Paper Technology Journal

News from the Divisions:CompactPulper – the new generationof Voith broke pulpers.
The success story of Shandong Huatai
Paper and Voith Paper keeps on rolling.
Adolf Jass, Germany – complete
production line for packaging papers.

17

PrintFlex P – development of a newpress fabric concept.
Paper Culture:
Japanese Paper Blossoms Anew.

Contents

EDITORIAL
Foreword

1

Mixed Tropical Hardwood –a minor and declining source of fibre for paper

2NEWS FROM THE DIVISIONS
Fiber Systems: CompactPulper – the new generation of Voith broke pulpers

7

Fiber Systems: Rejects and residue disposal from recycled fiber plants –Europe as the pioneer in rejects handling systems

10Paper Machines: The success story of Shandong Huatai Paper
and Voith Paper keeps on rolling

15

Finishing: China’s first Twister – automated paper roll wrapping par excellence20

Trade fair and more... Voith Paper demonstrates its technological competence
and close relationship with customers

23

Paper Machines: Kimberly PM 96 – position for lang-term competitiveness

26

Paper Machines: NipcoFlex and TissueFlex –Shoe press technology for the dewatering of all paper grades

28

Paper Machines: Hengfeng PM 12 – new quality benchmark for cigarette paper

32

Paper Machines: Adolf Jass Paper Mill, Schwarza, Germany –another complete production line for packaging papers

36

Paper Machines: Zülpich PM 6 – still one of the most productive
paper machines for Testliner and Corrugating Medium

39

Finishing: Excellent threading performance achieved at Condat

42

Finishing: Voith Tail Threading pilot machine

44

Service: Strato Series – rubber covers in the paper machine

45

Service: Voith Process Solutions Seminar and Voith Paper Service
opening ceremonies in Kunshan and Dong Ying, China, October 22 to 27, 2003

48

Service: Voith Process Solutions –plant optimization by process analysis

52

Service: Voith Process Solutions – North American case studies

55

DuoShake – continues to be successful

58

Voith Fabrics’ PrintFlex P – development of a new press fabric concept
for improved surface uniformity and sheet dryness

60

Reliability beyond Equipment: “ahead 2004 – The International Customer
Conference for the Board and Packaging Paper Industry

64

PAPER CULTURE
Japanese Paper Blossoms Anew

65

Highlights

70

Title page:
Traditional productionof Japanese Paper.

1

Dear Customer, Dear Reader,
In our last issue of twogether (No. 16) I stated that the 10th business year of the “newVoith Paper” could develop into one of the best ever as far as sales is concerned. I am
now pleased to say that it will happen, and we appreciate the reception and confidence
we are receiving worldwide from the pulp and paper industry.
It’s also important to note that the close cooperation between Voith Paper andVoith Fabrics continues to show impressive results that will deliver innovative, unique
technology, products and services.
Focusing our strategy away from worldwide consolidation of the supplier network
toward growth through innovation is evidenced by the decision of the Voith Group
Hans Müller

Board of Management to invest in the most modern, up-to-date Process Technology
Center (PTC), which will be built in Heidenheim, Germany. The heart of this PTC
will be our pilot paper machine and its infrastructure, which will allow pilot trials todevelop processes and paper products that closely resemble mill conditions.
I’d also like to draw your attention to the article on page 2 that discusses the use of
mixed tropical hardwood as a raw-material base for the pulp and paper industry.
Much has been written and, unfortunately, misrepresented regarding this raw material
source. The article, written by Jaakko Pöyry, has been included in our magazine toshow the responsible behavior of the pulp and paper industry regarding its highly
valued worldwide resource – the forests.
I wish you all the best and enjoyable reading.

Hans Müller
on behalf of the Voith Paper Technology team

2

Mixed Tropical Hardwood –a minor and declining source of fibre for paper

Economic Growth will beperboard production prospects vary con-Fastest in Asia and Easternsiderably between regions, with a fairly

Europemodest growth for North America, Western Europe and Japan, but still significant

Petteri Pihlajamäki
Jaakko Pöyry
petteri.pihlajamaki@poyry.fi

Economic growth continues to be a major

growth potential for Asia, Latin America

driver for paper demand. Despite the cur-and Eastern Europe (Fig. 2). In relative

rent economic slowdown in the West andterms, the paper industry will growJapan, the global economy is expected tofastest in Eastern Europe (4.9 %/a), Asia

grow at a rate of 2.9 %/a in the longexcl. Japan (4.4 %/a) and Latin America

term. The long-term GDP growth will be(3.9 %/a). The main growth areas will

fastest in China, Asia-Pacific and Eastern

be China/the rest of Asia accounting forEurope including Russia (4-7 %/a), while

46 % of the projected global productionin North America, Western Europe andgrowth through 2015.

Japan the growth is expected to remain
at a much lower level (1.5-2.5 %/a).

This means that, due to the non uniform
growth of paper and paperboard produc-World demand for paper and paperboard

tion, the traditional supply areas such as

is expected to grow at a rate of 2.2 %/a,North America and Western Europe will

Hannu Hytonen

reaching 453 million tons by the year

become gradually less important. How-

Jaakko Pöyry
hannu.hytonen@poyry.fi

2015 (Fig. 1).

ever, these regions will continue to dominate the world paper industry, accounting

1

Because of the above mentioned differ-

for over 50 % of the global production byences in economic growth, paper and pa-

2015.

2

Forecast

Million tons
500

Rest of the World
400

Latin America

North America
Nordic countries

300

Rest of Asia
China

Rest of W. Europe

Japan

200

Japan
Eastern Europe
Western Europe

100
North America

Eastern Europe

China
Rest of Asia
Production 2000
Growth 2000-2015

Latin America
Rest of the World

1980

17/04

1985

1990

1995

2000

2005

2010

2015

0

20

40

60
80
Million tons

100

120

3

Fig. 3: Distribution of
the World’s Forests
by Major Ecological Zone.
 Boreal Temperate Subtropical TropicalWorld Fiber Sources

paper industry uses mainly pine, eucalypt

Mixed tropical hardwood is a generally

for Paper Making

and acacia for paper making. Mixed

accepted term referring to wood fromtropical hardwood (MTH) is used fornatural tropical forests. The term refers

Dependent on the climate (ecologicalpaper production mainly in Asia, thanks

to a specific characteristic of naturalzone), different wood species are avail-to the regions huge forests. Because oftropical forests, namely the large number

able as a fiber source for paper making

its growing paper production, the re-of wood species.

(Fig. 3). Paper maker distinguish be-

gion’s industry is facing new challenges

tween hardwood and softwood.

in meeting its fibre needs, i.e. some local

The main virgin fiber sources in Western/

forest and other fibre resources are

World Consumption of Paper-

Eastern Europe and North America for

scarce. As a result, Asia, particularly

making Fibers

paper making are spruce, fir, pine, beech,

China, will become increasingly depen-birch, oak and chest nut. South America

dent on imported fibre.

Cost-cutting pressures are one of themain drivers of fiber mix changes in the4

Forecast

Million tons
500

Fig. 1: World
Demand for Paperand Paperboard
by Region
1980-2015.

400
Recovered paper300

Non-wood
Sulphite
Unbleached kraft
Bleached hardwood kraft

200
100

Bleached softwood kraft
Mechanical and semi-chemical
1980

1985

1990

1995

2000

2005

2010

2015

Fig. 2: Paper andPaperboard Production by Region
2000 and 2015.
Fig. 4: World
Consumption ofPapermaking Fibre
1980-2015.

paper industry, though there are manyother factors involved, including paper
quality requirements, changing mill andprocess

requirements,

pulp

qualitychanges, increasing use of pigments/
fillers etc. In general, the share of mechanical/semi-chemical pulp is decreasing in all key paper industry productareas because of the growing use of recovered paper.

17/04

4

Fig. 5: Total BHKP Consumption in the Worldby Subgrade.
Fig. 6: Furnish Composition of Fine Paper.
5

Copy
Paper

Writing and
Printing Paper(uncoated)

Art Paper(coated)Weight (g/m 2)

80

70 -12070 -170

Softwood Pulp (%)

0 -15

0 - 20

10 - 60

Hardwood Pulp (%)

85 -100

80 -100

40 - 90

Filler (%)

17- 2510 - 25

10 - 20

Forecast

Million tons
80
70

Birch
60
Eucalyptus

50
40

Mixed northern
30
20

Mixed southern
Coating Pigment (%)

10
1980

1985

1990

1995

2000

2005

up to 60 %,AcaciaMixed tropical
2010
2015

based onbase paper

The total paper making fiber consumption

currently accounts for most of thehas an undesirable impact on the pulping

at 2002 is about 325 million t and it will

world’s MTH pulp production.

process, and ultimately on pulp and paper quality. In some cases, for example

be about 460 million t at 2015. It is important to know that recovered paper

Most of the MTH-pulp is used for thethe species with the highest density haveprovides already 50 % of the worlds con-production of fine paper. Fine paper is a

to be separated before processing the

sumption of paper making fiber. Bleachedgeneral term for Copy Papers, Woodfree

raw material mix. The big variations in

hardwood kraft consumption is also ex-

Writing and Printing Papers (uncoated)wood properties make it difficult to con-pected to increase and MTH contributes

and Art Papers (coated grades). The dif-trol and optimise the process, resulting

as one source among many others

ferent papers consist mainly of reinforce-in low yield.

(Fig. 4). Bleached hardwood kraft pulp

ment pulp (kraft pulp-long fiber), hard-(BHKP) consumption will grow fromwood pulp such as e.g. MTH-pulp (shortIndonesia is the only country where MTH

47.5 million t at 2002 up to 70 million t at

fiber) and filler material (calcium carbon-

is used in large-scale pulp production.

2015 (Fig. 5).

ate and/or clay). Further additives (starch,

Driven by the growing demand for fibredye, e.g.) and coatings on art paper (pig-in Asia, Indonesia’s pulp production isments, binders, etc.) are a must in order

expected to increase from 3.5 million

MTH Plays a Marginal Role into achieve further improvements on cer-tons in 2000 to 7.2 million tons in 2015.

Pulp and Paper Production

tain important paper properties (Fig. 6).

Pulp production provides, directly and indirectly, significant employment and in-

The world production of MTH pulp is

There are several reasons why MTH iscome opportunities for a large number of

estimated at around 3.5 million tons

not favoured from paper makers and pa-

rural people in remote areas. Despite the(Fig. 5). This is about 1 % of the total

per machine suppliers. One of the most

rapidly growing pulp production, the use

papermaking fibre supply (325 million

important is the large number of woodof MTH is expected to decrease in linetons) and about 2 % of virgin wood pulp

species, leading to large variations in thewith the increasing use of plantation-

production (161 million tons). Indonesia

most important wood properties, whichgrown acacia.

17/04

6

5

Fig. 7: Pulpwood Demand Scenario in Indonesia.

The main reason why MTH continues towas processed into sawnwood and one

be used in pulp production in Indonesia

third (37 million m 3) into plywood.

