PAPER TECHNOLOGY JOURNAL

T WOGE THER
#33 | 2012

COVER STORY

CLOSE TOTHE CUSTOMERNEW PLANTS

DONGHAE PM 1: RESOURCE-SAVING
AND ECONOMICALCover picture:
When you are in the business of
supplying products and services,it pays to be close to yourcustomers.

IMPRINT
Published by:Voith Paper Holding GmbH & Co. KG
Editor:Julia Bachmeier/Nadine Queiser
Voith Paper Holding GmbH & Co. KG
St. Poeltener Strasse 43
89522 Heidenheim, Germany
twogether.voithpaper@voith.com
Technical editors:
Simone Heinrich
Elisabeth Marton
Helena Pirttilahti-Feichtinger
Stefanie Bunz
Design, layout and typesetting:Beate Hornischer
Voith Paper Holding GmbH & Co. KG
Images:S. 5/51
S. 10/11
S. 21
S. 23
S. 43/44/74
S. 50
S. 56/57
S. 74

Shutterstock.com
Shutterstock.com
Cascades Tissue Group
Shutterstock.com
Shutterstock.com
Shutterstock.com
Shutterstock.com
iTunes/Applestore

Other pictures: Voith Paper archive
Paper:The recycled paper Respecta consistsof at least 60% recycled ﬁber and was
produced with Voith equipment.

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

“twogether” is published twice annually inGerman, English, Chinese and Russian.
Contributions by independent authors do
not necessarily reﬂect the opinion of the
publisher. Please address all correspondence
to the editor.
#33 | 2012

2 | T W O GE THE R 3 3 /20 1 2

EDITORIAL

DEAR CUSTOMERS,DEAR READERS,
Having a local presence in order to provide fast solutions anddevelop trusting relationships with customers is something we
regard as key to success, particularly in the product market. In
our cover topic, our eight examples from North and SouthAmerica, Europe and China illustrate how, particularly in this eraof globalization, market expertise and a local presence areimportant to operate successfully in the market (p. 6).
The development of new and improved technologies is an
integral part of our work. For example, the DuoDry CC drying
concept signiﬁcantly reduces the tendency of paper to curl(p. 43). The SØNAR roll management program provides rolldata around the clock in a clearly presented format (p. 48). In
Germany, folding box board producer Mayr-Melnhof shows
how the right combination of forming fabric and measuring
technology in the wet end achieves better board quality and asubstantial reduction in drive output (p. 60). Our new
CompressPlus press concept for the wet end can raisemachine speed by up to 150 m/min without any loss of quality(p. 63).
Our recently modernized and reopened Tissue Innovation
Center (p. 30) in São Paulo is working on resource-saving
technologies for tissue production. The center offers customers
from all over the world the opportunity to test the latest
tissue developments on a high-speed machine. It is
possible to switch between conventional and ATMOS
technology in a very short time. ATMOS can provide
energy savings of up to 60% compared with otherpremium tissue production processes.
I hope that you will enjoy reading this issue of thetwogether magazine in our brand new design.

On behalf of the Voith Paper TeamDr. Hans-Peter Sollinger,
Member of the Voith GmbHManagement Board andCEO of Voith Paper.

TWOGE TH E R 3 3 /2 0 1 2 | 3

27

24
XX

XX

XX

14

CONTENT
COVER STORY

06

CLOSE TO THE CUSTOMER
Europe, Asia, North or South America.
Wherever you call home, you’ll ﬁnd Voith.

NEW PLANTS

14 FIRST NON-STOP PRODUCTION LINEIN SOUTH KOREA
Moorim Paper Group’s DongHae PM 1REBUILDS

20 PREMIUM TISSUE
Cascades Tissue Group
set to save up to 60%
energy in future

24 VAREL SHOWCASE
PLANT
Comprehensive rebuildof packaging paper
machine27 REEL CHANGES ON
THE FLY AT UPM
New reel change systemfor coater

30 TISSUE INNOVATIONCENTER IN SÃO
PAULO
02 DISCLAIMER
03 EDITORIAL
72 FORUM

4 | T W O GE THE R 3 3 /20 1 2Center reopens withmodernized pilot
machinePRODUCTS ON SITE

32 NEW QUALITYCONTROL SYSTEMAT SALZER PAPIER
Focus on total cost ofownership (TCO)

34 EFFICIENT
SCREENING
Ideal combination of
screen baskets androtors37 ONV CONDITIONMONITORINGSYSTEM
Unscheduled downtimes
a thing of the past

40 INNOVATIVE DISKFILTER IN USE INPORTUGAL
Tissue mill saves energy
in pulp dewatering

51

37

66

NEW TECHNOLOGIES

42 NEW CLEANERTECHNOLOGY
Higher stock consistencies at the same level of
efﬁciency

43 DUODRY CC
DRYING SYSTEM
Reduce curl, saveenergy costs, enhance
runability

34

SPOTLIGHT: WET END

51 CORRECTCHEMICAL FEED
Online CT diagnostic
module monitors wet
end processes

54 ROLL COATING FOR
DRYER SECTION
Improved dirt repelling
and resistance to wear

58 NEW ADDITION TO
FORMING FABRIC
RANGE
PrintForm IQ saves
more than 150,000
euros

60 FORMING FABRIC
AND SENSOR
PRODUCTCOMBINATION

66 AN AUDIT FOR
EVERY SCENARIO
Customized audits
provide planningcertainty

70 SERVICE FOR
AUTOMATIONCOMPONENTS
Experts deployedworldwide

Improved board quality
at Mayr-Melnhof

46 ROLL COVERS WITH
RUBBER POLYMERMATRIX

62 SAFETY FIRST

Consistent service lifeand excellent machine
availability

Online measuringsystems reduce
accident risk

48 ROLL MANAGEMENTWITH DATABASE

63 COMPRESSPLUS
PRESS CONCEPT

Constant information onroll condition

SERVICE

Higher machine speed
without loss of quality

TWOGE TH E R 3 3 /2 0 1 2 | 5

COVER STORY

CLOSE
TO THECUSTOMER
6 | T W O GE THE R 3 3 /20 1 2

COVER STORY

To understand your customers’ needs, you must have a presencein the specific market. When your business is about products,
physical proximity really pays off; it allows faster delivery ofcomponents and better service by experienced Voith technicians
who can be on site in a very short time. The following eight successstories illustrate how local presence benefits customers aroundthe world.
01

When you are in the business of supplying products andservices, it pays to be close to your customers.

TWOGE TH E R 3 3 /2 0 1 2 | 7

COVER STORY

A paper machine in Chile needs a roll change. Since thefunction of the roll has a major impact on machine efﬁciency,
its replacement cannot be delayed. But a roll change in thepress section alone will entail a machine downtime of several
hours, and that costs money. However, even if a replacement
is not urgent, rolls still have to be reground and recalibrated atregular intervals. This is why the location of service and sales
facilities are important strategic decisions that Voith needs tomake in many countries such as Chile. For a long time, paper
mills in Chile have either had to maintain their machines
themselves, engage small local workshops to do it, or have thework carried out in another country. Voith established a service
center site in 2006 and provides know-how in design,
fabrication and maintenance of machines in the Chilean market.
In China too, the beneﬁts of Voith having its own production
facility for thermal coatings have long been demonstrated. In
China, Voith is able to supply paper producers throughout Asiawith high-quality thermal roll coatings with very short delivery
times. The decision to also locally produce an increasingly
larger proportion of what is needed in a market, tailored to local
requirements and developed by local engineers and specialists,
has proved to be a highly successful business model. It makes
Voith a supplier with a genuine local presence throughorganizations embedded in their local communities. It is allabout having the know-how available in the region in which a
project is to be planned and realized. This means that theworkforce at the particular location is familiar with the local
market and technological conditions and knows the needs ofthe various customers. This includes providing the appropriate
products and maintaining facilities over their entire service life.
Despite globalization, being close to customers turns out to bea distinct advantage, especially as Voith Paper is able to offer
its customers in all countries integrated solutions from a single
source. And it does so consistently with uniform standards andcommon procedures for each of the regions. Customers too
proﬁt from this proximity, as demonstrated for example by thehalving of energy consumption in a plant in North America(p. 11), the increase in dry content at International Paper’s Luiz
Antônio mill in Brazil (p. 9) or the 20% higher capacity at
Shanying Paper in China (p. 12).
8 | T W O GE THE R 3 3 /20 1 2

02

São Paulo, Brazil.

COVER STORYDRYNESS IMPROVEMENT
IN BRAZIL
The story of Voith Paper Brazil started in 1964 with thefoundation of Voith S.A. Máquinas e Equipamentos, the first
production subsidiary set up by the group on the South American
continent. The São Paulo plant is the competence center fortissue paper machines and a specialist in the production ofdrying cylinders. Voith Paper set up the Tissue Technology
Center in Brazil so tissue producers could verify the compatibilityof their processes and raw materials with equipment they wereplanning to acquire.

Service work on the headbox with short downtimes. The
pulp mill Fibria Celulose S.A. is located in Aracruz, the Brazilian
state Espírito Santo – 70 km from Vitória. It comprises threeﬁber lines with an annual capacity of 2.3 million metric tons of
bleached pulp. As Voith supplied the dryers for PDMs 1-4,
Voith, in turn has been given responsibility for the dewatering
line main shutdown.
In 2011 Voith was called to rebuild the considerably corroded
PDM 3 headbox. Especially the bottom part had to be changed.
Therefore, a new bottom part, completed according to theoriginal drawings, had to be designed and installed in theheadbox during the main shutdown service within ﬁve days. It
is always a big challenge and great responsibility to stop a
dewatering machine and to rebuild one of the most importantsections like the headbox. It is essential to return to normal
production without changing its parameters. The harmonic
service was supported in perfect cooperation with the
production and maintenance staff from Fibria. This rebuild also
included the longitudinal beam for the fourdrinier, which was
also supplied for PDM 4 and installed at the same shutdown.
Moreover, during the same year Voith was called upon again
to provide exactly the same rebuild for PDM 3.

South America

Voith Paper
location

Land mass: 17.7 million km²
Population: 393 million
No. of employees: 851

woodfree copy paper on PM LAN2. In 2011, this mill began theimplementation of a project for optimizing the press efﬁciency
of its PM LAN2. Voith offered a complete press analysis withspecialist measurement tools and knowledge to collect andanalyze the necessary data. With the analysis results, a water
reduction was performed followed by engineering
recommendations for fabric designs, roll cover material andsurface geometry. By this means, a combination of Voith
products such as SolarFlow suction roll cover, PrintFlex V4L
fabric and G2000 press roll cover together with PrintFlex S3 in
the third press helped.
The high water storage capacity of the Voith polyurethane
covers along with the press fabrics resulted in a 2.7% increase
in dryness from 41.12% to 43.85%. Another beneﬁt was thatthe machine reached record reel speeds of 1,180 m/min,exceeding its previous speed by 10.4%. Consolidating thoseresults, through process adjustments and machine crew
development, will generate a potential production increase of
19.3 t/d. Production Manager Eurípedes L. Valadão Junior ofIP’s Luiz Antônio mill states: “This development was a clear
demonstration that, with the combined efforts of the supplierand customer, motivated people can enhance efﬁciency andquality in the production process.” //Increased dryness with product combinations. In Brazil,International Paper’s Luiz Antônio mill produces uncoated
TWOGE TH E R 3 3 /2 0 1 2 | 9

COVER STORY

EuropeVoith Paper
location

Land mass: 10.1 million km²
Population: 740 million
No. of employees: 5,557

03

Rome, Italy.

ENERGY SAVING AND
PRODUCTIVITY GAIN IN EUROPE
Europe, the second largest producer and consumer of paper and board, isstill a region where quality is a very decisive factor. European paper
production is now increasingly being driven by ecological objectives, which
require technologies that help save energy and increase productivity.
New quality control system and service contract. Since
December 2011 the new quality control system has beenrunning at the BM 4 at the Cavanella Po plant of the papermaker
Cartiere del Polesine in Italy. Two Voith LSC scanners, 5.60 m
and 6.50 m wide, are included in the delivery. They have four
sensors in total. In addition, the automation system was
expanded to include OnQ GradeControl MD controls for basis
weight and moisture. The installed OnQ Proﬁlmatic basis weight
CD proﬁle control was supplemented with a new CD moisture
proﬁle control for the nozzle moisturizer. This ensures therequired quality for the basis weight and moisture CD proﬁlesof the machine.
Furthermore, Cartiere del Polesine has chosen to conclude a
service contract for the automation systems of BM 3 andBM 4. Within the framework of the “remote diagnostics” service
module, the package allows a remote diagnostic service of thesystems used, if the customer so desires.
The service module also includes 24/7 telephone support by
the Voith service team. This guarantees very short reaction
times and allows Cartiere del Polesine to get competent advice
and support any time it is necessary.
1 0 | TWOGE THE R 3 3 /20 1 2The customer is very satisﬁed with the Voith solution. Therefore,in December 2012, OnQ ModuleTap, an automatic control
system for the metering of dilution water will be installed at the
headbox of the BM 3.
11% less energy consumption at AMS Gomà-Camps. To
save energy and increase production, the Portuguese producer
AMS Gomà-Camps agreed to install a high-performing press
fabric for tissue machines: Evolution by Voith Paper. Along withthe advantages of improved dewatering in the nip and quicker
start-up times, Evolution reduces thermal drying and provides
potential energy savings of about 300,000 euros/year. Overall,
the annual cost reduction is even higher due to the production
increase. With Evolution, it was possible to increase themachine speed by 50 m/min.
In Vila Velha de Ródão, Portugal AMS produces a wide rangeof products including facial tissue, napkins, toilet tissue andtowels. The plant, designed to operate with virgin pulp, willproduce both jumbo reels and ﬁnished products and will supply
the Iberian and North African markets. //COVER STORY

North America

Voith
Voith Paper
Paper
Standort
location

04

Land mass: 24.9 million km²
Population: 528 million
No. of employees: 1,362

New York, USA.

HIGHER EFFICIENCY INNORTH AMERICA
Voith Paper’s entry into the North American market dates back nearly to thebeginning of America’s paper industry itself. Voith remains present today throughout theentire region, with no less than 14 facilities. So, one can easily see how the proximity tocustomers is essential for long term satisfactory cooperation.
Improved press solids save more than 4 million euros. One
example of a local project with local manpower is the press
optimization with a Canadian pulp mill. It produces pulp for
customers in Asia, Europe and areas of North America. Voith has
worked continuously and closely with this particular mill to
improve productivity and lower production costs.

ambitious ecological challenge. The approach was to improve
quality on one hand, while also lowering energy consumption on
the other. The mill had a ﬁne screening system with old screensof a competitor. Voith upgraded the existing screens byimplementing a combination of the MultiFoil rotor and C-bar
screen cylinders.

Voith presented a proposal to optimize the pulp machine’s press
performance. As a result, Voith supplied the press roll covers,press fabrics and also forming fabrics for the wet end. The scopeof the project included softening the covers to increase nip
retention duration and increase the void volumes in the nip tofacilitate increased water removal capacity. The 3rd press rollcovers were softened and blind drilling replaced grooving.

The C-bar Q screen basket offers a higher capacity than standard
screen cylinders. Aside from improving ﬁnal product quality,
stickies content was greatly reduced and overall fiber loss
dropped. Before the screens were retroﬁtted with the C-bar
technology and MultiFoil rotor from Voith, the mill had four
screens running. Afterwards, three screens were found to be
sufﬁcient, so there is now one less machine and a big energy
saving.

