Paper Technology Journal

News from the Divisions:Eltmann PM 3: successful start-up.
New techniques in liner and fluting
production.
Mentakab PM 1 – State-of-the-art
technology for Malaysia.
Janus MK 2 – a concept confirmed.
Corporate News:
The top address for system know-how.

9

Voith Sulzer Automation – key to the“Perfect” Paper Machine strategy.
Paper Culture:
The art of making moneyout of paper …

Contents

EDITORIAL
Foreword

1

Highlights

2

NEWS FROM THE DIVISIONS
Eltmann PM 3: successful start-up

6

Stock Preparation: New techniques in liner and fluting production

11

Stock Preparation : EcoBright™ – a quantum leapin product quality constancy

16

Stock Preparation: New drum pulper concept –continuous, compact, flexible, efficient and innovative

18

Paper Machines: Strategic reinforcement – Perlen PM 4

20

Mentakab PM 1 – State-of-the-art technology for Malaysia

24

Paper Machines: Confidence fully justified –Burgo Ardennes PM 1 modernization

28

Paper Machines: Successful rebuild of board machine 3
at Frohnleiten mill of Mayr-Melnhof Karton

30

Paper Machines: Adolf Jass paper mill – Fulda PM 3 fit for 2000

34

Paper Machines: Consolidated Papers, Inc. expands to SCA Plus Grades

38

Finishing: A concept confirmed

41

Service: Ground-breaking ceremony – new Service Centre in Indonesia

44

Roll grinding machine for Vietnam

46

CORPORATE NEWSThe top address for system know-how

47

Voith Sulzer Automation – key to the “Perfect” Paper Machine strategy

52

Building the future – Voith Sulzer Paper Technology in China

57

High distinction for Dr. Herbert Ortner

60

PAPER CULTURE
The art of making money out of paper …

Frontispiece: The new stock preparation of Papierfabrik Palm, Eltmann/Germany.

62

1Dear Customer, dear Reader,
Despite difficult market conditions, especially in Asia and America, Voith Sulzer
Paper Technology can look back on a satisfactory business year with an order book of
2 billion German Marks.
Orders received included 13 complete paper machines, seven of which will be installedin Europe, three in the USA, two in China and one in Australia. Apart from smallerorders, 18 major rebuilds were also booked.

Hans Müller,
President and CEO
Voith Sulzer Paper Technology

We are particularly proud of the start-ups of two writing and printing paper machines
in Germany at Papierfabrik Palm GmbH & Co in Eltmann and at Gebrüder Lang GmbHin Ettringen. Both machines belong to a new, future-oriented generation of plants
operating with totally closed draws. The technological breakthrough in this machine
concept for increasing production speed and enhancing paper quality was achieved
mainly by onward development of our NipcoFlex shoe press technology and by the
new Janus Mark II generation of calenders. We believe the innovative role we haveadopted in keeping ahead of the field will attract considerable attention in the paperindustry, with our new ideas rapidly gaining worldwide acceptance.
In July 1999, the Voith Group of Companies acquired the roll cover, service and paper
machine clothing activities from the Scapa Group. This significant expansion in ourservice capabilities means we can provide our customers with even better assistanceand support. Today, we operate 45 Service Centers in Europe, America and Asia. With
the expansion in paper machine clothing technology, we are consistently pursuing our
objective of expanding our base as a comprehensive systems supplier.
In establishing Voith Sulzer Automation we have combined all Group paper technology
automation activities in our company. This concentration of forces has already shown
first successes in the new “Millennium” range of products, bringing us one step closer
to the most reliable paper manufacturing process.
For the new Millennium we wish you every success and hope that this issue of our“twogether Magazine” again proves interesting reading for you.
Yours sincerely,

Hans Müller
on behalf of the Voith Sulzer Paper Technology Team2

HIGHLIGHTS

Startup highlights in 1998/99

Stock Preparation

Recovered paper stock preparationlines and systems for graphicalgrades
UPM-Kymmene, Shotton,
Great Britain.
Malaysian Newsprint Industries
Ltd., Mentakab, Malaysia.
Norske Skog Golbey S.A.,
Golbey, France.
Stora Enso Langerbrugge N.V,.
Langerbrugge, Belgium.
Haindl Papier GmbH, Schwedt,
Germany.
Papierfabrik Utzenstorf AG,
Utzenstorf, Switzerland.
Papierfabrik Palm GmbH & Co.,
Eltmann, Germany.
UPM-Kymmene, Grand-Couronne,
France.
Kuebler & Niethammer Papierfabrik
Kriebstein AG, Kriebethal, Germany.
Cia. Suzano de Papel e Celulose,
Sao Paulo, Brazil.
Celpav, Sao Paulo, Brazil.
Asia Pulp & Paper Co. Ltd.,
Dagang, China.
Champion International Corp.,
Sartell, MN, USA.
International Paper Co.,Franklin, VA, USA.
International Paper Co.,
Eastover, SC, USA.
Recovered paper stock preparationlines and systems for board andpackaging papers
United Pulp and Paper Co. Inc.,
Calumpit, Philippines.

Papeteries de Gascogne,
Mimizan, France.
Harzer Papierfabrik GmbH & Co. KG,
Rhumspringe, Germany.
RAKTA, Alexandria, Egypt.
Mayr-Melnhof Eerbeek B.V.,
Eerbeek, Netherlands.
Mayen Techno GmbH, Mayen,
Germany.
Kartonfabrik Buchmann GmbH,
Annweiler, Germany.
Daehan Pulp Co. Ltd., Chongju,
South Korea.
Les Papeteries Emin Leydier,
St.Vallier, France.
Niederauer Mühle GmbH, Kreuzau,
Germany.
Orsa, Sao Paulo,
Brazil.
Industria de Papel Fernandez S.A.,
Sao Paulo, Brazil.
Rigesa Celulose Papel e Embalagens
Ltda.,Sao Paulo, Brazil.
Sulamericana Industrial Ltda.,
Sao Paulo, Brazil.
Republic Gypsum Co. Lawton, OK,USA.
Solvay Paperboard Inc.,
Syracuse, NY, USA.
Willamette Industries Inc.,
Albany, OR, USA.
Willamette Industries Inc.,Port Hueneme, CA, USA.
Recovered paper stock preparationlines and systems for tissue
Wepa Papierfabrik P. Krengel GmbH& Co. KG, Giershagen, Germany.
Procter & Gamble, Apizaco, Mexico.
Klabin Kimberly, Cruzeiro,
Brazil.
Sepac, Parana, Brazil.

Kimberly-Clark Ecuador, Ecuador.
Colpapel, Columbia.
Van Houtum Papier B.V., Swalmen,
Netherlands.
Gold Hong Ye Paper Co. Ltd,
Suzhou, China.
City Forest Corp., Ladysmith, WI,
USA.
Fort James Corp., Rincon, GA, USA.
Kimberly-Clark Tissue Co.,
Mobile, AL, USA.
Kimberly-Clark de Mexico SA de CV,
Iztaczoquitlan, Mexico.
Kimberly-Clark de Mexico SA de CV,
Ecatepec de Morelos, Mexico.
Chesapeake Corp., Flagstaff, AZ,
USA.
Chemical pulp systems
Kanzan Spezialpapiere GmbH,
Düren, Germany.
Waste paper stock preparation lines
and systems for other grades
Brodrene Hartmann, Tondern,Denmark.
O.P. Papirna Lillehammer s.r.o.,Olsany, Czechia.

Paper machines
Graphical papers
Asia Pulp & Paper Co. Ltd., Dagang
PM 1, China.
Asia Pulp & Paper Co. Ltd., Dagang
PM 2, China.
Papierfabrik Palm GmbH & Co.,
Eltmann, Germany.
Gebr. Lang GmbH, Ettringen,Germany.

Board and packaging papers
Guangzhou Victorgo Co. Ltd., China.
Lee & Man Paper Co. Ltd., China.
Zhuhai Hongta Renheng Paper
Production, China.
Tissue machines
City Forest Corp., Ladysmith, USA.
Installations and rebuilds
Burgo Ardennes, Virton, Belgium.
Consolidated Papers Inc., Biron,USA.
Munkedals AB, Trebruk, Sweden.
Burgo S.P.A., Mantova, Italy.
Munksjö Paper Decor GmbH,Calparsoro Vsta, Spain.
UPM-Kymmene, Pietarsaari,
Finland.
Dr. Franz Feurstein GmbH,
Feurstein, Austria.
Inforsa Industrias Forestales S.A.,
Inforsa, Chile.
Munksjö Paper Decor GmbH,
Besozzo, Italy.
Japan Paper Industry Co. Ltd.,
Geibo, Japan.
Otake Paper, Otake, Japan.
MD Papier GmbH, Plattling,
Germany.
Mayr-Melnhof Karton AG,
Frohnleiten, Austria.
Union Camp Corp., Eastover,USA.
Nippon Paper Ind. Co. Ltd., Iwakuni,
Japan.
Triple Play, USA.
Papierfabrik Scheufelen GmbH &Co. KG, Oberlenningen,Germany.
Champion International Corp.,
Roanoke Rapids, USA.

3

Lake Utopia Paper, St. George,
St. George, Canada.
MoDo Paper AB, Husum Paper Mill,
Husum, Sweden.
Munkedals AB, Munkedal,
Sweden.
Dong Ying Xie Fa Paper Industry Co.
Ltd., Dong Ying, China.
Patria Papier & Zellstoff AG,
Frantschach, Austria.
MoDo Paper AB Stockstadt,
Stockstadt, Germany.
E.B. Eddy Forest Products Ltd.,
Espanola, Canada.
Wellkisten- und Papierfabriken
Fritz Peters & Co. KG,
Gelsenkirchen, Germany.
Ambro S.A. Suceava, Suceava,
Rumania.
Cartiera di Carmignano S.p.A.,
Condino, Italy.
UPM Kymmene Oy, Tervasaari,
Finland.
Holmen Paper AB Braviken Paper
Mill, Norrköping, Sweden.
Allard, France.
Oy Metsä – Botnia AB, Kemi Board
Mill, Finland.
Beaupre, Canada.
Cartesar, Italy.
Cascades Arnsberg GmbH,
Arnsberg, Germany.
Cartiera Marsoni Treviso S.r.l.,Villorba, Italy.
Buchmann Rinnthal, Rinnthal,
Germany.
Stora Papyrus Grycksbo AB,
Grycksbo, Sweden.
Aconda Paper, S.A., Flassa, Gerona,
Spain.
Papier- und Kartonfabrik Varel
GmbH & Co. KG, Varel,
Germany.
Stora Feldmühle Kabel GmbH,Hagen, Germany.
Metsä-Serla Oy, Äänekoski,
Finland.
Cascades Blendecques S.A.,
France.
Smurfit-Stone Container Corp.,
Quebec, Canada.

Mayr-Melnhof Karton AG,
Werk Hirschwang, Austria.
SCA Fine Paper, Hallein,
Austria.
Roermond Papier B.V.,
Netherlands.
Jiangsu Zhonghua Paper Making
Co. Ltd., China.
W. Hamburger AG, Austria.
Balkrishna Paper Industries Ltd.,
India.
Zinc Nacional, San Nicolas,
Mexico.
EHV-Weidmann Ind. Inc.,
St. Johnsbury, USA.
Fernandez S/A Industria de Papel,
Brazil.
Champion Papel e Celulose Ltda.,
Brazil.
Votorantin Celulose e Papel,
Luis Antonio, Brazil.
Roman Bauernfeind PapierfabrikGmbH, Austria.
Coating technology
Asia Pulp & Paper Co. Ltd.,
Dagang, China.
Consolidated Papers Inc.,
Biron, USA.
Consolidated Papers Inc.,
Rapids, USA.
Cartiera del Garda S.p.A.,
Garda, Italy.
Industria de Papel Arapoti S.A.,
Inpacel, Brazil.
Cartiera di Carmignano S.p.A.,
Condino, Italy.
Ziegler Papier AG, Grellingen,
Switzerland.
Salach Papier GmbH, Salach,Germany.
Hafreström Paper Mill AB,
Hafreström, Sweden.
Goricane Tovarna Papiria Medvode,D.D., Medvode, Slovenia.
Stora Enso Fine Paper, Hagen,Germany.
Cartiera di Toscolano, Toscolano,
Italy.
VCP-Votorantim Celulose e Papel,
Celpav, Brazil.

Champion Papel e Celulose Ltda,Champion, Brazil.
Kombassan A.S., Kombassan,
Turkey.
Guangzhou Victorgo Co. Ltd.
Victorgo, China.
Inpacel – Industria de Papel Arapoti
SA, Brazil.
Winding technology– Sirius
Gebrüder Lang GmbH, Ettringen,Germany.
Papierfabrik Palm GmbH & Co.,
Eltmann, Germany.
– DuoReel
MoDo Paper AB Stockstadt,
Stockstadt, Germany.
Asia Pulp & Paper Co., Dagang,
China.
Asia Pulp & Paper Co., Dagang,
China.
Consortium with Andritz for Suzhou
Hongye Paper Mill, China.
Fort James, Usine de Kunheim,
France.
– Pope reel winders
Consolidated Papers Inc., Biron,USA.
Abitibi Consolidated Inc.,
Kenogami, Canada.
Klabin Fabricadora da Papel e
Celulose SA, Piracicaba,
Brazil.

FinishingJanus Concept
Gebr. Lang GmbH, Ettringen,Germany.

Visy Paper, Conyers, USA.
Visy Paper, Staten Island, USA.
Visy Paper, Sydney, Australia.
Visy Paper, Brisbane, Australia.
Cart. Cariolaro, Italy.
Papeterie du Leman, France.
Papeterie de Vizille, France.
Munksjö Decor, Besozzo,
Italy.
Gloria S.A., Peru.
Papresa, Renteria, Spain.
Mentakab, Malaysia.
Dagang, China.
Modo Paper Hallein, Austria.
IP Miller Falls, USA.
Ohio Paper, USA.
CPI Stevens Pt, USA.
API West Carralton, USA.
Victorgo, China.
Visy Paper, Atlanta, USA.
Calenders
Papierfabrik Palm GmbH & Co.,
Eltmann, Germany.
Supercalenders
DaeWoo, Mudanjiang, China.
Twister / Roll Handling
Mentakab, Malaysia.
StoraEnso, Wolfsheck, Germany.
Madison, USA.
Süddekor, Laichingen, Germany.
Papresa, Renteria, Spain.
Sappi Maastricht, Netherlands.
Yuen Foong Yui, Taiwan.
Toro
Mentakab, Malaysia.
Dagang, China.
Stora Grycksbo, Sweden.
Gebr. Lang GmbH, Ettringen,Germany.

Rebuilds
StoraEnso, Maxau, Germany.
Ecosoft calenders
Dow Europe, Horgen,
Switzerland.
Henry Cooke Makin, Milnthorpe,
Great Britain.

Automation
Papierfabrik Scheufelen,
Oberlenningen, Germany.
MoDo Paper AB, Hallein,
Austria.

4

HIGHLIGHTS

Recent large orders

Stock preparation

Recovered paper stock preparationlines and systems for graphicalgradesKübler & Niethammer Papierfabrik,
Kriebstein AG, Kriebstein,
Germany.
Steinbeis Temming Papier GmbH &Co. KG, Gemmrigheim, Germany.
Papierfabrik Utzenstorf AG,
Utzenstorf, Switzerland.
Haindl Papier GmbH, Augsburg,
Germany.
Haindl Papier GmbH, Schwedt,
Germany.
Romanello Domenico, Basaldella,
Italy.
Norske Skogindustrier ASA, Skogn,
Norway.
Holmen Paper AB, Hallstavik,
Sweden.
Munkedals AB, Munkedal, Sweden.
Stora Enso Langerbrugge N.V.,
Langerbrugge, Belgium.
P.T. Aspex Paper, Cileungsi,
Indonesia.
Daio Paper Corp. Ltd., Iyomishima,
Japan.
Daio Paper Corp. Ltd., Kawanoe,
Japan.
Nippon Paper Industries Co. Ltd,
Kushiro, Japan.
Oji Paper Co. Ltd., Nichinan, Japan.
Cia Suzano de Papel e Celulose,
Sao Paulo, Brazil.
Champion International Corp.,
Sartell, MN, USA.