7
35
Scenario

Actualis that the plantation establishment and30

development programmes introduced in
Mixed Tropical Hardwood

the rapid development of the industry.

and Sustainability

Pulpwood demand has increased more
rapidly than the wood supply from plan-

Indonesia’s plantation development pro-tations, regardless of the plantation pro-gramme was launched in the 1980s andgrammes that all major companies havebecame widely applied in the early 1990s,

been developing since the 1980s.

making Indonesia a leading plantation

25
Million m3

the 1980s have failed to keep pace with

Plantation
Pulpwood
Supply20
15
10

MTH Harvest Requirement

5
1990

1995

2000

2005

2010 2015

forest country in Southeast Asia. Industrial plantation forest concessions (called
Mixed Tropical Hardwood

HTI concessions) with an area up to

pered by many factors such as insuffi-

Mostly Used in Sawmilling and

300,000 ha were granted to interested

cient funding, land ownership disputes

Plywood Manufacturing

parties. The pulpwood concession areas

and forest fires, and there is a continu-

consisted of different types of land andous challenge to intensify plantation de-

The estimated MTH volume used globally

forest, from tropical forests, already de-velopment to keep pace with the indus-

for pulp production is 13 million m3, i.e.

graded by selective cutting of plylogs andtry’s capacity growth. Political changes inabout 10 % of the total industrial use ofsawlogs, to open grasslands. Any larger

Indonesia have also put land-use issues

tropical wood. The balance is processedunlogged virgin forests were left out fromhigh on the agenda, as local people haveinto sawnwood and plywood, and used

the pulpwood concessions and smaller-

much more freedom and courage tomainly in construction, joinery and furni-

scale undisturbed forests within the con-speak for themselves than in Suharto’s

ture industries.

cessions were strictly protected, not al-

time. These changes were not anticipatedlowing their conversion into plantations.

in formulating the HTI pulpwood conces-

Production of tropical logs in ITTO (Inter-

As a result, most of the MTH pulpwood

sion policies and they have difficulties innational Tropical Timber Organization)

comes from conversion cuttings of de-coping with these changes.

producer countries, which include thegraded natural forests, which are mainly

great majority of tropical countries andreplanted by acacia and eucalypts.

forests, decreased to 121 million m3 in

The first Indonesian pulp mill operating
100 % based on plantation wood is al-

2002. Most of this wood (111 million m3)

Typically, only 30-50 % of the granted

ready in operation (the Musi mill in

was processed within ITTO producer

gross concession area was suitable for

Sumatra). The use of plantation wood iscountries and the balance (10 million m 3)

plantation establishment. The balance in-steadily increasing also in other mills.

was exported to other countries (mainly

cluded areas such as nature reserves, in-

There are different scenarios concerning

to Japan and the EU) for processing.

frastructure areas and low-quality land

the future acacia pulpwood supply andRoughly two thirds (74 million m3 ) of theunsuitable for planting. Since the 1980s,

MTH pulpwood requirement in Indonesia.

volume processed within ITTO countries

plantation development has been ham-

The scenario presented in Fig. 7 is con-

17/04

6

Fig. 8: Forestry Services of
Jaakko Pöyry Consulting.
Strategic Management Consulting Services● Business strategies and plans for forest-based businesses● Valuation, information memoranda and due diligence studies● Investor search, merger, acquisition and divestment services● Business restructuring and re-organisation services
Fibre Strategies

Forest Management

Wood Supply Chain● Corporate fibre strategies● Resource-based expansion opportunities● Fibre supply optimisation● Wood market studies and marketingstrategies● Wood price and cost analysis● Environmental assessments and audits● Bioenergy strategies● Sustainable forest management strategies
and plans● Forest inventory and GIS-based management
planning● Forest plantation development strategies
and plans● Seedling production and tree improvement
strategies● Carbon sequestration strategies● Wood supply and procurement strategies● Harvesting logistics systems analysis anddevelopment● Operations/efficiency improvement analysis
and monitoring● Reduced impact harvesting systems
development● Chain-of-custody systems development

Project Preparation and Implementation Services● Project identification/specialist opinion studies● Prefeasibility/feasibility studies● Project management and implementation support services● Project monitoring and evaluation services

theannually into forest plantations. Accord-

ed as deforestation, but as a change of

speed of conversion to plantation wood.

ing to the Food and Agriculture Organiza-

the type of forest.

The use of MTH in pulp production maytion of the United Nations, most of thedecrease also faster depending on cur-deforestation across the tropics was due

Jaakko Pöyry Consulting

rent/future planting rates in industrial

to the direct conversion of forest into

Services

plantations and economic availability ofpermanent agricultural land or pastures,

MTH pulpwood.

and to a lesser degree to the gradualService offering of Jaakko Pöyry includes

intensification of shifting agriculture.

independentsideredconservative

concerning

evaluation/assessmentofsustainability of forestry practices of for-

Tropical deforestation is driven by otherfactors than pulpwood plantations. Re-

Assuming that the average MTH pulp-

est industries (including pulp producers)

cent data concerning changes in thewood volume in degraded tropical forest

as well as other entities managing forest

global forest area indicate that the forest

is 50-80 m 3/ha, the area needed annually

resources. These analyses aim at com-area has remained unchanged or in-to satisfy the annual MTH pulpwood re-prehensive view on sustainability of man-creased in non-tropical regions. The net

quirement is some 160,000 - 260,000 ha.

agement of forest resources including

loss of tropical forest area during theThis means that the conversion of de-conservation and biodiversity, sustain-

past decade (1990-2000) amounted tograded natural forests into plantations

ability of wood production, health andabout 14.2 million ha annually, consisting

would equal only about 1- 2 % of the total

vitality of forests, soil and water quality,of a total annual loss of 15.2 million ha,tropical deforestation. Yet, it is important

global carbon cycles, socio-economic

including 1.0 million hectares converted

to note that this conversion is not regard-

benefits and cultural heritage (Fig. 8).

17/04

7

Axel Gommel
Fiber Systems
axel.gommel@voith.com

CompactPulper –the new generation of Voith broke pulpers
New paper machines today are getting faster and wider
all the time, with ever-increasing production tonnages, even forchallenging paper grades. This also means more exacting demandson the operating efficiency of broke pulpers, since these must

Wolfgang Müller
Fiber Systems
wolfgang.mueller@voith.com

ensure reliable pulping of broke at all times and whatever the circumstances.

17/04

8

Fig. 1: Previous AK design.
Fig. 2: New CompactPulper design.
Fig. 3: 3D presentation of the new CompactPulper.
Fig. 4: Chest widths: comparison between
conventional and new design.

At sheet breaks the broke pulper mustseem simple at first sight, but a closer

enabled intensive investigation ofreach full operating speed from start-up

look quickly reveals just how many

machine parameters which usuallyin the shortest possible time. The proce-boundary conditions have to be simulta-

cannot be changed in mill operation

dure is as follows:

neously taken into account in order to en-● Extensive mill trials and comparison

sure reliable operation:with the Technology Center’s trial

As soon as a sheet break is detected, the● Paper machine width and speed

results.

sheet is diverted directly into the broke● Paper grade, basis weight and location

pulper located ahead of the sheet break.

of the sheet break in the machine

Figs. 1 and 2 show the differences

At the same time the showers open, and● Pulping intensity and suspension level

between the conventional broke pulper

the sheet is wetted and pulled down with● Dwelltime

design and the new CompactPulper.

the water flow. In the meantime, the● Broke removal rate through the pulper

pulper rotors have reached full speed,

screenplate.

The trials clearly showed that a large partof broke pulping energy is used for mov-generating enough circulation energy todraw in the sheet, which is then rapidly

Additionally, the pulping consistency has

ing the stock round. Compared withpulped down and pumped off through theto keep within certain limits to ensure apulpers for slushing recovered paper orpulper screenplate.

reliable sheet draw-in, good pulping andvirgin fiber pulp, in broke pulpers thestable pump operation.

sheet is brought into the pulper in aclearly defined way. It has already been

Based on Voith’s long experience, withover 375 AK series pulpers delivered

The development project was carried out

thoroughly wetted on both sides by thesince 1990, the objective of this devel-on two levels due to the complexity of theshowers. This means that pulper dwell-opment project was to further increase

process and also the need for field trials:

time is reduced by the time otherwise re-broke pulper efficiency whilst at the same

● A full-size trial pulper, incorporating

quired for breaking down and wetting thethe new optimized geometry of thepaper when presented in bale form.The

CompactPulper, was tested in Voith

pulper chest can therefore be much

Paper’s Technology Center. This

smaller, as confirmed by the trial results.

time reducing investment costs.
Slushing conditions in the broke pulper
1

2

17/04

Fiber Systems

93

The smaller chest volume and the opti-

ings revealed a better pulping efficiency

In summary, the new CP CompactPulpers

mized flow provided by its new geometry,with the AK rotor compared with all otheroffer significant improvements:

as shown in Fig. 3, has meant pulping in-rotors investigated. Since the high shear● Savings in space thanks to the slim

tensity is up to 40 % higher for the samepotential of the AK rotor is fully exploited

installed power. The result is a signifi-

due to the improved stock movement, thecantlydecision was made to continue using it

bettersuspension

movement,

which in turn improves sheet draw-in andin future.

and compact pulper design● Up to 40% more pulper working width
for the same installed power (Fig. 4)● Maximum chest width 12 m
● More intensive pulping thanks to faster

pulping intensity.
The mill trials clearly showed, however,circulation and better rotor contact

A benchmarking comparison with popularthat optimum operation also depends on● Reduced splashing and better draw-inrotor geometries was also carried out

correct functioning of the showers andduring the development trials. The find-control system.

by using an optimized deflector design● Optimal exploitation of rotor
performance potential and less air

48

ingress into the broke system thanks

Chest width for one rotor [m]7

to good submersion of the rotor.

6

Like every new Voith product, the first5

CompactPulper was intensively monitored4

after commissioning. The assumptions
were shown to be correct and all3

25 CompactPulpers so far installed are
2

operating faultlessly. The good order in-

1
0

take since market launch of the CompactAK4 CP130

AK12 CP280

AK26 CP340

Pulper reflects customer confidence inthis technology.

17/04

10

1

Rejects and residue disposal fromrecycled fiber plants – Europe as the pioneer
in rejects handling systems
Up to now not everyone realizes that the costs for rejects
disposal can be up to 5 % of the earnings from paper production.
Until now, return on investment (ROI) has been the only decisive
criterion for capital investments in rejects handling systems.
This will change considerably once the legislation demanding
much more stricter standards for rejects disposal in Germany(from 01.06.2005 onwards) and Europe comes into force.
Bernhard Niemczyk
meri Entsorgungstechnik GmbH
Ravensburg Officebernhard.niemczyk@meri.de

Gisbert Wünsche
meri Entsorgungstechnik GmbH
Ravensburg Officegisbert.wuensche@meri.de“I don’t care about rejects, just get rid ofthem!” Not too long ago rejects handlingwas very simple: collection, basic dewatering, loading onto trucks, and transport
to a nearby landfill. The costs were low,
not much work was involved and the topic was of minor importance in planningand operating a paper mill.
Basically, the main objective has always
been to get rid of rejects before theycause problems. As long as there wereplenty of options for disposal, this objective was easy.
And now a few figures: a 1000 t/24 h corrugating medium mill using 100 % recy-

17/04

cled fiber can generate more than 50 t ofrejects per day (Fig. 1). Deinking plants
can exceed this amount many times over.
Landfill costs vary greatly from one
region to another. In Germany, for instance, they can range from 60 to 200 €per ton. With a recycled fiber consumption in Germany of about 11 million tons
per year, 500,000 tons of rejects need tobe disposed of every year.
But what exactly does “disposal” mean
today? Taking rejects directly to the landfill will no longer be possible in Europe in
the near future. In Germany, for instance,from 01.06.2005 onwards landfill will
only be permitted for material with less

Fiber Systems

11

Fig. 1: Automatic container loading station.
Fig. 2: Lightweight coarse rejects after
compacting.
Fig. 3: Heavyweight fine rejects from thecleaners.
2

3

Heavy coarse rejects are all kinds of metal of different shapes and sizes, stones,
wet strength waste paper that has not
disintegrated, wires etc.
Light coarse rejects (Fig. 2) consist ofbits of plastic, plastic foils, CDs, etc.

than 5% organic content. In Austria thisruling has been effective since 01.01.
2004.
The “export” of rejects for disposal incountries with lower standards involves
tremendous transport costs, and is only
possible to a very small extent becauseof regulations on waste shipment. As aresult, rejects from recycled fiber operations must generally be incinerated andonly the combustion residues can belandfilled.