By increasing the dwell time in the nip, the dryness regularly
improved, which in turn meant less steam was used in thedryers. The beneﬁt from the optimization was a 2.9% increasein production per hour. The annual proﬁt increase and the valueadded savings from increased production totaled 4 million euros.
50% less energy consumed. This project, with a large board
and packaging mill in the state of Washington, USA, was an

According to the customer’s latest information, a 50% energy
reduction was achieved with the new equipment. This matches,by the way, the requirements of the Washington State Financial
Incentives for Renewables and Energy Efﬁciency. Implementationof technologies that increase energy efﬁciency are eligible forsupport. //TWOGE TH E R 3 3 /2 0 1 2 | 1 1

COVER STORY

SOLUTIONS FOR CHINA’S
HUNGER FOR PAPER
China’s paper industry is still growing. According to the China
Paper Association (CPA), production in 2010 was 92.7 million
metric tons – an increase of more than 7%. Within the last ten
years, the capacity of China’s paper industry has tripled.
Voith Paper became active in this market in 1937 with thedelivery of a paper machine to Shanghai Zhong Ban Paper.
Today, one of its most important locations is Kunshan. The
decision to build a facility in this location was well thought out,
given that the high-tech industrial park of Kunshan is one ofChina’s fastest-growing cities.
Local service and advice. It takes 3 to 4 hours by car for Voith
Paper’s specialists to reach Shanying Paper, located in the
Chinese province of Anhui. Shanying manufactures andmarkets paper products including corrugated paper,
paperboard, and paper boxes. The company sells its products
domestically. As there were plugging problems in the initialsystem, Shanying decided to rebuild the board & paper
machine’s cleaner system in 2011. The solution was an
EcoMizer Cleaner HCH5 upgrade in the OCC line. The results
were quickly visible, with reduced ﬁber losses in the last stage,combined with high cleaning efficiency and low energy
consumption. Further, useable ﬁbers are not lost with therejects but back-ﬂushed to the accepts, minimizing losses. A
more compact layout of the cleaner stages has also been madepossible in most cases.
The customer now reports a 20% increase in capacity while
using the existing feed pump. So, this ﬁrst project with Shanying
Paper has proved a real success story with further positive
outcomes: The paper producer later ordered two whole stock
preparation lines to be realized in 2012.
Non-radioactive quality control for YinGe Paper. China ison the way to having the world’s most modern tissue machines
1 2 | TWOGE THE R 3 3 /20 1 2

China

Voith Paper
location

Land mass: 9.6 million km²
Population: 1.3 billion
No. of employees: 1,466

and the country’s demand for tissue remains high. To meet thisneed, Luohe YinGe Tissue Paper Co., Ltd., has ordered twolarge tissue machines from Voith for a greenﬁeld mill in thesuburb area of Luohe City, Henan province. Both machines areequipped with a 2-layer MasterJet II T headbox, Crescent
former and Voith shoe press, named NipcoFlex T. The design
speed is 2,000 m/min, and the wire width is 5,600 mm.
Each of the two machines can achieve annual production of
60,000 tonnes. NipcoFlex T is a technology developed by Voith
Paper that is the shoe press concept applied for tissue
machines. This solution requires less energy consumption for
paper drying and provides excellent tissue bulk.
As also part of the scope, Voith will supply two quality control
systems (QCS), including the sensor Voith LSC TecoSens thatis fully integrated into the automation’s system. This sensor
allows simultaneous online measurement of moisture content
and basis weight on an infrared sensor, saving time and money
for the customer as it is a solution that minimizes costs overits entire lifetime.
As an important component for good performance, machine
efﬁciency and energy savings, YinGe has also selected Voith
to supply the machines’ clothing. //COVER STORY

05

Shanghai, China.

TWOGE TH E R 3 3 /2 0 1 2 | 1 3

NEW PLANTS

DONGHAE PM 1: RESOURCE-SAVING AND ECONOMICALEFFICIENTNON-STOPPRODUCTION

1 4 | TWOGE THE R 3 3 /20 1 2

NEW PLANTS

The commissioning of DongHae PM 1 saw the launchof the first non-stop production line in South Korea.
The resource-saving mill concept allows for an integrated
production line from pulp to finished paper. From the very
outset, the plant’s efficiency was impressive and met all
expectations. The signing of service contracts ensuresthat the excellent relationship between Moorim Paper
Group and Voith Paper will continue after startup.

01

Working successfully together: excellent relationshipbetween Moorim Paper Group and Voith Paper.
TWOGE TH E R 3 3 /2 0 1 2 | 1 5

NEW PLANTS

02

In March 2011, almost five weeks
ahead of the contractually agreed
deadline, the South Korean Moorim
Paper Group’s DongHae PM 1 went
successfully on stream. Just fivemonths after startup, Moorim has
signed off on the final acceptance certificate for the production line. With awire width of 9,300 mm, PM 1 produces around 450,000 metric tons ofwood-free coated and uncoatedpapers in the basis weight range of
75–150 g/m² per year. Just threemonths after startup, the paper machine achieved its design capacityof 1,250 t/d and design speed of
1,300 m/min, exhibiting outstandingtime efficiencies of more than 90% in
the second month and more than 95%
in the third month.
No fossil fuels needed. The integrated
mill concept allows for a non-stop
production line from pulp to finishedproduct. The new PM 1 will mainly use
the short-fiber pulp produced on-site.
This means there is no need to dry thepulp, which can be pumped directly tothe paper machine in liquid form. This
1 6 | TWOGE THE R 3 3 /20 1 2

therefore reduces the total drying
energy required for pulp dewatering,
while also eliminating the cost oftransporting the pulp to the mill. In
addition, the steam yielded in pulp
production can also be used for paper
production. This allows the resourcesaving mill system to dispense withfossil fuels under normal operating
conditions.
Services ensure plant efficiency.
Voith Paper is providing Moorim withsupport in the first two years after startup in the form of a service team available six days a week. The “Advanced
Production Support” team will optimize
the plant and coordinate and supervise
all activities necessary for a stable
operation of DongHae PM 1. The teamwill also train the machine operatorsand support and advise thecustomer in hydraulics, mechanicalsystems and the automation of the paper machine, offline coater and Janus
calenders.
Moreover, a Total Roll Management(TRM) contract, that will run for an initialperiod of ﬁve years, provides a fully inclusive “worry-free” roll environment.
The TRM covers all rolls and thecomplete roll environment: It includes
covers and coatings, roll servicing,
drying cylinder coatings, grinding anddoctor blades. This maximizes roll availability, increases machine efﬁciency andkeeps maintenance costs to a minimum.
Improving the roll running properties is
an integral part of the TRM concept. This
is why it is vital to focus not just on therolls themselves but the entire roll environment – from clothing to doctors or
machine. All of this guarantees optimum
paper production.
Moorim will use SØNAR (see article on
p. 48), Voith’s proprietary roll management software, to gather data about all
its rolls. Service reports for every roll,
grinding intervals, running times, operating logs and special features of each rollare stored in the software’s databases.
These data help Voith’s roll service
specialists to identify and implement
optimization potentials. As a result, it ispossible to signiﬁcantly reduce costs formaintenance in some areas.

NEW PLANTS

DongHae PM 1: facts and ﬁgures
Paper machine
Headbox (MasterJet F with ModuleJet)
Forming section (DuoFormer D)
Press section (Tandem NipcoFlex press)
Pre dryer section (TopDuoRun)
Coater (SpeedSizer AT)
After dryer section (CombiDuoRun)
Finishing (EcoCal calender)
Reel (Sirius)
Re-reeler (Sirius)
Ofﬂine coater with 4 coating units
Two ofﬂine Janus calenders
Winder
VariPlus
VariFlex

02–03

03

The spirit of partnership comes to thefore in the TRM concept: Voith andMoorim are working together to further
enhance the roll inventory and improve
running properties. By appointing Voith
to manage its roll inventory, Moorim canconcentrate fully on the production of
paper. Voith ensures optimum care of
the rolls through its experienced service
specialists.
The scope of supply includes theentire paper machine, offline coater and
two Janus calenders. The stock preparation unit features two IntensaPulper
IP-Vs, which ensure reliable pulping
in the highest quality and energy efficiency courtesy of the innovative technology used. The VariPlus and VariFlex
winders also help to provide maximum
flexibility when producing a wide rangeof roll widths in optimum winding
quality. Voith Paper also supplied all
clothing, roll covers and SkyLine doctor
blades for machine startup. In addition,
it undertook the complete basic engineering for the production line as wellas assembly and start-up supervision.
To ensure ideal paper quality, Moorim

DongHae PM 1 with ofﬂine
coater produces woodfree
coated paper in a basis weight
range of 75–150 g/m².

Paper opted for a quality control systemwith a total of nine scanners. These include, for example, two Voith LSC
QuantumSens optical caliper sensors
for non-contacting measurement of
paper thickness. In addition, Voith
Paper supplied the process control system for the stock preparation unit andthe ancillary systems, and the machine
control system. A large number ofbuilt-in actuators and the machineryand technology monitoring rounds off
the package.
One of the great challenges of thisproject was the large number ofinterfaces between the various
suppliers. All participants worked in a
spirit of partnership. In particular, it was
through close cooperation with Voith
Paper's representative in South Korea,
that the common objective - thesuccessful startup of the production
line - was realized. J. K. Choi, Presidentof Voith Paper Korea Representative
Co., Ltd., explains: “The excellent
and friendly cooperation was the basis
for the outstanding success of thisproject.” //Auxiliaries
Hood and ventilation system
Steam and condensate systems
Central oil lubrication
Mechanical drives
Automation
Machine control system
Drive control system
Quality control system
Machinery and technology monitoring
Clothing
Forming fabrics, press sleeves, dryer fabrics
Rolls
Roll covers and SkyLine doctor bladesServices
Basic engineering
Installation and start-up supervision
Advanced production support
Total Roll Management

Contact
Bernhard Häussler
bernhard.haeussler@voith.com

TWOGE TH E R 3 3 /2 0 1 2 | 1 7

NEW PLANTS

04
05

04

The locally produced liquid pulp ispumped directly to PM 1.

05

The close cooperation of all those
involved assured an excellent startup
for DongHae PM 1.

Info: Moorim Paper GroupThe South Korean Moorim Paper Group
produces premium quality, wood-free coatedand uncoated papers and specialty papers
for the Asian market. With the new DongHae
PM 1 production line at its Ulsan facility, about
300 km south-east of Seoul, the company
will increase its total production of ﬁne papers
to more than 1 million t/y, making it the largest
producer of ﬁne papers in South Korea.
This ﬁgure also includes production fromthe company’s existing paper machines in
Jinju and Daegu.

1 8 | TWOGE THE R 3 3 /20 1 2

NEW PLANTS

06

I. S. Park, Vice President Moorim Pulp &Paper (r.) in discussion with Joachim Huber,
Sales Manager at Voith Paper (l.).

BRIDGE TO THE FUTURE
1. What is Moorim Paper Group’s objective ininvesting in the new production line at the
Ulsan site?
Park: For Moorim, this investment represents a bridge to the future. We hope thatthe new paper machine supplied by Voith
will help make us the market leader forpremium quality papers in Asia.
2. What is your assessment following
the successful startup of the
DongHae PM 1?
Our requirements in this project were very exacting, andour expectations have been more than satisﬁed due to theexcellent professional cooperation with Voith Paper. Even justa short time after startup, the efﬁciency of the plant was out-

standing. We are also going to continue this excellent cooperation with Voith in the future.
3. What form will this future collaboration take?
I. S. Park,
Since startup of the machine, the fabrics
Vice President of
supplied by Voith Paper have proven
Moorim Pulp & Paper
effective. This is why we are also goingaims to becomemarket leader for
to rely on them in the future. In addition,
premium quality
we will continue this partnership with apapers in Asia
Total Roll Management contract for
the next ﬁve years to maintain machine
efﬁciency at this high level and reduce running costs. All these
activities are targeted towards our goal of becoming thepreferred supplier of sophisticated, premium quality papers in
Asia. //TWOGE TH E R 3 3 /2 0 1 2 | 1 9

REBUILDSCASCADES TISSUE GROUP BANKS ON ATMOS TECHNOLOGYPREMIUM TISSUE GOES GREEN

Suzanne Blanchet,CEO of Cascades
Tissue Group“Long before it
was in fashion,
Cascades believed
and invested insustainable development.”

The Cascades Tissue Group has upgraded its TM 2 from a
conventional tissue machine to an ATMOS system. This has not
only allowed the Canadian producer to manufacture premium
tissue with considerable energy savings since the autumn of2010, but has also made the Group the first manufacturer inNorth America to produce premium and ultra quality tissue fromup to 100% secondary fibers.
With its investment in the TM 2 rebuild
in Candiac, Canada, the Cascades
Tissue Group is not just meeting
consumer demand for high-quality

tissue products in North America, it isalso demonstrating its commitment tosustainable solutions. All theserequirements were met by Voith Paper’s

01 ATMOS principle

YankeeWet shaping box

2 0 | TWOGE THE R 3 3 /20 1 2

Steam & air hood

Vacuum roll

ATMOS press

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03

02–04
Excellent quality andresource conservation are nocontradiction: Premium and ultra
quality tissue produced from up
to 100% secondary ﬁbers andwith considerable energy savings.

ATMOS technology. Compared withother
available
manufacturing
processes, the new system allows
resource-conserving production ofpremium tissue paper using up to
100% secondary fibers and with energy
savings of up to 60%. Suzanne
Blanchet, CEO of the Cascades Tissue
Group, explains: “Long before it was in
fashion, Cascades believed andinvested in sustainable development,
so it only made sense for us to look fortechnologies that would enable us to
produce top quality tissue paper with areduced environmental footprint.”
Customized rebuild. Working together,
Voith and Cascades carried out
a detailed technical analysis of the02

existing tissue machine during the
project planning phase, to ensure thatthe rebuilt machine could operate inboth ATMOS and dry crepe modes.
This allows Cascades to adapt
production to market demands andgives it the competitive edge in bothconventional and premium tissue
markets. In addition, it was importantto re-use as much of the existing
equipment as possible in the rebuild to
reduce the overall costs of the project
without compromising the ATMOS
process.
In the wet section, the rebuild included
the installation of a new MasterJet Pro T
headbox and a crescent former. An
ATMOS module comprising of ATMOS

04

suction roll and ATMOS press, as well
as a new calender for producing
premium toilet tissue, were also
installed. A new center wind reel was
also part of the scope to ensure
optimum reeling of the bulky tissue.
In October 2010, the Cascades
Candiac TM 2 went back on stream
after the ATMOS rebuild. Since then it
has been producing conventional andpremium tissue at a speed on reel ofmore than 1,800 m/min in conventionalmode and 1,200 m/min in ATMOS
mode. The successful startup of thesecond ATMOS machine installedworldwide illustrates the benefits ofthe technology: ATMOS is regarded
as the most up-to-date solution for
TWOGE TH E R 3 3 /2 0 1 2 | 2 1

REBUILDS

Info: Cascades Inc.
Cascades Inc., founded in 1964, manufactures, processes and sells packaging
and tissue products. These products arecomprised mainly of recovered ﬁbers.
Cascades employs almost 12,500 people
worldwide at 100 sites in North America andEurope.

producing premium and ultra premium
tissue in a way that saves resources
and at the same time enhances thecompetitiveness of the producer.
Suzanne Blanchet can confirm this:“This investment gives evidence of ourcommitment to the growth of the
Cascades brand in the top tiersegment.” Blanchet is extremely
satisfied with the outcome of the
project: “The investment started a new
era in the production of high-quality
premium tissue paper in North America
and worldwide and confirms Cascades
position as a leader in sustainable
manufacturing of premium and ultra
premium tissue paper.”
The ATMOS principle. In conventional
tissue manufacturing, the press stage
has an adverse effect on volume andsoftness of the paper. The initiallybulky, open fiber mixture is often
compressed to a flat sheet in the nip
between press section and Yankee
cylinder at pressures of more than
30 bar. As a result it is neither
particularly absorbent nor really soft.
Although this tissue then undergoes
creping on leaving the Yankee cylinder
to give it a fuller appearance, thedefinitive properties of the paper
scarcely change. Voith has achieved asignificant improvement in tissue paper
quality through its development of
ATMOS technology at the Tissue
Innovation Center in São Paulo, Brazil.

Contact
Rogério Berardi
rogerio.berardi@voith.com

2 2 | TWOGE THE R 3 3 /20 1 2The key to ATMOS technology is theATMOS suction roll and its specially developed AtmosMax clothing for supporting the web run. The AtmosMax
fabric lends a three-dimensional texture
to the web, which is gently dewateredby the ATMOS suction roll at a vacuumof 0.5 bar. In addition, the AtmosMax
clothing and the paper web are sup-ported by two other fabrics as they
pass over the suction roll. There is a
dewatering felt named AtmosFelt under
the paper web that reinforces the
suction effect of the vacuum. On top is
the open tensioning fabric AtmosBelt
that gently presses water out of theweb. To reduce the viscosity of the web
to be dewatered, and thus increase thedry content of the tissue, hot, damp
exhaust air from the hood of the
Yankee cylinder is blown through theclothing fabrics and paper web into the
ATMOS roll. A short press nip locateddirectly at the outlet to the ATMOS
module removes more water from thetissue web to increase its dry content
and also the fiber bonds resulting inhigher tensile strength.
In tissue manufacture, the largest cost
factors are fibers and energy. Using
ATMOS technology, up to 30% fewer
fibers are required than in conventional
tissue machines. This tissue paper
nevertheless still has the same strength
properties and very high water absorption capacity necessary for kitchen andhand towels, and it also offers a firstclass “hand feel” and bulkiness fortoilet tissue. In addition, up to 100%
secondary fibers can be used depending on application without prejudicing
quality: An ATMOS tissue producedwith secondary fibers has a quality
comparable to or even better than theleading premium tissue products available on the market. Along with thebenefits relating to paper quality,
ATMOS also offers impressive energy
savings, with consumption up to 60%
lower than other premium tissue
production processes. Voith’s ATMOS
technology therefore allows ecologically compatible production of tissue
papers in the premium segment. //REBUILDS
05“The investment started a new era in
the production of high-quality premium
tissue paper in North America andworldwide, and conﬁrms Cascades
position as a leader in sustainable
manufacturing of premium and ultra
premium tissue paper,” explains
Suzanne Blanchet, CEO of Cascades
Tissue Group.