Alliance Forest Products Inc.,
Donnacona, QC, Canada.
International Paper Co., Franklin,
VA, USA.
Donohue Industries Inc., Houston,
TX, USA.
UPM-Kymmene Corp.,
Grand Rapids, MN, USA.
Recovered paper stock preparationlines and systems for board andpackaging papers
Kartonfabrik Buchmann GmbH,
Annweiler, Germany.
FS-Karton GmbH, Neuss,
Germany.
Roman Bauernfeind PapierfabrikGmbH, Raubling, Germany.
Papierfabrik Hermes GmbH &Cie KG, Düsseldorf, Germany.
Moritz J. Weig GmbH & Co. KG,
Mayen, Germany.
Delkeskamp Verpackungswerke
GmbH, Nortrup, Germany.
Klingele Papierwerke GmbH & Co,
Weener, Germany.
Mayr-Melnhof Eerbeek B.V.,
Eerbeek, Netherlands.
SCA Packaging de Hoop B.V.,
Eerbeek, Netherlands.
Les Papeteries Emin Leydier,
St. Vallier, France.
Iggesund Paperboard (Workington)
Ltd., Workington, Great Britain.
S.A.I.C.A, El Burgo de Ebro,
Spain.
Daehan Pulp Co. Ltd, Chongju,
South Korea.
RAKTA, Alexandria, Egypt.
Papel Misionero S.A.I.F.C.,

Misiones, Argentina.
Visy Paper, Australia.
Rio Pardo – Ind. de Papeis e
Celulose, Sao Paulo, Brazil.
Miguel Forte, Parana, Brazil.
Ningbo Zhonghua Paper Co. Ltd,
Ningbo, China.
Shandong Rizhao Wood Pulp Co.
Ltd., Rizhao, China.
Willamette Industries Inc., Albany,
OR, USA.
Willamette Industries Inc.,Port Hueneme, CA, USA.
Recovered paper stock preparationlines and systems for tissue
Wepa Papierfabrik P. Krengel GmbH& Co. KG, Giershagen, Germany.
FACEPA, Belem, Brazil.
Astoria, Porto Alegre, Brazil.
De Luxe, Rio de Janeiro, Brazil.
Papeles Industriales, Chile.
Kimberly-Clark Tissue Co.,
Mobile, AL, USA.
Chesapeake Corp., Flagstaff, AZ,
USA.
Kimberly-Clark de Mexico SA de CV,
Orizaba, Mexico.
Kimberly-Clark de Mexico SA de CV,
San Rafael, Mexico.
Fabrica de Papel Santa Clara SA deCV, Mexicali, Mexico.
Proctor & Gamble, Apizaco,
Mexico.
Cascades Industries Inc.,
Rockingham, NC, USA.
City Forest Corp., Ladysmith, WI,
USA.
Kimberly-Clark de Mexico SA de CV,
Morelia, Mexico.

Chemical pulp systems
Julius Glatz GmbH Papierfabriken,
Neidenfels, Germany.
Kanzan Spezialpapiere GmbH,
Düren, Germany.
Papierfabrik August Köhler AG,
Kehl, Germany.
SOPORCEL, Lavos, Portugal.
Champion Papel e Celulose Ltda.,
Sao Paulo, Brazil.
Recovered paper stock preparationlines and systems for other grades
Minfeng Special Paper Co., Jiaxing,
China.
Sano-Fibercement Plant,
Rio de Janeiro, Brazil.
Papel Misionero S.A.I.F.C.,
Misiones, Argentina.
Celulosa Argentina SA, Argentina.
Fox River Fiber Co., De Pere, WI, USA.

Paper machines
Graphical papers
Quena Newsprint Paper Co., Kairo,
Egypt.
Alliance Forest Products,
Donnacona, Canada.
Soporcel – Sociedade Portuguesa
de Cellulose S.A., Portugal.
Haindl Papier GmbH, Schongau,
Germany.
Perlen Papier AG, Perlen,
Switzerland.
Papierfabrik August Koehler AG,
Oberkirch, Germany.
Papierfabrik Hermes GmbH & Cie
KG, Düsseldorf, Germany.
Minfeng Paper Mill, Jiaxing, China.

5

Board and packaging papers
S.A.I.C.A. (Sociedad Anónima
Industrias Aragonesa), Spain.
Shandong Rizhao Wood Pulp Co.
Ltd., China.
Modernkarton Sanayi ve Ticaret A.S.
Turkey.
Republic Paperboard Co., USA.
Visy Paper PTY Ltd., Australia.
Klabin Fabricadora de Papel SA,
Brazil.
Tissue machines
San Francisco, Mexicali, Mexico.
City Forest Corp., Ladysmith, USA.
Occonto Falls Tissue Co.,
Occonto Falls, USA.
Cascades Services and Achats,
Rockingham, USA.
Installations and rebuilds
Trierenberg Holding, Tervakoski,
Finland.
Hallsta, Holmen Paper AB,
Hallstavik, Sweden.
PT. Indah Kiat Pulp & Paper Corp.,
Tangerang, Indonesia.
Kitakami Paper Industries Co. Ltd.,
Ichinoseki, Japan.
DAIO Paper Corp., Mishima,
Japan.
PT. Tanjungenim Lestari Pulp andPaper, Musipulp, Indonesia.
Champion Papel e Celulose Ltda,
Mogi Guacu, Brazil.
Papierfabrik Adolf Jass GmbH & Co.
KG, Fulda, Germany.
West Coast Paper Mills, Kagajmill,India.
Champion International Corp.,
Sartell, USA.
Usine de Condat Le Lardin,
Condat, France.
Grünewald Papier, Kirchhundem,
Germany.
Visy Paper Inc., Tumut, Australia.
Smurfit Towsend Hook,
Snodland, Great Britain.
Mishima, Japan.
Consolidated Papers Inc.,
Wisconsin, Rapids, USA.

Bosso Carte Speciale SpA Mathi,
Canavese, Italy.
Longview Fibre, USA.
Patria Papier & Zellstoff AG,
Frantschach, Austria.
Balkrishna Industries Ltd.,
India.
Cartesar S.p.A., Italy.
Mondialcarta S.p.A., Italy.
Tambox CCC S.p.A. Stabilimento di
Tolentino, Italy.
Union Camp Corp., Franklin,
USA.
Papel Misionero S.A.I.F.C.,
Argentina.
Papirus Industria de Papel SA,
Brazil.
Melhoramentos Papéis Ltda.,
Mogi das Cruzes, Brazil.
Klabin Fabricadora de Papel e
Celulose SA, Telêmaco Borba,
Brazil.
Fernandez SA Indústria de Papel,
Amparo, Brazil.
J. Bresler SA Indústria de Papel,
Brazil.
Klabin Fabricadora de Papel e
Celulose SA, Celucat, Brazil.
Celulose Irani SA, Brazil.
Ledesma SA, Argentina.
Coating technology
Modernkarton Sanayi ve Ticaret
A.S., Turkey.
Quena Newsprint Paper Co., Quena,
Egypt.
Zhuhai Hongta Renheng Paper
Production Co., Ltd., Zhuhai,
China.
Dong Ying Xie Fa Paper Industry Co.
Ltd., Dong Ying, China.
Champion Papel e Celulose Ltda.,
Champion, Brazil.
Ningxia Meili Paper Industry Co.,
Ltd., Ningxia Zongwei, China.
Soporcel – Sociedade Portuguesa
de Celulose S.A., Portugal.
Perlen Papier AG, Perlen,
Switzerland.
Modo Paper GmbH, Stockstadt,
Germany.

CNTIC Trading Co. Ltd., Rizhao,
China.
Repap New Brunswick Inc.,
Miramichi, USA.
Mingfeng Special Paper Co. Ltd.,
Mingfeng, China.
Steinbeis Temming Papier GmbH& Co., Glückstadt, Germany.
Stora Enso Magazine Paper,
Corbehem, France.
Shandong Rizhao Wood Pulp Co.
Ltd., China.
S.A.I.C.A. (Sociedad Anónima
Industrias Celulosa Aragonesa)
S.A., Zaragoza, Spain.
Winding technology– Sirius
Haindl Papier GmbH, Schongau,
Germany.
Perlen Papier AG, Perlen,
Switzerland.
Produits Forestiers Alliance Inc.,
Donnacona, Canada.
Soporcel – Sociedade Portuguesa
de Celulose S.A., Portugal.
S.A.I.C.A. (Sociedad Anónima
Industrias Aragonesa) S.A.,
Zaragoza, Spain.
– DuoReel
Consolidated Papers Inc., Biron, USA.
Fort James, Turkey.
– Pope reel winders
Haindl Papier GmbH, Schongau,
Germany.
Holmen Paper AB, Hallstavik,
Sweden.
Quena Newsprint Paper Comp.,
Cairo, Egypt.

FinishingJanus Concept
Perlen Papier AG, Perlen, Switzerland.
Haindl Papier GmbH, Schongau,
Germany.
Alliance Forest Products,
Donnacona, Canada.

Ecosoft calenders
Sun Paper, China.
Rizhao, China.
Soporcel, Figuera de Foz, Portugal.
Holmen, Hallsta, Sweden.
Ningxia, Zhongwei, China.
Zhejiang Yalun, China.
GP Port Edwards, USA.
Papierfabrik Hermes, Düsseldorf,
Germany.
Weyco Springfield, USA.
Jagenberg GmbH.
CalendersRizhao, China.
Perlen Papier AG, Perlen,
Switzerland.
Twister/Roll Handling
Klabin Fabricadora de Papel e
Celulose SA, Telêmaco Borba,
Brazil.
Steinbeis Temming, Gemmrigheim,
Germany.
Soporcel, Figuera de Foz, Portugal.
Toro
Rizhao, China.
Soporcel, Figuera de Foz, Portugal.
Triple Play,Lawton, USA.

Automation
Perlen Papier AG, Perlen,
Switzerland.
Crown Vantage, Parchment,
Michigan, USA.
Crown Vantage, Miford,
New Jersey, USA.
Republic Paperboard, Lawton,
USA.
Charles Turner Ltd., Bolton, GreatBritain.
Gebr. Lang GmbH, Ettringen,Germany.
Huatai Paper Co. Ltd., Dawang,
Dongying City, Shandong,
China.
Haindl Papier GmbH, Schongau,
Germany.

6Eltmann PM 3: successful startup

The author:
Dr. Thomas Welt,
Mill Manager of Eltmann mill,
Papierfabrik Palm

After exactly fifteen months construction

That day was the culmination of exactly

and erection time, with a total invest-

fifteen months construction and erection

ment exceeding 250 million Euro,time, with more than 500 people working

Papierfabrik Palm’s third newsprint line

long hours during peak phases. Not toat Eltmann mill started up troublefree

mention the intensive design effort in-last September. The long-standing

volved in this decision for future-oriented

cooperation between Papierfabrik Palm

technology – with no existing basis or

and Voith Sulzer Paper Technology thus

reference plants.

bears fruit yet again.
To come to the point: everything went
extremely well – as expected – with thisAt 5.30 a.m. Central European Time on

startup despite the exceptionally innova-

September 3, 1999 came that moment

tive PM 3 concept. Not only does this in-again when every papermaker’s heart

clude a whole series of newly developed

beats faster – the first startup of a com-components, but also the latest stockpletely new paper machine. At the touchpreparation technology for recovered fur-of a button. 50,000 kilowatts were un-nish, and a completely new effluent treat-

leashed on 10,000 tonnes of high-techment system. The startup phase has al-

paper machinery before the expectant

ready been completed in less time thaneyes of a tired but happy crew.

planned, thanks to full compliance with

7

Fig. 1: Papierfabrik Palm, Eltmann mill, showing
the new PM 3 bay.
1
2

3

Figs. 2 and 3: Disperger and deinking systems in
the new stock preparation line.

8

5

6

9

4

Figs. 4 to 7: Eltmann PM 3, rated capacity
250,000 t.p.a. newsprint at basis weight
34-60 g/m 2. A team well satisfied both withtechnical results and product quality.

the speed rise curve. And even more

has certainly paid off. Not only for Palm,

gratifying – to end customers as well as

but also for Voith Sulzer Paper Technolo-

Palm – is the paper quality attained. The

gy, whose courage of conviction ideallytarget of improved sheet formation withcomplemented our own. Eltmann PM 3

optimally uniform fibre and filler distribu-

is indeed an exemplary reference fortion, tear strength and surface quality has

efficient and environment-friendly paper

been reached in full, as well as superior

recycling to unprecedented quality stan-handling and stability characteristics.

dards.

This pioneering venture – setting a tech-

Papierfabrik Palm, founded more thannological milestone in newsprint produc-

125 years ago, has always used recov-

tion from 100 percent recovered paper –ered furnish and was the first in Germany

710

SensoReeling – the new Voith Sulzer
winding technology, Sirius concept.

to produce good newsprint from 100 per-producers alike: the highest possible de-rated capacity of 250,000 t.p.a. at an oper-

cent recovered paper. This firmly estab-

gree of recycling. This strategy is backed

ating speed of 1,800 m/min or 108 km/h!

lished recycling strategy meant venturing

up again and again by sizeable invest-

into new realms several times during thements such as Eltmann PM 3: production

company’s growth, both in process tech-will soon be increased from 180,000 to

nology and machinery concepts. Fortune

430,000 t.p.a.
I Sectionally consistency-controlled

favours the bold, so the saying goes –ModuleJet headbox for optimal CD

and the ongoing success of Papierfabrik
Palm is proof indeed. Not only courage isTechnical concept

The centrepiece of expansion

profile.

required, however, but also know-how
and perseverance in developing new

Eltmann PM 3, built by Voith Sulzer

ideas and making them work.

Paper Technology in Heidenheim, has a

As a family company now in its fourth
generation,

Papierfabrik

Palm

would

hardly be able to compete with the large

I DuoFormer TQ for optimal sheet
formation.
I First ever tandem NipcoFlex press in a
newsprint machine, for lowest possible
dewatering pressure.

international mergers dominating today’s
markets without its flexibility and independence. On this basis, Palm has pio-

I TopDuoRun dryer section with
38 cylinders.

neered again and again the quality advances assuring the company of a com-

I HardNip calender.

petitive edge. And most important, thePalm philosophy is the only one whichmakes sense in central Europe today for
publishers, consumers and newsprint

I Sirius concept for uniform winding
with minimal tear.

N e w s F R O M Stoffaufbereitung
THE DIVISIONS

11

New techniques in liner and fluting
production

Higher product quality demands on theremember that the speeds of some of the

one hand and lower furnish qualities on

paper machines recently ordered are well

the other hand require specialist fineover 1000 m/min, even up to 1500 m/min.

tuning of the stock preparation sub-The author:
Eckhard Gutsmuths,
Stock Preparation

systems pulping, high consistency

With the new technologies for fluting

cleaning, screening and process waterproduction and even higher paper ma-

management into a more efficientchine speeds expected in the future, theoverall system concept.

demands on stock preparation systems
such as product quality and the reduction

Marketpackagingin specific water consumption and addi-

grades over the past few years have beendevelopments

fortive costs also need to be increased to

aimed at cost savings, basis weight re-ensure reliable paper machine operation.

duction and quality enhancement. With
new production techniques for these

By selecting appropriate stock prepara-

grades, there is a growing demand fortion system modules – such as pulping,packagingbasis

screening and thickening – the necessary

weights. For example, the basis weight ofgrades

with

lower

high-grade stock quality can be ensured.

fluting has dropped in recent years from

Another module important for high prod-

130-140 g/m 2 to 100-115 g/m 2. In future,

uct quality is the water, sludge and re-this trend will continue to well below

jects (WSR) system.

90 g/m 2, as shown by production lines
currently under construction. The onlyState of technology today

way of compensating for the associatedPulping

loss in production tonnage is to increase

The pulping system of a modern stock

paper machine speeds. Here we should

preparation line for packaging grades

12Fig. 1: TwinPulp LC pulping system –higher pulping capacity

Fig. 2: Heavies removal with the Protector System– Protection of downstream screening stages
from abrasive heavies

Features:
I Higher pulping capacity
I Secondary pulper provides deflaking potential
I Efficient heavies and coarse rejects removal
I Fibre-free rejects from Junkomat and drum
screen.

Features:
I 2-stage cleaner system
I Continuous rejects removal from HC cleaners
I Efficient heavies removal in second stage
using LC cleaning.

consists of low consistency (LC) pulper, 1

2

Junkomat, TwinPulp continuous pulper
detrashing system, and ragger (Fig.1).

DrumscreenContaminants liable to stringing such as

Raggerfoil strips, strings and wires are removed

LC cleaners

HC cleaners

PulperCons.
~1.5%

by the ragger rope. The Junkomat removes coarse heavies which would other-

UniPulperCons.
~4.5% H 2O

H2O

wise cause serious wear or other severe

Junk
trap

Sedimentation tankmechanical damage in the secondary
pulper (Fiberizer) of the TwinPulp System.
Junkomat

Junk
trap

and large area light rejects are washedtects downstream screening stages frompapers comprises 3-stage hole screeningout in the drum screen. The rejects fromabrasive heavies (Fig.2).

(Fig.3).

fibres, thus saving rejects dumping and

The 2-stage Protector System consists of

For the first two stages disk screens

freight charges as well as minimizing

HC cleaners with continuous heavies re-(Fibersorter) with 2.4-2.6 mm hole diam-fibre losses.

moval in the first stage, and LC cleaners

eter are used. Disk screens are particu-

In the TwinPulp System a partial flow

Fiberizer

continuously taken from the pulper is deflaked, the accepts being fed forward

the drum screen are virtually free ofwith intermittent heavies removal in thelarly well suited for these positions, since

Many stock preparation lines today havesecond stage. HC cleaning is undertaken

apart from good screening efficiency, they

already been retrofitted with the TwinPulp

at about 4.5% stock consistency, withhave a high deflaking potential. Flake con-detrashing system. It has been found that

rejects continuously dumped in the sedi-tent is reduced in the first two stages fromby using two secondary pulpers (Fiberiz-

mentation tank and diluted to about

12% in the inlet to 2.5-2.9% in the accepts.

ers) in parallel, the capacity of the prima-

1.5%. This ensures highly efficient sepa-

ry pulper for the furnishes generally usedration of fibres and heavies in the follow-

For the final screening stage in lines within Central Europe can be boosted 20-25%

ing LC cleaners.

a relatively high production rate, Combi-

by feeding the secondary pulper accepts

sorters are used. The machine is a com-

forward. A further advantage of this ma-

The advantage of the Protector System isbination of disk and basket screen. Flakechine configuration is that the stock isthat significantly higher removal efficien-content in the Combisorter accepts is

subjected to a specific pulping energy of

cy is achieved thanks to the continuous

about 5.9%, so that by feeding forward

up to 30 kWh/t, thus reducing flake con-heavies removal in the first stage, com-the accepts of all screening stages, flake

tent after pulping to < 12%.

pared with single stage HC cleaning andcontent in the intermediate storage chest

intermittent rejects removal.

is about 3%. Another advantage of the

Heavies removal

Combisorter is that with inlet stock con-

Efficient heavies removal is ensured to-Coarse screening (holes)

sistencies of 2-3%, rejects consistencies

day by the Protector System. This pro-

The coarse screening stage for packaging

of 25-30% can be reached.

