an upper reservoir

for hydro power.

to look at more precise predictions

The newly equipped laboratory.

78

Contact
Marie Luise Leonhardt
marie-luise.leonhardt@VS-Hydro.com

Festive gala dinner for the Brunnenmühle's
100th anniversary.

27 I 2008 I Voith Paper I twogether

News

Roland Kuehnel, Voith Siemens Hydro (left)
and Braam Conradie, Eskom, shaking hands
after contract signing in Johannesburg.

Planning, erection and conversion of piping
systems – Voith Industrial Services can offer
all the necessary services from a single source.

The Voith Radial Propellers keep floating
offshore platforms stable by dynamic positioning, whatever the weather conditions.

Voith Siemens Hydro

Voith Industrial Services

Voith Turbo

140 million Euro orderfrom South Africa

Strategic acquisition
strengthen its position

Market division Marine
expanded

Eskom, the major South African

Voith Industrial Services is based in

The demand for offshore vessels withutility, has awarded a contract to

Stuttgart and has in the past focusedmaneuverable and efficient propulsi-

Voith Siemens Hydro for the equip-

its activities mainly on the automotive

on systems is on the increase. For

ment supply for the Ingula pumped

industry. But for some time now it has

this reason, Voith has decided to ex-

storage project close to the city ofbeen working on expansion of its range

pand its competencies in the offshore

Ladysmith in eastern South Africa.

of services to processing industries.

area. By reviving the production ofThis region is contributing a major

The acquisition of the Ermo Group ear-the Voith Radial Propeller, Voith Turboshare to the country’s electricity

ly in 2008 laid the foundation stone forresorts to proven and solid know-how

generation. Order value runs up to

further growth in this sector and is also

and evolves into a special supplier for

140 million Euros. Voith Siemens

a further important step towards imple-

the offshore industry.

Hydro will supply the complete

mentation of the strategy calling for ex-

electro-mechanical equipment withpansion of its range of services. Voith

A second important step within

the four pump-turbines at a rated

Industrial Services is now well on theVoith's corporate growth strategy

output of 342 megawatts each, four

way to becoming a specialist provider

was the establishment of Voith Turbo

motor-generators and the completeof comprehensive services for proces-

Marine Engineering GmbH & Co. KG

automation and control system forsing industries. It now offers a broadin Rostock.

commissioning in 2013. The Ingula

spectrum of services closely related topumped storage plant is being built

industrial production – including stand-

Radial Propellers keep floatingclose to the city of Ladysmith instill management, plant maintenanceoffshore units stable by dynamic

eastern South Africa.

and audits, construction of storage

positioning, whatever the wind andtanks, piping systems and allied equip-

weather conditions. To achieve this,With start of operation in 2013,

ment. It can also offer engineering andan offshore platform is fitted with

Ingula’s four pump-turbine units

other services for modernization, con-up to eight propellers. Increasingly

will significantly contribute to gridversion, dismantling and re-erection

extreme drilling depths make offshore

stabilization by pumping water withprojects planned by companies in thefacilities with dynamic positioning aexcess electricity during low demand

processing industries. It now employs

necessity: today, extraction activities

periods to the upper reservoir and re-some 1,350 qualified personnel infor the raw materials oil and gas takeleasing it from there again for peaking

Europe for provision of services to theplace in deposits situated at overenergy generation.

processing industries alone.

3,000 meters below sea level.

27 I 2008 I Voith Paper I twogether

79Voith Paper

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

Copyright 1/2009: No part of thispublication may be reproduced or copied
by any means whatsoever without theexpress permission of the editor.

1

27 I 2008 I Voith Paper I twogether

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

Issue 27, January 2009