What are the consequences of incineration? The rejects have to meet certain
quality requirements. What at first seems
to be a paradox is going to become amajor design criterion for recycled fiber
plants:● Inspection of the incoming raw
material will become more and more
important● With baled material the dewiring
efficiency will influence the required
technology for rejects handling● Removal of incombustible, inert
material such as metal, glass or sandfrom the rejects is essential● The metal fraction should be as clean
as possible to facilitate its recycling,
instead of disposal● Rejects dry content has a decisive
influence on suitability for incinerationand on the transport costs involved.
The main objective is still to get rid of therejects. Immediately, wherever and whenever they arise.
What exactly are rejects composed of?
First of all, there is a basic difference between rejects and sludge. Sludge is homogeneous, like for instance the residue
from deinking cells, from micro-flotation
or from primary clarification.
Rejects, however are not homogeneous.
They consist of coarse and fine rejects.
Coarse rejects are found in pulping andcoarse screening, fine rejects in the subsequent process stages of cleaning andfine screening as well as in the approachflow system.

The composition of the coarse rejects depends mainly on the type of pulping system: here one can distinguish between
systems that discharge heavy- and lightweight coarse rejects separately (e.g.
TwinPulp System) or systems wherethese are removed together. With the increasing use of drum pulpers the focus is
more and more on the latter option.
With fine rejects one distinguishes between light- and heavyweight, too.
Heavy fine rejects mainly consist of sand,glass, staples and other metallic officewaste as removed by HD and LD cleaners, as well as via the heavy junk traps of
combined screening and cleaning equipment (Fig. 3).
Light fine rejects from slot screening orlightweight cleaning contain fiber debris,stickies, wax, fillers, etc.
And now back to the main concern: how
can we ensure that all these types of rejects are got rid of at all times and in allplaces?
To answer this question we have to go
back and look at the available options for
disposal. Here we again come face toface with the increasingly exacting standards set by legislation and with the requirements for rejects quality.

17/04

12

Fig. 4: Reject compactors of theCompax series.
Fig. 5: Two Sediphant machines
installed in the new paper mill
Palm in Wörth, Germany for dewatering the fine rejects.
5

4Those rejects suitable for incinerationmust be discharged with the highest possible dry content, i.e. with the highest
possible thermal value (> 11 MJ). The sizeof the rejects must also suit the available
incineration technology. Additional drying
may be necessary. The percentage of organic contaminants in the incombustible,
inert material must be reduced to a minimum to enable its disposal.
Reusable material such as metal has tobe removed as clean as possible to makeit acceptable for recycling.
Designing a rejects handling system must
therefore reflect these disposal objectives
as well as the composition of the rejects
and where they are removed in the stock
preparation process.

17/04

The equipment used in the rejects handling system is, of course, the key tosuccess. Long life and adaptability to theindividual task, minimum maintenancefor ensuring maximum runnability are
the basic pre-conditions, as offered, forexample, by the Compax series of rejectcompactors (Fig. 4). These have beensuccessfully proven over many years
and in several hundreds of installations
worldwide.
The Sediphant (Fig. 5 and 6), is anotherhighlight among the many rejects handling machines available from meri. The
machine is a unique, patented combination of sediment separator and thickener,
ideally suited to separate out light andheavy fine rejects containing fibers anddewater them. The incombustible heavy
particles fraction is discharged with a low

moisture content (Fig. 7) and the lightweight rejects are pre-dewatered andcan be incinerated after further dewatering (Fig. 8). The filtrate has a uniform
quality.
The installation example at the end of thisarticle (Fig. 11) illustrates how an overall
rejects handling concept with intelligent
interplay of the conveyors and their reversing and bypass functions, as well as
smart layout, are all important factors forrunnability and reliable operation.
This and numerous other installations
clearly show how the handling of rejects
has developed within only a few years
into a complex task which can no longer
be accomplished by just installing individual machines. Detailed systems knowhow is required here.

Fiber Systems

13

Fig. 6: 3D function layout for the Sediphant.
Fig. 7: Heavyweight fraction after removal anddewatering with the Sediphant.
Fig. 8: Lightweight fraction from the Sediphantafter further dewatering.
Fig. 9: Example of disposal costs as a percentage of the earnings from paper production forvarious paper grades.
Lightweight contaminants
containing fibers

6

Inlet

7

8

Heavyweightcontaminants

Filtrate

Market priceTotal non-paper
per ton paper
production losses(typical values) (typical values)

Amount sent tolandfill per ton paper
at 60% dry content

Landfill costs
per ton paper at
100 Euro/tDisposal costs
as a percentage
of earnings

Newsprint

500 Euro18 %300 kg30 Euro6.0 %Corrugating medium

300 Euro

5%

83 kg

8 Euro2.7 %Graphic papers

1000 Euro25 %416 kg42 Euro4.2 %This is where meri Entsorgungstechnik
GmbH, a joint venture company between
Voith Paper Fiber Systems and meri Anlagentechnik, can help, using experiencegathered from 30 complex rejects handling systems in operation, and morethan 600 machines installed in the paperindustry. Meri provides the papermakerwith tailor-made subsystems as well as
special machine technology.
It should not be forgotten that the filtrates from the rejects/sewer zone represent an important interface with the water
system of the overall plant and therefore
they have to be taken into consideration
for a complete overall view.
Standards set by legislation are increasingly influencing the design of rejects
handling systems. Since specific disposal

costs nowadays can amount to around
5 % of earnings from paper production(Fig. 9), investment in an optimized rejects handling system should be viewed
with great interest from an ROI point ofview. The potential savings from an increased rejects dry content alone can betremendous (Fig. 10).

● Integrate metal separation and rejects
size reduction● Allow good accessibility for operationand maintenance● Regard the rejects handling as anintegrated system.

Example (Fig. 11)
When designing new plants, the following
should be considered:● Include rejects handling in the overall
concept as early in the design stage as
possible● Define present and future options forrejects disposal● Allow for future expansion of therejects handling system from theoutsetThis recent example describes a state-ofthe-art rejects handling system in a
newsprint production line where a drum
pulper is installed. The objective was toprepare the rejects for incineration in agiven particle size, and to minimize theincombustible content. The concept mustensure continuous pulper operation evenduring shutdowns in the rejects systemor when maintenance work is required
here.

17/04

9

14

Fig. 10: Relationship between disposal costs
per ton paper and dry content of the rejects goingto landfill.
Graphic papers
Newsprint
Corrugating medium

Initial reduction in size

Further
reductionin sizeFig. 11: Example of a complete rejects
handling system for preparing the rejects forincineration.
CompaxEuro
80
Disposal costs per ton paper

10Magnetic separators 1+2

70

Sediphant

60

Dinoscreen

50
40
30

Automatic containerloading station

20
10

30
40
50
60
70
Dry content of the rejects going to landfill (in %)A Dinoscreen is used for removingcoarse contaminants from the sewer
channel, dumping them into a separate
container. Rejects from HD and LD cleaning and from slot screening are dewatered in a Sediphant. The heavyweightmaterial from the Sediphant is also discharged into a separate container.
The complete rejects from the drum
pulper are collected on a conveyor. A
metal detector removes large pieces ofmetal, which are dumped into a container
by reversing the conveyor direction. A
magnetic separator, located above theconveyor, removes ferrous metal, also
dumping it into a container.
The rejects are then shredded into small
pieces in a Lion shredder. Rails allow theshredder to be moved into a maintenanceposition without interrupting operation of
the rejects handling system. A second
magnetic separator then removes any remaining ferrous metal from the conveyor
feeding the post-shredding stage. Here,
two Lion shredders operate one above
the other and at 90° to each other. These

17/04

Drum pulper
11

reduce the rejects to the required size.
The feed conveyor can be swung so thatthe post-shredding and the subsequentcompactor stages can be bypassed.
In normal operation the shredded material is dewatered with a Compax rejectcompactor, achieving a dry content of
more than 60 %. After compacting, therejects are distributed automatically into
four containers. A movable conveyor
equipped with sensors can fill every container from several positions so that all
four container capacities are used to thefull. The rejects are now suitably readyfor incineration.

Up to now, most of the examples of complex rejects handling systems are inEurope, but in other countries there is anincreasing need to pay more attention to
rejects handling. This is motivated either
by the need to reduce operating personnel or to simplify disposal and make it
more cost efficient.

15

1

The success story of Shandong Huatai Paper
and Voith Paper keeps on rolling
The business relationship between Huatai Paper and Voith Paper
started nine years ago when Huatai began to negotiate and purchase theirHigh Tech components for the new PM 1 of their new paper mill complex.
This relationship was extended into a
partnership, when the former Haindl
Schongau paper mill decided to replace
their PM 9 with a new modern One Platform Concept machine from Voith.
As PM 9 had always been in good condition and was producing top quality
newsprint paper at very high efficiency,
the decision was made to sell this machine.

PM 9 was completely dismantled, boxedand shipped to China to be reinstalled for
its revival at Shandong Huatai Paper millsite in Dawang.

units, the machine was completed. The
dismantling as well as the erection, commissioning and start up was performedby Huatai Paper together with Voith Paper.

A new building was erected to give hometo this machine and in short time it waspossible to start it back up again.

After a picture-book push button start up
good quality newsprint paper could be
produced from the first day.

With a face lift, as far as the optical appearance is concerned, and minor new

With an impressive efficiency of up to
97% including an average of 1.5 sheet

Wanting Zhao

Bernhard Häussler

Hannes Liebscher †Eduard Krasser †Joachim Huber

Paper Machines Graphic
wanting.zhao@voith.com

Paper Machines Graphic
bernhard.haeussler@voith.com

Paper Machines Graphic

Paper Machines Graphic

Fiber Systems
joachim.huber@voith.com
17/04

16

Li Jian Hua
President andspeaker of theboard of the
Shandong
Huatai groupstates“Voith Paper offers the most modern
technology as well as a first classservice to their customers. Since ourlong and close co-operation we developed a deep friendship between bothpartners Voith and Huatai. The very
successful commissioning of the
200,000 tons per year newsprint linefrom Voith elevated Huatai Paper into
the position of the number one newsprint producer in China with a very
good reputation.”