Stock Preparation

13

Fig. 3: Low flake level after hole screening.
Fig. 4: Relative stickies area flow in slotted
screening – stickies size reduction 7%.

Accepts
12

12

Rejects
5.9

2.5

2.9

10%

“short fibre”

19%“long fibre”

Minisorter// 0.20 mm

Inlet

Combisorterø 2.0 mm

16

MultiScreen// 0.20 mm

21MultiScreen// 0.20 mm

21MultiScreen// 0.20 mm

Fibersorterø 2.4 mm70

Combisorterø 2.4 mmBrecht Hollflake content( ø 0.7 mm) [%] 16

100%Intermediatechest

Fibersorterø 2.4 mm4

Dump tower

3

64%

3.0

Fine screening

cepts have the highest stickies area flow

size reduction in fine screening as a

The fine screening module mainly com-at about 15%. For this reason this flow iswhole is about 46%, relative to flakeprises 3 to 4 stage LC slot screening

not fed forward, but partially returned tomass flow in the first stage inlet. This

(Fig.4). In new plants, slot screening withahead of the third stage. Stickies size re-machine configuration therefore results

slot widths of about 0.2 mm is used induction in fine screening as a whole, par-in gentle screening without breaking

stock preparation. For an optimum con-ticularly in the final stage, is about 7%.

down contaminants, but at the same time
it provides a high deflaking effect.

cept with multi-layer headboxes, it is better to generate the various stock qualities

Fig. 5 shows the flake mass flow, withrequired (short and long fibre) in the slot

100% taken for the inlet to the first

WSR system

screening stage.

stage. Flake content in the first stage ac-

The process water system is closely

cepts (short fibre fraction) is about 7%,

linked with stock preparation. Various

Balancing the stickies area flow is under-

and about 15% in the second and third

process water qualities are generated,taken here in fine screening. The stickies

stage accepts (long fibre fraction). Aboutand various water qualities are required

area flow in the inlet to the first screen-

32% of flake content is removed in thefor paper production, from pulping water

ing stage is taken as 100%, with the ac-

final stage (A/B layout), so that flake con-to high-pressure shower water.

cepts (short fibre fraction) showing atent in the Minisorter accepts is about

10% content. The accepts of the second

13%. The accepts are partially returned

One of the simplest but most importantand third screening stages make up theto ahead of the third stage, thus recover-measures for ensuring efficient process

long fibre fraction and contain about 19%

ing valuable long fibres. The high deflak-water management is the countercurrentof stickies area. The third stage rejects

ing potential (flake size reduction) ofprinciple. Fresh water for each produc-form the inlet to the final stage, compris-

35% with the Combisorter, and the re-tion line is added in the PM loop only.

ing an A/B arrangement of Combisorter

jects removal at this machine, mean the

Effluent is drawn off from the first (stockand Minisorter. Here, about 64% of stick-

Minisorter final stage is efficiently pro-preparation) loop and fed to the clarifica-

ies area is removed. The final stage ac-tected against a high flake content. Flaketion plant. The entire stock flow from

14

Fig. 5: Relative flake mass flow in slotted
screening – flake size reduction 46%.
Fig. 6: Use of Deltapurge microflotation (DAF)
and Trenner for fibre recovery and loop cleaning.
5
7%“short fibre”

15%“long fibre”

Minisorter// 0.20 mm

Combisorterø 2.0 mm

MultiScreen// 0.20 mm

MultiScreen// 0.20 mm

100%

MultiScreen// 0.20 mm

6
DAF fibre recovery
Stock preploop

PM loop

DAF

32%

DAF loop cleaning
Stock preploop

PM loop

DAF

Trenner
Coagulant

Flocculation
agent

Flocculation
agent

pulper to paper machine is in the oppo-

first fed to the Trenner spray filtration

move ash, fines and, by using suitablesite direction to the water flow. Thisunit, where the suspension is sprayed on

agents, also colloidal contaminants fromlargely avoids a build-up of dissolved or

to a special screen. Usable fibres (coarse

the system without losing valuable fibres.

colloidal contaminants in the PM loop,

fraction) are retained on the screen forwhich, apart from causing deposits on

direct return to stock preparation. Fines,

paper machine components (e.g. wires,ash and colloidal contaminants passfelts etc.), also has a negative effect on

through the screen and are sent to theAfter explaining the more important indi-chemical/physical processes.

microflotation stage.

vidual system modules required for stock

Microflotation systems have already been

If microflotation is used for loop clean-nents of the WSR system, Fig.7 shows allused successfully for fibre recovery ining, a precipitation or coagulation agent

subsystems integrated into a Most Effi-

the PM loop (Fig.6). Solids in the white-

is required as well as a flocculationcient Technology (MET) system for pack-water are flocculated using a flocculation

agent. Apart from solids, the colloids are

aging grades. The objective of this MET

agent, and then returned to the produc-

also agglomerated by this means and re-system, as indicated by its name, is totion line. With the increasing closure of

moved by microflotation. This flotate

achieve precisely the required productwater loops, and the associated reduction

must, however, be removed from thequality for optimum efficiency in overallof specific fresh water and effluent quan-

process. The advantage of this machine

plant operation, yet with minimum invest-

tities, a build-up of colloidal contami-

combination is that the papermaker canment and operating costs.

nants can be detected in the PM loop.

react flexibly to fluctuations in recovered

MET system

preparation, as well as the main compo-

paper qualities with their different fines,

The furnish is slushed in the TwinPulp

The machine combination of Trennerash and contaminant contents. He canSystem, and the various rejects removed

screenmicroflotation

also use this system without coagulation

as early as possible by the ragger, Junko-(DAF) is an effective and flexible way ofagent for stock recovery, returning the

mat and drum screen. Further cleaning

counteracting this trend. Whitewater isflotate back to the process, or he can re-stages are the Protector System for re-andDeltapurge

Stock Preparation

15

Fig. 7: MET (Most Efficient Technology)
for packaging papers.
7

duced amount of abrasive particles in the

Rejects
handling

Fresh
water
PM

MultiScreen// 0.35 mm
MultiScreen// 0.35 mm

Disk filter

PM loop

Disk filter

„LF“

„SF“
MultiScreen// 0.20 mm

MultiScreen// 0.20 mm

HW cleaner

Fibersorterø 2.4 mmProtector
systemTwinPulp

Stock preparation loop

quent converting processes, such as at
riffler rolls. This aspect will become evenmore important in future if we think of
the significantly finer new flute profiles.

Trenner
DAF
Sludgedewatering„SF“ = short fibre„LF“ = long fibre

product reduces machine wear in subse-

Cleanness
Fine intertuning the system’s cleaning
modules greatly improves stickies reduction between the dump chest and theheadbox.

For

example,macrostickies(>150 µm) in the headbox are 40-60%
moving abrasive contaminants, Fiber-

Fresh water is added at the paper ma-

less than in conventional systems. This

sorter hole screening, followed by heav-chine only, whereas effluent is removed

reduces paper machine shutdowns fories cleaning. Afterwards the stock is fine-in the stock preparation loop, following

cleaning and increases runnability by up

screened in a multi-stage MultiScreen

the countercurrent principle.

to 3%, thanks to fewer sheet breaks.

system, and the various stock qualities
generated to suit the headbox configura-With the MET system, mills have reported

Quality constancy

tion. The accepts from the first screening

the following practical experience:

The MET system also means productstage represent the short fibre fraction,

quality can be selectively influenced. For

while the accepts from the second andEfficient rejects removal

example, fluctuations in furnish composi-

third screening stages form

the long

By a consequent full-flow cleaning in thetion (ash and fines) can be compensatedfibre fraction. At the end of stock prepa-

stock preparation line, heavies and otherto a certain extent by the machine combi-

ration, each grade is thickened in disk

abrasive particles are removed early on innation of Trenner screen and microflota-

filters and stored separately. Following

the process. This significantly extends

tion. And thanks to the more homoge-

dilution to the required headbox consis-

the service life of screen plates, baskets

neous stock composition and greatertency, the stock then flows through aand rotors. It has been found that by in-cleanness, the end product exhibits less

0.35 mm slot screening stage (policing

stalling a Junkomat, the service life of

scatter in SCT and CMT strength values.

function) in the approach flow before be-secondary pulper screen plates in the

In some cases, an increase in SCT anding fed to the paper machine.

TwinPulp System can be extended by

CMT has also been noted. Based on theseabout 45%.

two observations, enormous savings canWhitewater is treated in the Trenner

be made in additives such as sizing, or,screen and microflotation stages. Here,

By installing a Protector System, the ser-alternatively, lower quality furnishes canfines, ash and, if necessary, colloidal

vice life of screen plates and rotors in

be used.

contaminants can be removed from thehole screening can even be extended by upsystem without losing valuable fibres.

to 300% in some cases. In addition, the re-

For further details, please refer to Voith Sulzer
Stock Preparation brochure VSR-SD-01-0013-GB-01.

16

EcoBright™ – a quantum leapin product quality constancy
Wouldn’t it be fantastic if papermakers

1with a significantly more consistentquality and even save money at thesame time? Can’t be true? EcoBright™,
our intelligent new brightness control
system, will help you achieve thisobjective.

Chemical costs [Mio US$/year]

could produce fibre stock and paper
3
Without EcoBright™
2

Savings approx. 560,000 US$/year
With EcoBright™

1

0

0

50,000100,000

150,000
200,000
Production rate [tons/year]

250,000

300,000

350,000

The first EcoBright™ control package has

ceptable brightness level. By registering

been operating successfully since Octo-

variations in furnish quality and specificber 1998 in a recovered paper stock

bleaching characteristics, EcoBright™ en-

preparation line in a Central Europeansures chemicals are dosed precisely.

newsprint mill. Here, final brightness ofthe finished stock is controlled in a per-While direct cost-savings in bleachingoxide bleaching stage by dosage of hy-

chemicals can be accurately assessed, –drogen peroxide directly at the disperger.

here they amounted to US$ 1.90 per
tonne of finished stock, – further benefits

The authors:
Volker Gehr, Thomas Köberl,
Boris Reinholdt,
Stock Preparation

This installation has proved to be highlyof the EcoBright™ system are not so eas-

successful. Compared with the previous

ily quantifiable. As mentioned, these ben-year, EcoBright™ has reduced hydrogen

efits mainly include a more consistentperoxide dosage by 30%, with similar sav-product quality, leading to reduced off-

ings in bleaching additives such as caus-

spec quality and lower loopwater loading

tic soda and waterglass. Precise automat-

thanks to less use of caustic soda andic control and extremely good correlationhydrogen peroxide. Reduced operator du-

between on-line and laboratory brightness

ties is a further significant advantage.

measurement has meant that the mini-

Only the required brightness has to be

mum brightness requirement for the fin-set, which EcoBright™ then automaticallyished stock has been reduced from 61%

targets and maintains by appropriate ad-

to 60.5% ISO. The mill no longer needs

justment of chemical dosage.

to set higher brightness levels to ensure acertain minimum brightness and so avoid

The EcoBright™ control system uses

the production of paper with an unac-

high-precision optical on-line sensors

Stock Preparation

172Fig. 1: Bleaching chemical savings with EcoBright™
Chemical costs:
1.3% peroxide (0.56 US$/kg, 100% concentration)
0.65% NaOH (0.26 US$/kg, 100% concentration).

65

Brightness [% ISO]

64
63

Fig. 2: Final brightness values in 1998 and 1999
before and after installing EcoBright™.

62
61
60
59
58

Start-up
EcoBright™

EcoBright™ – our services:57

Variation +/- 2.35% ISO
Variation +/- 1.3% ISO
56
5.1.98 24.2.98 15.4.98 4.6.98 24.7.98 12.9.98 1.11.98 21.12.98 9.2.99 31.3.99

I Definition of a customized brightness
20.5.99

control concept to suit your individualneeds
I Determination of measuring points
I Preparation of planning documentation

which can be easily calibrated and requirein post-flotation are registered and taken

minimum maintenance. On the software

into account. This makes EcoBright™ thefor control and instrumentationside innovative control strategies such as

first intelligent control system to be used

I Commissioning and calibration of

SPC (Statistical Process Control), fuzzy

in recovered paper stock preparation.

brightness sensors
I Bleaching trials in the laboratory andlogics and neural nets which have been“trained” beforehand in extensive labora-

EcoBright™ is fully customizable since it

tory and mill tests, are used. A feed-for-can be adjusted to suit the specific condi-

ward strategy is systematically applied sotions of the individual stock preparationthat action is immediately taken as soon

system and technology. With EcoBright™

as process changes occur, rather thanVoith Sulzer Stock Preparation therefore

waiting until they cause deterioration inoffers individual solutions for individual

product characteristics. EcoBright™ thus

stock preparation plant, while at the same

solves problems beyond the scope oftime drawing on the company’s extensive

I EcoBright™ system tuning

conventional or manual control systems.

technological know-how as leading equip-

I Final system fine-tuning.

in the mill
I Calculation of process dead times andprocess gains
I Software implementation for yourcustomized brightness control system
I Implementation of the EcoBright™
system in your stock preparation line

ment supplier in this field.
EcoBright™ hardware:

An important innovation of the EcoBright™ brightness control package is

The chemical savings achieved with the

I Brightness sensors with optional self-that for the first time more than one

EcoBright™ system cannot, of course, becleaning module. The number ofprocess stage is analysed and controlled.

precisely forecast. In general, however,sensors depends on the individualWith EcoBright™ all stages following

the highest cost savings can be expected

system configuration

bleaching, such as post-flotation, arein cases where furnish quality fluctuates

I Windows NT work station

also integrated into the control system.

widely and/or large amounts of chemicals

I Link-up to your existing process

For example, the synergy effects which

are used. Here, return on investment is

control system (DCS) via OPC, varioushydrogen peroxide from bleaching brings

fast, depending on production tonnage.

bus systems and/or serial interface.

18

1

New drum pulper concept – continuous,compact, flexible, efficient and innovative

The author:
Wolfgang Müller,
Stock Preparation

A key role in recovered paper stock
preparation is played by pulpers, whichmechanically break down the recovered
paper under simultaneous addition ofwater. The pulping system significantly
influences both the cost-effective designing of the entire stock preparationline, as well as finished stock quality.
All pulping systems aim to slush down
the paper completely, without damaging
fibres and without breaking down nonpaper components. Minimum investment and operating costs as well as
minimum energy consumption are further important requirements.

Existing systems, whether using continuous or batch pulpers or conventional
drum pulpers, can only meet these needs
to varying degrees. The new Voith Sulzer
drum pulper, however, combines all themain advantages of pulpers and conventional drum pulpers in a completely new,patented pulping principle. Successfully
proven in extensive testing with a trial

drum pulper, the first order for this convincing new concept was placed with
Voith Sulzer in less than one year fromthe original idea.

The new principle
The new Voith Sulzer drum pulper mainly
consists of a drum rotating around a
D-shaped stationary “displacement core”.
The drum and displacement core wall together form a semi-annular displacement
channel in which the furnish is carried
upwards from the “collection zone” at thebottom of the pulper (Fig. 2). Shear
forces in the displacement channel generate intensive fibre to fibre friction, ensuring intensive kneading and slushingdown of the furnish. The furnish thendrops over the top edge of the displacement core and back down into the “collection zone”. Here, the large available
volume provides a sufficiently long dwelltime. This secures complete wetting down
and swelling of the furnish, – essentialconditions for favourably influencing thepulping process.

Stock Preparation

19

Fig. 1: The recovered paper pulping system at
paper mill Niederauer Mühle, Kreuzau / Germany:On the left the new drum pulper (3.5 m dia.,
10 m long, 330 kW motor load, 18% pulping
consistency, capacity 240 t/24h liquid packaging
board). On the right, the drum screen.
Fig. 2: The Voith Sulzer displacement drum
pulper principle.
V Velocity drop
F1 35% filling level (light yellow)
F2 60% filling level (light and dark yellow)
S1 Centre of gravity for F1S2 Centre of gravity for F2

This continuously repeated wetting, soft- 2
ening and kneading process along thelength of the drum ensures gentle, yetefficient pulping of the recovered paper,
without breaking down non-paper components.