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REBUILDS

01

01

02

In the last eight years, theGerman paper mill Varel
has invested more than 300
million euros in its plant.
With two paper machines,
Varel plans to produce an
impressive 600,000 metrictons of packaging paper
every year.

The new PM 4 combines
a multi-product capability
with high productivity andcost-efﬁciency.

PAPER MACHINES THAT CAN DO ALMOST ANYTHINGA SHOWCASE PLANT
BY THE NAME OF VARELThe Varel PM 4 may not be the biggest or fastest
packaging paper machine in the world, but when it comesto flexibility it is surely at the top. There is hardly a paper
grade or grammage that the machine, which wascompletely converted into a multi-product machine,
could not produce.
The Varel paper and board mill andVoith Paper can look back on a longcollaboration. The most recent projectis already the fourth in a series that theGerman papermaker has entrusted toVoith, and this time it was a particularlycomplex task.
The stock preparation systems for the
PM 4 were optimized to reach the new
production quantities and achieve therequired qualities. Another goal is to
reduce the energy input and save

2 4 | TWOGE THE R 3 3 /20 1 2

resources. Along with the complete
new construction of stock preparationlines 2 and 3, the existing line 1 was
upgraded and optimized. All three lines
process all required raw materials, frommixed brown recovered paper tographic recovered paper. On the basisof preliminary tests at the Voith Paper
Fiber Technology Center in Ravensburg,
Germany, unique and customized stock
preparation concepts for optimized
operation were developed together withthe customer.

REBUILDS

02

Fine screening in all lines was fitted with
MultiFoil rotors and C bar Q screenbaskets, and the centralized fiber aftertreatment was equipped with the latest
generation of refining fillings. This has
resulted in an exemplary overall solutionthat is both technologically sophisticatedand economical. Line 1 has been in
operation successfully since July 2011.
Lines 2 and 3 started up in March andJuly of this year.
The future is becoming white. The paper machine was equipped with new approach ﬂow systems, two new headboxes and both Fourdrinier wires wereextended. A DuoFormer D hybrid former
was installed on the back ply, while the
top ply received a DuoShake shaking
unit. The dryer section was built completely new, and the old size press was
replaced by a SpeedSizer ﬁlm press withcontactless web run and a high-performance drying hood. In addition, thePM 4 received a soft calender and a MasterReel rewinder, and a new unwind station for larger full reel spools and a Gecko
size application system for start and end
gluing were installed at the winder. Afterthe extensive rebuild, the machine wasrestarted in mid-July 2011. Likewise, theentire paper machine control system
was upgraded and equipped with a CD
profile control system, among otherthings. Voith also supplied the roll covers, clothing and doctor blades.
Varel is an investment-friendly, familyowned business and is open to newthings. This pays off in paper production: Thanks to its extraordinary flexibility, the PM 4 is very competitive. There
are not many machines that can handle
the basis weight range from 100 g/m²
to 220 g/m² and produce so manydifferent packaging paper qualities.
Usually the PM 4 produces corrugatedmedium and test liner, but in the future
up to 50% white linerboard will be produced. Products that can replace kraft
liner are also planned. Since the 1950s,
recovered paper has been used exclusively as the raw material.
The PM 4 was out of operation forabout three months due to the rebuild.
Already in the first months after startup, the machine was running above theplanned start-up curve.
More, better and more versatile. The
PM 4 now has a net trimmed operating

width of 5.25 m and is designed foran annual capacity of 300,000 metrictons. The enlargement of the paper
web by 200 mm was a special aspectof the rebuild – the new components
were designed for 5.45 m. With somemodifications, it will be possible in
the future to enlarge the stock jet by
200 mm, for example.
But the increase in production capacityand expansion of the product range are
not all. Efficient use of energy and environmentally friendly paper production
are just as important for Varel. These
guidelines have strongly influenced theselection of new equipment.
For example, the new MasterJet Pro
headbox is even more energy efficientthan its predecessor model. The hybrid
former in turn brings savings due to theincrease in dry content. A film press instead of the size press saves energy if
the web is not so intensively remoistened and the amount of size in recirculation is reduced. Since the film press issuitable for pigmentation, Varel is well
positioned for the future. Higher wiretensions are now possible in the dryer
section, and if they are combined
TWOGE TH E R 3 3 /2 0 1 2 | 2 5

REBUILDS

But it is not just on the paper machine
where energy is saved. The CycloMech
deaerator in the approach flow system
reduces energy consumption throughthe functional separation of deaerationand stock transport. The amount ofstock is reduced, the formation is also
improved and higher strength values
can be attained.

Energy from sun and water. The Varel
paper mill wants to produce environmentally friendly products in the mostresource-conserving manner possible.
The goal is a clear reduction of CO 2
emissions throughout the entire paper
production process. To best measure
up to the claim of environmentallyfriendly paper and board products, allareas of production are ecologically optimized. This applies not only to the
preparation of raw materials but also towater treatment and energy production.

Many ideas and implementations comefrom Varel itself. Nowadays it is rare thata paper mill independently performs theengineering and planning work. At
Varel, however, the company has its
own engineering office. With the support of external advisors and Voith
Paper, the customer carried out theplant engineering. The piping aloneamounted to 30 km, not to mention the
420 km of wiring.

The plant’s entire energy requirement
for steam and power is produced in its
own power plant, and the excess electrical energy is fed into the public grid.
Natural gas and biogas are exclusively
used as primary energy, with the biogas
coming from Varel’s own wastewater
treatment system. About 5 million m³ of
biogas are produced annually in theprocess water treatment system. Varel
is trying to keep water consumption towith the innovative ventilation concept (ProRelease and blow doctors),
consumption of steam is reduced.

03

2 6 | TWOGE THE R 3 3 /20 1 2

04

a minimum. Thus process water is reused as often as possible and preparedusing three stages in the process water
treatment system. Varel also gets energy from the sun: A photovoltaic system is installed on the roof of the storage buildings.
The paper and board mill has taken
on a trailblazing role in both energy
efficiency and paper manufacturing.
Production capacity has clearly increased due to the rebuild, and Varel
has become one of the biggest packaging paper manufacturers in Europe. //Contact
Erwin Holzinger
erwin.holzinger@voith.com

03

Sven Schindler,machine operator in
Varel, monitoring thesystem.

04

Starting in mid-2012,
white covered grades
can be produced.

REBUILDS

NEW REEL CHANGE SYSTEM FOR COATER AT UPM

REEL CHANGES ON THE FLY
Anyone who witnesses a reel change taking place at full production speed
on coater 11 at UPM in Plattling, Germany, will be astonished to see howsmoothly this procedure runs. It has been made possible by the retrofittingof the cutting-edge reel change system, EcoChange W, to the existing Sirius
reeler in June 2011. This system uses high-pressure water jet technology
and offers distinctive features such as an innovative arrangement of cutting
nozzles and the gluing of the web end on the reel core.

01

TWOGE TH E R 3 3 /2 0 1 2 | 2 7

02

01–04
New reel change system
impresses UPM: Rebuild
improves production
capacity of coater 11.

03

UPM Plattling had a clear objective in mind when it came to retrofitting an
EcoChange W reel change system to coater 11: to improve reel change efficiency
and reduce winding broke. However, there was a special challenge involved, as theexisting knife-cutter reel change system was to be retained as a fall-back solution.
This represented new ground for Voith’s specialists. In addition, only minor
modifications to the existing equipment would be possible due to the short
downtime period available for installation and commissioning.
Thanks to the self-contained control package, the new reel change system could
be fully tested outside of the coater before being integrated into the Sirius. This
resulted in a substantial reduction in installation time and meant that the coater
could be restarted ahead of schedule. The new EcoChange W worked superbly
even on the first reel change. During subsequent reel changes, the system’s
individual operating parameters were optimized. After just two days, commissioning
could be successfully concluded.
Increasing production capacity. Just two months after startup, reel change
efficiency was more than 99.5%, while the volume of reel change rejects had been
reduced by 80%. Working in combination with a rubber-lined reel drum supplied byVoith there was even an increase in overall production capacity.
UPM was naturally very pleased with the outcomes. “Our objectives – to increase
reel change efficiency and reduce broke – could be met in full just a few days after
startup. The entire project could be realized in just four months from award of order
to commissioning, thanks to the excellent teamwork of all those involved,” explains
Alois Leeb, Head of Technical Planning at UPM Plattling. And he continues:“Installation and commissioning could be carried out in just one day due to a wellprepared and thought-out pre-assembly phase. The collaboration between all
project participants was exemplary, very agreeable and highly focused.”Highly efficient reel changes and reduced volume of broke. The offline coater
11 in Plattling mainly produces LWC papers with a basis weight of 39 g/m 2 to
85 g/m 2 at an operating speed of up to 1,570 m/min. Particularly in the case of

2 8 | TWOGE THE R 3 3 /20 1 2

REBUILDS

04

offline coaters, a reliable reel change helps to ensure optimum machine efficiency,
because after a web break the paper web has to be threaded manually again
at crawling speed. A special feature of the offline coater is that the separate raw
paper reels have to be “glued” together to form a continuous web again before thecoating process. This is done fully automatically at production speed using flying
splice in the coater’s unwinder. The joined section then runs through the individual
coating and drying units to the Sirius reeler, where it is wound into the outside layersof the full reel spool. As a result of the timely reel change close to the joining point,
the EcoChange W system reduces the volume of outer layer broke.
Along with outer layer broke, the broke from the core is also significant. Someof the reel change systems on the market create a large amount of core broke.
Belt-type reel changers, for example, cause a pressing through into the inner layers
and in some cases an oval winding profile in the reel core area. In the case of reelchange systems using knives or compressed air, the web often folds over in thecore, and there is a risk that shreds of paper flying around will get back into thecore layers or that the reel change will not be completed. This was also sometimes
seen in the existing reel change system at the Sirius of coater 11.
Cutting on the empty reel. As soon as the full reel has reached its change position,
the EcoChange W reel change system uses two high-pressure water jet nozzles to
cut a triangular tip out of the paper web by making an intersecting cut starting fromthe center and moving outward. The cut is made directly on the empty reel aroundwhich the paper web is already partially wrapped.
At the same time, a dosing nozzle is used to briefly apply a small amount of watersoluble adhesive agent onto the empty reel in the area of the web tail. This helps
to thread the web tail reliably onto the new reel without creasing, while thetwo cutting nozzles completely separate the web up to the edge. Because the web
is cut downstream of the nip between empty reel, paper web and reel drum, the
web is guided accurately throughout the entire change sequence. It is generally nolonger necessary to make a temporary adjustment of winding parameters for thereel change (reducing web draw). //Alois Leeb, Head ofTechnical Planning at
UPM Plattling“We were able toreach our goal infull – increasing reelchange efficiency andreducing broke – justa few days after
startup.”Contact
Stefan Niederer
stefan.niederer@voith.com

TWOGE TH E R 3 3 /2 0 1 2 | 2 9

REBUILDS

01

03

02

04

TISSUE INNOVATION CENTER OPENS WITH FULLY RENEWED MACHINETISSUE GOES HIGH-SPEED
In the presence of a large number of customers, Voith Paper recently opened its new Tissue
Innovation Center (TIC) in the Brazilian city of São Paulo. At the TIC, a completely renewed pilot
facility will now allow conventional tissue paper to be produced at up to 2,500 m/min andpremium paper at up to 1800 m/min. Therefore, customers from all over the world can trial thelatest tissue technologies on a high-speed machine.

05

06

01
Nestor de Castro Neto, Presidentof Voith Paper South America,
welcomed around 150 customers
from all over the world.
02–04
There were lots of interesting
facts to take in, along withinteresting things to touch
and watch.
05–06
Undoubtedly the highlight ofthe 3-day program: viewing thepilot machine.

3 0 | TWOGE THE R 3 3 /20 1 2

REBUILDS

At the end of November 2011, the official opening of the
Tissue Innovation Center following its major rebuild andrenaming was accompanied by a three-day program of
events. An innovation workshop, in which Voith Paper experts
presented the company’s latest technologies and strategies,
took center stage. Around 150 company owners, managing
directors and lead engineers from customers in Asia, Europe,
North and South America took part in the event.
“We won’t just be doing research here on better quality anda faster, more efficient production process,” explained Nestor
de Castro Neto, President of Voith Paper South America, in
his opening remarks. “As in other areas, the R&D focus intissue production is also about exploring how we can improve
raw material and energy efficiency by means of new machinetechnologies and thus enable our customers to produce
conventional and premium tissue for daily use in a costefficient and resource-saving manner.”
High-speed tissue. Following the comprehensive rebuildfrom pulper through to reel, the Tissue Innovation Center now
houses one of the fastest tissue machines in the world. It
enables maximum production speeds of 2,500 m/min forconventional dry crepe mode and 1,800 m/min in ATMOS
mode. This was achieved by increasing drying capacity as aresult of installing a new Yankee cylinder and new dryinghood.
The Yankee cylinder now has a diameter of 5.5 m (comparedwith 3.6 m previously). The larger size raises its drying
capacity accordingly. Air systems and heat recovery units
were also renewed. In addition, the tissue machine is fittedwith a Voith Ultra Hood drying hood that allows temperaturesof up to 650°C. This enables considerably higher production
capacities than standard hoods and reduces power
consumption.
For the first time, the pilot machine offers a fast and simple
configuration change between its conventional mode and
ATMOS technology that requires 60% less energy and
30% fewer fibers than conventional processes to makepremium tissue. In addition, for greater paper softness,thickness and tensile strength, the headbox can be configured
for one, two or three layers. The reel can be operated inconventional mode or with center wind reel, which ensuresa uniform winding of premium tissue and maximization ofbulk.

Practical tests. The benefits for tissue manufacturers areconvincing: They can test the latest technologies on the pilot
machine at the highest possible speeds. There has been
particular interest in the application potential offered by ATMOS
technology. The facility also offers the opportunity to carry out
tests with conventional dry crepe technology at high speeds andto compare a multi-layer with a single-layer headbox in terms ofsoftness and thickness. Moreover, tests can be run with the new
NipcoFlex T shoe press, which reduces energy consumption forthe production of conventional tissue paper by 20%.
The pilot machine has been fully booked since startup throughAugust 2012. Most bookings come from international customers
from Asia, Europe or North America. They are enthusiastic about
the new machine and the support services provided by the TIC,
such as the associated laboratory. Voith Paper itself is also using
the renewed tissue machine for R&D work.
A wise investment. The new TIC is testimony to Voith Paper’s
conﬁdence in the tissue production sector. According to current
forecasts, global demand will grow at an average of 4% in the
coming six years. The investment in the center is therefore
money well spent in terms of strategy and market dynamics.
This is also borne out by some successful sales ﬁgures. For
example, in the last three years Voith Paper sold more than 20
new tissue machines and performed several rebuilds.
Voith has always invested in innovative and sustainable
technologies that become market leaders. The engineers at the
R&D Center in São Paulo, which was established in 1994, havealready developed numerous new components and processes.
Their latest achievements include ATMOS technology and the
NipcoFlex T shoe press, both of which help to achievesustainable tissue production using fewer resources. //Contact
Rogério Berardi
rogerio.berardi@voith.com

Thomas Scherb
thomas.scherb@voith.com

TWOGE TH E R 3 3 /2 0 1 2 | 3 1

PRODUCTS ON SITE

01

View of wet section
PM 1.

02

Reel scanner with sensors forbasis weight, moisture, caliper,
ash and color.