17/04

breaks a day and an average operating
speed of 1,180 m/min, newsprint paper
based on DIP is produced now for the
Chinese market at a rate of 150,000 tons
per year.
Within very short time, the paper fromPM 9 was established in the market as asuperior quality brand.
This success as well as the fast ROI put
Huatai Paper Group in the position toproceed with yet another project. The
Huatai PM 10.
Huatai PM 10
As the newsprint project in China with themost modern technology, it was completed, producing the first consecutive jumborolls without a break on 28 th July 2003,

20 months after signing of the contract.
Only with the philosophy of their close
partnership Shandong Huatai Paper andVoith Paper made this green field millproject a success. To date production has
proceeded well and the development of asuperior quality product has been confirmed.
On a site covering more than six square
kilometres, this turnkey project grew inan amazingly short time. The impressive
scale of this plant indicates the foresightand ambition of the mill to establish an
operation comprising leading edge technology to manufacture a high quality
product.
A well equipped Voith Paper Service Center have been established in the neighbourhood to support the total operation.

17
Technical data PM 10
Max. operation (layout) speed

1,600 m/min

Mechanical design speed

1,800 m/min

Wire width

7,100 mm

Trim width max. on reel

6,420 mm

Jumbo roll diameter

3,500 mm

Output

807 t/dWinder speed up to2,500 m/min

Roll diameter at winder up to

3,500 mmfinishing equipment with slitter winders
and the packing and roll transportation
line.

2

Fig. 1: Huatai Group.
Fig. 2: Huatai PM 10.
Fig. 3: Ecosoft calender.

Future plans include the addition of further paper machines. All necessary infrastructure is already in place.
After an intensive planning phase, Voith
Paper was awarded the order end of No3

vember 2001 for one complete production line for newsprint with the reference
grade of 48.8 g/m 2 . The Voith Paper
scope of supply also covered the complete deinking plant, stock and chemical
preparation as well as automation, theA trouble free fabrication and supply of
all components was assured by comprehensive control measures based on theapproved Voith’s Quality Management
according to DIN ISO 9001 and also following Huatai Mill’s standards. All quality controls, therefore, were based on
predetermined criteria and certificationplans, both with respect to sub suppliers
and own fabrication.
In order to achieve effective projectprogress, several liaison and coordination meetings were held on a mutual determined basis. The time available fromreceipt of order to operation of the paper
machine was extremely limited and,
therefore, required big efforts from allparties involved.
Professional organisation and excellent
cooperation between Huatai and Voith
Paper during the entire period were thebasis for the final success.
Huatai Paper and Voith Paper were put tothe test by an extremely tight manufacturing and pre-assembly schedule for thepaper machine including all components
and the civil work. A large-scale logistic
coordination of all suppliers had to bemastered within a short time. Site erection was done by Chinese contractors,
supported by Voith Paper supervisors.
The entire erection time of the equipment
was only 5 month, which is exemplary
and unique and is the result of goodco-ordination and co-operation between
Huatai and Voith Paper.

17/04

18

4

The basis for the successful erection andcommissioning was a thorough scheduling of all activities together with Shandong Huatai Paper, as well as the agreement on certain milestones and preconditions. A master plan was always broken
down in weekly and daily schedules for
all necessary activities. Progress was
openly supervised – thus a systematicand planned work was the result.
Based on the new Voith Paper Project-,
Erection- and Commissioning Management System, the erection personnel
completed the functional checks together
with the commissioning crew. As in allother Voith Paper start ups, open andhonest team work with Huatai engineers
was the rule for the efficient work.
Especially the training of the Huatai
Paper operators was performed very consciously. Individual groups were trainedin class room sessions in Heidenheim,
Krefeld and Ravensburg / Germany. This
classroom training was followed by apractical training in a papermill with a5similar paper machine. Huatai Paper’s
stock preparation operators were trainedon their new equipment in Huatai.

consecutive Jumbo rolls without any web
break. In early August 2003 an output of
more than 650 tons per day at a speed of
1,520 to 1,555 m/min had been reached,producing first class newsprint. Even
1,655 m/min, which is far above the layout production speed, have been run fora few hours in order to check the limitsof the line. The production line was optimized in the following weeks to operate
at this top speed on an average basis,
producing the designed layout tonnage
day in and day out.

All the training in Germany as well as the
project management, erection and commissioning period were marked by thecommon goal of Huatai Paper group andVoith Paper:“Paper on the reel as fast as possible andramping up the production as fast as
possible, making a good quality paper –quality tons on reel.”

The efficiency figures are remarkably
high and are close to its neighbouring
paper machine No. 9.

This common goal was achieved sincesigning the contract to “quality tons onreel” in only 20 month.
Voith Paper’s “One Platform Concept” isa proven guarantee for fast start ups,
short times to reach the maximum operating speed and guaranteed paper quality
and thus a quick return on investment.

Huatai Paper manufacturing
plant machine components● Complete DIP plant from drum pulper
to the finished stock storage tower● ModuleJet headbox● DuoFormer TQv● Tandem NipcoFlex press

The PM 10 started up on July 28 at a
speed of 1,408 m/min, producing eight
6

17/04

19
Fig. 4: Huatai PM 10 final section.
Fig. 5: VariFlex L winder.
Fig. 6: The start-up team.
Fig. 7: Thune disc filter (on the left) and
EcoCell post-flotation deinking (on the right).
Fig. 8: The TwinDrum drum pulping system(drum pulper on the left, drum screen on theright).

7● TopDuoRun dryer section, 7 dryer
groups (32 cylinders)● EcoSoft Delta calender● Sirius reel
● Dryer hood
● Hydraulics and pneumatics● Control and Instrumentation andautomation● Oil lubrication system● Sets of spare parts● Erection supervision● Commissioning and training● 2 two-drum winders VariFlex withparent roll storage● Packing and roll transportation system● Tail threading
A VTT Turbo conveyor, installed with a
Flip Tray transfer device, provided thethreading solution at the Huatai mill. The
installed Flip Tray picks the tail up fromdryer 32 and places the tail on to theconveyor. The VTT Turbo then transfers
the tail into the Ecosoft calender rope
nip. The VTT Turbo utilizes an internal air
turbine, driven by compressed air, to create a stable vacuum and helps to optimize the threading process throughout
the machine.
● Fabrics
With Voith Fabrics Quantum II AR running on the 1st dryer section and Quantum II on the remaining sections, theHuatai PM 10 has seen improved fabriclife. Due to the success on the dryer section, Voith Fabrics has received repeat
orders and provided the customer withquick delivery times and superior service.
Voith Fabrics’ forming fabrics have also
performed well on the Huatai PM 9.

The recovered fiber system
Fiber Systems was responsible for thecomplete recovered fiber system for
500 t/24 h deinked finished stock, fromthe drum pulper charging system, rightthrough to thickening, storage, waste
water handling, chemicals treatment andbroke handling.
The drum pulper charging system was
supplied by group member B+G and isdesigned to handle a mixture of 70%
AONP and 30% AOMG comprising up to
100% loose paper and bales. The equipment included the complete conveyor
plant with bale breaker.
The TwinDrum drum pulper consists of
two separately rotating drum bodies(drum pulper with integrated displacement core and drum screen) (Fig. 8).
TwinDrum’s pulping and screening results are clearly superior to other pulping
systems so far on the market as regards
deflaking, gentle fiber treatment andavoidance of contaminant size reduction.
The pulped stock passes from the TwinDrum system to two-stage high consistency cleaning (HiPro system) for efficient removal of sand and heavy parti-

cles. A two-stage forward-flow MC hole
screening system then follows, using a
MultiSorter (1.4 mm holes) in the firstand a Combisorter in the second stage.
MC hole screening is followed by threestage IC cleaning with EcoMizer technology. The cleaned stock is then fed to EcoCell flotation (Fig. 7, right) consisting offive primary and two secondary cells forpre-flotation and four primary and one
secondary cell for post-flotation.
High performance 4-stage LC slot screening with 0.15 mm C-bar screen baskets
follows the pre-flotation cells. This is
succeeded by thickening I and disperging
using a Thune disc filter (Fig. 7 left),Thune screw press and a disc-type disperger. Next comes HC oxidative peroxide
bleaching, post-flotation, thickening II,
reductive hydrosulfite bleaching and, finally, storage of the finished stock.
Apart from the above mentioned processequipment, Fiber Systems was additionally responsible for the complete chemicals
preparation of the DIP plant, basic
process and control engineering as well
as for erection supervision. Plant commissioning was undertaken in close teamwork between Voith and Huatai.
8

17/04

20

1

China’s first Twister –automated paper roll wrapping par excellence
For the new PM 10 at Huatai Paper, an
additional requirement by the customer● Grade and format changes:
on a recurring basis.

was state-of-the-art roll wrapping.
In view of the high capacity and fairly

Volker Schölzke
Finishingvolker.schoelzke@voith.com

The new wrapping line had to meet theconsistent roll parameters, with unchang-following demands:

ing widths for lengthy time periods, we● Capacity:

decided to replace the travelling paper

more than 120 rolls per hour.
● Roll width range:
600 mm to 2,200 mm.

dispenser normally used for spiral winding on the Twister with a compact stationary dispenser (Fig. 1).

2

17/04

Finishing

21

Fig. 1: Wrapping paper dispenser.
Fig. 2: 3-D layout graphic of Huatai.
Fig. 3: 3-D layout graphic of Twister 2-Line.
Fig. 4: Inner header disk robot.
Fig. 5: Outer header disk robot.