The special features

Fig. 3: Conventional drum pulper principle.
3

Discharge
valve

Displacement channel

Displacement
core
S2

Furnish transport by centrifugal force

S1

F2
FurnishI The displacement principle ensures
operation of the Voith Sulzer drum
pulper with a significantly higher furnish input than with conventional drum
pulpers (Fig. 3). This can be up to 60%
of total drum volume (Fig. 2, light anddark yellow area F2). The high fillinglevel, combined with efficient application of pulping energy, means displacement drum pulpers are considerably shorter in length, and thus morecompact, than conventional drums.
I The displacement channel provides efficient upward transport of the furnish
at lower peripheral speeds than conventional drum pulpers (Fig. 3). Lower
upward feed quantities in the channel
are compensated by a more intensive
furnish friction, i.e. higher pulping
energy.
I Unlike in conventional drum pulpers,
no rotary flows are generated in thedisplacement drum pulper so that
operating efficiency is not negatively
affected by stringing of non-paper
components.
I By varying the amount of furnish(Fig. 2, F1 and F2), dwelltime in the
drum can be adjusted to suit the particular furnish whilst maintaining thesame throughput rate. The filling levelis easily adjusted via a discharge valve
on the pulper discharge side.

V
F1“Dead zone”

I Pulper power consumption remains
virtually constant, independent of filling level.
I Thanks to intensive pulping, even difficult furnishes such as liquid packaging
board or recovered brown grades present no problem. This was so convincingly demonstrated with the trial version that paper mill Niederauer Mühle,Kreuzau / Germany ordered a complete
Voith Sulzer Paper Technology drum
pulping and screening system for handling 240 t/24 h of liquid packaging
board even before the test trials were
finished.

Pulping of liquid packaging board at
Niederauer Mühle
The pulping system consists of a 10 mlong drum pulper, followed by a 12 mlong drum screen. For efficient wetting
down of the liquid packaging board,which is laminated on both sides withplastic foil, the board is first shredded
and then pulped at 18% consistency inthe drum pulper.

The pulp is then diluted ahead of thedrum screen to ensure optimum separation of fibres from other components inthe drum screen. Liquid packaging board
consists of about 33% plastic foil together with fibres similar to virgin pulp andhaving a high CSF. The screening function therefore represents a considerable
challenge. Nevertheless, the commissioning of this first Voith Sulzer drum pulping
and screening system in August 1999
proved to be problem-free.
Even with wide variations in furnish input
and consistency, the pulping results areconstantly good. The drum screening ishighly effective, with residual fibre content in the drum screen rejects remaining
well below expected levels. As a result,the subsequent fibre recovery system, installed as standard in conventional drum
pulping systems of the competition, has
now been shut down. This impressive
result confirms the process advantagesof separate pulper and screen drums, aninnovative concept allowing for optimum
adjustment to suit the individual operating conditions.

20

Strategic reinforcement – Perlen PM 4
Perlen Paper Mills, located near Lucerne

Project origins

in central Switzerland, currently produce

During the course of strategic expansion

newsprint, improved newsprint and tele-studies, Perlen Paper investigated withphone directory paper on PM 5, andexternal consultants various options forwoody offset printing paper on PM 1.

product types and output quantities. Afterdetailed analysis, the decision was madeThe author:
Bernhard Stützle,
Paper Machines
Graphic

A furnish mix mainly comprising TMP

for LWC offset paper production on a ma-

and DIP is used, with virgin pulp for thechine with 5,900 mm wire width.

lighter grades. Most raw material needs
are covered by regional supplies, since

The main goals behind this decision wereadequate quantities of timber and recov-

as follows:

ered paper are available locally. TMP furnish is produced in high speed pressurized

I To maintain and expand local furnish

refiners, delivered from Andritz, Austria.

supplies. Both the TMP and DIP lines
can be upgraded at relatively little

The deinking line in Perlen was supplied

outlay to enable greater output andby Voith Sulzer Paper Technology inhigher quality.

1991, and the TMP line in 1994 within
the framework of an extensive rehabilita-

I To exploit the company’s excellenttion project. Both lines comply with theknowledge of local markets for launch-latest state of technology.

ing new products.

21

1

Fig. 1: Perlen Paper Mills, central Switzerland.

I Adaptation of production output toAfter the well-tried TopDuoRun predrier

3,200 mm diameter, with lowest possible

achieve a good balance between

section comes a SpeedFlow coating ag-

reject rates.

furnish procurement and paper sales

gregate. This is fitted with carbon fibre

within a reasonable scale of activities.

reinforced plastic applicator beams which

Engineering

are unaffected by temperature changes.

Apart from the machinery, Voith Sulzer

A completely new predosing system wasPaper Technology also received the orderdeveloped.

for project engineering. This covers ma-

The orderchine design, process layout and MCR

After a year of feasibility studies, a completely new paper machine line was or-

Coating is followed by a hot-air suspen-systems for the entire paper production

dered from Voith Sulzer Paper Technolo-sion drier, as well as an infra-red drierline, including stock finishing and rollgy. The scope of delivery includes a Duo-for regulating the humidity cross-profile.

packaging. The scope of supply also includes procurement engineering by Voith

Former TQv in the wet section with awhitewater-regulated ModuleJet headbox.

The on-line Janus calender with six rolls

Sulzer Paper Technology for all machin-

Special attention was paid to cleanlinesshas a variable nip threading system. Ei-

ery as well as MCR and electrical sys-in the design of this former for highther all the nips can be used, or only thetems. All requirements were establishedrunnability. It ensures excellent sheet

top or bottom nips. This enables calen-

in teamwork with Perlen Paper, specifica-quality and is also suitable for newsprint

dering of the entire product range, fromtions compiled, tender invitations issued

production as a startup grade.

newsprint or matt offset grades to high-and subcontracts finalized.

gloss LWC offset printing papers.
Training

The press section comprises two NipcoFlex presses, the first of which with dou-

A Sirius roller ensures trouble-free wind-

Right from the beginning of this project,ble felting.

ing of high-gloss paper on rolls up toPerlen Paper gave the highest priority to22personnel training as an indispensable
success factor. Together with Voith Sulzer
Paper Technology and Gernsbach schoolof paper technology, a comprehensive
training plan was compiled which isbased on thorough training by our production specialists and commissioning
engineers. To complement this basic
training, Perlen Paper is using a processsimulator as described below.

when the plant comes into service. The

boxes, calender and infra red dryer. As acontrol system then executes the neces-

separate order, Voith Sulzer Paper Tech-

Process simulator

sary steps and issues a corresponding

nology was also entrusted with the com-

A modern production line has a program-command not only to the process itself,

prehensive quality management system

mable process control system which re-but also to the simulator. Process reac-

comprising:ceives operator inputs on the one hand,tions to this command are simulated, andI Voith Sulzer Paper Technology

and process or plant feedback data on

the (virtual) headbox pump runs faster to“Advantage Plus” measuring frames

the other hand. From this feedback data it

increase the pressure and the flow ratewith sensors for basis weight,

generates user display information on thethrough the headbox. Simulated pressuremoisture content, ash content, consis-

plant operating status.

and flow sensor signals are then trans-

tency, colour hue, porosity and gloss.

mitted back to the process control sys-

I Quality control system with machine-

For Perlen, all the PM 4 production line

tem, and the operator sees on the display

direction regulation of basis weight,

parameters were programmed from thethe results of his action.

moisture content and ash content,

outset into the process simulator, includ-

automated grade change and produc-

ing motors, pumps, limit switches, etc.

By this means, the operating personnel

This means that the process control

can familiarize themselves on the original

system with its various monitors can beuser interface with all main process func-

connected to the simulator, enabling thetions several months before the machine

I “Parsytec” web inspection system.

operating personnel to run the plant on a

actually starts operating. Another advan-

I “Web Eye” break analysis system.

virtual basis with the original control andtage for easier commissioning later on is

Perlen Paper thus receives a fully com-monitoring equipment – well before thethat during simulator programming, theprehensive hardware and software sys-actual machine comes on line.

process control system was thoroughly

tem from a single source, without thechecked.

interface problems usually encountered

Example: The original control monitor oftion data reporting.
I “Infopac” graphical quality analysis
system.

otherwise.

the programmed control system displays

Quality management systemamong other data the headbox pump

The main scope of supply includes our

System partnershippressure. This can be set to a higher val-well-proven Profilmatic cross-profile reg-

Coated paper production is a new fieldue by the operator, exactly as it will beulation system for the headbox, steam

for Perlen Paper. But by installing thisPaper Machines

23

Fig. 2: Technical data of Perlen PM 4:
Design speed 1,500 m/min
Wire width 5,900 mm
Web width on roller 5,360 mm
Design output 572 t/day
Product grades: coated offset papers,
glossy and matt, 45-70 g/m 2,
newsprint and improved newsprint.

modern plant and the peripheral systems
described above, they have laid the best
possible foundations for success – including highly competent operating personnel thanks to virtual training in advance!
To reap the full benefits of product quality from these resources, a long-term cooperation agreement was signed between
Perlen Paper Mills and Voith Sulzer Paper

The PM 4 project as seen by
Rolf Maisch, Managing Director
Perlen Paper Mills

Technology which also covers the product optimization phase after plant commissioning.

“Our goals with this new production
line are very ambitious. But if the concept targets, time and cost schedules
are complied with as well as they havebeen so far, this innovative machine
will be producing top quality paper asof October 2000.
Coated paper quality depends very muchon the furnish and the basis paper,
which must have fine high-strength
fibres and a uniformly high consistency.
Innumerable trials with TMP and deinked
recovered paper, using a wide variety oftreatment methods, have shown thatexcellent fibre mixtures and basis paper
qualities are obtainable with thesefurnish grades, so that our goals in thisrespect have already been reached.

Project teams have been formed comprising experts from both sides of this partnership, together with suppliers such as
the coating colours, and even including
printers for final product assessment.
Led by a committee made up of manageneering work in this respect has alreadybeen done and will continue well beyond
the commissioning of our new PM 4.

ment members from both partner companies, key matters are dealt with ranging
from stock finishing and base paper optimization to developments.

Such a large project places the highest
demands on the management of bothpartners. In order to comply with theshort realization time of only 18 months,
ongoing planning is required – in otherwords, simultaneous engineering.

Partnership results so far have alreadybrought excellent progress in product development. All partners involved confirm
that thanks to this transparent teamwork
in solving difficult tasks, both sides gain

A more difficult task is to develop coating materials and technology to therequired quality. Thanks to unprecedented teamwork between pigment
manufacturers, binding agent producers, Voith Sulzer Paper Technology andPerlen Paper Mills, a good deal of pio-

The civil engineering schedule allows
no room for delays: foundations andbedplate phases 1 and 2 have alreadybeen completed, and some imposing
concrete pillars have changed our
skyline. Furthermore, the project costs
and deadlines are fully on schedule.”

extremely valuable system know-how.
There is no doubt that with such a goodstart, PM 4 at Perlen Paper Mills will verysoon be producing LWC offset paper ofthe highest quality after commissioning
in October 2000.

24

Mentakab PM 1 – State-of-the-art
technology for Malaysia
On a 65 acre greenfield site near
Mentakab, in Pahang state, is
Malaysia’s first newsprint mill using
recovered paper – the third largest
newsprint mill in Asia.

The author:
Douglas Miller,
Paper Machines
Graphic

Fig. 1: LC cleaning in the Protector system.

Since April 1999, the long-term goals of
Malaysian Newsprint Industries (MNI)
have now become reality:

First it was necessary to find a suitablesite for Malaysia’s papermaking debut.
The stage was finally set in the middle ofthe peninsula near Mentakab, a town with
22,000 people. There were several reasons for choosing this site:

I Newsprint production from 100%
recovered paper, using modern plantaccording to the latest state oftechnology.

I Its proximity to the Sungei Pahangriver, Malaysia’s largest, thus ensuring
adequate water supplies and enabling
disposal of treated effluent.

I Coverage of nationwide newsprintneeds (currently 315,000 t.p.a.) as
well as export trading with neighbouring countries.

I Its central location halfway between
the east and west coasts.

In October 1996 MNI took over from
Genting Sanyen Corporation – Malaysia’s
leading producer of packaging paper andcorrugated board – a newsprint production project which was at the planningstage. Genting Sanyen relinquished its

Fig. 2: Flotation deinking plant.
Fig. 3: LC screening and partial washing with
two VarioSplit units.
Fig. 4: Deltapurge microflotation.

1

diversification plans and handed over the
project to MNI, including the order which
had been placed for a Voith Sulzer
newsprint machine.

2

I Its nearness to Malaysia’s main rail
connection with Singapore andThailand.
In a region still surrounded with jungle,
whose main source of income has so far
been the timber industry, erecting a
newsprint production plant using 100%

25

recovered paper is a courageous andvisionary step. By creating jobs for
265 people here and providing the necessary training, this plant sets a milestone
for the future in the conservation of resources.
In March 1967 construction work started
simultaneously on the paper mill, the water supply and effluent treatment infrastructures, and on an oil-fired combined
cycle power plant – in this isolated location, all heat and power has to be generated on site. The power plant has threesteam turbine units, each generating
24.2 MW with 47 t/h of steam. Two of thegenerators cover normal production andin-house needs, while the other is held inreserve.
The preparations for paper machine installation began on November 17, 1997
with site surveying and foundation alignment work. By November 30, 1998 – only
one year later – installation had been
completed. The entire responsibility forerection and commissioning was entrusted to Voith Sulzer Paper Technology.

On February 3, 1999 – nine days before
the scheduled date – at 8.08 local time,
the first roll of paper was completed at
an operating speed of 1,188 m/min. Sinceeight is a lucky number in Malaysia, thisnumerical combination both in time andspeed might well be a good omen for the
future. Commercial paper production hadoriginally been scheduled to start on
April 1, 1999, but by then the production
was already well above the guaranteed
625 t/day. Output soon exceeded the
projected production by 20 percent. Likewise the operating speed of 1,350 m/min
was not only reached much earlier than
three months after commissioning,but significantly exceeded. This madeMentakab PM 1 the fastest paper machine in the entire Fletcher Challenge
Corporation.

how transfer and professional support inbuilding up a well-trained operating andmaintenance team. In fact this thoroughtraining started well before commissioning – thanks to modern process simulation techniques.
This confidence in reaching the goal
“twogether” paid off in no uncertain
terms: the commissioning figures speak
for themselves.

The scope of supply by Voith Sulzer
Paper Technology and subcontractors for
Mentakab PM 1 was as follows:
I Complete flotation deinking plant
including dual pulping systems, disk
filters, oxidative disperger bleaching
and reductive bleaching stage, for an
output of 840 BDMT/day of finishedpulp

The customer’s requirement for peak paper technology was certainly an important factor in the cooperation with Voith
Sulzer – but that was only one of the reasons. At least as important was the confidence of the customer in benefiting at thesame time from comprehensive know-

3

I Complete rejects treatment and loopwater purification systems, incorporating Meri Effluent Technology machinery and know-how

4

26

Paper Machines

Mentakab PM 1 – key technical data
Furnish: 100% recovered paper
Product: newsprint at 40-48.8 g/m 2
Uncut web width: 7,940 mm
Design speed: 1,700 m/min
Production speed: 1,500 m/min
Output: 837 t/day at 48.8 g/m 2
Rated annual output: approx. 250,000 tonnes

27

Annual consumption of recovered paper:
approx. 300,000 t.p.a.
Freshwater consumption: 14,000 m 3 /day
Treated effluent: 11,000 m 3/day
Solid waste: 80 t/day.

I Stock preparation line for bought-in
thermomechanical pulp
(125 BDMT/day)
I Stock feed system with Deculator,
disk filter for fibre recovery, rejects
treatment and screening systems
I Complete paper machine including
GapJet headbox with Profilmatic,
DuoFormer CFD,
DuoCentri II press section with fourthpress and steambox with Profilmatic,
CombiDuoRun dry section(60% single tier, 40% double tier),
soft calender (2 x 1 nip) with
Nipco ® rolls,
pope roller with automated reel change
I Finishing section with two DuoRoller II
and complete roll packaging and transport system
I Engineering and hardware for the entire measuring, control and regulation
systems.
The electrical drive system for the paper
machine and DuoRollers as well as the
DCS system were supplied by Asea
Brown Boveri.
We wish MNI every success in their venture for setting up a newsprint production industry in Malaysia. May they
achieve a leading position in this growthmarket, both in Malaysia and the neighbouring countries.

28

Confidence fully justified –Burgo Ardennes PM 1 modernization“For this vital modernization project, weplaced our entire trust in Voith Sulzer
Paper Technology. We are extremely
satisfied both with the project handlingand execution, with the commissioning
and above all with the results.”

The author:
Gerhard Kaiser,
Paper Machines
Graphic

This how Claude Taverdet, General Manager Burgo Ardennes Paper Mills, lauded
the successful modernization of PM 1 at
his plant in Virton, Belgium. The resultant
improvements both in production capacity and quality now make this company
one of Europe’s leading manufacturers ofcoated base paper.
In 1989 the decision by former pulp millCellulose des Ardennes to commence paper production created quite a stir in thepapermaking world. Three years later in
1992, the company’s first Voith paper
machine went into service with two offline coating aggregates for an output of
about 580 tonnes/day.
After some structural problems andlengthy shutdown periods, the company
was taken over in 1994 by Cartiere Burgo

2

3

29

1

Italia, who proceeded with expansion
plans which also included substantially
increased production.
During the following years, production
outputs were achieved with PM 1 in the
54-200 g/m 2 range which significantly
exceeded the original design output.
However, further increases aimed at
1,000 t/day were thwarted by bottlenecks
in drying capacity and in various peripheral aggregates.
Investigations soon showed that the
paper machine itself could certainly produce more – subject to modernization.
Against strong competition, Voith Sulzer
Paper Technology received the modernization order in 1998.