TOTAL COST OF OWNERSHIP MAKES ALL THE DIFFERENCENEW QUALITY CONTROLSYSTEM AT SALZER PAPIER
With a view to future
maintenance costs, St. Pöltenbased Austrian papermaker
Salzer Papier GmbH decided
to replace the old quality
control system (QCS) on its
PM 1. With the new systemfrom Voith, Salzer will savecosts for spare parts andmaintenance in the longterm.
As quality control systems age, the costsof maintaining them rises signiﬁcantly as
obsolescent parts wear out and become
scare. Worse still, increasing quality
control system (QCS) downtime cancause serious and costly production halts
3 2 | TWOGE THE R 3 3 /20 1 2

and quality issues. This is why paper
producers usually replace their quality
control systems after about 15 to
20 years in service. Modern systems offer
considerably better measurement
resolution, process and paper quality
information accessibility and control
capabilities. Quite simply, a new QCS canoffer a better return on investment (ROI)
than an older one that is near the end ofits lifecycle.
Reducing future costs. Rather thanconcentrating only on reducing current
costs of service, papermakers are now
looking at the future costs of maintaininga system. This also plays a key role in the
choice of QCS supplier, as it is crucial tolong-term cost effectiveness.
For staff at Salzer Papier GmbH, thesewere precisely the criteria that matteredwhen it came to choosing a supplier forthe new QCS. The QCS installed on the
PM 1 book paper machine in 1988 wasscheduled for replacement. Following atechnical analysis, the company opted fora QCS from Voith. The new system wasinstalled in early 2011.
According to Thomas Salzer, CEO of thecompany, Voith’s proposal was far
superior to that of other vendors. “We
looked at the running costs of the new
system over a period of four years. The
differences in TCO were largely
attributable to the direct maintenancecosts of the system manufacturers –including local support, telephone help,
defined response times and costs forspare parts. In a comparison of TCO for
the project, the Voith system ranked very
well, even though the initial purchasing
cost was not the cheapest.”

PRODUCTS ON SITE

“It is important to have a partner
like Voith that will continue todevelop systems technology andremain active in the paper industry
for many years to come.”

Facts & ﬁgures Salzer Papier PM 1
+ Paper grades: book printing paper(bulky, wood-free uncoated paper)+ Paper volume:
1.2 to 2.2 times volume (cm3/g)+ Basis weight: 60–220 g/m2
+ Production speed: depending on paper
grade up to 440 m/min

Thomas Salzer, CEO of Salzer Papier GmbHTechnical and practical beneﬁts. Salzer
Papier staff were impressed by both thetechnical features and operation of theVoith quality sensors. One example is thefast replacement of sensors via plug-andplay, taking less than a minute. The QCS
is designed for simple maintenance by
paper mill personnel, so that there is noneed for on-site servicing by the
manufacturer as was usually the casewith previous systems. In addition, thecomprehensive diagnostic functions also
allow problems to be quickly isolated byVoith personnel. The service contract
includes scheduled preventive
maintenance operations on site, as wellas telephone and remote diagnostic
support with a speciﬁed reaction time andemergency on call service.
Thomas Salzer emphasizes that thedecision was influenced by Voith’s
reputation in the paper industry as aleading technology developer andreliable partner. “It is important to have apartner like Voith that will continue todevelop system technology and remain

active in the paper industry for many years
to come,” he adds.
Fast, well-executed startup. The new
QCS includes three scanners: one
O-frame scanner before the reel with basis
weight, moisture, caliper, ash and color
sensors, as well as one single-sided
scanner with a moisture sensor before
the machine calender and one before thesize press. In addition, the QCS comprises
all MD paper quality controls andCD proﬁle control of an existing actuatorsystem at the headbox. A CD moisturizing
proﬁler after the size press is also included,
to regulate the moisture profile at the
inlet to the calender. The QCS is linked
to the existing process control system,with monitors for operating staff installedin the control room opposite the dryer
section. Additional monitors are also
provided next to the wet section and in theshift foreman’s ofﬁce.

at Salzer Papier relates: “The projectplanning phase incorporated thoroughpreparation for the actual installation,
during which minor problems could thenbe readily resolved. Even in the ﬁrst weeks
and months of operation of the new
system, there was excellent cooperation
between Voith and Salzer, which has
resulted in the optimized system we havenow. Of course there is always room for
improvement, but we are looking forward
to full optimization of the system with
Voith’s support.” //Contact
Klaus Steinhart
klaus.steinhart@voith.com

The QCS was commissioned quickly andefficiently in January 2011. As Michael
Griessler, Project Manager for Automation
TWOGE TH E R 3 3 /2 0 1 2 | 3 3

PRODUCTS ON SITE

THREE NEW PRODUCTS FEATURING VOITH SCREENFIT TECHNOLOGY

SUCCESSFUL FORMULAFOR EFFICIENT SCREENING

01

Final quality
inspection of a
C-bar screenbasket.

01

3 4 | TWOGE THE R 3 3 /20 1 2

Inferior raw materials and increasing cost pressures have caused adramatic rise in screening requirements over the past few years.
Modern screening systems must provide a high degree of efficiency ina cost-effective manner. It is critical that the screen baskets and rotors
work in perfect harmony to assure optimum screening efficiency. As
experienced system designers, Voith offers the successful formulas
required for all modern screening processes.

PRODUCTS ON SITE

Unused process potentials are the mostfrequent cause of inefficient screening
systems. Having several decades ofexperience with the most variedcustomer systems, Voith Paper has the
specialized knowledge necessary to
make use of these potentials. With aproduct portfolio that spans all stagesof the manufacturing process, Voith
Paper is in a position to utilize freecapacities in the screening process.
Included here are both coarse and finescreening within stock preparation, as
well as broke screening and screening
in the approach flow system. The
following products in the area of rotors
and screen baskets particularly deserve
special attention: the MultiFoil rotors in
the Economy series, the EclipseRotor
series and the C-bar M slotted screenbaskets.

screen basket combination for theirown operating parameters, Voith hasdeveloped the ScreenFit program. In
illustrations 05 and 06 on the next
page, all possible combinations ofVoith screen baskets and rotors areshown. Using this, paper manufacturers
can put together a ScreenFit Upgrade
Kit tailored to their needs. Voith’srecommendation is in each casemarked with a blue circle. It stands forexcellent screening results with therotor/screen basket combination
shown.

paper manufacturers all over theworld used this online tool at
www.ScreenFitNavigator.com for areview of the energy use in their system.
After inputting a few parameters andindicating the importance of screening
quality to their process, immediate
evaluation takes place in the form of a
PDF document that is sent via email tothe customer. If unused processpotential is ascertained, the ScreenFit
doctors can then come into play, if
required. Taking into account theindividual customer objectives, themeasures proposed aim at longterm optimization of the screening
systems. //Optimal ScreenFit Upgrade Kit. In
order to give paper manufacturers
a quick overview of the optimal rotor/

Online tool creates great feedback. The recently introduced
ScreenFitNavigator is another useful
tool for optimizing existing screening
systems. The free online benchmark
test provides a quick, no-obligationenergy assessment of the fine screening
system (slot screening) in stock
preparation. Only a few weeks after the
introduction of the ScreenFitNavigator,

02 MultiFoil Rotor Economy series

03 EclipseRotor series

04 C-bar M slotted screen baskets

Thanks to its unique patented foil blade
concept, the new MultiFoil rotor reduces
energy consumption up to 15%. This
increases efﬁciency accordingly and enhances
wear resistance. The MultiFoil E series
rotor can be used in stock preparation for
all raw material grades.

With its novel hydrodynamic foil shape,
the EclipseRotor reliably screens heavily
contaminated stock in the high-consistency
range. The foil creates a uniform pressure
and a powerful suction zone that increases
production capacity up to 25% andcorrespondingly lowers energy consumption.
The EclipseRotor series is ideal for use instock preparation of all possible recycled
paper and for screening primary pulps.

The exceptionally stable C-bar M slotted
screen basket has nearly twice as muchopen screening surface compared to milled
slotted screen baskets and was developed
speciﬁcally for high shearing force stress andhigh-consistency applications. The C-bar M
is suitable as a replacement for conventional
weld gap or milled slotted screen baskets andis an alternative to replaceable basket models
of other manufacturers in stock preparationand in pulp screening.

Contact
Christian Steinmassl
christian.steinmassl@voith.com

TWOGE TH E R 3 3 /2 0 1 2 | 3 5

PRODUCTS ON SITE

05 Portfolio of slotted screen baskets and rotors

C-bar
Centrifugal

Slotted screen baskets

C-bar S
(Standard)

C-bar M
Centrifugal

C-bar C
Centripetal

C-bar Q
(Quantum)

Bump

EclipseStep & Lobed

EclipseCentrifugal
screening rotors

MultiFoil

3

1

2

3

4

C-bar R
(Radical)C-bar C – compatible with all centripetal foil rotors from other manufacturers
5

C-bar S
(Standard)

3

C-bar Q
(Quantum)

1

2

4

4
Voith standard recommendation

Bars
1

Screening of all recovered paper grades ≤ 2.8% stock consistency

2

Screening of all recovered paper grades ≤ 4.5% stock consistency

3

Screening of primary ﬁbers ≤ 4.5% stock consistency

4

Screening of all recovered paper grades and primary ﬁbers ≤ 4.5% stock consistency with high shearing force stress

06 Portfolio of hole screen baskets and rotors
EclipseStep & Lobed

CL-typeContoured hole

Hole screen baskets

Bump

EclipseCentrifugal
screening rotors

MultiFoil

3

F typeFiltrate holePL-typeCountersunkhole

SD-type
Smooth hole2

3 6 | TWOGE THE R 3 3 /20 1 2

1Voith standard recommendation

4

1

Screening of all recovered paper grades ≤ 2.0% stock consistency

2

Screening of all recovered paper grades ≤ 4.5% stock consistency

3

Screening of primary ﬁbers ≤ 4.5% stock consistency

4

Screening of wastewater/white water/ﬁltrates ≤ 1.0% stock consistency

PRODUCTS ON SITEEARLY FAULT DETECTION USINGONV CONDITIONMONITORING

MONITORINGSYSTEM SAVESCOSTSUnplanned paper machine shutdowns andquality fluctuations can cost a papermaker a lotof money. This is why mechanical faults have tobe identified during production in good time andtheir condition monitored, so they can be dealt
with promptly. The OnV ConditionMonitoring
system can prevent unplanned shutdowns anddetect quality variations immediately, and thus
save costs.

01

The switch cabinet is part of the OnV ConditionMonitoring
system and contains computers, data recording electronics,
voltage supply and the interfaces with the sensor system.

Bearing damage on rolls, gearing, drives and other units, aswell as wear
and material fatigue on other mechanical01
components in the production line, can often result ina production outage and poor paper quality. This is where
OnV ConditionMonitoring, with its customized range of sensors
adapted to machine type and customer requirements, comes
into play. The sensors provide processed data from the entire

paper manufacturing process – from stock preparation tofinishing. OnV ConditionMonitoring is a professional data
logging system with a comprehensive software tool thatcompiles analyses and diagnoses for production optimization,
troubleshooting and maintenance planning. It therefore supplies
all important information needed to make the appropriate
decisions relating to all aspects of paper production.
TWOGE TH E R 3 3 /2 0 1 2 | 3 7

PRODUCTS ON SITE

02

Numerous beneﬁts. Thanks to the OnV ConditionMonitoring
system, there are fewer unplanned shutdowns and therefore
enhanced higher machine availability. Maintenance shutdowns
can be better planned and preventive maintenance initiated.
This avoids more extensive damage on rolls, their covers andclothing, to bearings or also on the drive train, and as a result
prevents high repair costs. Quality ﬂuctuations can also be
identified directly online during the production process,assigned to a cause and rectiﬁed as quickly as possible.
Optimal condition monitoring. The purpose of machinemonitoring, which is one module of the OnV ConditionMonitoring
system, is to detect bearing damage at an early stage. This isdone by installing sensors at a wide range of sections on thepaper machine, stock preparation and other machine andauxiliary units in the paper mill. These sensors record theoscillation signals of the respective bearing. The signals arethen ﬁltered, digitized and stored in a database. The data on
bearing type and the velocity and/or bearing rpm of themachine part can be used to calculate the bearing fault
frequencies. These are compared automatically with themeasured signal. If a signal changes, it triggers a corresponding
alarm. The trends and frequency ranges produced are used toprovide deﬁnitive information on the type of bearing damage,imbalance, alignment errors and the current damage
propagation.
The second module of the Voith OnV ConditionMonitoring
system – technology monitoring – complements the bearing
monitoring process by providing the papermaker with machine
status data that are useful for optimum production.
Due to the high production speeds and quality demands inpaper manufacturing, the technology used has to meet stringent
requirements. There are a large number of parameters and wideranging inﬂuences impinging on the machine components usedin key processes such as the headbox, press, coater or calender.
3 8 | TWOGE THE R 3 3 /20 1 2

These factors can quickly impair the production process andpaper quality itself. In the event of any anomalies such as
vibrations or pulsations in the process, the causes are identiﬁed
in good time by means of synchronous time averaging (STA).
Rapid, periodic ﬂuctuations in basis weight or moisture are also
evaluated online and automatically assigned to originators suchas the screen separator and headbox pumps in the approach
ﬂow system. Measured data thus provide feedback during
production and indicate what is causing the malfunctions. Thismeans that there can be a quick response to quality variations,and action can be taken in good time to prevent a greater lossof proﬁt due to quality deﬁciencies.
Integrated user interface. The user interface of the OnV
ConditionMonitoring system is web-based. This allows thedata to be represented simultaneously at different locations,
without having to install additional operator stations. The
modular structure of the measuring equipment and sensors
allows additional measuring points to be incorporated into thesystem retrospectively at low cost. More than 2,000 sensors
can be connected to a single condition monitoring system,
depending on the customer’s monitoring requirements.
In addition, a user-deﬁned diagram display can be installed thatis fully tailored to customer speciﬁcations. This provides a quick
overview using an alarm log book and summary pages showing
group alarms. The system offers further advantages such as
automatic alarms and comprehensive documentation as well
as a representation of the damage trend.
Moreover, as a result of additional communication interfaces
with drives, lubrication system and extra sensors for measuring
temperature, pressure and ﬂow, a comprehensive monitoring
system is provided. This means that over the years a wide
range of information is collected, allowing fast and accurate
error diagnosis.

PRODUCTS ON SITE

03

04

If required, customers can opt for a service feature consistingof a comprehensive report with diagnoses and recommendations. Remote maintenance can also be provided.
Monitoring systems in use. When building its PM 4 in 2004,
the Leipa Georg Leinfelder GmbH paper mill in Germany also
opted for a vibration monitoring system. The 78 sensors in thetechnology module and the 401 sensors included in machinemonitoring are used all over the machine from the stock
preparation unit to the rewinder station. The system is muchappreciated by maintenance and production staff, as it issimple and user-friendly. According to Michael Gebauer, plantengineer for technical diagnostics at Leipa: “Initially we had ourdoubts as to whether the system would actually be beneﬁcial.
But Voith gave us such good support from the very outset that
our concerns quickly vanished. The system is simply
indispensable for identifying bearing damage or roll barring
early on and therefore saving costs.”

02

The bearings of a paper machine,
installed on rolls, pumps, drives andother rotating machine parts aremonitored by the OnV ConditionMonitoring system.

03

Bearing monitoring of the OnV
ConditionMonitoring system provides
vibration data of the entire paper
manufacturing process.

04

The ﬁgure shows how damage toa bearing on a Flexitherm roll could
be detected in good time using
the cumulative trend of oscillation
acceleration and a frequency
spectrum of the measuring point.

And Leipa still trusts in OnV ConditionMonitoring, as shown by
its 2007 order for the monitoring of special vacuum pumps.
This involved installing another 17 measuring points for bearing
monitoring.
The Indonesian customer Asia Pulp and Paper (APP) has also
shown confidence in the monitoring system. Large paper
machines such as Dagang PM 3 (1,200 sensors) and Hainan
PM 2 (more than 1,500 measuring points) have already beenﬁtted with the Voith system. The measuring system was also
installed at the OMC 2 coater in Dagang which was equippedwith 230 sensors and a stock preparation unit with around
170 sensors. The next big project, the Guangxi BM 1, will be
installed in 2012 and will use 1,800 sensors. //Contact
Markus Hochmüller
markus.hochmueller@voith.com

05
TWOGE TH E R 3 3 /2 0 1 2 | 3 9

PRODUCTS ON SITE

TISSUE MILL DEWATERS PULP WITH INNOVATIVE DISC FILTERHICONBAGLESS –EFFICIENTLY THICKENED
Thanks to the installation of the new HiConBagless disc filter, the AMS Gomà Camps tissue
mill in Portugal was able to reduce its use of standard pulp bales. Today’s raw material –bleached pulp suspension – is now thickened by the new HiConBagless disc filter and directlytransported to the tissue machine’s stock preparation unit. The installation saves energy as
well as money.