This dispenser comprises a feeding sys-

take inner disks from their respective

These 6-axis industrial robots are mount-tem with integrated gluer/cutter and fourstacks. Then one robot places the disk on

ed on a traverse, which gives them sevenwrapping paper rolls. It enables roll wrap-

the left face of the roll and the other onaxes of motion. As a result, the disk

ping in a single operation including end

the right face. Despite the fast operatingstack can be lined up in front of the ro-fold-over and gluing. Only with respect

cycle, this always ensures enough timebots instead of around them in a semicir-

to the stationary dispenser, the Huatai

for cleanly lifting the header disks off thecle. Not only does this look better; but

PM 10 roll wrapping machine layout dif-stacks (Fig. 4).

above all it greatly simplifies the deliveryof new disk stacks.

fers from the automated Twister 2-Line
installations at e.g. Steinbeis-Temming

The double gripper of the robots for theand SCA Laakirchen, and soon at Leipa.

outer header disks has a special adjust-The robots operate as completely au-

This is clearly shown in the 3-D layout ining mechanism to fit the different diame-

tonomous units, thus guaranteeing highFigs. 2 and 3.

ters and reliably separate the disks,reliability of the roll wrapping line. They

which are usually serrated. An additional

fit the header disks and labels with the

At Huatai the automated handling systemadvantage of this gripper design is that

greatest precision – roll by roll – to en-components are identical to the robots soeven the largest disks are supported oversure perfect wrapping.

far used in all Twisters for handling thetheir entire surface area on the header

inner and outer header disks and labels.

press, thus making bent edges a thing ofAnother interesting feature of these Voith

Two robots in the Huatai wrapping line

the past (Fig. 5).

wrapping machines is the cross-line roll
3

4

5

17/04

22

7

transport system. Since 1996 Voith haswith feeding system, the Twister concept

The Rolltronic module saves all the rollused high-speed plate type conveyors in-has been enriched with a new option.

data, both before and after wrapping, in

stead of the walking beam formerly used,

This ideally meets specialized customer

respective databases and prints out thewhich, due to its complexity, was proneneeds while benefiting from the experi-

shift log and production records. In theto breakdowns, wear and tear. Anotherence gained on numerous Twister instal-same way as the mechanical plant-

important argument for using plate typelations.

customizing, adjustment to specific cus-conveyors is that they enable precise roll

tomer needs merely required a change of

positioning in front of each workstation

After mainly dealing with the mechanicalfor winding, pressing, and labelling. This

aspects so far, it is time to take a look at

ensures high wrapping quality even withthe control system. Normally, the wrap-

Thanks to systematic application of thethe fastest operating cycles (Fig. 6).

ping line is connected to the mill comput-

Voith One Platform concept to the Huatai

module in a very well-proven software.

er, which keeps control of each roll fromPM 10 Twister installation, and smooth

As shown by the Huatai PM 10 roll wrap-

beginning to end via its wrapping andcommissioning teamwork between theping line, Voith's One Platform Concept

shipping data. An automation module,

customer and Voith, the maximum capac-

developed for paper machines does nottherefore, had to be developed for this

ity of more than 120 rolls per hour wasend at the Sirius or a standard reel, but

specific application. This comprises thealready attained at startup. In fact thealso includes the entire roll handling

Rolltronic, a powerful visualization andnormal 2 or 3-stage performance opti-

zone. Moreover, by changing only one

communications software module indi-

mization phase was not necessary at all.

module, in this case the dispenser station

vidually adjustable to communicate withWe are therefore particularly proud of the

any kind of mill computer system. How-

praise we received from Tian Zhiding,ever, the special possibilities in China as

Vice General Manager Huatai, during thementioned above enable operation of theofficial acceptance: “This fully automatedroll transport and wrapping line without aroll wrapping line meets all our require-mill computer.

ments. It is an excellent reference forFig. 6: Wrapped rolls.
Fig. 7: Let's roll!

Voith.”For Huatai the Rolltronic software was

6extended with a special module to take

The rolls are wrapped so well that they

over the tasks of a mill computer. This

arrive at the printers in perfect condition

module generates, manages and prints– obviously – even after the toughest

out the roll barcodes, and to this purpose

journey (Fig. 7).

is directly interfaced to the two Voith

17/04

VariFlex winders for automatically up-

PS: In Huatai I got the impression thatloading the cut roll dimensions. Afterthe robots felt very happy with theirweighing, each roll is then labelled withprofessional treatment by the friendly

all relevant data after wrapping.

operators!

23

Trade fair and more...
Voith Paper demonstrates its technological competence and close relationship with customers
China Paper Exhibition 2003
5 to 7 November in Peking

Anja Lehmann
Corporate Marketinganja.lehmann@voith.com

The China Paper Exhibition is the mostimportant trade fair for the paper industry in Asia and has been held every two
years since 1987. With a representative
presence at the fair this year, too, Voith
Paper has again succeeded in demonstrating its technological competence and in
making important contacts with customers.

17/04

24

Parallel to the fair, Voith Paper
organized a customer conference and apress conference to present there rangeof services to a broad public in the growthmarketplace of China.
Over 30 journalists from the international
technical press, the local daily newspaperand economic journal press as well asfrom the local television station accepted
Voith Paper’s invitation to the press conference.
Dr. Hans-Peter Sollinger, member of theManagement Board, underlined the growing importance of the Chinese market for
all Group divisions. Voith Paper took thistrend into account at an early stage by
considerably increasing the number of
employees in China over the past few
years and by expanding the local production and service locations.
Numerous questions from the journalists
concerning the One Platform Concept
showed the active interest in the strategies of Voith Paper for the Chinese marketplace.

17/04

25

At the customer conference,
Voith Paper demonstrated its processcompetence for graphic papers, board
and packaging papers as well as specialty
papers. Since 1997, Voith Paper has been
awarded 17 orders in China for new,state-of-the-art paper machines and has,
therefore, been able to establish itself
successfully in China.
Over 250 participants listened to thetechnical papers with great interest. They
were presented in Chinese by experts
from our office in Shanghai.

At the evening banquet, to which
150 major customers and government
representatives were invited, they enjoyed not only culinary delicacies of theChinese cuisine, but also musical highlights of popular Chinese music.

17/04

26

Kimberly PM 96 –position for long-term competitiveness
Stora Enso North America is the leading manufacturer ofcoated and supercalendered printing papers. In line with thecompany’s worldwide strategy of keeping its position as a leading
producer in the paper industry, it was decided to go ahead withthe rebuild of PM 96 at its facility in Kimberly, WI, USA. The rebuild
would significantly improve Stora Enso’s position for long-termcompetitiveness in the North American market place.
Mark Auger
Voith Paper, Appleton, USA
mark.auger@voith.com

The original PM 96 rebuild project atVoith would also supply start-up andKimberly Mill was suspended in 2000

erection services, training and spares forduring the acquisition of Consolidated

the project.

Papers, Inc., Wisconsin Rapids, WI, by
Stora Enso North America (SENA).

The target was to directly improve sheet
quality and would include a DuoFormer D

The major equipment for the machine re-twin wire top former, which would be in-build had already been purchased fromstalled on the 242-inch wide fourdrinier

Voith Paper, but had not been installed.

machine. The existing headbox would be
rebuilt, and two new VPS 20 pressure

17/04

In the fall of 2002, with SENA’s new

screens would be added in the approach

strategy in place, Voith was given the go-

flow, improving screening capacity andahead to continue the rebuild project.

fiber yield.

Paper Machines

Reconditioning of the headbox would bedone at Voith Paper in Appleton, Wiscon-

27

Asko
Hyttinensin during the shutdown to rebuild PM 96.
When the headbox was disassembled andcleaned, shortly after its arrival at Voith’s

Sr. Vice
President,
Strategy,
Investment
and M&A

facility, unexpected rework of the mounting plates was needed. The machine shop
at Voith Paper’s Appleton facility was
fully qualified to handle these unexpectedobstacles and repairs were made without
When faced with the task of rebuilding

significantly affecting the overall sched-

the No. 96 paper machine, the mill’s pro-ule.

ject team faced a number of difficult
choices in order to keep within very tightThe rebuilt headbox and the new Voith

budget constraints.

DuoFormer D were installed on what
could be considered a model shutdown.

The original Dominion paper machine, in-At start-up, salable production was quick-stalled in 1979, had a Voith W-type head-ly achieved and the important gains inbox. A decision had to be made whether

paper quality, expected in CD basis

to rebuild the original headbox or pur-weight profile, fiber angle and formation,chase a new one. After a thorough struc-quickly attained.

tural analysis, using a finite element
model, it was determined that a special

The Appleton facility is a valuable re-reinforcing would have to be installed forsource for Voith Paper’s customers in

the headbox to meet the new design con-

North America. The close co-operation

ditions.

between the SENA Kimberly mill andVoith Paper personnel, in using this fa-

The choice was made to rebuild the exist-

cility to its potential, resulted in a cost

ing headbox as originally planned. Thiseffective project of which everyone canrebuild would incorporate the latest in

be proud.

Profilmatic M dilution control technology.

“The rebuild of the Kimberly PM 96 is
an integral part of SENA’s Profit
Enhancement Program launched in
2002 which consists of machineclosures, product transfers, workforce
reductions, and significant capital
improvements totaling 250 Mio US$.
Initial performance of the rebuild production line shows us that our targetsof quality and productivity will be met.
During this project, the close cooperation together with Voith helped us
meet our goals.”
Sean
Wallace
Manager
PM 96 line
and rebuild
projectmanager“As a result of the rebuild, we havesignificantly improved our quality,
further enhancing our ability to be

The headbox would receive new state-of-With the rebuild completed on May 10th

the-art actuators as well as a new slice

2003, the PM 96 production line is now

lip and general modification to incorpo-

producing coated paper at quality levels

rate the latest in ModuleJet technology.

exceeding the Stora Enso planned targets.

our customers’ first choice.”

17/04

28

NipcoFlex and TissueFlex –Shoe press technology for the dewateringof all paper grades
The important technological and economic advantages have
expanded the use of shoe press technology to the dewatering of all paper
products from pulp to tissue. Whereas the development of NipcoFlex technology began in packaging paper machines 20 years ago, this technology
can today be found in virtually all applications for the mechanical dewatering of the paper web in new and modernized production systems. The portfolio offers an economic solution for increasing productivity and efficiency
Dr. Jens Müller
Paper Machines Graphic
jens.mueller@voith.com

for any requirement, whether a rebuild or a new machine. The advantagesof shoe press technology are now also utilized in calendering in the paperindustry.
Application range

vidually adapted to the technological requirements of the production process

Since the introduction of closed shoe

concerned and the pressure shoes arepresses in the paper industry in 1984,

manufactured accordingly. The pressure

over 400 shoe presses have been put into

profile is designed for gentle dewatering

operation. Of these, Voith has received

for a uniform sheet structure with as highorders for 280 systems (Fig. 1). The sizea bulk and dryness as possible. In theof these systems is between 2 m to al-

NipcoFlex Roll (Fig. 2) the pressure shoe

most 11 m paper width in the press nip.

is pressed-on by individual loading ele-

Equally large is the range of the speeds

ments. The pressure shoe is generallythat have been implemented. These ex-made in two parts. The top and bottom

tend from 50 m/min in pulp dewatering

are thermally isolated from each other in

up to 2,000 m/min on tissue machines.

order to extensively avoid deformations
due to temperature. To achieve the mostGraphic paper

favorable inlet geometry for the press
sleeve, the pressure shoe is shifted to-

17/04

The first shoe press for graphic papers

wards the ingoing nip. Shortly after thewas put into operation in 1995. The bene-

outgoing nip, cool lubricating oil is ap-

fits of shoe press technology have led toplied to the inside of the sleeve. A large

the fact that today more than 100 Nipco-part of this lubricating oil is removed out

Flex Presses are used for the productionof the oil sump that forms ahead of theof these grades. In contrast to a conven-ingoing nip. The other part of the lubri-

tional press nip, the shoe press offers thecating oil serves for hydrodynamic lubri-

possibility of varying the pressure in the

cation between pressure shoe and press

press nip. The pressure profiles are indi-

sleeve. If the production speed, linearPaper Machines

29

Fig. 1: Application ranges of NipcoFlex shoepresses:graphicboard
packagingtissuepulp.
Fig. 2: NipcoFlex Press NFR in top position.
Fig. 3: Pressure shoe with additional
lubrication.
Fig. 4: NipcoFlex and press roll.
1

2

Design speed [m/min]

2500
2000
1500
1000
500
0
2000

4000

6000
8000
Wire width [mm]10000

load and nip width require it, additional
3

lubrication (Fig. 3) can be applied in thepress nip.
Board and packaging
As mentioned at the beginning, the use of
shoe press technology began with the
production

of

board

and

packaging

grades. Almost all new machines forthese grades are equipped with at least
one shoe press. Shoe presses are also integrated into the press sections during
the modernization of many board andPress roll