4

Upgrading this paper machine involved
retrofitting a ModuleJet to the existing
headbox for basis weight cross-profile
regulation, replacing the third press witha NipcoFlex shoe press, and carrying out
small modifications to the predrying section. The result was that immediately after recommissioning, all guarantees were
not only fulfilled more quickly than expected, but significantly exceeded.
After a “paper to paper” interruption lasting only 14 days, Cartiere Burgo restarted
production in July 1999 at the Belgian
plant with what is now its most efficientmachine for coated base paper. Operating
speeds and outputs well exceeding
1,000 m/min and 1,000 t/day respectively
are no longer any problem.

Scope of modernization
I Detailed engineering, delivery andretrofit of Voith Sulzer ModuleJet
and Profilmatic cross-profile
regulation system to the existing
headbox.
I Installation of dilution water loops
to the ModuleJet, with deaeration
tank and vertical screen, including
electropolished piping both for the
LC and HC loops from verticalscreen to headbox.
I Installation of NipcoFlex press forthe third nip, complete with hydrostatic oil supply aggregate andcontrol system.
I Hot air injection piping for the predrying section.

Fig. 1: Burgo Ardennes Paper Mills, Belgium.
Fig. 2: Claude Taverdet, General Manager
Burgo Ardennes Paper Mills.
Fig. 3: Julien Verhoeven, Technical Manager
Burgo Ardennes.
Fig. 4: Final installation of the pre-assembled
NipcoFlex press.

30

Successful rebuild of board machine 3 at
Frohnleiten mill of Mayr-Melnhof Karton

The author:
Adolf Wachter,
Paper Machines
Board and Packaging

In January 1999, the Mayr-Melnhof
group rebuilt board machine 3 (BM 3)
at its Frohnleiten mill in Austria. The
seven suction formers were replacedwith two fourdrinier wires and new
headboxes for underliner and middle
layer. In the press section, a NipcoFlex
shoe press ensures gentle drainage
with high dry contents. The stock
preparation system and approach flow
systems have also been adapted.
Detailed scheduling and excellent
cooperation of all companies involved
made it possible to put the machineback into operation ahead of schedule,with enhanced quality and increased
output.

The Mayr-Melnhof group and
Frohnleiten mill
The Mayr-Melnhof board group, with2,000 employees and an annual capacityof approximately 1.2 million tons, is theworld’s leading recycled board producer.
The parent company of the Mayr-Melnhof
board group is located in Frohnleiten,
Austria. With an annual output of
375,000 tons, the Frohnleiten mill is also
the largest producer of recycled folding
boxboard in Europe.

BM 3 rebuild
Two board machines are presently operating at the Frohnleiten mill. In late 1997,1

Paper Machines

31

Fig. 1: Mayr-Melnhof Karton GmbH,
Frohnleiten mill, Austria.
Fig. 2: Board Machine 3 before the rebuild.
2

the decision was made to adapt BM 3 tothe future market requirements by anextensive rebuild of the wet end. Withan operating speed of 400 m/min, thesuction formers had reached a limit
where satisfactory sheet formation was
no longer ensured. The main goal of therebuild was, therefore, to improve theboard quality in terms of formation withconstant specific bulk and to increase theoutput.

The concept and the new components
BM 3 produces white lined chipboard(duplex and triplex grades). Before therebuild, the sheet forming section included two fourdrinier wires for the top andback layer and seven suction formers forthe middle layer. All layers are produced
from 100% recycled furnish.
For high-quality grades, with special demands placed on bending stiffness, asmall quantity of groundwood (refiner
mechanical pulp) is added to the middle
layer. Such pulp is supplied from a millowned refiner mechanical pulp systemwith a maximum output of 170 t/d.
To realize conversion into a multiple
fourdrinier section, the existing fourdrinier wire for producing the top layer
had to be extended to provide space for
installing the new wires for the underliner
and middle layer. On this fourdrinier
wire, the top layer is formed, which is on
the bottom side of the produced boardweb.
As a result of extending the length of the
top layer wire, it was also necessary to

The new Step Diffusor headbox for theunderliner is arranged in machine direction.

drainage zones are drained through a top
wire. Apart from increasing the drainage
capacity, the DuoFormer D unit improvesformation. Due to the high layer weight,
the formation of the middle layer influences the board quality significantly.

It is equipped with a centrifugal distributor to ensure as good fiber orientation as
possible across the machine width. A
new Step Diffusor headbox with pulsation
attenuator and double diffusor block withintermediate chamber is also used on the
middle layer wire. This ensures optimum
conditions to eliminate variations in fiber
orientation.

CD profile control is effected by a
ModuleJet dilution water system at the
headbox for the middle layer, since thehighest layer weights are produced here,
and the CD basis weight profile can be
optimally adjusted by 72 valves acrossthe machine width. For dilution, suction
box water passing through a verticalscreen is used.

The middle layer is produced against machine direction; first it is couched withthe underliner and both are then placed
onto the top layer. The fines distributionof all layers can, thus, be utilized to ensure optimum bonding strength.

The fourdrinier wire for the back layer,
also operating against the machine direction, and its headbox have not beenchanged.

reposition the existing headbox together
with the approach flow system.

A hybrid former (DuoFormer D) is installed on the fourdrinier wire for middle
layer. In this unit, up to 30% of theamount of water discharged in three

The couch press on the suction couchroll is followed by a double-felted suction
press in the first nip position. The third
nip is formed by a single-felted press.
These components have not beenchanged.

32

With the decision to replace the secondpress with a double-felted NipcoFlex
press, Mayr-Melnhof has taken an innovative step forward. Within the MayrMelnhof group, this is the first shoepress used in a board machine. The maximum nip pressure of this press is
800 kN/m. However, to achieve optimum
specific bulk, the press is not loaded withmore than 500 kN/m during operation.
Still, the dryness compared to that before
the rebuild could be increased considerably.
Apart from the upgrades of wire andpress sections, modifications were doneby Andritz AG, Austria, in the stock
preparation system (new disk filter andcleaner system for middle layer). The
scope of supply from Voith Sulzer Paper
Technology included the three new approach flow systems, a new couch brokechest and a separate line with verticalscreen for headbox dilution water.

Startup completed in record time
The deadline for this rebuild was extremely short and could only be met byvery detailed scheduling.
On January 4, 1999, the machine wasshut down and the old suction formers
were disassembled.
February 1, 1999, was the scheduledstart-up date for the rebuilt machine.
Excellent and constructive cooperation
between Mayr-Melnhof, Voith Sulzer
Paper Technology and all other companies involved made it possible to com-

Dir. Dipl.-Ing. Martin Mühlhauser,
Technical Director of Mayr-Melnhof
Board Division, on the rebuild of
BM 3 at Frohnleiten:
The modernization of BM 3 was MayrMelnhof’s first project with the “new”
Voith Sulzer Paper Technology. The
team of Voith Sulzer Paper Technology and the staff at Frohnleiten havedone an excellent job. What we appreciate in particular is that our customers are well aware of the superior
quality of our product and that thesame quality is now demanded fromour competitors as well. With regard
to BM 3 output, we have successfully
set a new milestone in the development of enhanced white lined chipboard quality.

plete the rebuild slightly ahead of schedule, and to start production again on
January 31, 1999.

Goals achieved
The rebuild was a success in a very shortperiod of time:
Just four hours after start-up, salable
board was produced. Only two days later,
the highest output of BM 3, achieved before the rebuild, was already exceeded,
and with better surface quality.
Compared to the suction formers, formation of the board could be greatly improved after a short optimization phase.

Improved sheet forming results in higher
smoothness of the base board, which
positively influences printability and/or
the finishing and converting characteristics of the finished board.
This board quality has set new standards
for white lined chipboard from recycled
furnish in Europe.
The ModuleJet™ system of the headbox
for the middle layer ensures the smallest
2-sigma values of the CD basis weightprofile, and the NipcoFlex shoe press improves the moisture profile significantly,
resulting in improved MG cylinder operation.
Just after the first few months, the guaranteed increase in production was far exceeded due to the satisfactory operationof the NipcoFlex press. Despite the highnip loads, high dry contents after thepress section can be achieved throughgentle dewatering by the shoe press,
without reducing bending stiffness.
At the time when this article was written,
the NipcoFlex press and the Qualiflex
sleeve had been operating without any
problems for nine months.
To strengthen the good and successful
partnership between Mayr-Melnhof andVoith Sulzer Paper Technology, a meetingat St. Pölten took place in to 1999. Following a football match (unfortunately
not successful for the Voith Sulzer team,but very successful for Mayr-Melnhof)
and a very pleasant evening in the Austrian Wachau, both companies look forward
to working together again on future projects.

33

Key data of BM 3:

Main components of rebuild:

I Wire width: 5,000 mm
I Design speed of new parts:
600 m/min
I Max. operating speed: 550 m/min
I Main grade: white lined chipboard(100% recycled furnish)of 300 g/m 2 at 400 m/min.

I Two wire sections including hybrid
former DuoFormer D
I Two headboxes
I ModuleJet dilution water system for
CD profile control
I Approach flow systems of new wiresections and of ModuleJet

I Extension and adapting of existing
top layer wire
I Double-felted shoe press in second
position
I New couch broke chest
I Engineering work for the entire
rebuild
I Complete installation
I Supervision of startup.

34

1

Adolf Jass paper mill – Fulda PM 3 fit for 2000

The author:
Jürgen Gutzeit,
Paper Machines
Board and Packaging

The paper mill Adolf Jass GmbH & Co KG,
Fulda, Germany, is among the 10 largest
producers of corrugated board basepapers in Europe today. In 1998, together with Voith Sulzer Paper Technology,
a major rebuild of the PM 3 production
line was accomplished. After having
placed large-scale orders for PM 4 in1988 and 1991 and for PM 3 in 1991 and
1996, the mill has taken a further step
toward strengthening its position in thecorrugated board base paper market
with the investment made in 1998.

PM 3 of Adolf Jass Paper Mill in Fulda,
produces corrugated medium from 100%
recycled furnish. The mill's most recent
rebuild of this production line follows atrend towards thinner flute profiles in
corrugated board production. As a result,the producer of corrugated board basepapers is demanded to produce lower basis weights.

At the same time, it can be noticed thatthe quality of the recycled fiber grades
used for paper production deteriorates.
Nevertheless, advanced machine concepts and the correlating technologicalknow-how counteract the declining recycled fiber quality and allow superior final
products. The rebuild concept of PM 3
has also taken this development into account.
The goal of the recent rebuild of PM 3
was, therefore, to increase the output andimprove quality and at the same time to
reduce the corrugated medium basis
weights from 115 to 100 and to 80 g/m 2.
An important task was to increase thestrength values. In addition, the susceptibility to faults was to be reduced and therunability was to be enhanced.
After the rebuild, the operating speed increased from approximately 630 m/min
to 900 m/min. On a wire width ofPaper Machines

35

Fig. 1: DuoFormer CFD.
Fig. 2: Slotted find screening system.
25,550 mm, 700-800 tons/day of paper are
produced depending on the basis weight,
which corresponds to an annual output of
220,000 tons. Together with the testliner
machine PM 4, Adolf Jass Paper Mill produces approximately 450,000 tons/yearof packaging paper.
The most recent rebuild project on PM 3
involved both the stock preparation system and the paper machine. High importance was placed on jointly realizing acomprehensive and well-adapted overall
concept for the production line.

Stock Preparation
For enhanced paper quality and runability
with lower basis weights, an especiallyhigh and uniform finished stock quality isneeded, in particular the amount of contaminants such as stickies was to be reduced. To this end, the stock preparation
system was equipped with new components and up-to-date automation equipment.
The two existing pulpers, feeding the
PM 3 and PM 4, were upgraded into two
separate slushing systems. The newstock screening concept, with new machines, permits discharging the rejects
from the individual stages of the cleaning
process as early as possible. The MC
hole prescreening stage was equippedwith fiber sorter, drum screen and Combisorter for final stage screening.
The existing cleaner system of the old approach flow system was integrated with
the new stock preparation system, withthe accepts fed directly into the multi-

stage LC slotted fine screening systemcomprising vertical screens, Combisorters and Minisorters. Thickening of
the finished stock is effected by a newdisk filter system supplied by Andritz.

To reduce stickies and to separate thewater circuits of PM 3 and PM 4, a new
microflotation equipment was installed in
PM 3.

The existing rejects systems were extended by several components from the
MERI product range. The rejects handlingequipment also accounts for the more
stringent environmental regulations announced for the years to come, demanding a separation of the rejects dependingon specific properties.

Paper Machine (PM 3)
To upgrade PM 3, the most important
modifications had to be done in the wiresection: PM 3 was equipped with a new
two-layer StepDiffusor™ headbox with
ModuleJet‚ SD for CD basis weight profile
control by dilution water injection.

36

Fig. 3: Mill owner Adolf Jass and mill manager
Friedrich Specht in front of the DuoFormer CFD.
3transport equipment for transporting theparent rolls to the winder, was installed.
Finally, the broke pulping system of PM 3
had to be upgraded: Some of the pulpers
were relocated and equipped with newslushing equipment and pulper vats.
Apart from the upgrades/extension of ancillary systems for the PM, the rebuild
project of the entire line involved extensive services, such as plant engineering,
engineering for buildings, logic diagramsfor process control system and engineering for electrical equipment and instrumentation. In the last phase of the rebuild project, the complete machine wasdisassembled and the installation work
was done in the stock preparation systemand on PM 3, as well as the operational
and technological start-up and optimization of the production line.

Project Execution
The production line was put back into
operation in early September 1998 just
12 months after placing the order.
A DuoFormer CFD has replaced the fourdrinier wire. The combination of a twolayer headbox and gap former essentiallycontributes to improving the paper quality. Above all, the strength values and CD
profiles could be positively influenced.
Two new approach flow systems werealso installed in PM 3.
The press section had already been revamped during an earlier rebuild, so only
the existing three-roll combined presswith Nipco-Intensa press had to be integrated with the new rebuild.

The existing dryer section was extendedby two new UnoRun dryer groups. To extend the dryer section, it was necessary
to relocate the size press, and in the end,
the entire dryer section was fitted with aropeless transfer system. On the one
hand, the new transfer system improves
the machine runability; on the other, it increases the safety of the operating personnel.
At the final section, a new horizontal reelwith roll density control and automatic
reel spool changing device as well as

For the rebuild work, Adolf Jass Paper
Mill set a goal to manage with as few
downtimes as possible during the entire
project. Thus, the new stock preparationequipment was installed step-by-step inthe first six months of 1998 and went online while PM 3 and PM 4 were continuously producing. A large number of interim solutions were necessary to integrate
the new processes with the existing line.
With production stops of not more than
one week required to connect the newPaper Machines

equipment, the new stock preparation
system finally supplied the old PM 3 withstock.
The rebuild of the paper machine and of
the ancillary systems took 42 days tocomplete, including checking work forthe new process control system. Up to
520 fitters and construction workers, aswell as 50 start-up engineers worked
around the clock, and paper was on thereel again on the scheduled start-up dateof September 6, 1998.

To comprehensively control and supervise the progress of the project, Voith
Sulzer Paper Technology appointed a site
project manager who was responsible for
all Voith Sulzer and customer activities
from order placement to contract fulfillment. The primary tasks of this project
manager were the scheduling and followup of dates as well as the coordination ofinterfaces between the suppliers. In addition, the project manager was the firstcontact partner for the customer and assured that an active flow of information
between the customer’s project team, the37

Voith Sulzer company and the subsuppliers, was ensured.
In the course of the sophisticated rebuild
project and during the start-up, Voith
Sulzer engineers were also present onsite for extended shifts. Short information channels were thus achieved, andthe highly motivated team succeededfulfilling the customer’s expectations,despite the enormous pressure of time.
Within a short period of operation of the
new PM 3 production line, the innovative
overall concept of stock preparation
system and paper machine proved a suc-

38

Consolidated Papers, Inc. expands
to SCA Plus Grades
Dave Beal, Operations Manager from
Lake Superior Papers reports: “The rebuild of Lake Superior Paper’s (LSPI)SCA paper machine in Duluth, Minnesota,that began on February 2, 1998, wascompleted in less than 20 days and has
started up very successfully. In fact, thefirst day of production produced over
700 tons, most of it as first-line quality.
The focus now is to optimize the printability and runnability characteristics.
The rebuild to a Voith Sulzer DuoFormer
CFD gap former has already made a dra-

matic improvement in print quality. The
striking improvement in printability
comes from a strong and clear dot impression that is sharper in appearance
and has fewer skips. There is an improvement in ink holdout in the darker
color tones and a cleaner contrast due tochanges in sheet color or shade.
The improvement in skipped dots is particularly noticeable in flesh tone areas
and light background tones. The overall
printability improvement will not only
benefit all customers; it will allow Lake

Paper Machines

39

Fig. 1: The paper machine after the rebuild.
Fig. 2: Roger L. Wangen, vice president
Consolidated Papers Inc.
2

Strength properties, depending on whichcharacteristic is measured, are either improved or about the same. The degree of
uniformity, however, is greatly improved
as measured by cross deckle basis
weight profile, machine direction profileand randomness. Formation and ash
distribution have also been dramatically
improved.