The AMS Gomà Camps tissue mill in Vila
Velha de Ródão, Portugal, was openedin 2009. Primary markets for its products
are the Iberian Peninsula, North Africa
and the Portuguese-speaking countriesof Africa. The centrally situated locationin Portugal – close to eucalyptus andpine forest stands – provided directaccess to high quality pulp suspension.
There was an immediate need for acompact, ﬂexible and reliable machinefor dewatering the pulp, which at thesame time had to ensure a ﬁltrate qualityof under 50 ppm solid content. The new
HiConBagless disc ﬁlter presented itself
as the solution.

01

New HiConBagless disc ﬁlter, installedon the stock tower of the AMS GomàCamps tissue mill in Vila Velha de Ródão,Portugal.

4 0 | TWOGE THE R 3 3 /20 1 2

Dewatering high freeness virgin pulps
using disc filters has always been achallenge. The rapidly dewatering andstrongly ﬂocculating virgin pulp makes asafe pulp discharge difﬁcult, whereas
severe thickening in the vat might indeed
threaten the integrity of the wholemachine. With the introduction of the
HiConBagless disc ﬁlter, these problems
are now a thing of the past.
Expanded operating window. The
installation of the HiConBagless discﬁlter allows AMS Gomà Camps a highlevel of ﬂexibility: Without mechanicalalterations to the disc ﬁlters, the mill can
now vary its production from at least
25 metric tons per day to up to 150 tons
per day.
The HiConBagless even handles theswitch between the pulp grades of shortfiber eucalyptus and long fiberPortuguese pine. Future production
increases are also possible so that up to
250 tons per day can be processed. The
clear ﬁltrate produced by the disc ﬁlter
has a solid content of only 20-25 ppm.
This ﬁltrate is recycled in order to pick up
new, fresh ﬁbers for the tissue machine– and the loop is closed.

PRODUCTS ON SITE

“Thanks to the good cooperation with the Voith team,
all the installation goals were met on time. Compared
to a conventional virgin pulp bales pulping system,
the energy savings achieved in processing andpre-thickening of a pulp suspension with the
HiConBagless disc filter is approximately 30%.”
José Miranda, General Manager of AMS Gomà Camps

Guided discs. The rugged and unique
Voith Bagless discs last longer than any
dewatering disc on the market. In the
new HiConBagless disc filter, thetrouble-free operation of the disc ﬁlter istaken a step further by the help of a
guiding feature for the Bagless discs.
Low-friction guiding blocks located at
the periphery of the discs travel througha track in the vat. A collision between
sectors and chutes at elevatedconsistencies in the vat is now avoided
at all times.
To enhance the performance of themachine at increased feed consistency,
a special HiCon version of the Baglesssectors has been developed. These
sectors promote a targeted agitation of
the fiber suspension. In combination
with the corrugated stainless steel
surface of the Bagless, the elevatedforces exerted by the pulp do notjeopardize the operating lifetime of discs.
The HiCon can also be installed as an
upgrade-kit on existing disc filters incombination with the Bagless discs. Thisis a particularly attractive way to increase
capacity of the machine. Up to 30%
higher capacity can be reached in somecases. //02 HiConBagless disc ﬁlter – mode of operation
The pulp suspension thickened by the new HiConBagless disc ﬁlter is transported to the tissue
machine. The clear ﬁltrate is fed back into the circuit to pick up new pulp for tissue production.

e
en
ick
Th pulpd

Pulp
suspension

Clear
ﬁltrateContact
Dr. Jonas Bergström
jonas.bergstroem@voith.com

TWOGE TH E R 3 3 /2 0 1 2 | 4 1

NEW TECHNOLOGIESEFFECTIVE STOCK PREPARATIONNEW CLEANER TECHNOLOGYSAVES 40% IN COSTS
Poor Cinderella may have had to sort out the good from the badby hand, but in a paper mill, this job is performed by the stock
preparation unit, which removes impurities and recovers usablefibers. In the process, cleaning stages ensure quality in the low
stock consistency range. HiClean, Voith Paper’s new cleaner, iscapable of processing substantially higher stock consistencies atthe same level of efficiency.
What is special about the HiClean (HCL5)
is its patented, ﬂow-optimized head. In
combination with the EcoMizer rejects
dilution system, HiClean achieves
efﬁciencies of more than 95% in ﬁne sandremoval, even with stock consistencies inthe 3% range. In a comparison test, acleaner without the new head could
achieve the same efficiency with aprocess consistency of only 2%.
The combination of HiClean and
EcoMizer has proven ideal not just for
new systems but also for upgrading
existing cleaners in stock preparation
systems. Just adding EcoMizer
technology alone allows cost savings ofaround 25% to be achieved. But the fullpotential is only realized when combinedwith the HiClean headpiece. Using bothtechnologies together makes savings inoperating and investment costs of up to
40% possible.

01

The patented,
ﬂow-optimized
head of the new
HiClean (in blue)
allows operation
at considerably
higher stock
consistencies.

4 2 | TWOGE THE R 3 3 /20 1 2

There are already two dozen plants with4,000 individual HiClean model cleaners
successfully operating worldwide,
including 3,000 in Asia. An excellent
example in Europe is the PM 7 at Perlen
Papier’s paper mill in Switzerland, where
the new HiClean cleaners are used in theapproach ﬂow system. The higher stock
consistency allows a completely newprocess mode. The beneﬁts are lower
energy costs and greater ﬂexibility withrespect to grade changes.
The latest HiClean development also
allows the additional removal oflightweight contaminants such as wax
and polystyrene, but also air. This new
generation model, the HiClean Combi(HCL5-C), successfully went into
operation for the first time in the USA in
July 2011. //Contact
Dr. Martin Störzer
martin.stoerzer@voith.com

02

The new HiClean facility in the approach ﬂow
system of Perlen Papier’s PM 7 in Switzerland
results in lower energy costs and enhanced
ﬂexibility with respect to grade changes.

NEW TECHNOLOGIESNEW DRYER BIDS FAREWELL TO CURLCURL ISHISTORY
The best inventions are usually thesimplest. And this is exactly the case in
the fight against curl. The new DuoDry CC
reliably reduces curl, saves energy costs
and enhances runability.

TWOGE TH E R 3 3 /2 0 1 2 | 4 3

NEW TECHNOLOGIESVoith Paper’s latest drying concept is the DuoDry CC, with
the CC standing for curl control. It effectively reduces the curlthat occurs in single-tier dryer sections. While it is not an
issue for corrugating medium, it can be a serious problem fortestliner, for example. In most cases, curl has to be reduced
to prevent difficulties in converting. The means used to do
this depend upon the paper grade.
Although a conventional double-tier dryer concept is effective
against curl, tail threading can become more challenging as
machine speed increases, and runability is impaired. In theevent of a web break, it is time consuming and often difficult
to remove the paper. As a result, the limits of the double-tierconcept are quickly reached.
With the advent of very high-speed machines, single-tier dryer
sections were established in the market. In terms of runability,
this concept is very reliable, but the paper does tend to curl
due to the single-sided drying. The unwanted curl can becounteracted by using a moisturizer, but in terms of energy
efficiency it does not make sense to remoisten the dry web if
this can be avoided.
Simple but good. The basic idea behind the DuoDry CC
concept is simple and reliable: a vertically inverted single-tierdryer group installed as the last group. It can replace theusual double-tier curl correction group, thus improving
runability thanks to the continuously supported web run.
4 4 | TWOGE THE R 3 3 /20 1 2

NEW TECHNOLOGIES

01

Lower energy consumption, enhanced runability – theDuoDry CC meets these challenges.

And not only this, but it can also replace the single-tierdryer group combined with moisturizer and reduce thermalenergy. This improves the CO 2 balance and cuts energy
costs.
The concept comprises only proven components, such as
drying cylinders or web stabilizers. Ropeless threading
through the DuoDry CC also functions smoothly. The steam
and condensate system is identical to those used in otherdryer groups, and no additional heating medium is necessary.
Although the DuoDry CC is arranged vertically, it is not higher
than the press section, thus ensuring unimpeded crane
movement.

Reduced energy costs and CO 2 . In paper production,energy efficiency is playing a major and increasingly significant
role. Compared with a single-tier dryer group with amoisturizer, valuable thermal energy and CO 2 emissions canbe reduced, as the web does not have to be remoistened anddried. The DuoDry CC is powered by steam, the least
expensive heating medium. Compared with solutions driven
by gas or electricity, this therefore keeps running costs at amuch lower level.
The first DuoDry CC will go into commercial operation in thefirst quarter of 2013 on the Narew PM 5 at Stora Enso’s millin Ostroleka, Poland. //The matching hood design was developed in conjunction with
Voith Paper Air Systems and takes detailed account of therequirements of machine operators. Basic prerequisites, suchas easy access, effective ventilation, and an acceptableclimate for operation and maintenance, have been met.
The occupational safety of the operating crew was also adecisive factor in the development of the DuoDry CC. The
removal of broke from the pockets of the double-tier dryer
group can be very difficult and even dangerous, particularlyin the case of very wide paper machines. The new concept
eliminates the risk of paper accumulating in the pockets inthe event of a web break, with the paper falling safely into thepulper or basement.

Contact
Stefan Lehner-Dittenberger
stefan.lehner-dittenberger@voith.com

TWOGE TH E R 3 3 /2 0 1 2 | 4 5

NEW TECHNOLOGIESRELIABLE ROLL COVERS FOR SIZING AND PIGMENTINGCONSISTENTLY GOOD QUALITY
A new rubber polymer matrix makes it possible: eVen roll covers are speciallydeveloped for applying high-quality pigments and starches in size and film presses.
They provide consistent performance and high machine availability.

In field trials the new eVen roll coverdemonstrated consistent and reliable
runability. In some cases, service life
was double that of previous covermaterials. Customers have benefited
from the physical properties of the new
rubber matrix through its improved
resistance to tear, abrasion resistanceand lower hysteresis, which contributes
substantially to reduced paper machine
downtime and application quality.

01

Voith specialists on site.
Paper producers demand highperformance from their machines.
This means that application
know-how and process expertiseare key factors in meeting
expectations of service lifeand paper quality.

4 6 | TWOGE THE R 3 3 /20 1 2The superior resistance to surface
tearing results in consistent paper
quality by maintaining sheet profiles. In
addition, eVen covers demonstrate alower risk of thermal barring, which canoccur primarily through a combinationof speed, cooling and nip load. The
result is a longer machine service lifeand lower running costs.
More than 30 field tests have confirmedthat eVen roll covers are stronger andmore resistant to impact damages
caused by paper wraps after a sheet
break and are less sensitive to thermal
influences.
Voith designed the eVen roll covers to
be flexible, having a wide operating
window. eVenFilm is developed for film
presses and eVenSize for puddle sizepresses. The cover can be used for sizing and pigmenting, sometimes on theNEW TECHNOLOGIES“We managed to double
the roll service life outright,
without any grinding.”
Paulo Santos, Superintendent of PM 2, Portucel Soporcel Groupsame machine based on paper grade
requirements. The unique fillers provide
the cover with consistent surface
roughness and abrasion resistanceensuring consistent application of thesizing and pigment structure. This could
be clearly seen from the field trials
where eVen demonstrated that thecover does not tend to swell.
Extended service life at Soporcel
PM 2. In a recent field test on the PM 2of paper manufacturer Soporcel in
Portugal, eVen roll covers successfully
demonstrated their performance in the
production of uncoated wood-free
paper (copy and offset grades). The rollcover was used at a machine speed of
1,450 m/min and width of 8.60 m. The
results clearly demonstrated the benefits of the new covers: improved paper
quality and running times that weredoubled, due to longer intervals between grinding and a correspondingly
lower number of roll changes. “We
could immediately double the running
time of the roll without grinding,” explains Paulo Santos, the manager of thePM 2, who is satisfied with the performance of the eVenFilm roll cover. In
another paper mill, a similar outcome
was achieved when producing label paper with a basis weight of 50 g/m2 at a
speed of 950 m/min: Using the eVen rollcover allowed operating costs to be
reduced. In Indonesia too, the new
eVenSize was a success on a board machine with a puddle-type sizing press
running at a speed of 350 m/min where
double life was achieved on a position
that traditionally had limitations due
to surface tears. The new cover also
exhibited excellent resistance to deterioration in this challenging application.
Previously, service life had been limited
due to surface tears. //The beneﬁts of eVenSize and
eVenFilm at a glance+ Runability of machine:– Longer grinding intervals– Greater mechanical strength– Higher abrasion resistance+ Consistent performance:– Minimal swelling– Low hysteresis– Stable surface condition+ Savings in maintenance costs:– Longer service life
– Higher machine efﬁciency– Low maintenance requirement

Contact
Martin Loeblmartin.loebl@voith.com

TWOGE TH E R 3 3 /2 0 1 2 | 4 7

NEW TECHNOLOGIES

4 8 | TWOGE THE R 3 3 /20 1 2

01

Screenshot with graphical navigation.

02

Screenshot of a roll tab.

NEW TECHNOLOGIESANYTIME, ANYWHERE ACCESS TO ALL THE ROLL INFORMATION YOU NEEDROLL MANAGEMENTMADE EASYSØNAR provides all available data for all of a paper machine’s
rolls, right around the clock. From now on, maintenancepersonnel and papermakers just need a few clicks of themouse to see the status of their rolls, when the next rollchange is scheduled and the scope of servicing required.
Rolls are an indispensable part of a paper
machine. They are key components
without which the paper machine would
not function and whose failure can bevery expensive. The greater the numberof rolls on a machine, the more difﬁcult it
is to keep track of them. This is why
documenting the history of the rolls isvery important, as it helps those
responsible to make the right decisions,which can affect machine efﬁciency, at
the appropriate time. Very often therefore,
maintenance or production teams keep
separate, manually compiled lists
providing information about when a roll
was installed, when it has to be changed,
the scope of servicing necessary after thech an ge or u n d e r wh a t s p e c i f i ccircumstances a roll has to be replacedprematurely. However, maintaining theseseparate lists is not only time consuming,
they are often not available to everyone
involved and so it is easy to lose track –and this is precisely where SØNAR
comes in.
SØNAR is a roll management software
program, a database providing roll dataaround the clock in a readily accessible
framework. The papermakers themselves
enter the data into the system. It then
only takes a few clicks of the mouse todetermine, for example, whether a sizingpress roll will soon need to be re-covered,or if and when a wire guide roll requires aservice. SØNAR can be used by all
customers, regardless of the number ofrolls installed on their machines. They
simply log on with user name andselected password to access themachine via an encrypted Internet
connection. Its graphical user interface
makes SØNAR very easy to operate, as
the user navigates through the machineby means of symbols. The navigation
process is very simple, moving throughthe entire machine to the speciﬁc section
and from there to the individual rollposition or installed roll (Fig. 1).
Status at a glance. It is possible to see
at a glance whether a roll is installed,
in service or currently available for use(Fig. 3). General information such as yearof construction, potential operating
locations and spare rolls available for thislocation, is provided for every roll. In
addition, the system provides details ofroll length and diameter as well as residual
cover thickness in the case of coveredrolls. Scheduled running times, rollchange and servicing dates can be input
for each roll, thus allowing a downtime
schedule to be compiled, for example.
This option helps those responsible
to optimally schedule downtimes andcoordinate them with the targetedroll running times. At a glance, it is

03 Roll status at a glance

Installed

In service

Ready for use

TWOGE TH E R 3 3 /2 0 1 2 | 4 9

NEW TECHNOLOGIES

possible to schedule a roll change,
reserve the crew needed for it and informthe respective service center if necessary.
Speciﬁc details for each roll can be savedin comment ﬁelds, with around 300 data
ﬁelds available for each roll (Fig. 2).
All logs and reports included. The rollhistories are also enormously important
to Voith’s service specialists. The readyavailability and coherent structure of theroll data help them provide a good
service. For example, weak points in aroll can be identiﬁed and rectiﬁed. For
preventive maintenance in particular, theroll history is very important. Voith alsooffers the option of having all data
resulting from the roll service saved inthat particular roll history. Grinding andbalancing reports, spare parts lists anddrawings are also included with the rolldata as well as detailed service logs. This
allows customers to easily keep acomplete track of all servicing operations
performed on a roll. In addition, it iseasier and quicker to exchange various
documents. Thanks to SØNAR, allrelevant documents for each roll areavailable at all times in one location andfrom a standardized and readily04

5 0 | TWOGE THE R 3 3 /20 1 2SØNAR app for
smartphones.

comprehensible system. The program
therefore offers a complete range ofoptions for easy management of thecomplete roll inventory – for all machines
and all roll types.
Available as an app for smartphones
and tablet PCs. SØNAR is not justavailable as an online version, butalso comes as an app for smartphones(Fig. 4) and tablet PCs. As with theconventional Internet version, thecustomer logs on with a user name andpassword. In the app, the menu interface
has been adapted for typical intuitive
app navigation. This allows a quick
glance at the most important data.
Moreover, the SØNAR app is alsoavailable ofﬂine. This is necessary due tothe poor reception frequently found at
paper machines. The app can be usedby customers to view and modify data.
As soon as reception improves again,
the app automatically synchronizes withthe database.
Furthermore, the option of ﬁtting the rollswith RFID chips is already available. Viaan RFID antenna plugged into thesmartphone or tablet PC, the SØNAR
app can then use digital information toclearly identify the available rolls. Thismeans that it takes just one click to
immediately retrieve the respective data
for the selected roll. This system offers
the customer the additional advantage ofassociating the standard RFID with its
own applications such as a maintenancemanagement program. //Beneﬁts at a glance+ Comprehensive roll management tool
+ Intuitive GUI+ Available in multiple languages (English,
German, French, Spanish, Polish)+ No more scattered lists stored in different
places; everyone has the same information
status+ Overview of the history of all rolls on amachine+ All reports and measurements for therespective roll
+ Fast access to planned roll running times+ Simple planning of roll changes andservicing+ Overview of residual cover thicknesses,
important for maintenance budget planning+ Available at all times: online and also ofﬂine
as an app
+ Expansion capability, e.g., SØNAR app
and RFID identiﬁcation

Info: Radio Frequency Identiﬁcation
RFID (Radio Frequency Identiﬁcation) is awireless process for identifying products orobjects. The exchange of data over certain
distances is based on a non-contacting,electronic wireless signal communication.
The system consists of a data carrier (known
as an RFID tag), an antenna and a read/write
device. Major advantage: The RFID tag does
not have to be directly in the line of sightof the reading device, and readability is notaffected even by severe contamination.