4

packaging paper machines. The pressure
profile and linear load are selected taking
into account the technological requirements. These, together with the installation geometry in the framing of the press
section, define the shoe press module. In
particular for the modernization of machines with a small to medium trim width,the use of press rolls as a backing roll for
the NipcoFlex proves useful (Fig. 4). For
the press roll as a backing roll, all possi-

NipcoFlex roll

17/04

30

Fig. 5: Pressure profile of a conventional press
nip and a TissueFlex press nip.
Fig. 6: TissueFlex.
56
Suction press roll

TissueFlex Press

Pressure [MPa]

3

2

1

0
0

20

40

60
80
Nip length [mm]

90

100

120

ble roll cover variants from rubber to ce-

the loading of this press sleeve over thefunctional parts the well proven technolo-

ramic can be used as for the Nipco P

concave pressure shoe. The advantages

gy of the NipcoFlex has been taken overRoll. The press roll is a compact unit thatof an extended press zone permit gentle

from packaging paper and graphic paper

eliminates the bolted connection between

dewatering with flat pressure gradients

applications (Fig. 6). The flexibility of theroll head and body. A further advantage

and low max. pressures compared topressure shoe and the type of pressureof the NipcoFlex and press roll in multi-

conventional presses. The pressure pro-shoe loading by individually adjustableroll presses is the use of CARB Bearing

file in the nip can be established by thefront-side and drive-side loading cylin-

Technology. In this way, efficient shoe

shoe contour and is particularly charac-

ders ensure an even moisture profile.

press modules can be integrated into

terized by the steep pressure drop in thecompact framing of the press sections. It

outgoing nip (Fig. 5). This is not possible

goes without saying that press rolls canwith conventional rolls and permits thealso be used in many graphic paper ma-

minimization of rewetting. Particularly in

Through the economic advantages ofchines as well as in pulp dewatering.

the production of tissue – where maxi-

shoe press technology and the high dry-mum specific bulk in addition to highnesses, NipcoFlex Presses are increas-

drynesses is required – this is of great

ingly used for pulp dewatering. Thissignificance. The maximum linear loads

applies both to new machines and to the

One of the latest developments is the use

depend on the loadability of the Yankee

rebuild of existing installations. Due toof shoe press technology in the produc-

dryer and are up to 200 kN/m.

the high linear loads required and the, in

TissuePulp

many cases, large working widths of thetion of tissue. Ten TissueFlex are currently in operation and another system will

To meet the special requirements of tis-

pulp dewatering machines, the Nipco P

start production this year.

sue production, the loading unit, theRoll is suitable as a backing roll for thepressure shoe and the flexible QualiFlex

NipcoFlex shoe roll. The Nipco P Roll

A characteristic feature of a TissueFlex

press sleeve have been specially further(Fig. 7) unites the advantages of posi-

module is the flexible press sleeve anddeveloped for use with tissue. On othertion-stable support with the features of a

17/04

Paper Machines

31

Fig. 7: Longitudinal section of a Nipco P Roll.
Fig. 8: NipcoFlex Calender.
7

Tender
side

Drive
side

ender is characterized by the functional
separation of the main operating parameters of nip pressure and dwell time in thenip. This allows specific thermoplastic
deformation of the paper and board.
Here, too, the possibility of varying thepressure profile in the nip is of decisive
importance. The first commercial installation went on stream at the beginning of
this year. Intensive research and pilot tri-

Bearing
housing

Roll
shell

Support Pressure
beam
oil

Loading
element

Oil return

Gear box

als are being conducted at the moment inorder to evaluate the potential of shoepress technology for further calendering

8

applications.
Outlook
Shoe press technology is today state of
the art in the dewatering of board andpackaging papers as well as graphic papers. This is proven by the success ofover 400 shoe presses in operation forthese grades. For the newer applications,pulp dewatering and tissue, the trends
are clear: in addition to the very imporconventional Nipco Roll on which the rollequally large pressure areas, which en-tant increase in dryness and productivity

sleeve is hydrostatically supported by hy-

able the joint supply of hydraulic oil tofor the user, technological result can be

draulic loading elements. The fact thatthe rolls with one pressure line.

improved still further with shoe presses,
especially for tissue. The latest develop-

the Nipco P Roll sleeve is directly supported in the plane of the bearing center

Calendering

ment, the use of shoes presses in calendering, will certainly still require further

distance makes it independent and position-stable with respect to the unavoid-

Shoe nip technology is now also used fortrials and also operating experience.

able cross shaft deflection. This in turnthe finishing of board. On the basis of the

However, the significant advantages of

permits the most uniform linear load dis-

proven NipcoFlex technology, the Nipco-shoe press technology have already been

tribution in cross direction of the press

Flex Calender (Fig. 8) has been devel-

confirmed today: the possible variation ofnip. The loading elements in the Nip-

oped. In contrast to conventional softthe pressure in MD as well as the inde-

coFlex and Nipco P are characterized bycalender technology, the NipcoFlex Cal-

pendence of nip width and linear load.

17/04

32

1

17/04

Paper Machines

33

Hengfeng PM 12 –new quality benchmark for cigarette paper“We want to become China’s leading manufacturer for
cigarette papers, both in quality and quantity.” With this statement,
Mudanjiang Hengfeng Paper contacted Voith in the summer of2001. A little less than two years later, at the end of June 2003,
the PM 12 started production at 80% of design speed and washanded over to the customer after successful trial operation on
July 8, 2003. The official inauguration with a festive ceremony
Roland Pechtl
Special purpose machinesroland.pechtl@voith.com

was on August 8, 2003.
The contract
Voith was able to demonstrate its systemcompetence also in the area of specialty
papers. The scope of responsibility included the complete production line fromchemical pulp preparation to winding, including secondary plants, broke preparation as well as chemical additives metering and fiber recovery.

The project
The project managers, one each from thecustomer and supplier, had to face twolarge challenges.
The first task was to meet a very ambitious schedule – just about 17 months
would elapse from project start tosaleable paper. The difficult climatic con-ditions were an additional problem. For
example, the necessary data for thebuilding had to be available within a very
short period of time to allow completionof the building in time before winter began. In addition, it was necessary tostore all rolls with temperature-sensitive
covers on the construction site before thefirst frost.
The second task was not as obvious, but
the basic condition for success. How do
the project managers ensure smoothcommunication between specialists fromvery different cultures?
An interesting observation was made in
the course of this project: The teams
from the customer and supplier became
one team within just a few weeks. Thisteam, composed of competent experts,
pursued a common goal in a professional

Fig. 1: Mudanjiang Hengfeng
Paper Group Co. Ltd.
Fig. 2: Layout PM 12.

2

17/04

34

manner. The success and the highlights
mentioned here are a consequence of thissymbiosis.
During the first meetings it alreadybecame clear that the communication
between the customer, supplier and local
engineering contractor worked excellently.
Based on a jointly optimized delivery
schedule, it was possible to start erection
three weeks earlier than planned. The
erection work, carried out by the customer and supervised by Voith personnel,
was very soon far ahead of schedule.It
was, therefore, possible to complete erection at the construction site eight weeks
ahead of the scheduled date, managed
excellently by the customer.
The startup process already promised tobe record-breaking: after starting at 80%
of max. operating speed, it was possible

to produce cigarette paper of high quality
at 100% max. operating speed after only
eight weeks. Only 5 months after startup, Mudanjiang Henfeng Paper produced
high-porosity cigarette paper on its PM 12
at a speed that is 15% above its layout.
On the one hand, this is due to the technological competence of the customer
and its highly qualified personnel, andon the other hand it is due to the provenand at the same time innovative machine
concept.

A highly efficient cleaner plant, operating
according to the EcoMizer concept, as
well as the MultiScreen pressure screen,especially designed for low-pulsation anduniform stock throughput ahead of theheadbox, ensure a very good uniformityof the stock suspension ahead of theheadbox and in the machine direction paper profile. The use of ComMix for stockcomponent mixing and HydroMix for thenecessary stock dilution additionally reduces the stock volume in the systemand, therefore, allows fast grade changes.

The machine concept

A RollJet K headbox ensures uniform distribution of the stock across the machine
width. Just as the freeness and the
aproach flow system are important for
uniformity in machine direction, theheadbox is the decisive link for uniformity in cross direction. Hardly any othersupplier beside Voith can offer a productin this area that is as mature and perfected. This headbox is still being developed

On two lines for long and short-fiber
pulp, the customer is able to make use of
the advantages of the TwinFlo refiners in
an excellent way: in order to maintainporosity within the narrow limits required, a freeness value that can be exactly adjusted and, above all, is constantover time is of fundamental importance.

5

4

17/04

35

Technical data

Fig. 3: Hengfeng PM 12.
Fig. 4: TwinFlo double disc refiners.
3

Paper grades

cigarette paper

Sheet weight

25 - 45 g/m 2

Wire width

3,800 mm

Untrimmed working width

3,300 mm

Design speed

600 m/minOperating speed

190 - 350 m/min

Theoretical gross production

41 t / 24 hFig. 5: SpeedFlow.
Fig. 6: Final section PM 12.

further, because the rectifier roll can offer advantages especially with stock of ahigh freeness.
The high requirements for cigarette paperon porosity and formation at the sametime are a challenge for wire section dewatering. In order to achieve optimum
formation, a DuoShake is used. The benefits of this reaction-free shaking unit,
which is unique on the market, were soconvincing for Hengfeng that the existing
shaking unit at the PM 10 was replaced at
the same time.
The Combi 2 press is characterized by
the closed web run from the wire section
until after the second press nip. Hence,
the first free draw is after completion of
mechanical dewatering. Due to the low
sheet weight, high paper strength is thebasic condition for high machine efficiency. The following marking press is feltless and includes the Nipco technology.

Thus, the linear force and, therefore, theintensity of marking can be adjusted overa wide range – and with roll lives that are
two to three times longer!

with the paper quality, also improve themachine efficiency and production line
efficiency.
Perspectives

Small dryer groups and sheet stabilization ensure the maximum machine efficiency also in the dryer section. A SpeedFlow ensures a uniform application ofglow salt and size. The proven reel ensures an excellent wind-up quality. In
addition, Voith is responsible for broke
preparation, the chemical additives
preparation and metering as well as fiber
recovery.
Voith Fabrics has an important share in
the high quality of the end product. For
example, one hundred percent of thepress felts and dryer fabrics are from
Voith Fabrics. In the press section,
Omega 2 felts are used, and in the dryer
section, the Velvet and Quantum II dryer
fabrics. These innovative products, along

With Voith, Hengfeng have found a partner who is available for technologicalsupport even after the guarantee period.
This is particularly important for specialty papers. We are therefore very pleased
that Hengfeng appreciated our performance with the placement of a subsequent order in September 2003. From
autumn 2004, the new PM 14 will produce filter wrapping papers.
After Minfeng PM 18, Voith again proved
with Hengfeng PM 12 that Voith is thefirst-choice supplier for cigarette paperlines. At the same time, Hengfeng took along step towards their goal of becoming
the leading producer of cigarette paper in
China.