1

Superior Paper to penetrate the magazine
publication market with a new SCA+
grade later in the second quarter.
The increased smoothness and improved
printing surface was dramatic from thevery first production. The gloss at thesupercalenders was much easier to attain, and production crews on the finishing line immediately noticed the differences. They also noticed the improvements in optical properties, such as increased opacity and brightness after
supering.

By the end of the first week of operation,
everyone at LSPI was tremendously
proud and excited about the opportunities the new gap former provides to better serve our customers. We are particularly grateful that Consolidated Papers(CPI) has put their confidence in Lake
Superior Papers with such an investment.
The gap former will position LSPI to better serve the customer with new and improved product in the future.”
Voith Sulzer Paper Technology built theoriginal machine in 1988, with the first
SC paper being produced 20 days aheadof schedule. The decision to rebuild of
the machine’s forming section from a
DuoFormer F into a DuoFormer CFD gap
former 10 years later came from thecompany headquarters in Wisconsin
Rapids, WI. This is the third CFD unit
purchased by Consolidated, which was
one of the deciding factors in the final
supplier selection for the project. Extensive testing of the furnish on pilot equipment was performed, as well as visits toother mill locations already using Voith
Sulzer’s CFD gap formers on similar
grades.
Roger Wangen, vice president of groundwood operations stated, “We are very
pleased with the quality gained from thisproject. It allowed us to make a strong
entry into the SCA+ market and further
improve our excellent SCA grade.”
The CFD unit is designed for highgroundwood containing stock and wasused by Consolidated Papers on lightweight coated grades. The wrap on theforming roll can be varied, thus adapting
to various grade productions – newsprint
to SCA. The lower the freeness thegreater the wrap.
The new forming system allowed Consolidated Papers, Inc. to develop and market
a magazine publication grade called SCA
Plus for rotogravure printing. The SCA
Plus grade is designed to compete with
LWC and other grades of this type.
Standard SCA is still Lake Superior’s
main product, however, after the installation of the new gap former, they are now
equipped to produce a high-quality SCA
Plus grade. The new grade is being soldunder its trade name “Expedition”. It hasreceived top recognition for its higher

40

Fig. 3: Lake Superior Paper in Duluth,
Minnesota, USA.
Fig. 4: Charles A. Schultz, Director of Engineering
Consolidated Papers, Inc.

brightness, gloss and better printability
due to increased smoothness – above thestandard SCA grade. LSPI states thatthey are the first North American mill tocommercially qualify for the SCA Plus
grade.
Another major machine component replaced during the rebuild was the original
W-headbox. The new Voith Sulzer ModuleJet dilution control headbox technology was selected to replace the older,slice-control type headbox.
Voith Sulzer Paper Technology supplied
all screens and pumps required for the
project, as well as air-removal systems.
The Duo-Centri II press followed by aconventional straight through fourthpress remained, for the most part, intact.
A Voith Sulzer press-to-dryer section ropeless sheet transfer system was successfully installed at the time of the rebuild. Wire changes are quickly accomplished with use of the Voith Sulzer’s
wire changing system, eliminating theuse of cumbersome heavy metal poles.

3“Key members from CPI Corporate Engineering and Purchasing, LSPI Engineering and Production worked very closelywith Voith Sulzer engineers and erectors
to successfully bring this project inahead of schedule. Once again, we werevery impressed with the detailed involvement shown by Voith Sulzer team members and the timely, staged delivery of

key machine components from bothAppleton and Heidenheim”. So Charles A.
Schultz, Director of Engineering Consolidated Papers, Inc.

4

One very important consideration during
the project’s planning stages, was theability to produce larger diameter rolls.
Improved sheet profiles were, therefore,a major target in preliminary project discussions.
The DuoFormer CFD, as well as the ModuleJet headbox, would directly show apositive influence in improving sheet formation, which would not only aid in the
production of larger diameter rolls but
have the desired improvement in print
quality. Improvements in cross direction
profiles and basis weight control havebeen significant. Both CD and MD 2sigma deviations were substantially lowered.
The 8,050 mm wide paper machine is another positive step into the new millennium for Consolidated Papers and Voith
Sulzer Paper Technology.

Finishing41

A concept confirmed

1

A good many articles – quite controver-meetings were held to ensure successful

sial in some cases – have already been

project implementation.

published on the new Janus calender

The author:
Hans Witschel,Finishing

generation, i.e. the MK 2. Successful

This project greatly benefited from thestartup of the new PM 5 with its MK 2

open cooperation between all concerned

Janus calender at Gebrüder Lang,– which was indispensable to ensure suc-

Ettringen (Fig.1) now confirms thiscess in the face of pessimistic attitudes

concept in full.

which had been spread on the market.

The target set for this new machine was

Detailing all the differences between aambitious: online production of calen-

conventional vertical calender and thedered rotogravure printing paper match-

MK 2 design would exceed the scope ofing all the surface characteristics of an

this article. Even checking the new rolloffline supercalendered paper.
When the Janus concept was first introduced, offline calendering speeds had
jumped from 600 to 1,000 m/min. The
Janus MK 2 in Ettringen brings anotherquantum leap from 1,000 to 1,500 m/min– but this time online. After Lang had
decided not only for the Janus concept
again, but also to install the first MK 2
calender, a good many risk assessment

Technical data
I Furnish components:– 55 g/m 2 SC paper– DIP approx. 83 %– Groundwood approx. 12 %– Softwood pulp approx. 5 %I Gloss  45% Hunter 75°
I Roughness  1.2 Hm PPS-S10
I Porosity < 20 ml/min Bendtsen
I V max for newsprint 1,800 m/min
I V max for SC-A grades 1,500 m/min

42

Fig. 1: The Janus MK 2 calender.
Fig. 2: Web threading on the Janus MK 2.
Fig. 3: Janus MK 2 at Lang Papier,Ettringen, Germany.
2changing concept required not only 3-D

nevertheless calendered at 1,250 m/min.

This had not really been planned as yet,but in view of the completely stablecomputer simulation, but also a physical
1:10 scale model of the complete calen-

In addition to the new MK 2 calender, thetransfer from Janus to Sirius at a speed

der.

numerous innovations on the paper ma-

of 1,350 m/min, it was spontaneously de-chine included a completely new control

cided to open up the entire width and use

At the end of August 1999 the first mile-and visualization concept. Commission-

all calender nips.

stone was reached: the calender was

ing was therefore a special challengeclosed without any problem. This had

both on the side of the customer and the

The other operating mode – newsprint

been preceded by initial optimization of

supplier.

calendering in the upper nip alone – wasthen tested straight away the next day.

the paper machine, including test-threading through the calender from the end of

After a successful startup, the generalthe dry section to the Sirius reel (Fig. 2).

sense of relief around midnight was cer-

As shown by the technical data, the de-tainly worth a celebration!

sign operating speed for fully calendered
SC grades is 1,500 m/min. The design

The MK 2 was then started up in one of
the three possible operating modes:

This was followed by a phase of very in-speed for newsprint increases to 1,800

newsprint calendering in the lowest nip

tensive optimization, during the course ofm/min, and at the time of writing

only. The second alternative is newsprint

which all functions of the Janus MK 2

(November 1999) test runs had alreadycalendering in the upper nip – and thewere coordinated to perfection with the

been carried out at 1,465 m/min withthird alternative is of course the actual

paper machine and Sirius functions.

newsprint.

design mode, using all three calenderrolls for rotogravure paper.

Toward the end of this phase in the second half of September, rotogravure paper

Here are some of the calendering areas

Although no speed records were broken

was calendered for the first time using all

where the innovations involved in thisto start with, the first reel of paper was

nips.

concept demanded special attention:

43

3

I Post-humidification

sary dwell time for conditioning. ThisAs expected with the 45° orientation of

I Web threading

concept proved very successful.

the MK 2, most of the questions arising

I Frame layout

before startup concerned the calender

I Roll deflection

Web transfer through the calender for

stand and stack layout. Throughout the

I Vibration freedom

winding is based on the concept alreadyentire project design phase, attention was

I etc.

well-proven on PM 4 in Ettringen. The

repeatedly paid to matters such as vibra-

leading edge is transferred from the lasttion and noise damping as well as resul-

The conventional way of humidifying SC-

drying roll by Fibron vacuum belts to thetant cross-profile effects.

A grades – rapid drying followed by water

calender rope system. After leaving thespraying to the required web humidity –calender, a so-called pullstack generates

But all these suspicions were dispelled

was not possible in this case due to thethe web tension indispensable for stabili-on the first startup. Simply a “laying on

risk of transparent calendering in case of

ty of the leading edge, which is thenof hands” is enough to establish the al-water drops. Instead, measures were tak-transferred by vacuum belts to the Sirius

most complete freedom from vibration of

en to ensure the flattest possible humidi-

reel. Despite the experience gained on

the calender.

ty cross-profile – at a high level – already

PM 4, it goes without saying that theat the paper machine / dry section.

right settings had to be established em-

Although PM 5 has not yet entered into

pirically for each of the various paper

routine operation, we and our customer

Fine correction of the humidity level isgrades. Those grades with high moisturealready have every reason to celebrate:

carried out afterwards by precisely con-content and high fillers content demand-

trolled spray nozzles installed before theed the greatest efforts for establishing

Choosing a Janus MK 2 was the rightlast drying aggregate, due to the neces-the right settings.

decision.

44

1

Ground-breaking ceremony –new Service Centre in Indonesia

After some delay because of thezone, this was the reason why the loca-

political and economic situation, thetion was chosen.

ground-breaking of the Voith Sulzer
Paper Technology service centre in
Jakarta has finally taken place inService offering

November 1999.
The centre will first be equipped with the
The author:
Martin Scherrer,
Voith Sulzer Paper Technology
Service Indonesia

Indonesia has the highest pulp and paper

normal facilities of a modern roll service

production capacity in South-East Asia. It

workshop. In addition, there will be ais also not far from Australia and otherNipco test facility together with roll hon-

importanting, mobile grinding and polishing equip-

paper

production

centres.

Voith Sulzer Paper Technology therefore

ment.

decided years ago to open not only asales office here, but also a service

Later on, a polyurethane covering service

centre.

using ribbon flow technology will be
added. That will greatly improve the cur-

Located 60 km east of Jakarta in therent situation in this region: most rolls

Karawang industrial zone, this new centre

now have to be shipped to Europe, Japan

should open its doors on September 1,

or Australia for overhaul and recovering,

2000. National and international connec-

which is both time-consuming and ex-

tions in this region near the capital arepensive.

excellent, with port and airport only
about one hour away. Together with good

In the final phase, composite covers forhighway links to the West Java paper millcalender rolls will be produced at thisService

45

Fig. 1: Simulated image of the new Voith Sulzer
service centre in Indonesia.
Fig. 2: Martin Scherrer, General Manager of the
new Voith Sulzer service centre in Indonesia.

Fig. 3: The new Voith Sulzer service centre islocated 60 km east of Jakarta.
Fig. 4: Laying the foundations: the first pile has
been driven.
2

3

Eastern-Malaysia
BorneoSumatraI n d o n e s i a

JakartaJava
Karawang

centre. Appropriate employee training is

as well as heavy-duty overhead cranes

also planned for expanding our mobile

big enough to handle 100-ton rolls, 15 m

roll-grinding and thermal coating service,long and 2 m in diameter. The materials

thus enabling this work to be carried out

for extruded or manually finished rubber

in paper mills by local personnel in In-

roll covers will largely be made on site –donesia. In the future it is also planned

another way of saving customers time

to extend the services to other parts ofand money.

the papermaking process, such as stock
preparation.
Prospects
It seems that the South East Asian

Staffing and facilities

economies have largely overcome the criAbout 50 people will be employed at thesis of recent years. Likewise Indonesia is

new service centre to start with, some ofrecovering, and after a phase of reces-

them

from

sion the paper industry here will need toEurope and Canada. In the medium term,

make substantial investments for holding

personnel will be expanded to about

its own on markets both national and in-

100 people.

ternational. Voith Sulzer Paper Technolo-

experienced

professionals

gy will provide solid partnership in thisTechnical facilities at this 6,200 m 2 ser-development by continuing with long-

vice plant will be state-of-the-art rightterm plans for expanding our local pres-from the beginning: large CNC lathes,ence and service offering in Asia, wellgrinding, milling and balancing machines

beyond Jakarta.

4

Celebes

46

Roll grinding machine for Vietnam
Bai Bang Pulp and Paper Mill, Phong

replaced.

Againsttoughcompetition,

Chau, is located in Phu Tho province

Voith Sulzer Paper Technology then re-about 60 km north-east of Hanoi on theceived the order in April 1999 for delivery

Red River. Constructed in the mid-and installation of a modern roll grinding

seventies, this plant has a pulp produc-machine. The new machine is currently

tion capacity of about 50,000 t.p.a.,being manufactured at our Appleton

and 100,000 t.p.a. paper and board.

works in Wisconsin, USA, for delivery
and installation in June 2000.

The author:
Peter Biener,
Voith Sulzer Roll Grinding
Machines Europe

The completely state-owned Bai Bang millis to be expanded, and one requirement

This is the first order booked in Vietnam

for this is modernization or replacement

by Voith Sulzer Paper Technology, andof the existing Bruderhaus roll grinding

visiting Bai Bang mill in 1998 was theaggregate.

author’s first opportunity to travel in acountry where the ravages of war are still

Initial negotiations in this connection

all too obvious, not only in Hanoi. But

during the mid-nineties were followed bythis sad impression was more than offset

inspection of the existing machine toby my cordial reception in Bai Bang anddecide whether it should be upgraded orby the friendly people in Phong Chau,whose livelihood depends almost exclusively on the paper mill as main regional
employer, whether directly or indirectly.
We are delighted at this first order in
Vietnam, and trust that prompt delivery
with full customer satisfaction in June
2000 will set the scene for ongoing fruitful cooperation in the future.
Currently 315 Voith Sulzer roll grinding
machines are in service worldwide, withcapacities up to 15 metres roll length.

C O R P O R AT E N e w s

47

The top address for system know-how
On July 1, 1999, the Voith Group

regardless of the original equipment

acquired the roll covers, roll service

manufacturer. No other company today

and paper machine clothing businesses

can offer such broad-ranging andof the Scapa Group plc, Blackburn/UK.

complete papermaking equipment sales

After integrating these companies intoand service as Voith. With this strategic

the corporate structure, Voith became

expansion in roll covering, roll repair

the first company in the world capableand service as well as clothingof meeting all the papermaker’s

technology, Voith is ideally positioned

machine needs from headbox to reel,to help papermakers optimize their

including stock preparation and sheet

papermaking process and produce

finishing. Voith now can supply themore and higher quality paper at apaper machine, clothe it and service it,lower cost.

1

48

Fig. 1: Inspection of inner surface of a suction
press roll.
Fig. 2: High precision tooling of a dummy head.
Fig. 3: Inspection of suction press roll on the
drilling unit.
Fig. 4: Manufacturing of a rubber cover.
2

3
4

competent personnel, Voith is better able

complement of exceptional products andto meet such demands. Thanks to thisservices that include:

strategic expansion, the Voith brand pro-

I operations and optimization products –vides increased customer benefits. The

regardless of the OEMformer Scapa companies have been as-

I paper machine and roll servicing

signed to two independent business units

I roll coverings and thermal coatingsof the Voith Group. They work together

I technical and diagnostic services

closely both in customer service andI stock prep, paper machine andR&D for ongoing product development.

finishing equipment and parts.

Roll cover and roll service sector

Scapa was noted for technologicaladvancements that include:
I the industry’s toughest premium poly-

The industrial globalization and consoli-

The Scapa roll covering and service activ-

dation currently taking place worldwide,

ities have been integrated into the Voith

urethane cover system for press rolls

particularly in the paper industry, de-Sulzer Paper Technology Service Division

I high-performance drilled polyurethanemands a radical change of approachwith headquarters in Charlotte, Northroll cover for suction press rolls

among suppliers. Today’s papermakers

Carolina, USA. The operation remains in

I outstanding resin composite covers

expect true partnership from their suppli-

the capable hands of Ray Hall. The acqui-that yield improved sheet finishingers, with full system competence andsition has enabled Voith Sulzer to add

I state-of-the-art ceramic covers thatturnkey responsibility. They want a sin-

service centers and products such as

usually eliminate the need for releasegle-source supplier that can handle com-

Scapa’s well-proven roll covers and ex-

agents.

prehensive solutions and provide excel-

pand its existing roll repair and servicing

lent service. By acquiring the Scapa

function. Voith Sulzer now offers un-

Now Voith Sulzer has technological lead-assets with proven products and highly

matched technical expertise and a fullership in polyurethane, resin and ceramicCorporate News

49

Fig. 5: 25 Voith Sulzer Paper Technology
Service Center worldwide.
Fig. 6: Ivan J. Fearnhead, Voith Fabrics.
5

Fig. 7: High speed weaving machine.