Contact
Jan van der Hoek
jan.hoekvander@voith.com

NEW TECHNOLOGIESSENSORS BRING TRANSPARENCY TO CHEMICAL AND PHYSICAL DATAHIGHER PROCESSSTABILITY, FEWERCHEMICALS
Many manufacturers would like to have greater clarity than they do atpresent in monitoring levels of dissolved substances in the paper
machine wet end. Because the consequences of inadequate laboratory
data are greater levels of broke and costly overdosing of chemicals. But
now there is a solution: the new Advanced CT Control System. Its Online
CT Diagnostics module continuously monitors the precise chemical andtechnical status of all processes in the wet end and provides data for
automatic control of individual sub-processes. This therefore allows the
addition of chemicals in real time to be improved and significantly
reduced.

01

TWOGE TH E R 3 3 /2 0 1 2 | 5 1

NEW TECHNOLOGIES

02

03

I
Jörg Michel,
Member of the Boardof Management ofPerlen Papier AG“We would never
have thought that theinteraction between
the CT sensors could
be so consistentand reliable. But wehave been totallyconvinced by the
online CT diagnostics,
which represent an
ideal addition to theIntegrated EcoMill.”n a situation where a machine may have been stopped for an hour due to a web
break, there are a number of questions to be answered prior to restarting the process.
For example, how much anti-foaming agent is now necessary for the next few hours?
How much ﬁxing agent will be needed at short notice in the higher amount of broke?
How many bacteria have been generated in the vats in the meantime, to what extent
has the pH value been lowered and how much oxygen consumed? How quickly does
the stock now need to be processed to avoid discoloration? It is not just in thesesituations that the chemical and physical baseline values have to be available during
the production process itself so as to adjust chemical feed in real time. This is equallycrucial when using recovered paper and in the event of grade and grammage changes.
The new Advanced CT Control System is the answer. As the latest component of
the Integrated EcoMill (IEM), it provides a new basis for chemical feeding: a demanddriven dosing using accurate readings instead of approximate empirical values. To
do so, the online CT diagnostics module continuously measures the current valuesof individual chemical and physical parameters in the paper machine wet end andrepresents them in a readily comprehensible format. As a result, paper producers
obtain data that would take 120 man-years if collected manually by laboratory
personnel.
On the basis of the transparent measured values, the amount of chemicals used canbe adjusted immediately to ﬁt the process. This not only avoids incorrect dosing ofchemicals, but also prevents the production of broke. By adapting the chemical feedto the respective baseline values, considerable amounts of chemicals can often be
saved, protecting the environment and reducing costs as a result. At the same time,
the quality of the paper improves thanks to consistent process parameters.
For the first time, future process characteristics can be predicted. But the new

analysis system offers even more. Apart from the current status, it also shows thesituation from four hours ago and the likely process characteristics in four hours’ time.
To do so, it calculates future development based on the previous pattern and deduces
the process water quality from the corresponding chemical and physical values. To
this end, Voith quantitatively recorded several hundred measured values and correlated
them with the corresponding paper quality. This sophisticated forecasting technology
is unique to date and allows the timely adjustment of chemicals. In addition, the online
CT diagnostics store the data for a period of one year so that subsequent complaints
about paper quality can be processed and dealt with more easily.
5 2 | TWOGE THE R 3 3 /20 1 2

NEW TECHNOLOGIES

02–04

04

Seamless sensor
integration:
OnQ FormingSens,
OnV FlocSpotter and
OnC ConSens 700(left to right).

The seamless integration of a large number of established CT sensors into theexisting mill data network suitable for industrial use supplies measured data forcontrol purposes around the clock. At Perlen Papier AG, a large European papermaker,
the sensors have been in operation for approximately one year. “We would never
have thought that the interaction between the CT sensors could be so consistentand reliable,” says Jörg Michel, member of the Board of Management of Perlen
Papier AG, Switzerland. “But we have been totally convinced by the online CT
diagnostics, which represent an ideal addition to the Integrated EcoMill.”
Ideas for the paper mill of the future. The Integrated EcoMill is Voith’s holistic

concept for an economic and ecologically compatible paper mill, in which all relevant
sub-processes inside and outside the paper mill are integrated to save resources andreduce costs. This approach also includes the entire ﬁber, energy and water systems.
The Advanced CT Control System is the latest component of the IEM. Using realtime measurements and stored process data it determines trends, allowing events
caused by chemical and technological inﬂuences to be accurately predicted for theﬁrst time. This enables paper manufacturers to avoid problems before they occur
and to intervene in the process without waiting on laboratory results, or to have thisdone by controllers specially developed by Voith for the system. In the unlikely
event of problems, Voith offers comprehensive support for all systems from a single
source, including remote maintenance.
These services are complemented by CT Service, individual system analysis of thechemical system and advice on how to use it efﬁciently. In addition, Voith’s FlowJec
system offers a high-performance, system-compatible dosing device. “Thanks to
FlowJec and CT Service, our sheet formation has improved. At times we can save
up to 10% retention agent and improve PM uptime,” explains Jochem Meier, Headof Production at Smurﬁt Kappa Zülpich Papier, Germany. And he goes on: “In an
integrated paper mill it is extremely important to use optimal chemical mixing witha reliable dosing technology. This allows the additives in the approach ﬂow system
to deliver the required results and prevents them from causing picking in a downstream
machine section such as the dryer section.”
Voith is working systematically on expanding the systems and on fundamental issuesof chemical use. In future, for example, controllers that are even better coordinatedwith one another should be available and will automatically add the ideal amount ofchemicals – yet another step towards efﬁcient and sustainable paper production. //Jochem Meier,Head of Production
at Smurfit Kappa
Zülpich Papier“Thanks to FlowJec
and CT Service, oursheet formation has
improved. At times
we can save up to
10% retention agent
and improve PM
uptime.”Contact
Dr. Christian Naydowski
christian.naydowski@voith.com

TWOGE TH E R 3 3 /2 0 1 2 | 5 3

NEW TECHNOLOGIESNEW ROLL COATINGS FOR THE DRYER SECTION

HARD AGAINST DIRT
Higher productivity and less downtime? New roll coatings from Voith move papermakers one
step closer to this target. Newly developed coatings for cylinders, guide and vacuum rolls in thedryer group minimize dirt deposits, improve corrosion and wear resistance. In addition, these
new coatings can be applied directly inside the paper machine.

Dirt, stickies, slime deposits and chemical
fall out can have a negative effect onmachine efﬁciency from within the dryer
section. Contamination of rolls and dryer
fabrics continually harm the roll surfaces
during operation. Rising demands inproductivity, higher machine speeds, alarger variety of chemical additives andlower quality of raw material require
improved roll surfaces. Cleaning devices
can also have a strong inﬂuence on the
corrosion of rolls. The move towards
shorter ﬁrst dryer groups and the use of
harder particles such as sand in the pulp
necessitates the need for better wear
resistance of the roll surface.
Repellent and resistant. The coating
experts from Voith have developed a newgeneration of coatings for guide rolls anddrying cylinders. Their work has focusedon evaluating all the inﬂuencing variables
to combine properties such as dirt
repellence, wear resistance and corrosion
protection into the correct ratio. Eachcoating characteristic has to be adapted
to the respective requirements of thedryer fabrics and cleaning systems.
Together with external scientiﬁc support,
Voith Paper has developed a method forinvestigating the interaction between rollsurfaces and stickies, dirt, dust, glue andstarch. In contrast to other materials and
5 4 | TWOGE THE R 3 3 /20 1 2

methods, the new coatings can then be
tailored to the special requirements of thepaper industry.
On completion of the development
stages, preliminary field trials wereintroduced on demanding applications
with selected customers. The results
achieved higher levels of coating
performance than in laboratory tests.
The interaction between release forces
and surface energy clearly shows that an

improved “anti-stick” performance can beachieved compared to existing productsin the market. In addition, the successful
trials demonstrated that a higher wear
resistance could be realized with theunique Voith coating system.
Roll coating inside the paper machine.
Another main target was to apply thecoatings directly inside the paper machine– since the disassembly of dryer cylinders
and the associated downtime normally
incurs enormous costs and loss in

01

The new coatings stand forcorrosion prevention andcontamination resistance.

NEW TECHNOLOGIES

production. The new coatings can beapplied on site by a skilled service teamto signiﬁcantly reduce the time needed
for a machine shutdown (“Express” inproduct name). In order to achieve thisgoal, the method of application has
upgraded to avoid a high temperature
treatment in an expensive oven, so
coatings can be applied at lowert e m p e r a t u re s w i t h o u t a ff e c t i n g
its performance (Figure 02). Thosemachines having temperature sensitive
materials, such as carbon fiber
reinforced roll bodies, can also beneﬁt
from this new method of coating.
The new roll coatings will be available inthe beginning of 2012. //02 Comparison of the characteristicsof the new roll coating with standard
versions
Corrosion
resistance100%
80%
Doctorblade life

60%

Wear
resistance

40%
20%

Info: The Terra coating family is
now available for cylinders androlls in the dryer group
In response to customer feedback, Voith
Paper is introducing a generic name forall coatings in the dryer section of a paper
machine. The established hard coatings in
the press and calender sections (TerraSpeed
and TerraGloss) form the basis of the new“Terra Family” for cylinder and rolls in thedrying section incorporating the thermal spraycoating processes. The Terra family name isalso used for the demanding on-site coatingsof Yankee and MG cylinders.

Peel
force

03 New Terra coating family
Application

Coating property

New coating name

Fabric guide roll

Dirt repelling
Exceptional dirt repellency

TerraDry G / TerraDry G Express
TerraDry GR / TerraDry GR Express

Paper sidestretch roll

Dirt collecting

TerraStickPaper guide roll

Dirt repelling
Exceptional dirt repellency

TerraDry PG / TerraDry PG Express
TerraDry PR / TerraDry PR Express

CylinderDirt repelling
Exceptional dirt repellency andtoughness

TerraDry C / TerraDry C Express
TerraDry CT / TerraDry CT Express

Stabilizer rolls

Wear and corrosion resistance

TerraDry V / TerraDry V Express

YankeeHigh wear resistance
Improved wear resistance
Improved wear resistance& thermal conductivity

TerraDry HC Express
TerraDry HC+ Express
TerraDry LL Express

MG cylinder

Improved glazing surface

TerraDry MG Express

Anti-stick properties
New development

Dr. Hasso Jungklaus
hasso.jungklaus@voith.com

The product naming and description is
included in Table 03. The new developments
as described are part of the Terra range,
which contain a thermal spray coating
base, and according to the location and therespective position of installation, best ﬁt to
the existing requirement.

0%

Surfaceenergy /contact
angle

Contact

Piko AM 3
CeraGuide +P

TWOGE TH E R 3 3 /2 0 1 2 | 5 5

SPOTLIGHT: WET END

5 6 | TWOGE THE R 3 3 /20 1 2

SPOTLIGHT: WET END

CHALLENGES IN THE
WET END – QUALITYAND ENERGY UNDERCONTROLTWOGE TH E R 3 3 /2 0 1 2 | 5 7

SPOTLIGHT: WET END

Info: I-Series forming fabrics
I-Series forming fabrics were presented for theﬁrst time in twogether magazine in 2009 andwere launched on the market as PrintForm
IS and PrintForm IT. In 2010, issue 31 of
the magazine then introduced MultiForm IC,
the forming fabric for board and packaging
papers.
The high-shaft weaving technology developed
by Voith has so far been used exclusively in
SSB standard fabrics with a 1:1 warp ratio,such as PrintForm HQ. The article “Highshaft technology – a weaving innovation
breaks new ground in forming fabric design,”
which appeared in twogether issue 21 in
2006, provided a detailed description of thistechnology.
01

HIGH-SHAFT WEAVING TECHNOLOGY FOR I-SERIES FORMING FABRICSIDEAL SUPPORTThe new PrintForm IQ forming fabric combines two technologies – high-shaft weaving and a
3:2 warp ratio – to create a new member of the I-Series product family. High stability, fineness anddewatering performance are familiar requirements from previous forming fabric developments. The
innovation in PrintForm IQ is that these features are now combined for the first time without having
to make compromises. As a result, savings of more than 150,000 euros per year are possible.
5 8 | TWOGE THE R 3 3 /20 1 2

SPOTLIGHT: WET END

Because PrintForm IQ uses the beneﬁts
of both technologies it offers muchhigher ﬁber support, leading to bettermechanical retention and more uniform
sheet formation. The main area of
application for PrintForm IQ is in paper
machines with very high quality
requirements and/or high machine
speeds. In a product comparison withstandard fabrics, PrintForm IQ is
considerably thinner and features 25%
more ﬁber support points.

Results from paper machines show that
PrintForm IQ has a higher initial
dewatering capacity for wood-free
paper grades. In several trials on thepilot machine with a TQv former, aPrintForm IQ was used that was denser
than the reference fabric. The test
program covered a wide operating
window with basis weights of 40 g/m 2
to 110 g/m2 in the mid- to high-speed
range. Tests were conducted withextensive variations in former settings,
ranging from headbox volume throughvarious vacuum settings to different
former strip pressures. This enabled
dewatering behavior and thus theoperating window of specific fabricpairs to be analyzed and deﬁned.
Thanks to its denser design, PrintForm
IQ achieved a controlled dewatering.
Apart from excellent paper quality parameters, such as formation, MD/CD
tensile ratio and lower susceptibility tomarking, the new fabric also allowed
energy consumption to be reduced. At
the same headbox volume setting, power consumption could be lowered by
up to 15% using PrintForm IQ. In amodern production plant running at
1,600 m/min, this reduction representssavings of more than 150,000 euros
per year. //02 Discontinuous diagonals prevent marking in paper
Continuous weave pattern

Discontinuous weave pattern

Beneﬁts at a glance+ High fabric stability for good CD proﬁles+ High level of ﬁber support+ Very good dewatering performance+ Less marking on paper+ High mechanical retention+ Improved sheet formation+ Good MD/CD tensile ratio+ Lower power consumption

03 Power consumption of drives atvarious headbox volumes
Process parameters identical

100
Power consumption [%]T

he I-Series is based on the provenwarp ratio of 3:2 (three top side
to two bottom side). The ratio of
warp thread diameters is therefore
greater than in the usual 1:1 ratio. This
makes the combination of an even ﬁner
paper side and a more stable wear side
possible. The ﬁner paper side helps toimprove mechanical retention and sheet
formation, while the stable wear side
ensures better CD proﬁles. In addition,
the high-shaft weaving technology usedin PrintForm IQ offers a proliferationof binding options. With more than
50 shafts, it has more than double thenumber of shafts required to produce
standard SSB fabrics. This allows
for a binding system that can use
discontinuous diagonal patterns, forexample, which reduces the marking
tendency of fabric designs.