6

17/04

36

Adolf Jass Paper Mill,
Schwarza, Germany –another complete production line
for packaging papers
A total of four orders received by Voith within one year
for the delivery of packaging paper production lines underline
impressively the customers’ high confidence and Voith’s processcompetence in the field of packaging papers.

Karl-Theo Wetzler
Paper Machines
Board and Packaging
karl-theo.wetzler@voith.com

After Voith had won three orders forthis design has almost become standard

packaging paper production lines sinceforDecember 2002 (Cheng Loong/Taiwan,

Schwarza mill will be the first to use thisVarel/Germany and Emin Leydier/France),

advantageous design in “packaging paper

the most recent order in this impressive

machines”.

“graphic

paper

machines”,

theseries was signed by the German paper
manufacturer Adolf Jass in late November 2003. The paper mill Adolf Jass

Stock preparation

GmbH & Co. KG, Fulda, Germany, placed

Dr. Hans-Ludwig
Schubert
Fiber Systems
hans.schubert@voith.com

an order with Voith for the delivery of a

Schwarza’s stock preparation system iscomplete state-of-the-art production line

designed for a capacity of 1,300 t / 24 h

for testliner and corrugating medium

finished stock from 100% recovered pa-

from 100% recycled furnish. The orderper. The entire process equipment – from

includes the stock preparation equip-

bale dewiring and conveying to pulping,ment, the paper machine, and a winder atfollowed by screening, fractionation andthe end of the process.

thickening, as well as process water
treatment and rejects handling – will be

The new line will be set up as a greenfield

supplied by Voith.

mill in Rudolstadt-Schwarza, Thuringia,

17/04

Germany. This investment will be not

The bale dewiring equipment, consisting

only a milestone in the history of Adolfof only one unit, is being supplied by B+G

Jass Paper Mill, but also a decisive devel-

Fördertechnik, and will be capable of han-oping factor for the region around the

dling the full capacity of about 120 recov-

mill location. The new mill is expected toered paper bales per hour. Proven B+G

create more than 200 new jobs at the lo-

conveyors are used for feeding the bales

cation and more than 250 additional new

to the dewiring equipment and to thejobs in the region.

drum pulper.

Based on the One Platform Concept, theIn addition to the mills in Düren-Nieder-

new line, same as the three lines orderedau, Burg, Hürth and Schwedt, the Twin-

earlier, will be built according to Voith

Drum at the Schwarza mill will be thePaper’s industrial design standard. Since

fifth of six TwinDrum pulping systems

LF refining

StorageThickening

SF heavyweight cleaning37

LF slot screening

LF heavyweight cleaning

Fractionation

Hole screening

Dump chest

High density cleaning

TwinDrum pulping system

Raw material feed

Paper Machines

Fig. 1: Simplified flow sheet of the stock
preparation system at the Schwarza mill.

Rejects thickening

Sludge thickening

Water cleaning

operating or planned to be installed infiber fractions. While the short fiber frac-

The stock preparation philosophy used inGermany. With a capacity of 1,300 t / 24 htion will be clean enough to be justthe Schwarza mill will ensure the re-of finished stock, Schwarza will operatepassed through cleaners before being

quired end product quality is achieved

the TwinDrum pulper with the highest

thickened, the long fiber fraction is first

without the need for dispersion.

pulping capacity up to now.

fed to EcoMizer cleaners and then to a

The drum pulper’s principle has been

three-stage LC screening system with

The rejects handling machines, such as

0.20 mm slots.

magnetic separators, shredder and compactors, will be supplied by Voith Paper’s

described in detail in twogether 9.
Jass has thus adopted a simple, yet clear

joint venture partner meri. For water

Based on the positive experience with thestock preparation concept with the aim oftreatment the well-known DeltaPurge and

TwinDrum pulping system at the Burgremoving disturbing components fromElephant units have been selected. For

mill, two-stage hole screening with an

the stock as early as possible. Conse-

sludge thickening, a gravity table and a

MSS screen (1.6 mm holes) in the firstquently, screening in the approach flow

Thune screw press will be installed.

stage and a Combisorter in the second

system is merely a policing function.

stage will be used. This concept ensuresefficient, cost-effective and space-saving

By installing Voith Bagless disc filteringcoarse screening.

for thickening the short and long fibers,

Paper Machine

Jass has selected the most advanced disc

The forming section of the Voith paper

After pre-screening, an MSF fractionatorfilter technology available, as presented

machine is equipped with a DuoFormer

separates the stock into short and longin detail in twogether 16.

Base including a two-layer MasterJet

17/04

38

Fig. 2: In the presence of Jürgen Reinholz,
Minister of Economy for Thuringia Land,
Germany (3rd from left) and other guests, thefoundation stone was laid by Jass company
representatives Mrs Jass-Teichmann,
Adolf Jass (4th and 5th from left), Angelika
and Holger Prinzhorn (outside right).

the after-dryer section. The machine and2the main components of the stock preparation system will be equipped with thecondition monitoring system of Voith
Paper Automation.
The order package also includes twocomplete sets of machine clothing supplied by Voith Fabrics for the forming,press and dryer sections.
The paper machine will produce testlinerand corrugating medium in a 75-125 g/m 2
basis weight range. The daily production
will be 1,300 tons at a maximum operating speed of 1,400 m/min.
headbox and a ModuleJet dilution water

wound on a Sirius reel which is equipped

The order for the delivery of this packag-

system for the bottom layer. This means

with a centerwind drive and a RollMastering paper machine for Adolf Jass under-

optimum CD profiles and strength prop-

roll hardness control, allowing top-quali-lines impressively Voith’s leading posi-

erties, while ensuring an economical usety parent rolls of 4,400 mm diameter totion with regard to packaging paper tech-of raw materials. The DuoCentri Nipco-

be wound. An automatic roll transport

nologies. The first in an impressive series

Flex press technology guarantees excel-

system between Sirius and winder is in-

was the order for an entire production

lent runnability and high dryness.

stalled at the end of the process. A fullyline, from stock preparation to finishing,automated VariFlex L winder with flying

from the Taiwan paper manufacturer

The single-tier TopDuoRun dryer con-splice technology rounds off the perfectly

Cheng Loong in December 2002. In May

cept is used for the entire pre-dryer sec-

tuned One Platform Concept.

2003, two orders from the European market followed: a paper machine for Varel

tion and the first three dryer groups ofthe after-dryer section. The last group of

Besides, a Voith automation package will

Paper Mill, Germany, as well as a produc-

the after-dryer section is designed as abe delivered. In addition to the basic

tion line for Emin Leydier Paper Mill in

two-tier CombiDuoRun. In addition to

package for the machine control system,

Nogent-sur-Seine, France. The new pro-other Voith components, DuoStabilizers

allowing optimal control functionality, theduction line for Adolf Jass Paper Mill inand ProRelease boxes are also installed

automation package also includes the

Schwarza, Germany, rounds off a highlyin the dryer section.

Profilmatic M CD profile control system

successful year and confirms the paper

for the MasterJet headbox, a Module-industry’s confidence in reliable tech-

A SpeedSizer unit is used to achieve

Steam steam blow box for the press sec-

nologies well tuned from the raw material

uniform film application. The web istion and ModulePro nozzle dampers forto the final product.

17/04

Paper Machines39

1

Zülpich PM 6 –still one of the most productive paper machines
for Testliner and Corrugating Medium
For many years now, the name of Kappa Zülpich Papier
has been standing for a highly successful papermaking company.
The philosophy of Kappa Zülpich’s management is to consistently
optimize both performance and efficiency of the two paper machines in Zülpich. This applies especially to PM 6, which has been
optimized in the past years, both by Kappa Zülpich itself and in
Erwin Holzinger
Paper Machines
Board and Packaging
erwin.holzinger@voith.com

close cooperation with Voith. With a specific production rate of
221 tons per meter working width and day at a basis weight of
140 g/m2, PM 6 is today’s most productive machine in the world.

The Kappa Zülpich Papier

cessful and well-established international

Company, Germany

competitor.

Zülpich has a long papermaking tradition.

On two production lines, Kappa Zülpich

As early as 1873, the first paper had been

Papier produces testliner and corrugatingproduced at this location. Over a long

medium for the corrugated board indus-

period of time, straw was used as raw

try. PM 4, which had been installed inmaterial, before they started to produce

1970, was adapted to the increasing mar-corrugating medium base paper from re-ket requirements by rebuilds in 1977 andcycled furnish in 1962.

1991. In 1996, PM 6 was taken into operation. Both paper machines together have

Fig. 1: Kappa Zülpich Papier, Germany.

Over the years, Kappa Zülpich grew into

a production capacity of approximately

an internationally active papermaking

400,000 tons per year.

company and today, it is a highly suc-

17/04

40

2

PM 6 – Excellent Performance

until then. A conventional size press is

In September 2003, the most extensivefrom the Very Beginning

used for surface treatment. A fully auto-

rebuild so far was carried out, with thematic reel rounds off the well-tuned ma-target to increase machine speed fromchine concept.

the previous maximum of 1,050 m/min to

In the mid-1990s, Kappa Zülpich took adecisive step to face the ever increasing

1,200 m/min in the future, without im-international competition by investing

pairing technological sheet properties.

in a new paper machine. Voith delivered

The Long-Term Optimization

the PM 6 with a wire width of 5,600 mm

of PM 6and a maximum production speed of
1,000 m/min at that time.

One of the key measures was to rebuild
the DuoFormer CFD to improve drainage

Together with Voith, the first strategic

capacity and to adapt it to increased ma-

optimization measures were taken in thechine speeds. The existing forming roll,

The machine concept comprises a hori-

year 2000. Installing a double doctor atwith a diameter of 1,260 mm, was re-zontal DuoFormer CFD with a highthe first dryer and coating several dryers

placed with a new vacuum-augmented

drainage capacity, even at high basis

to prevent stickies or other sticky impuri-

forming roll with a diameter of 1,760 mm.

weights and speeds. The press concept

ties from adhering to the surface were

Because of the new, much larger forming

includes a tandem NipcoFlex press with athe first effective steps to be realized. Inroll, the top wire suction box and its wa-

single-felted second nip. The dryer sec-line with the long-term optimization con-ter discharge channels on drive side, astion was designed in close cooperation

cept, web stabilizers and ventilating doc-

well as the bottom wire deflectors, werewith the customer and has some special

tors were installed in the after-dryer sec-

modified.

features, such as dryers with a diametertion in the following year, thus signifi-

of 2.20 meters and a ropeless tail trans-

cantly improving both web run and CD

In the press section, a new double doctor

fer system. At the time, Kappa Zülpich

moisture profile.

system was installed at the plain bottom

was the first customer to use this type ofroll of the second press nip which can beropeless system for packaging papers

Another measure was to upgrade tailpivoted completely for maintenance pur-with higher basis weights, which hadtransfer with optimized blow nozzle sys-poses. Absolutely reliable doctoring isbeen used exclusively for graphic papers

tems in the pre-dryer section.

now guaranteed in this critical area where

17/04

Paper Machines

41

Fig. 2: DuoFormer CFD at rebuild.
Fig. 3: PM 6 after start-up.
Fig. 4: Scheme of ventilating doctor.
3

the point of highest evaporation of the4

web and, therefore, maximum humidity.
An essential advantage of these ventilating doctors is that no major rebuilds are
required in existing dryer sections. Thereis no need to install additional crosspipes in the very narrow pockets, since
the existing doctor back can be re-built
or replaced with a new doctor back in thesame position (Fig. 4).
These steps were taken based on thepositive experiences made by Kappa Zülthe paper is subjected to the first open

considerably and the free web run is sta-pich a year earlier with the same rebuild-draw. A Fibron transfer system with abilized. The DuoFoil works according to

ing measures in the after-dryer section.

universal P&T transfer unit and a VTT

the same principle as the DuoStabilizer.

vacuum belt was installed after the press

The only difference is that with the Duo-Conclusion

section. The P&T transfer unit takes overFoil, the box is evacuated through theToday, PM 6 is able to produce testliner

the paper tail fully automatically from thesuction roll arranged underneath, where-

and corrugating medium in a basis weightplain bottom press roll and transfers it

as the DuoStabilizer operates as an out-

range of 90-140 g/m 2 at 1,100 m/min.

into the dryer section by means of theside suction box for the drilled roll posi-

Kappa Zülpich’s well-defined optimization

vacuum belt.

tioned below it.

strategy and the good cooperation with

As a prerequisite for a permanent speed

New web stabilizers were installed toseven years after installation, PM 6 still

increase, all rotating siphons were re-achieve a more stable web run in the con-ranks among the world’s most productive

placed with stationary state-of-the-art

ventional, two-tier dryer groups of themachines.