7

product lines and, along with the Magna

Paper machine clothing sector

is a world leader in clothing for forming,press and dryer sections. Voith Fabrics

series of premium rubber covers, is able
to provide operational and service life

The paper machine clothing businessengineers and manufactures high quality

benefits for any paper machine or finish-acquired from Scapa was merged withpaper machine clothing suitable for every

ing application.

the former Voith Appleton Mills division

position in every section of every paper

to form a new, independent company.

machine in the world. The entire offering

Merging the Scapa and Voith Sulzer busi-

Voith Fabrics is headquartered in Raleigh,is backed up by first-class service, with anesses has substantially improved cus-

North Carolina, USA. CEO is Ivan J.

close-knit global network covering all

tomer benefit with regard to field ser-Fearnhead.

customer locations. Voith Fabrics has
production plants in Germany, Great

vices. Voith Sulzer now has 25 first-classservice centers located in almost every

With annual sales around DM 700 million

Britain, France, Italy, Austria, Holland,major papermaking region in the world

and about 3,500 employees, Voith Fabrics

Sweden, Spain, the USA, Canada, Mexico,
China, India and Malaysia.

and can provide a rapid response when apapermaker calls with a problem or need.
Further 20 service centers for paper ma-

Voith Fabrics will continue the existing

chine clothing are added to these. The

product lines of Voith Appleton Mills divi-

addition of Mill Service Managers offers

sion and Scapa Paper Machine Clothing

the coordination of all the resources ofand further develop them whilst exploit-

the Voith papermaking concerns for pa-

ing synergies at the same time. The new

per mill management. Each is supported

company is focusing on developing inno-

by the Voith global network to ensure

vativethat customers receive the Voith prod-

runnability and lower the cost of making

ucts and services where and when they

paper.

are needed.
6

newmaterials

that

increase508Corporate News

51

Fig. 8: Automatic seaming.
Fig. 9: Heat setting equipment.
Fig. 10: R. Ray Hall, Service Division.
Fig. 11: Checking of surface micro structure.
911“We have identified numerous areas of

Research and development

synergy between Voith Fabrics and Voith

cise diagnostics, thus identifying the
optimal solution for each specific appli-

Sulzer,” observed Voith Fabrics CEO Ivan

Research and development will continue

cation.

Fearnhead. “We are particularly excitedas the cornerstone of Voith Fabrics andabout working closely on the develop-

Voith Sulzer’s product offerings. Engi-

Ray Hall sums up future prospects asment of fabrics for the new generation ofneers from Voith Sulzer Paper Technolo-

follows: “New developments in paper

machines and the new technologies thatgy and Voith Fabrics will work very close-

machine technology directly influence theare on the drawing board. The merger ofly at the R&D centers in Europe, North

choice of roll covering

Scapa Paper Machine Clothing and Voith

and South America, and on pilot paper

fabric design and vice-versa. Advances

Appleton opens up opportunities neither

machines located throughout the world.

in these materials can also bring im-company had before.” He points to such

This enables customized trials and pre-provements in machine design. For opti-

materials andtechnological advances as Voith Apple-

mal progress, all system components

ton’s development of a new, non-woven

have to be precisely coordinated – which

membrane and Scapa’s production of ais naturally much easier for a single-

cast polyurethane composite structuresource supplier. With the acquisition of

for use within the press felt.

Scapa Paper Machine Clothing and Scapa
Rolls, Voith offers unprecedented system“We now have the ability to combine flowcompetence. With Scapa, Voith has notcontrol technology with composite tech-

only gained vast experience in roll covernology. This will permit us to make prod-technology and service, but also en-

ucts that will be the benchmarks forhanced local contact and global market

press felts in the 21st century,” added

positioning – to the

Fearnhead.

makers worldwide.”10

benefit of paper-

52

Voith Sulzer Automation – key to the“Perfect” Paper Machine strategy
With the Millennium product family onpresident of Voith Sulzer Paper Techno-

the way to the “Perfect” Paper Machine:logy. “This is a machine with negligible

Advantage Plus™

quality variations, no breaks and two

Profilmatic™

minute grade changes. We can only

InfoPac™

achieve this objective with the new breed

Smart Paper Machineryof ‘smart’ paper machinery that includes
embedded application-specific sensors,
actuators and controls to eliminate varia-

The author:
Geoffrey Lawrence,
Voith Sulzer Automation“Our goal is nothing short of the ‘Perfecttions at their source and enable faster

Paper Machine’,” says Mr. Hans Müller,

machine transitions.”

MMI(Man MachineInterface)“Shared Window”

Ethernet TCP/IP

NIC

AdvantagePlus
Quality Sensors
1 SS-Frame
3 C-Frames
2 O-Frames

NIC

NIC

NIC

NIC

NIC

ModuleJet
Dilution
Headbox

ModuleSteam
Steambox

InfraPac
IR Profiler

Corporate News

53

Fig. 1: Millennium system for new Voith Sulzer
machine being built for Perlen in Switzerland.
System includes full integration of DCS, drive
system, web break and web inspection systems.

Toward that end, Mr. Müller announced

face, toward “single window” systems

mills are quickly approaching a “results

the formation of Voith Sulzer Automation

integrated into a single DCS platform.

ceiling”.

(headed by Geoffrey Lawrence), a new

Though a step forward in system evolu-

company formed by the combination oftion, these single DCS platform solutions

Voith Sulzer Automation provides new

Impact Systems (acquired by Voith Sulzer

present several drawbacks including re-application-specific solutions to paper-

in January 1998) of Los Gatos, California

stricted access to information, excessive

making problems by introducing the Mil-and Voith Sulzer Controls, of Heiden-complexity, high maintenance costs, andlennium-concept. The major strength ofheim, Germany. Impact Systems pio-

limited flexibility and expandability. In

the Millennium architecture is the distrib-

neered the development of CD actuators

addition, in recent years the QCS func-

ution of QCS functionality into fully func-

and IR dryers, and later introduced an in-tionality has shown signs of a maturing

tional, stand-alone subsystems (e.g. scan-

novative on-line Quality Control Systemwith few new products that add signifi-

ning platforms, CD actuators, etc.) that

(QCS); Voith Sulzer Controls is well-cant value for the paper mills and their

are integrated on a high-speed Ethernet

known for its development of ModuleJetcustomers. Consequently, most paper

network.

dilution headbox as well as major advancements in CD control theory.

AdvantagePlus™

Measurement of quality data

Scanners and Sensors

Profilmatic ©

Reduction of quality
deviations

Actuators and CD Controls

Smart Paper Machinery

Components withembedded quality controls

e.g. ModuleJet dilution
headbox with Profilmatic MQ,
embedded stockflow control

InfoPac™

Analysis and Diagnostics
of quality and machineparameters

e.g. quality maps of reels
and rolls, video surveillanceof sheet breaks

A new paradigm in paper machine
control
During the last decade, process control
systems have moved from stand-alone
PLC, DCS and QCS “islands of automation,” each with their own operator inter-

InfoPac– ReelBrowser– Quality Analyzer– Machine Monitoring– Technology Monitor

Service andEngineering Centerwith Modem

1
NIC

Nipcorect
Calender

NIC

SpectrumIR
Gas Drying
System

NIC

NIC

Rollmaster

MDControls

Pope Reel

Quality Control
in Machine
Direction

Web BreakDiagnostic
SystemWeb
Inspection/
AnalyseM

DrivesPartnerships with system suppliers

DCS/PLC I/O54ModuleJet

ModuleSteam

AdvantagePlus™

“plug-and-play” modularity, independentThus, the Millennium architecture per-Measurement Platforms

subsystem maintainability, and highly

mits Voith Sulzer Automation to focus all

The scanning platform, AdvantagePlus,

flexible expandability.

of our resources on paper machine optimization, while offering full integration

measures all relevant quality data during
the paper-making process, see Fig. 2.

System communications, both internallyof the ‘best-of-breed’ general purposeand externally, conform to the latest

automation systems (e.g. PLC, DCS, roll-

Microsoft and other open communication

tracking, etc.).

Profilmatic™

standards, allowing easy and complete

Actuators and CD Control Systems

integration with other standards-based

The performances of the Millennium sys-

The Profilmatic family of subsystems

control and information systems.

tem has been very impressive. The Profilmatic CD controls have shown astound-includes actuators, e.g. the gas drying
system SpectrumIR, the electric drying

In addition, the operator and maintenanceing results at a recent installation at asystem InfraPac or the caliper profiler

video displays from the Millennium sub-customer in the United States. The new

ThermaJet and the CD controls for thesystems and from other suppliers control

Millennium control algorithms, achieved

various systems and applications.

and information systems are integrated

a 56% and 62% improvement in CD

on a “shared window” using web-brows-

weight and CD moisture control respec-

Each subsystem freely communicateser, ActiveX and other display standards.

tively. Voith Sulzer Automation achieved

with any other through its Network Intel-

This unique approach provides all thethese results using the mill’s existing CD

ligent Controller (NIC). The result is an

benefits of a “single window” without theactuators.

integrated Quality Control System with all

major disadvantage of having to rewrite

the benefits of full network distribution

the displays in the DCS platform.

including subsystem independence, true

Also the new Voith Sulzer LWC paper machine at Perlen in Switzerland benefitsCorporate News

AquaPac

InfraPac

AdvantagePlus

SpeedFlow

55

SpectrumIR Gas

ThermaJet

Nipcorect

AdvantagePlus

2from the power and flexibility of the(Fig. 2). The sensor and new related con-with Millennium and other control sys-

Millennium system (Fig. 1). It includes

trols will reduce short-term CD and MD

tems. Our customers like the fact thatthe full integration of PLC/DCS, drive

variations

decrease

they can map the quality of a full reel orsystem, and other systems from outside

grade change times. The patented Mod-roll, and trend paper machine perfor-suppliers.

uleJet was the first dilution control head-mance for any selected time period. The

box, and today there are over 120 suc-

InfoPac “ReelBrowser” has been particu-

andsignificantly

cessful installations worldwide. Module-

larly well received. In just about every

Smart Paper Machinery

Jet, using the unique Profilmatic M con-case when we started up ReelBrowser,

Paper Machine Components withtrols, has already produced paper withwithin hours the mill detected perfor-

embedded sensors and quality controls±0.1 g/m 2 2-sigma CD basis weight varia-

mance problems that they simply didn’t

In a next step we are working on combin-tion.

know existed (Fig. 3). If a mill moves to acomplete millwide information system,

ing paper machinery, process knowledge,

then InfoPac readily ties in since it fol-and automation expertise to create embedded application-specific sensors and

InfoPaclows standardized database and commu-

controls into the various sections of theInformation Systems for Paper Machines

nications standards.

machine (e.g. headbox, former, presses,

Papermakers can look to Voith Sulzer

coater, dryers, etc.). These new “smart”

Automation for innovative process-im-

machines eliminate variations at theirprovement solutions.

source. For example, Voith Sulzer Auto-new “InfoPac” family of Paper Machine

The “Perfect Paper Machine” – with nomation has developed a consistency sen-

Information Systems has proven to be abreaks, two-minute grade changes, andsor to be embedded in each dilution ap-

big hit in the mills. Over 20 InfoPac or-negligible paper quality variations, – isproach line to the ModuleJet headbox

ders have already been received, for use

the mission of Voith Sulzer and Voith

For example, theYour vision is our mission

56

Fig. 3: InfoPac ReelBrowser showing quality map
for one reel of paper. Mill determined that highmoisture streak was caused by felt shower.
3

Sulzer Automation. We are moving rapidly toward this objective by combining

Reel Browser
Splice View

Roll Browser

world-leading paper machinery knowledge and advanced automation expertise.

Quality Map
Splice Analyzer

Our new generation QCS along with new
Quality Map“smart” paper machinery and integral
paper machine information systems now
allow mills to gain a new level of bene-

Roll Master

Quality Analyzer

fits. These new capabilities are alreadyproducing some dramatic results; we are

Winding Analyzer

Excel Add-ons

breaking through the “results ceiling”
now being approached by traditional QCS“add-on” systems. The paper business isour only business, and our mission isVideo Web
Break Monitor

VMM

worldwide. Together we will move toward

VTM
Machine Monitoring
Technology Monitor

New “NIC” Technology
The Millennium System provides a newmodular architecture, including a “Network Intelligent Controller” (NIC) associated with each subsystem (e.g. scanner, actuator, etc.) on the Ethernet network. The NIC technology allows eachsubsystem to operate independently,
freely communicating with any othersubsystem. The overall system operates
as if it were programmed on one large
computer, though it is distributed overthe network using a highly efficient
communications technology. Today’sscanning sensors each generate a highresolution profile array of 500 or moredata boxes every 10 - 25 seconds, andvarious CD actuators need this data im-aligned with the visions of papermakers

mediately. These demands could easily
overload traditional communication networks and compromise control performance. The new Voith Sulzer Automation“Data Distribution System” (DDS) addresses this issue by providing the next
generation in real-time control communication technology. Each subsystem NIC
is “publisher” and “subscriber” for sending and receiving information.
For example, a scanner NIC is a publisher
that transmits the high resolution profiles
immediately after each scan and each CD
actuator NIC is a subscriber that receives
the appropriate profile data immediately.
This automatically occurs without any
custom communications setup or configuration.

the “Perfect” Paper Machine... indeed,that future is not so far away.

Full distribution of functionality tostand-alone subsystems allows Voith
Sulzer Automation to build, test, install
and troubleshoot the system more efficiently; allowing for faster installationand startup, less risk of total system
failure and lower ongoing maintenancecosts.
The stand-alone subsystem design provides the system with a new level ofmodularity, allowing “plug and play”
additions of new subsystems without
expensive upgrades and reprogramming. Millennium users now have unlimited expandability, allowing themto take full advantage of future Voith
Sulzer Automation developments.

57

1

Building the future:
Voith Sulzer Paper Technology in China
Beijing on a dull November morning.
Our limousine makes its way slowly
through the yellow-grey smog, for traffic
jams have already built up on the third
ringroad. What a contrast to the “goodold days” when a lonely black limousine sailed through a throng of bicycles– now they overtake us all the time!
The author:
Frank Opletal, Voith Sulzer
Paper Technology, Beijing
Central Representative Office

After quite a long journey, BeijingInternational Exhibition Centre looms
up through the fog. We soon find awarm welcome at the Voith Sulzer Paper
Technology stand, where the message

is clear: Chinese customers can shop
here for all their papermaking needs.
In other words, Voith Sulzer Paper
Technology has come to stay.

Our customers stayed on for some long
discussions and friendly chats, in fact
they felt very much at home: “Your booth
this year is very Chinese and very very
good!”. The new Chinese brochures andour first two coloured Chinese editionsof “twogether” magazine (Nos. 7 and 8)
were so popular, that only one day later

58

2

3

they were nearly all gone. Happy reading
to all our Chinese business friends!

porting 6 to 7 million tonnes p.a. as well
– is not so easily retrofitted.

At the Voith Sulzer press conference heldon the opening day of this trade fair,questions asked by journalists clearly
showed what interests China’s paper industry most of all: local manufacturing,
service and roll cover centres, and hightech equipment such as our ModuleJet
headbox.

The last few years have seen some of theworld’s biggest and most efficient machines come on stream in China for various grades, but so far they only coverabout 20 percent of national paper andboard needs. At this rate, replacing all
the outdated machinery will take quite
some years.

Voith Sulzer’s customer seminar, held on
the last day of the China Paper & Forest’99, was a rendezvous for high-ranking
officials and top paper industry managers
from all over China. Here again, the main
focus was on Building the Future in the
Chinese paper industry – comprisingsome 4700 mills, mostly small and outdated.

At the same time, according to Chinese
economy growth forecasts, paper andboard consumption will rise by 2010 toabout 60 million tonnes p.a. as against
34 million t.p.a. at the present time. In
other words, another 60 or so machines,
each with 200,000 t.p.a capacity, will be
required for graphical grades and 70
more for board production. This is on topof the 40 paper and 50 board machine replacements required for current needs.

Chinese leaders have seen the necessityof modernizing their paper mills formeeting tougher competition in years tocome. But an industry with around 4700
mills churning out 28 million tonnes of
paper and board annually – and still im-

Just think what that means – 120 board
machines and 100 paper machines aregoing to be required over the next
decade!

Although the challenges to be faced in
China are quite different to those inEurope or America, our seminar guests in
Beijing were asking the same kind ofquestions:
I Which supplier should I choose as myoverall papermaking process partner
in order to minimize risk?
I Which high-tech components are mostappropriate for upgrading my oldpaper machinery?
I Will investing in the greater efficiency
of a high-tech paper machine and/or
stock preparation line give me aleading edge over competitors?
I Which concept best utilizes the raw
materials already so scarce in China?
I Where do I get the necessaryfinancing?
Despite the advent of computers and Internet technology in China, books andnewspapers will be a more economical

Corporate News

59

Fig. 4: Information centre on the Voith Sulzer
stand.

Fig. 1: The Voith Sulzer Paper Technology standat the China Paper & Forest '99 trade fair in
Beijing.

Fig. 5: Frank Opletal and B. Z. Chen (both of VPTBeijing office) welcoming guests to the customer
seminar.

Fig. 2: Lu Shin Lin, President Director Minfeng
Corporation, talking with Hans-Peter Sollinger
and Harry Hackl.

Fig. 6: Jiang Heping (Chairman Jiangxi Paper
Group) and VPT Beijing office manager Ming
Ming Liu, singing a Chinese folk song together.

Fig. 3: Official opening of China Paper & Forest‘99 in the presence of high-ranking government
officials, including Deputy Light Industry Minister
Yang Hay Shan.