90
80
70
60
Small

MediumHeadbox volume

Large

Reference fabricPrintForm IQ

Contact
Matthias Höhsl
matthias.hoehsl@voith.com

Elisabeth Oxandaboure
elisabeth.oxandaboure@voith.com

TWOGE TH E R 3 3 /2 0 1 2 | 5 9

SPOTLIGHT: WET END

AN IDEAL COMBINATION: ONQ FORMINGSENS AND PRINTFORM HRHIGHER QUALITY PLUS
ENERGY SAVINGS
A familiar scenario: moisture fluctuations downstream of the former, and as a result,problems in the press. What is the answer? The folding box board producer Mayr-Melnhof
Karton AG (MM) worked with Voith to find the ideal solution for its plant in Neuss, Germany.
Two OnQ FormingSens units and four PrintForm HR forming fabrics are now giving
improved board quality on the BM 5. In addition, installing these products allowed therequired drive output in the forming section to be reduced by 13%. This alone represents
a cost saving of 87,000 euros per year.

F

ollowing a successful startup of the
two OnQ FormingSens sensors
upstream of the DuoFormer D
and suction couch roll, and of the fourPrintForm HR forming fabrics, MM andVoith’s forming specialists jointly carriedout a series of tests, including adjusting
the vacuum at various dewatering
elements. The aim was to improve board
quality and reduce drive power, while
maintaining the dry content. The resultsof all tests were impressive:+ Output of main drives reduced by
180 kW, equivalent to a cost savingof 87,000 euros/year+ Dry content downstream of former
increased by 1%+ Formation improved by 7.5%
+ Bursting strength increased by 5%+ Tensile strength improved by 7%
in MD and 2% in CD+ Reduced fabric wear
+ ROI in less than six months

01 Multiply board and packaging machine with two OnQ FormingSens sensors
OnQ FormingSens sensors shown as red squares

6 0 | TWOGE THE R 3 3 /20 1 2The tests focused on dewatering of theﬁller ply and back ply, as this is where
the highest absolute water content isintroduced to the board. Consequently,
these areas have the greatest potential
to reduce energy consumption andimprove quality. One quality parameterthat is particularly signiﬁcant is board
formation. The formation of thefiller ply has a decisive impact on
the formation of the entire board, so
the decision was made to install anSPOTLIGHT: WET END“Thanks to the new sensors and forming
wires from Voith, we were able to improve
our board quality even further and at thesame time save costs and energy.”
Dieter Garztecki, Production Manager BM 5 in Neuss, Mayr-Melnhof Karton

OnQ FormingSens there, before entry
to the DuoFormer D unit.
In an initial test, the vacuum in the crucial
dewatering elements in the back ply was
reduced by 15% on average. In the caseof the ﬁller ply, the ﬂat suction box was
switched off altogether and the vacuum in
the OrthoFlow suction box reduced by
50%. Dry content was consistent during
this test. The underliner was then included
in a second test. In this case the relevant
vacuum levels could be reduced by 30%
on average with a constant dry content.

control the former. A complex forming
section with a very large number ofdewatering elements always needs
at least two sensors to optimize individual dewatering elements and control theentire dewatering performance.
OnQ FormingSens has a very compact
design, allowing the sensor to bepositioned at almost any location in theformer.
Other applications successfully
mastered. At Koehler Kehl GmbH,every forming wire has different features,
repeated resetting is always necessary inorder to achieve consistent results. In addition, it takes time to achieve an accuratealignment of all dewatering elements.
Thanks to real-time measurement of dry
content by the OnQ FormingSens sensor,
operating personnel can accurately set andGermany, OnQ FormingSens was
installed downstream of the HiVac, thelast dewatering element on the
PM 2 thermal paper machine. By
reducing the vacuum at a relatively early
dewatering element – in this case the wet
suction box – the water weight at the endof the former could be reduced. A lower
water weight means a higher dry content,
and in this case a higher production
speed. By reducing the vacuum at the wet

02 Tensile strength before and after
optimizing vacuum elements

03 Vacuum reduction at various
dewatering elements

In m

In kPaTwo sensors for optimum results. As

BeforeAftersuction box by 20%, the dry content at
the end of the former could be increased
by 0.4%. This reduced the required drive
output and the amount of wear on theforming fabric.
Perfect product combination. By using

OnQ FormingSens units and PrintForm
HR forming fabrics, Voith was able tooffer its clients an ideal solution from asingle source. The customers beneﬁtted
from having just one point of contact
and enjoyed further advantages as aresult of Voith’s combined processexpertise in clothing and automation:
+
+
+
+
+
+

Improved dewatering
Less maintenance and wear
Improved formation
Higher strength qualities
Better couching of multi-ply board
Reduced power consumption of
vacuum pumps and drives+ Enhanced occupational safety //Contact

BeforeAfter

Timo Balser
timo.balser@voith.com

150

4,450
4,150

129

1,650

19

1,725

19

12

1
Tensile strength MD

Tensile strength CD

Back

Filler ply

Underliner
TWOGE TH E R 3 3 /2 0 1 2 | 6 1

SPOTLIGHT: WET END

01

There will be no need for these
dangerous manual measurementsin the future thanks to Voith online
measuring devices.

01

RISK-FREE ONLINE MEASUREMENTS IN THE WET END

IMPROVED SAFETY ON
THE PAPER MACHINE
Safety of personnel is a critical element for all paper mills.
When performing technical services on a paper machine,
field personnel are exposed to a dangerous and sometimes
unfamiliar environment. Online measurement systems from
Voith eliminate this risk.

Above all, service work on running
paper machines often holds
real potential risk including
measurement procedures in all sections.
The existing procedure is in many cases
manual and exposes the service
representative to real danger. For thisreason, Voith has developed online
measurement systems that greatly reduce
the risk of accidents, as they eliminate
the need for manual measurement in
the machine. Examples of this are
OnQ FormingSens and OnV FeltView
as well as the newly-developed ProTect,a self-traversing carriage.
Precise water weight measurement.

The OnQ FormingSens sensor isequipped with high-frequency microwave
sensor technology and measures
the water weight online in the former
6 2 | TWOGE THE R 3 3 /20 1 2with the highest accuracy. Manual
measurements are no longer necessary
and the safety risk for the service
personnel is practically eliminated.
Radioactive sources, such as those usedin many manual measuring devices, are
not required with OnQ FormingSens.
With the continuous data supply, thesensor is ideal for optimizing thedewatering performance and energy
consumption in the former.
Dewatering in the press section inview. The OnV FeltView analysis system

is suitable for continuous online
measurement of fabric moisture andpermeability of press section clothing.
OnV FeltView also eliminates the needfor manual measurements, a great beneﬁt
especially on fast-running machines.
Continuous measurement supplies

valuable data in order to map dewateringin the press section and to optimize it
accordingly.
Press felt measurements with selfsufficient carriage. Thanks to the newdevelopment ProTect, the safety of
online measurements can be increased
noticeably in the future. The systemallows automated press felt measurements
without service personnel having to enter
the danger zone of the paper machineduring operation. ProTect essentiallyconsists of a self-traversing, self-sufﬁcientcarriage, into which measuring devices
can be inserted outside of the fabric run.
The system is operated by simply
pressing a button; no more manual
measurements. With the new ProTectsystem, fabric measurements will bepossible at inaccessible places andwithout safety risks for the service
personnel.
After the successful series of tests at theVoith Paper Technology Center (PTC),
a prototype of the ProTect system iscurrently undergoing ﬁeld trials. The
system is expected to be available to themarket mid 2012. //Contact
Kerst Aengeneyndt
kerst.aengeneyndt@voith.com

SPOTLIGHT: WET END

INCREASE IN PRODUCTIVITY WITH BEST QUALITYCOMPRESSPLUS
CREATES ADDED VALUEThe CompressPlus press concept developed at the Paper Technology
Center (PTC) allows a machine speed that is up to 150 m/min higher
without any loss of quality compared to conventional concepts. The highest
dry content is achieved, not least because the clothing is specificallydesigned for use with the concept.
01

01–02

02

From the PTC into the PM: prototype on the pilot paper machine (left), the ﬁrst customer installation in Asia (right).

TWOGE TH E R 3 3 /2 0 1 2 | 6 3

SPOTLIGHT: WET END

03 CompressPlus press

04 Comparison of felt sets on the PM:
Dryness after press as a function of line load

Schematic layout of the new press concept

Increase in dryness compared with standard clothing

Dryness after press section [%]54
Voith PrintFlex

52

Design A
50

Design B
Design C

48
46
44
42
40
0

800

1,000

1,200

Line load (shoe presses) [kN/m]

C

oated paper has to meet the highest quality requirements. The use of high-end graphic grades on the one
hand requires very good optical characteristics such as
brightness and whiteness; on the other hand, great importanceis attached to surface quality, i.e., smoothness, gloss anduniform densiﬁcation. As a consequence, the characteristicsof the base paper come into focus, since defects – e.g., cratering– cannot be completely eliminated in subsequent process steps(e.g., pre-calendering, coating and/or calendering).
The press concept newly developed by Voith, in which thepaper web is continuously supported by clothing from theforming section to the pre-dryer section, allows productionof this high-quality paper at high speed while signiﬁcantly
reducing the frequency of breaks.
High speed with closed draw web run. Efﬁcient operationof a paper machine at high speed requires high dry content
and a completely supported web run in the press and dryer
section. Presses that are state of the art, such as many well-used
and proven newsprint paper machines, do indeed deliver highdry contents but have the disadvantage that the base paper
quality – in particular, the surface quality – does not reach thehighest quality level. Illustration 03 shows the schematic layoutof the new press concept.
The ﬁrst and the second press nip are designed as NipcoFlex
shoe presses, double-felted. Two top felts and two bottom felts
symmetrically dewater the web and achieve the highest dry
6 4 | TWOGE THE R 3 3 /20 1 2

content. The maximum possible press loads and shoe lengths(press impulses) are individually determined fromapplication to application.
The third and last press nip is formed by a roll press with a
special top felt and a transfer belt. In complete contrast to aconventional offset press or a straight-through press, the web
is continuously supported in the press. By means of felt suctionrolls and a patented guiding of the web, a trouble-free web
run is thus ensured over a large basis weight range. The
pressure proﬁle of the roll press, the particular surface structureof the last top felt and the smooth transfer belt, mean a very
good initial surface is created and the compaction is uniformly
increased. CompressPlus – it’s all in the name.
The pilot results were so convincing that an Asian manufacturerof premium paper did not hesitate to choose the CompressPlus
concept for its new graphic line.
Innovative clothing. In order to be able to get the best out of

the new technology, extensive and elaborate pilot tests wereplanned and carried out at the Paper Technology Center. The
aim was to ﬁnd the optimum clothing for the new press concept
so as to support a quick startup of the new PM respectively
to ensure the best quality output from the first hour of
production.
For this new press concept, the press felts of the PrintFlex
series were speciﬁcally adapted for each position. The felt

SPOTLIGHT: WET END

05 Roughness as a function of dryness after press
The additional beneﬁt is a maximum speed increase of approx.
150 m/min without loss of quality.

06 Surface densiﬁcation (oil absorption test) as afunction of dryness after press
Higher surface compaction due to CompressPlus

50
CompressPlus

450

400

TandemNipcoFlex
4 felts

350

TandemNipcoFlex
3 felts

300

250
49

Cobb oil test
Average top and bottom side [g/m²]

Bendtsen roughness
Average top and bottom side [ml/min]

500

CompressPlus
45
TandemNipcoFlex
4 felts

40

TandemNipcoFlex
3 felts
35

30
50

51

52

53

49

50

51

52

53

Dryness after press section [%]Dryness after press section [%]designs for the second and third press are special highlights.
Low-void designs were used here so that through optimal
saturation in the felt the highest dewatering ﬂows and thus
the highest dry contents are achieved. Figure 04 shows theconsiderable potential of the developed clothing(Voith PrintFlex in Fig. 04) in comparison to standard clothing(curve A to C in Fig. 04) on the PM.

After just one year of operating the ﬁrst installation, the highbasis weights consistently run with the best quality and without
an appreciable number of breaks. Dry contents of more than
50% were achieved immediately, and the web run, felt life andstart-up behavior all fully met the customer’s expectations. //Of course, the surface characteristics are of interest, as is
the goal of achieving the highest possible uniform densiﬁcation of the surface for this grade – wood-free coated paper.
Figure 05 shows the advantage of CompressPlus in roughness(Bendtsen) as a function of dry content in comparison to otherpress concepts and Figure 06 shows the higher surface
densiﬁcation.

Contact
Daniel Gronych
daniel.gronych@voith.com

When compared to the Tandem press with three or four felts,
the new press concept delivers lower roughness values andnoticeably higher compaction of the base paper with very gooddry content. The concluding tests during commercial printing
clearly showed the advantages in printability. The results arealso comparable with the DuoCentri NipcoFlex with fourthpress (straight-through press).
Such press types are still the ﬁrst choice for very demanding
applications such as SC-A qualities. Thanks to the newtechnology it is now possible to replace these press types. The
additional beneﬁt is a maximum speed increase of approximately
150 m/min without quality losses.
TWOGE TH E R 3 3 /2 0 1 2 | 6 5

SERVICE

PLANNING CERTAINTY AND COST SAVINGS

AUDIT = EXPERTISE

6 6 | TWOGE THE R 3 3 /20 1 2

2

SERVICE

01

TWOGE TH E R 3 3 /2 0 1 2 | 6 7

SERVICE
02

Voith has experts for
all machine sections
and paper grades.

Performing an audit in the run-up to a project provides planningcertainty. The aim of the audit is clear – it has to help the customer
make improvements. Regardless of whether it involves a single
component, a machine section or the entire process, a customized
audit can be carried out in all cases and is always useful.

For every project there are a large number of options available,
and the need to examine these drives up project costs.
Nevertheless, paper producers have to make informed
investment decisions quickly. This is why it is crucial to obtain
detailed information about market, products, processes,
technology and existing equipment.

audits: safety, energy, process (including chemical technology)
and maintenance. Depending on requirements and objectives,
needs-driven reports and follow-up proposals are compiled.
What is particularly interesting about this process is that many
improvement proposals entail only minimal investment or canbe carried out for the customer at no additional cost.

It can often help to have an outsider’s perspective in identifying
those details that can get overlooked in the course of thedaily routine. This is where there is synergy between theexperience of Voith and that of the customer. A successful
audit is always one that is carried out jointly and makes use of
the expertise of both parties.

Wide range of different audits. Every paper producer faces
a wealth of different safety regulations. It is here that Voith
Paper can particularly support its customers with relevant
specialists, especially in the case of rebuilds.

As a result of its project experience all over the world, Voith
Paper has sound know-how of technology, products, services
and processes and is a much sought-after partner for
optimization projects, being involved in around two-thirds ofpaper machine upgrades worldwide. It has its own experts andtrained specialists for all machine sections and paper grades.
Its know-how is growing steadily, not just as a result of training
but also due to ongoing R&D activities to improve products andprocesses.
Audits help to save costs. In the run-up to a rebuild project,
an audit gives planning certainty for the investment to be undertaken. The aim is to jointly work out the best possible solution.
An audit is a systematic, independent process that documents
how goals can be reached. Voith Paper offers the following four
6 8 | TWOGE THE R 3 3 /20 1 2An energy audit calculates energy consumption and preparesa concept for saving energy. Voith Paper can also survey theenergy requirements of an entire production line, and on thisbasis, elaborate on a concept for optimally integrating systems
such as a power plant, steam network, incinerator or waste
water treatment.
An important tool in this process is OnV EnergyProﬁler, asoftware that monitors energy consumption and obtains thenecessary information from the existing process control
system. The most cost-effective solution for the case in handis then determined from the results. The best solution can be
implemented quickly and effectively together with Voith Paper.
Informed investments. Detailed surveys are necessary inorder to provide proposals that are appropriate and tailored tocustomer requirements. Through an audit, the most attractive
rebuild solutions can be identiﬁed more quickly and be adapted

SERVICE

02

to the respective situation. The desired design criteria arechecked against the existing components and elaborated onin an offer. This means that investments can be made in sucha way as to minimize the scope of the project and keep total
costs down.