Fig. 7: Ming Ming Liu talking with Zhao Wan Li,
General Manager Hongta Renheng, Zhuhai.
4

5

answer for decades to come – especiallywith regard to education: each year 15 to
20 million children start school in China.
With growing competition, there will also
be a higher demand for packaging. Better
wrapping and protection of all the goods
produced by Chinese and foreign enterprises will increase folding boxboard andcorrugated container needs enormously.
Furthermore, tissue requirements forcosmetic and hygiene purposes are also
growing rapidly.
Against this background of economic
expansion and promise for the future,
the Voith Sulzer Paper Technology seminar in Beijing was particularly appurtenant. Our most reputed customers in
China gave some very interesting reports
on experience with their LWC and cigarette paper lines, packaging paper andfolding boxboard machines – in fact theirboundless enthusiasm was so infectious,that these addresses were the highlightof the seminar.

The day was rounded off by a muchappreciated address from the banking
world – how many interesting possibilities there are for financing such a vast
modernization process!

6

And during the traditional Voith Sulzer
banquet that evening, appropriately
entertained by Chinese folk singers, a
special kind of “Twogetherness” wascelebrated: an exciting partnership for
Building the Future.
Sincere thanks to all our customers forbeing with us: you made this seminar a 7
memorable occasion! We also owe agreat deal of thanks to our colleagues
from all over the world for their outstanding presentations. And finally, wherewould we be without all the help andhard work by our enthusiastic people in
Beijing?

60High distinction for
Dr. Herbert Ortner
On September 30, 1999 Herbert Ortner
was inducted into the Paper Industry
International Hall of Fame in recognition of his outstanding services to paper
technology research and development.
Paper is such an everyday part of life
these days, that only insiders have any
idea of how much ingenuity and sheer
hard work it takes behind the scenes tokeep the printing press well fed. Whatwould we know about the world’s great
writers and composers, scientists andengineers, politicians and economists,
for example, if they had not put down
their ideas in writing? And what would
have been the point of inventing theprinting press without paper? Furthermore, how many Nobel prizewinners
would there be without reading andwriting?
But the very people who make paper possible in today’s high qualities at such low
cost are not necessarily known even to
insiders. Some international paper industry leaders, therefore, thought about improving this situation, how the most outstanding of these people could be honoured in an appropriate manner. So withthe assistance of the Neenah Historical
Society, in 1992 they founded the Paper
Industry International Hall of Fame in
Wisconsin, USA. The declared aim of thisinstitution is to make public outstandingachievements in the paper industry, andpay due tribute to the persons responsible. Induction into the Hall of Fame is reserved for those who have made outstanding contributions for the benefit of
the entire paper industry, whether in research and development, engineering or
management.

One of the few personalities to be honoured with this high distinction since
1992 is Herbert Ortner, long-standing
head of Voith Stock Preparation Technology, and from 1994 to 1998 Senior Vice
President Integrated Paper Mill Projects,
Voith Sulzer Paper Technology Heidenheim, Germany, with main emphasis on
Far-East and Southeast Asia. He received
the award last year for his outstanding
contributions to modern papermaking
technology based on well-founded scientific methods and principles, in particularwith regard to the preparation of recovered paper.
Herbert Ortner combined his vast knowledge of the entire papermaking processwith innovative ideas and a great deal offoresight. He played a decisive role, forexample, in developing the flotation
deinking process. The worldwide breakthrough of recycling as a fundamentallyenvironment friendly and economical
principle in the paper industry today was611largely achieved thanks to his enthusiasm, determination and sheer hard work.
Herbert Ortner was convinced long agothat in a world more conscious of theneed to conserve resources, the recyclingof recovered paper would be necessary
for the future of a paper industry boundto global responsibility and credibility.
His publications and presentations, his
ideas and patents cover an enormous
range of themes. Apart from his pioneering work in flotation deinking, he has
also played a decisive role in paper surface sizing developments, coating methods, preparation of recovered paper, dispersion, refining, screening and in thedevelopment of various process-oriented
systems and machinery.
2

Herbert Ortner is a member of the Academic Society of Paper Engineers (APV) at
Graz Technical University, Austria; theAustrian Association for Pulp and Paper
Chemistry and Technology (OEZEPA); theInstitution of Pulp and Paper Chemists
and Engineers (ZELLCHEMING), and theTechnical Association for the Pulp andPaper Industry (TAPPI).
On September 30, 1998, Herbert Ortner
entered his well-earned retirement at theage of 66. Dr. Herbert Ortner continues to
be available to the company as a special
consultant. The editorial team of Twogether Magazine sincerely congratulates
him on this well deserved tribute to hislife work and achievements. And we arejoined in this congratulation by all his

colleagues and friends at Voith Sulzer
Paper Technology, who owe a good dealof their international recognition to his
outstanding work.

Fig. 1: The flotation deinking process –a development in which Herbert Ortner playeda decisive role.
Fig. 2: Together with Herbert Ortner (centre)
seven outstanding personalities from the paperindustry and papermaking technology were
inducted into the Hall of Fame in 1999.
Fig. 3: Among the first people to congratulate
Herbert Ortner were his wife, Christa Ortner-Fiala(left), Martina Mann-Voith, the daughter ofHanns Voith, and Werner Witek, Senior Vice
President Voith Sulzer Paper Technology USA.
3

P a p e r C U LT U R E

62

The art of making money out of paper …
... this is what papermakers ought tobe good at, simply on account of theirprofession. In the following article,
however, we shall not be looking at
making money out of paper production
in general, but specifically at the
production of paper money in the true
sense of the term, and at the art andculture associated with this trade, its
history and some of its peculiarities.
Arguments between experts as to who
first had the notion of inventing money,
and where and when this ingenious principle was born, have been going on almost as long as money itself has been incirculation. Nobody knows the answer
exactly. At some time after division-oflabour social structures began to develop, somebody must have become tired of
the wearisome principle of the barter

economy with one commodity exchanged
for another, and become aware of thebenefits of alternative, lightweight andmore easily carried means of payment.
That was when money began its breathtaking career, with a gradual metamorphosis from mussels and birds’ feathers,
from pearls and stones, to gold, silver,
copper and nickel, finally to paper andeven more recently to plastic rectangles
coated with an informative magnetic strip– a process that has obviously not yet
been completed.
The change from the first primitive typesof payment in kind to coined money madeof metal took several thousands of years.
The invention of gold and silver coins is
ascribed to the Lydian King Kroisos, who
has entered many other languages as theproverbially rich “Croesus”. Humanity has

thus known minted and stamped coinssince the seventh century before our calendar. Compared with these epochs ofdevelopment the era of our printed paper
money can almost be considered as an
episode.
The first banknotes appeared as early as
the 11th century, as it happens. Like
many other innovations we owe this innovative use of paper to China, the country where paper originated: In 1024 China
was the first country to decree the printing of paper money. When Marco Polo
(1268-1298), a citizen of Venice, reported
this after his return from China and also
exhibited samples of Chinese paper money, he was accused of telling infamous
lies. Neither in Venice nor in Genoa, thenthe most significant trade centres of theWestern world, was anybody capable of1

Paper Culture

63

Figs. 1 and 2: Draft and final design of modern
paper money – a 500 Swiss Francs note from thereserve series of the Swiss National Bank in
Berne.
Fig. 3: Chinese paper money from the time of
Marco Polo’s journeys.
2comprehending the brilliantly abstract
thinking that lay behind the Chinese payment system, based on simple paper
notes of different value.
Like the production of paper itself, theuse of paper money continued its advance towards the West. Reports about apaper money printing shop in Tabriz havesurvived from the year 1293. But it took
another 300 years or so before the firstprecursors of paper payment appeared in
1606 in Bologna, in 1608 in the Netherlands and 1681 in England in the form ofcheque forms from the banks.
On the whole, the issue of printed money
in Europe was considered more of a substitute, a type of promissory note, which
could then be exchanged for hard cash.
This also explains the term “money”
which became more and more common
as printed currencies came into use. Curiously enough, it is derived from theLatin “moneta” and just as clearly associated with the English “mint”, the word
used both for the production of coins andthe place where they are made. Other languages use words such as “Geld” (German), which goes back to the Anglo-Saxon and Low German term “gildt”, meaning debt, charge or tax. As understoodinitially, paper money did not represent
the actual act of payment, but only a generally accepted liability to pay. Although
paper money had long since proved successful in the very advanced civilisationof China under a largely standardised
government and tax system, the Westpersisted with the use of coined precious-metal talers, talleros, taaldars andthe later dollar for another couple of centuries. In a population where the majority

to the extremely widely circulated“Reichs-Thaler” of Charles V, coined in
Joachimsthal, Germany, from 1520 onwards. Charles V’s empire extended fromthe Caribbean to the Carpathian Mountains and was therefore, as everyone
knows, “where the sun never set”.

could not read and write and in unsafe
times, one tended to trust the gold andsilver coins, generally termed “talers”,
which could be melted down if necessary.
This very common European designationof coined money, of which the current“dollar” is clearly a derivative, goes back3

In 1661 the Bank of England put paper
money into circulation for the first time.
Its example was followed by the RoyalBank of Sweden in 1694. In 1720 France
became the first European country to introduce paper money as a generally validmeans of payment, and in 1790 in thesame country, the first paper mill in theWestern hemisphere was awarded thecontract to make a special paper for the
production of “assignments”, with thehelp of which the First Republic tried towithdraw and replace the currency of theousted monarchy.
In Germany in particular, every attempt
to change the currency to paper money

64

4Fig. 4: The banknote with the highest value
ever printed.

initially provoked a storm of indignation.
It was condemned as the “devil’s tool”
and the “paper plague”. Like playing
cards, the paper “notes” with their figures, their pictorial symbols and their often wrongly interpreted inscriptions wereassociated with all sorts of witchcraft,myths and dark dealings. The latter association has clung to the exchange of mysterious bundles of paper money until thisvery day, though money itself can hardly
be blamed. “Non olet. (Money) does notstink”, as Vespasian had correctly observed long before.
It was not until the middle of the 19th
century that banknotes finally prevailed
for payment transactions in Germany.
This late start into the paper-money era
seems symptomatic. Even today Germany
is noted for its marked restraint when it
comes to currency modernisation. In the
United States up to 90 per cent of alltransactions are paid for with “plastic
money”, whereas in the Federal Republicof Germany cash transactions still predominate. Scepticism towards alternativemeans of payment is reminiscent of thedisapproval of “notes” 200 years ago.
Of course, the valid banknotes with thehighest value can be found today in theland of limitless opportunities. We aretalking about 100,000 dollar notes, which
are reserved exclusively for paymenttransactions between the Federal banks
and the Treasury Department. The highest notes in regular circulation have adenomination of 10,000 dollars: of these,
a limited edition was printed in 1969. The
cost of producing such a banknote: fourcents! Only paper has such an unbeatably
low price, bearing in mind that a quarter-

dollar coin today costs almost as muchas its purchase value to produce.
Germany, on the other hand, can claim
the doubtful fame of having circulated thenotes with the highest denominations in
the history of paper money. They were issued during the years of hyperinflation in
1922/23, after the First World War, bearing figures with 12 and 14 zeroes, andeventually reaching such astronomicalsums as one hundred trillion Marks. They
documented the irrationality of a currency collapse with a dimension that is today
scarcely comprehensible. At the end of
October 1923 a kilogram of potatoes cost
90 billion Reichsmarks, an egg 320 billion. On 15 November 1923 the nightmare came to a halt with the introductionof the new Rentenmark currency. Hereare some excerpts from the chronicle of
the Palm paper mill, which at that time
was one of the few mills that specialised
fully in waste paper recycling:“At the beginning of 1924 we were literally ‘rolling in money’. Load after load of
the valueless billion and trillion Reichsbank notes arrived by freight train at therecycling plant. This unexpected flood ofwaste paper was at first more of a burden than a blessing. The extremely bad
print quality of the notes made separation of the poor, oily inks very difficult.
Special methods had first to be developed and the flood of money stockpiled
temporarily. Only a year later, in thespring of 1925, was this mountain ofmonetary memories reflecting the consequences of the First World War finally
cleared away to a large extent”.
Although the appearance of the first
paper currency was simply geared tocommunicating its value and details of its
origin, the designs developed in thecourse of time into a heavily symbolic
demonstration of power and national
consciousness. This trend was full of
dangers, since one or the other system ofstate or rule which had hitherto been
considered stable was always likely to be
toppled more rapidly than one might haveimagined. Of what use is a currency to a
new government if it still glorifies theportraits and heraldry of the ousted predecessors? It had to be replaced rightaway, or else the new powers-that-be
would be putting their own status at risk.
This was easier said than done. Even today, with the help of ultra-modern tools
and machinery, the changeover to a newseries of banknotes can take 2 to 3 years
or even longer. For example the Russia
that emerged from the October Revolution had to tolerate the hated money ofthe tsar for a very long time. Since then,people have learned from experience. Occupying powers and subversives tend toprepare their new currencies secretly andin good time. This is a profitable business for the relevant suppliers, since themerchandise is generally paid for in advance, and is often left behind as waste
paper if the coup d’état should fail, as
happens now and again. Respectable, farsighted state banks try to avoid too muchcontemporary political symbolism on
their notes. They prefer harmless motifs:
portraits and achievements from the artsand sciences or images from the country’s animal and plant life.
Modern anti-forgery devices can be perfectly integrated into such motifs, for example the quite common multiple water

Paper Culture

65

Fig. 5: Large-scale forgery.

mark, the metal safety thread, perceptible
surface printing, fluorescent colour effects or hologram-type changes to the
pictorial elements. Despite these sophisticated anti-counterfeit measures, thenumber of cases of counterfeiting has remained more or less unchanged for many
decades. Every year there are about
25,000 cases of attempted forgery of theGerman Mark alone, although its safety
features, among the best in the world, areto all intents and purposes not reproducible. According to estimates, worldwide attempts to forge US dollar bills exceed the 100,000 mark every year. However, none of these counterfeit banknotes
stand up to close examination.
In the history of paper money, no absolutely perfect counterfeits are known –except for one nearly successful fraud ofparticularly significant dimensions.
When the Hitler regime threatened to
run short of foreign currency at the endof the Second World War, operation“Bernhard” was launched, named for asabotage specialist whose first name wasBernhard. English banknotes with a denomination value of 135 million pounds
were printed, a sum which in 1944
equalled the value of the British Empire’s
entire gold reserves. Agents presented
these forgeries to international banks, forexample in Zurich and in London, and behold, even the Bank of England declaredthem to be authentic. Only when an aeroplane crashed in 1945 into the Mediterranean, resulting in several tons offorged notes being fished out of the sea,
was the fraud exposed; it was not only
aimed at procuring foreign exchange but
to an equal extent at destroying the

British currency. After the war the network of agents which was appointed
to distribute the counterfeit banknotes
and which had already spread as far as
South America was never revealed in full,and only part of the remaining forgedmoney was seized. Certain amounts were
found in Northern Italy, Austria andTurkey. This was one of the reasons thatlater prompted the British Government toissue new pound notes of noticeably different appearance as a precautionary
measure. To sum up, this criminal operation was of a perfection and perfidy thatwill hopefully remain unique in the history of paper money.
Compared with other 5quantities of paper,for example that required for newsprint
or magazines, consumption in the production of banknotes
is very low worldwide.
The German Central
Bank, the Bundesbank,needs only a mere 700
tons of paper per year
to produce new notes
to replace damaged
ones or money withdrawn from circulation. Of course when it
comes to the introduction of a new currency such as the Euro, things are completely different. But changeovers of suchmagnitude take place only on very rareoccasions: the issue of a complete newseries of banknotes has become a very
costly undertaking. In addition, the “stability” of a currency tends to be definedby its ability to keep its appearance unchanged for as long as possible.

In terms of the amount of paper used,
the production of banknote paper itself isrelatively insignificant, but its reputation
within the guild of paper makers is relatively high nevertheless. Banknote paper– which even today is normally produced
only from rags – with its water marks andcunning safety features and its consistently high quality, is still consideredsomething special, as indeed is the teamwork among the experts responsible forit. From preparation of the paper stock,the draft design – which today is generally supplied by renowned artists – to theengraving of the print cylinders and theactual printing process, this complex
procedure calls for an exceptional degreeof cooperation, skill, experience andexcellent technology. In this latter area
Voith and Sulzer have been involved
worldwide ever since the breakthrough ofpaper money in the 19th century. Approximately three dozen paper machines specially installed for the production of banknote papers around the globe since then,bear the name of Voith Sulzer. They havecontributed a great deal to the history of
paper money.

Published by:Voith Sulzer Papiertechnik GmbH & Co. KG
Editor:Dr. Wolfgang Möhle, Corporate Marketing,
Voith Sulzer Papiertechnik GmbH & Co. KG,
Tel. (++49) 73 21 37 64 05
Fax (++49) 73 21 37 70 08
P.O. Box 1970, D-89509 Heidenheim
http://www.voithsulzer.com
Editorial coordinator:
Manfred Schindler, D-73434 Aalen

Paper Technology Journal

Newsmagazine for theinternational clientele,
partners and friends of

Design, layout and typesetting:
MSW, P.O. Box 1243, D-73402 Aalen
Copyright 2/2000:
No part of this publication may be reproduced
or copied by any means whatsoever without
the express permission of the editor.

2/2000/20 MA Printed on chlorine-free bleached paper manufactured with Voith Sulzer Paper Technology machinery.

“twogether” is published twice annuallyin German and English. Contributions by
independent authors do not necessarilyreflect the opinion of the publisher.
Please address all correspondence andinquiries to the editor.