Example of an audit

This also applies to maintenance issues, where there is always
scope for improvement. An intelligent maintenance program,
such as one using a Computerized Maintenance Management
System (CMMS), can uncover a great deal of hidden savings
potential.

From the investment point of view, quite many of the recommended tasks
can be completed by the paper mill internally. According to the audit,
minor investments are required in the areas of coater edge deckles, edge
sealings, coating colour screening and tools for coater head’s set-up.
Expected improvements in proﬁtability and quality stability are signiﬁcant.

Audits are not just done for new investments. They can also
help a customer to compare existing processes with thestandard market requirements and thus align itself even betterto the market. //In the last two years alone, Voith Paper has performed far more than one
hundred audits. One of the customers is Iggesund Paper in Workington,
Great Britain. An audit of the coating section was carried out in Workington during the winter 2010. This audit pointed out a high potential toreduce time and material losses in the coated board production.

The remarks were divided to different categories. If recommendations of
the A-category (critical issues) are accomplished, the losses are expected
to be reduced by 8 to 12%. If additionally the recommendations of the
B-category (issues required to reach all goals) were executed, an additional cutback of 2 to 3% is to be expected.
The next step is to jointly deﬁne which actions are to be realized and inwhat time frame.

Contact
Peter Haider
peter.haider@voith.com

TWOGE TH E R 3 3 /2 0 1 2 | 6 9

SERVICEAUTOMATION SUPPORT: ANYTIME, ANYWHERESERVICE AROUND THE WORLD
Any failure of automation components has major repercussions, as paper quality and theperformance of the entire paper machine depend on them. You then need to call in experts who
are familiar with the complex systems and can support your team on site. Voith’s automation
specialists offer a comprehensive service for complete systems. Our service personnel are
deployed all over the world to ensure that installed technology runs smoothly. A few of these
professionals will now describe some aspects of their work.

Country: North America
Service specialist: Larry Hall
Senior Manager Automation Services
Customer, location: Sonoco Products Co.,
Hartsville, South Carolina
Paper machine: Nine production sites in the USA
and two in Canada, packaging papers“We have been looking after Sonoco’s 11 production sites in the USA and Canada for more than
10 years. During this time we have been able toforge a very good relationship with our customer.
At Sonoco we offer a comprehensive service forall paper mills, including on-site service formeasuring systems and remote maintenance
via a VPN connection. This allows us to quickly
restore system availability in an emergency andalso maintain the facilities at a high standard overthe long term.
This combination of automation and process knowhow provided by Voith is probably unique in thepaper industry and is no doubt the reason why wescored so highly for our availability, expertise andeffectiveness in Sonoco’s recent vendor evaluation.”

Country: Brazil
Service specialist: Ricardo Chinji Iguti,
Technical Specialist
Customer, location: International Paper
do Brasil Ltda., Três Lagoas, Mato Grosso do Sul
Paper machine: IP Três Lagoas PM 1,
wire width: 5.85 m, length: 120 m,
wood-free copy paper“Directly after startup in February 2009 we carriedout a six-month ‘babysitting program’ for the PM 1
at IP Três Lagoas. For some time afterwards wewere contracted to provide preventive maintenanceof the system at two-monthly intervals, during which
we also rectify any faults in direct consultation withcustomer. In the process we regularly optimize the
MD and CD controls and service the hardware andsoftware for the OnQ Quality Control System, either
during the service itself or by online remote maintenance. This is how we guarantee high system
availability and machine performance.
In addition, we offer ongoing training for the machine
operators and maintenance team. This reduces therisk of failures and ensures that in the event of an
emergency the customer’s team can resolve theproblem itself or obtain immediate support from
Voith specialists.”

7 0 | TWOGE THE R 3 3 /20 1 2

SERVICECountry: Switzerland
Service specialist: Bernd Armbruster, Field Service Engineer
Customer, location: Perlen Papier AG, Perlen, Switzerland
Paper machine: PM 4 and PM 7, wire width: 5.9 m and10.45 m, length: 115 m and 129 m, LWC offset and newsprint

Service package
overview“Since the end of the commissioning and optimization phasefor the PM 7 in September 2011, we have been looking after
the automation components of Perlen Papier’s new PM 7 andthe existing PM 4 as part of a service agreement. This comprises the preventive and remote maintenance of the installed
automation systems and a 24/7 on-call service by the Voith
service team with a contractually guaranteed response time.

OnS OnCall

All these services are covered by the Remote Diagnostics
service package. Regardless of where in the system the fault
occurs, the customer always has access to the relevant
person. Apart from the areas I specialize in myself, such as thequality control system or the field instruments, technicalspecialists are also available around the clock for MCS and
DCS including system technology and for automation components on the winder or wrapping system. This means that weare able to give Perlen Papier prompt and direct assistance inall areas.”

Remote Diagnostics: This service package
enables remote maintenance of the installed
automation systems via online connections,to check the current status, rectify faults if
necessary, or carry out optimizations.
Emergency on Call: In the event of technicalproblems that cannot be resolved on
the telephone or via remote support, theEmergency on Call service provides for a
Voith service technician to be on site withina contractually guaranteed response time(usually 2-8 hours) in order to avoid long
downtimes.

OnS PreVide
Babysitting: In the event of start-up problems
with a new PM, the ‘babysitting’ service
includes the presence of an automation service
engineer at the customer’s premises during
work days. This ensures ongoing training andsupport for the operating and maintenancecrew plus help with monitoring.
Preventive maintenance: On contractuallyagreed days a qualiﬁed service engineer
undertakes preventive maintenance tasks,
testing and scheduled replacement of parts
and thus supports the customer’s team on
site.

Country: China
Service specialist: Higen Chen,
Automation Service Manager
Customer, location: Asia Pulp and Paper(APP), Yangpu
Paper machine: PM 2, wire width: 11.8 m,
length: almost 600 m, fine papers“For the PM 2, APP took out a two-year
contract with us, what is known as a‘babysitting agreement.’ Since commissioningin May 2010 a Voith service team has always
been on site to respond quickly and directly
and to provide all-round support to the APP
Hainan maintenance crew through a Resident
Service Agreement.
We are responsible for all automation
components, from the ten scanners to theprocess control system with its 14,000 inputs
and outputs. Our aim is to achieve highproduction capacity with optimum paper
quality. Given that it is a ‘Greenfield’ projectwith a brand new team of papermakers,
operators and maintenance personnel at themill in Yangpu on Hainan, an important factor
is the training of personnel on site to establish
long-term product know-how and process
understanding among the customer’s
workforce.”

OnS AllRound
Resident Service: This service module
consists of ongoing maintenance by a Voith
service engineer including basic system
support, preventive maintenance andtroubleshooting around the clock.

Service on Demand
Even in the absence of a service agreement,
the customer can always consult Voith in an
emergency. Service requests received during
normal working hours are passed on to theﬁrst available technician, although we cannot
guarantee to reply to your call or provide
support within a certain time period.

Contact
Rainer Wenzl
rainer.wenzl@voith.com

TWOGE TH E R 3 3 /2 0 1 2 | 7 1

FORUM

LARGE ORDER IN THE NETHERLANDS FOR VOITH INDUSTRIAL SERVICESRELIABLE TRAMSThe 45 trams in the Dutch region of Utrecht will be serviced over the next eight years by Voith
Railservices. The tram operator, the Greater Utrecht Authority (Bestuur Regio Utrecht, or BRU),
made the decision after a public tendering process.
I n t h e U t re c h t a re a , 1 2 m i l l i o npassengers use the light-rail train line
annually. The Greater Utrecht Authority
is the owner and operator of the
tramway tracks, the depot, the tram
stops, and the 45 trams. The
maintenance contract for the trains wastendered in the summer of 2011
according to the European open tenderp ro c e d u re . T h e G re a t e r U t re c h t
Authority attaches great importance tomaintenance – including repair ofdamage and overhauling – being done
well and in a manner that is operationallyreliable and cost effective. In addition,
most of the trams will come up for ageneral overhaul in the next few months.
The tram operator decided in favorof a tendering process in which thequality of the contracted service hashigh importance. Evaluation of thebids was done on the basis of the
documents submitted and discussions
with employees of the tenderparticipants who would be responsible
for the maintenance work. This led tothe decision in favor of Voith Railservices.
Voith submitted an ambitious andspecific bid with a clear emphasis on
maintenance. In the meantime, the bid
has been developed into a specific project plan. The Greater Utrecht Authority
is convinced that maintenance over the
next few years is in good hands with
Voith. In 1983, 27 light-rail trains weredelivered to the Greater Utrecht Authority and in the coming months will be

subject to a general technical overhaul.
They will also receive a new design.
The philosophy behind the service
contract is that all parties – client andcontractor – take on the tasks for which
they are best suited. The goal consists
in finding a contractor who minimizes
risks and at the same time uses
opportunities to improve maintenance.
The client indicates which goals have tobe implemented, but their detailed
implementation is the business of thecontractor. According to experience,
this approach benefits the quality of theprocesses and results. //01

7 2 | TWOGE THE R 3 3 /20 1 2

In the future, Voith will service trams in
the Dutch region of Utrecht.

FORUM

VOITH TURBO: WORLD’S FIRST SECONDARY WATER RETARDER

IT DOESN’T ALWAYS HAVE TO BE OIL
Safe, economical and sustainable – the first secondary retarder in the world that brakes with water. Unlike
the classic oil retarder, the Voith Aquatarder SWR uses the coolant of the motor as its operating medium.
Why an extra operating medium for atruck brake system, if there is alreadyone there that you could use? The answer is a new retarder technology that
Voith Turbo developed for the Actros
long-distance transport trucks from
Mercedes-Benz.
It’s the Aquatarder SWR, the first secondary water retarder in the world thatuses the coolant of the motor as its operating medium. A noticeably morecompact design and the omission of
the otherwise required oil-water heatexchanger result in a combined weight
reduction of about 35 kg. In addition,
the maintenance-free retarder is environmentally friendly since it only oper-

ates with cooling water. A weight savingof 35 kg is, on the face of it, no big deal
for a long-distance transport truck, buteach kilogram of weight saved means ahigher payload. And for most carriers,
payload is the decisive factor for economical operation of their vehicles.
Those 35 kilograms also help at least
partially compensate for the additional
weight of the coming Euro-6 technology. Voith developed the Aquatarder
SWR in close collaboration with Mercedes-Benz. Voith began series production for the new Actros in the fall of
2011, a model change that will alreadymeet the exhaust maximum permissible
values of the Euro-6 legislation coming
into force in 2014. //VOITH HYDRO: FIRST COMMERCIALLY ACTIVE WAVE POWER PLANT WORLDWIDEWAVE ENERGY WINS AWARD
Voith Hydro Wavegen, the Scottish Voith subsidiary specializing inwave energy, has won an award for outstanding achievements in theutilization of renewable energy.

01

The ﬁrst commercially operating wave
power plant is in Mutriku, Spain.

01

The new environmentally friendly
Aquatarder SWR.

With the award, the Scottish Council for
Development and Industry recognized
the delivery of the first commerciallyoperating wave power plant worldwide
in the norther n Spanish town of
Mutriku. Sixteen wave turbines were
installed in the wave breaker there.
They have a total output of 300 kilowatts
and produce enough power for 250
households.
The Scottish Prime Minister Alex
Salmond presented the award inNovember of 2011 in Glasgow. In thecommendation it was said that Voith
has raised the entire industry to a newlevel with completion of the wave power
plant connected to the power grid. The
facility in Mutriku is the first wave power
plant to offer all guarantees required forcommercial operation. //TWOGE TH E R 3 3 /2 0 1 2 | 7 3

FORUMQUICK INFODANDY ROLL
A dandy roll is a wire spanned roll, which
is used to improve sheet formation on
fourdrinier wire machines. Moreover,genuine watermarks can be producedwith a dandy roll. The key to every Voith
dandy roll is the self-supporting
honeycomb body with its large open
surface. The fabric-covered dandy roll
body is immersed into the free-ﬂowing
suspension in the wire section, and stock
water penetrates its interior. As a result,ﬁbers in the suspension reach the dandy
roll fabric where they are deﬂocculated,thus improving formation. //DID YOU
KNOW?
Voith’s website has a completely new
look: www.voith.com

QUICK SNAPSHOTAWARD FOR MINGMING LIU
MingMing Liu (2nd from right), President of Voith Paper Asia, has won the award“Asia’s Most Innovative Woman Entrepreneur 2012.” This award is bestowed
annually by the Women in Leadership (WIL) Forum as part of the Asia Awards.
It is designed to recognize the performance and successes of women who
break new ground and have asserted themselves in their industry. The second
Asia Awards took place in Kuala Lumpur under the patronage of her Excellency
Datin Paduka Seri Rosmah Mansor, wife of the Prime Minister of Malaysia. //A QUICK GOOGLE“PAPERCAMERA”

PUZZLECORNERPut these letters into the correct
order to ﬁnd four technical terms
from paper manufacturing.

SEDRCTERYNIOXHOEBADGFNOIRMLROL
TPLREEFSS

Amateur photographers canbecome real artists using an
app called “Paper Camera.”
The paper camera app turns
uninteresting photos into
pictures, sketches, cartoons
and water colors. The
thickness of the lines, contrast
and brightness can be adjusted
individually. This is art on paper
without the hard work and paintspatters. //Solution:
forming roll, press felt
Dryer section, headbox
7 4 | TWOGE THE R 3 3 /20 1 2Download:
http://itunes.apple.com

FORUM

TWOGETHER TIP

A QUICK WORD

LIVING WITH
PAPER

INTERVIEW
Marcelo Karabolad dos Santos

Items of furniture made out of paper,
such as screens, lampshades andmagazine racks are familiar and popular
objects all over the world. But bookcases,
tables, chairs and chandeliers made frompaper and cardboard are more of a rarity.
Designers of innovative furniture are no longer just using the traditional wood or
metal, but are increasingly working with strong cardboard. Thanks to its
honeycomb structure, cardboard is extremely stable and is also ecologicallyappealing: Produced entirely of recovered paper, the construction material itself
can also be completely recycled. As long ago as 1968, industrial designerProfessor Peter Raacke launched his “Otto” armchair from the “seats for the
dispossessed” range. The chair is one of the first industrially produced pieces offurniture to be made from cardboard and has been exhibited in various museums
such as the Museum of Modern Art in New York, the Guggenheim in Bilbao and
the German Museum of Technology in Berlin. It was resurrected in 2007 by“pulpo,” a German company supplying functional homewares and furniture. //Area: Pulp dewatering
Location: São PauloThe engineer has been
employed by Voith forover 25 years in theengineering, sales andapplication sectors.

What do you like about Europe?
That there are so many countries!
You don’t have to travel far tofind different cultures, food andlanguages.
What interests you about paper?
The interest is in our family’s genes.
My grandfather had a small paper
and pulp company. Voith Paper,
which enjoys a good reputation
among engineers in São Paulo,
was looking for trainees when I
was a student.

TWOGETHER CULTURE TIP

THE UNOFFICIAL CAPITAL
OF BRAZIL

São Paulo is Brazil’s biggest city and its most importanteconomic, ﬁnancial and cultural center. With around 12 million
inhabitants, it is the largest industrial conurbation in SouthAmerica and the most populous city in the Southern
Hemisphere. At its heart: Voith Paper’s second-largest
production facility.
São Paulo offers immense cultural diversity. The famed Teatro
Municipal theater or Independence Park are as much part ofWhat is special about Brazil?
People are very creative and flexible.
If customers have problems or amachine needs to be rebuilt, Voith
staff see that as a challenge andimmediately attempt to solve theproblem. //it as the numerous museums. Well worth visiting are galleries
such as the Museu de Arte, and for lovers of contemporary art
the Museu de Art Contemporânea, with their collections ofwestern and Latin American art including works by Picasso.
Close to the city center is the “Mercado Municipal,” a must forlovers of ﬁne food. The market halls offer a huge selection of
local products such as Brazilian spices and exotic delicacies.
This is also where the locals, the “Paulistanos,” like to shop. //TWOGE TH E R 3 3 /2 0 1 2 | 7 5

For more information about us, please go to:www.voith.com

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The magazine fordrive technology

Publisher:
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St. Poeltener Strasse 43
89522 Heidenheim, Germany
www.voith.com

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Voithians