ClearStar siphons for boosting steam andpre-dryer section. In order to improve

condensate system efficiency. The differ-pocket ventilation, and consequently the

Kappa Zülpich is a successful example ofential pressure required is much lower

CD moisture profile, the existing dryer

how a company can adapt to the market’s

than with rotating siphons.

doctors were re-built. Special Voith venti-

rapid development and growing demands

lating doctors were used which havethanks to intelligent optimization mea-

In the sensitive single-tier dryer section

been specifically developed for the heav-sures and the right partner. Kappa

areas, after the press section and afterier basis weights of packaging papers.

Zülpich’s success story underlines oncethe size press, the existing suction rolls

The doctor back of the ventilating doctors

again that strategic optimization andwere lowered and equipped with DuoFoil

is used as a “cross distribution pipe” andclose cooperation with a strong partner

boxes arranged above. This way, the free

is equipped with evenly distributed holes.

are key factors for boosting efficiency

evaporation length of the web is extended

This way, the hot air is emitted right at

and increasing profitability.

Voith have made it possible that even

17/04

42

Excellent threading performanceachieved at Condat
Condat, a member of the Lecta Group since 1998 together with
Garda in Italy and Torras Paper in Spain, is a manufacturer of woodfree
coated papers. In autumn 2001 Condat decided to carry out an important
re-build of line 89 within the scope of the Lecta Group’s investment program.

Robert Hotter
Finishing, Tail Threading Grouprobert.hotter@voith.com

Before the work began, the customer

delivery included DuoShake, DuoFormer D

stated clearly the most important goals

and JetFlow F components along withfor this major optimization plan. The tar-three VTT conveyor sections, complete

get of the first stage was to improve theerection, personnel training and start-up

formation process and overall machinesupervision.

productivity through reduction in boththe number and duration of breaks. A

The DuoShake installed on Condat’s PM 6

major part of this included reducing

had already proven its efficiency. Duo-threading times and the clean-up times

Shake contributes to the quality of forma-

after a break.

tion by allowing the MD/CD ratio to be reduced. It also ensures that no disturbing

Christophe
Le Morzadec
Finishing, Tail Threading Groupchristophe.lemorzadec@voith.com

Fig. 1: Before and after chart for production
capacity, speed and grades at Condat line 89.
BeforeAfter

After 10 years of production Condat line

vibrations are produced. The DuoFormer

89 faced some specific problems; an in-

D is a hybrid former with optimum posi-

efficient forming section, a large number

tion on the wire and an efficient design ofof breaks in the dryer section, long clean-

the top wire suction box and counterup times and an unreliable and slow

blades. The JetFlow F is a free jet coating

threading process. The threading was dif-system that can be easily incorporated

ficult mostly due to the on-line coaters

into the coaters, taking the place of theon this paper machine. After completing

applicator roll. With JetFlow F the web noa comprehensive threading analysis forlonger has to pass through a nip whichLine 89, the following problems werereduces the risk of breaks. The design

identified with the original threading

and control of JetFlow F and the coatingprocess: threading of coater 1 was diffi-

color circulation system prevents conta-

cult and inconsistent; the tail ran out ofmination, which significantly reduces

the ropes between the dryer sections;cleaning efforts after a break.

threading performance varied with crews;
manual threading was compromising op-

A TEAMS assessment (Threading Evalua-erator safety and the clean-up times weretion And Managed Solutions) was con-long after dirty thread-ups.

ducted by the Voith Tail Threading Group

Wire Width

5,768 m

5,768 mPaper Width

5,245 m5,245 mPaper Weights

90 -135 g/m 2

90 -135 g/m 2

Design Speed

1,000 m/min

1,200 m/min

Voith received the order for the re-build

threading problems. In the TEAMS as-

Capacity

566 tons/24 h

592 tons/24 hof line 8 in March 2002. The scope ofsessment phase, two Threading Process

17/04(TTG) before the optimization to identify

Finishing

43

2
Fig. 2: VTT Turbo conveyor
installed at Condat.
Fig. 3: Dryer to size press
drawing; optimized threadingat Condat.
Fig. 4: Threading times before
and after optimization.
 Before optimization
 After optimization

3

Specialists visited the mill and examined

tem was very unreliable and compro-

manual intervention, improved operator

all current threading processes thorough-mised operator safety. The optimized so-safety, limited maintenance requirements

ly. They discussed the threading difficul-

lution included a multiple VTT Turbo con-and space savings. Voith TTG took fullties with personnel at the mill and devel-

veyor section with a Flip Tray transfer de-ownership of the threading process dur-

oped a detailed optimization plan based

vice and a Tail Ripper. The Flip Tray wasing start-up resulting in a significant

on their findings.

mounted directly on the dryer cylinder

threading improvement.

doctor to allow for the movement of the
The first problematic threading section

scanners and other equipment. The pur-Within six months of the start-up, total

was Dryer 52 to the last Coater ropespose of the Flip Tray was to stabilize thetime losses at the coater sections had

section. Originally, the tail was trans-

tail during the transfer. The Tail Ripper

been reduced by 35%. The optimization

ferred into the rope nip by air nozzles lo-

was used to efficiently eliminate the dou-

resulted in a significant 65% reduction incated under a mini doctor blade. Thisble tail.

threading downtime. The mill and opera-system did not operate properly and re-tors are also impressed with the reliabili-

quired operator involvement when blow-

The third section to be optimized wasty of the threading system and the effecting the tail into the rope nip. The new so-Dryer 2R to the 1st Coater Ropes section.

the system has had on operator safety.

lution from Voith TTG included a multiple

Again, air nozzles were used in the origi-

The ultimate result of this optimization is

VTT Turbo conveyor system to stabilize

nal transfer. As the air nozzles were lo-

a 4% increase in total machine efficiency.

the tail, eliminate the double tail and tocated under the doctor blade, the systemprovide a reliable, controlled transfer into

didn’t operate properly and required op-

In a very short time, less than seven

the rope nip. The VTT Turbo conveyors

erator involvement. The new solution in-months, this installation has proven to be

are built with internal turbines that gener-

cluded VTT Turbo conveyors, a Flip Tray

very successful. The co-operation be-

ate a large amount of vacuum. Theseand a Tail Ripper. In this section, the Flip

tween Voith and the customer Condat

conveyors also include an internal Drum

Tray moves the tail onto the conveyor

made it possible to reach all the dead-Drive for efficient operation and space

where the tail is kept under control andlines and make this installation a truesavings. This section was rebuilt duringtransferred into the rope nip. The rope

success.

the summer of 2002, approximately eightnip was also relocated to allow for a bet-

weeks before the main shut, allowing a

ter tail transfer into the coater ropes.

smooth and efficient take-over for the opThe results of the optimization process

up after the main rebuild as the operators

were exceptional. Right after the system

30

were already familiar with the newstart-up, threading was successful 85%

25

threading technology.

on the first attempt and 100% within

20

three attempts. Threading times were
The second optimized section was thealso significantly reduced allowing for in-

Dryer to Size Press section. Again, thecreased machine efficiency and produc-original system used air nozzles to blow

tion. Other benefits from the optimization

the tail into the ropes. This manual sys-

included elimination of double tail, noMinerators. This contributed to a good start-

20
15

15
10

4

30

15

10
5

5
0
Coater 1

Coater 2
Sections

Film Press

17/04

44

Voith Tail Threading pilot machine
Voith Tail Threading Group now has a Threading Pilot
Machine, TailPlus, in Voith’s Heidenheim (Germany) R&D facility.
Elisabeth Rooney
Finishing, Tail Threading Group
beth.rooney@voith.com

The TailPlus Pilot Machine was developed to offer customers complete threading support including product and applications testing.

The TailPlus machine is capable oftesting all grades and speeds up to
3,000 m/min. The sheet width varies
from 500 mm to 800 mm. The machine islocated together with the main Voith pilot
machine in the Heidenheim Research andDevelopment centre.
The TailPlus machine contains the following machine sections; unwind unit, lastdryer cylinder, felt, simulated Janus calender and a Sirius Reel. These sections
are located on the machine to accommodate optimization of tail threading in thedry end (reel threading). The machine isalso used for optimizing threading forhigh speeds and demanding sheet runs.

17/04

The equipment on the pilot machine includes a wide range of threading optimization solutions. A WaterJet TailCutter
is installed to cut the tail on the dryer
can.

A high speed digital camera system, WebVision, is also installed on the threading
pilot machine. This allows the customers
a slow-motion view of the threading
process.

A VTT Turbo conveyor with a TT3000
transfer device is installed to pick up thetail from the dryer can. For certain installations, a Flip Tray transfer device canalso be used. The VTT Turbo conveyor
moves the tail onto another conveyor andinto the rope nip on the Janus Calender.

The purpose of the threading pilot machine is to create a facility where the customers can get their specific threading
applications tested, and to provide a fullR&D facility for threading optimizationand product development. Currently,
tests for Leipa Schwedt PM 4 and Maxau
PM 6 are being carried out. The test facility has proven it’s usefulness as a customer specific testing site and an R&D
facility.

The tail is transferred through the Janus
Calender and onto the Sirius Reel with arope system.

45

Strato Series –rubber covers in the paper machine
Roll covers in the paper machine can have a major impact
on the quality characteristics of the finished paper. At Voith Paper
we engineer our roll covers to meet the demanding requirements ofthe paper maker. These requirements are both for excellent paper
quality and predictable, extended run cycles.
Rubber covers are widely used in many

tent, efficient dewatering capabilities andKurt Eaton

different functions in a paper machine

provide excellent sheet release for low

Servicekurt.eaton@voith.com

from wire rolls to reel drum covers. Eachdraw and improved operating efficien-

position has different quality require-cies. In the sizing and coating section thements for the roll cover. When selectingroll cover plays an even more importantthe correct roll cover, we must consider

role in the surface characteristics of thethe specific application and the require-paper. The correct roll cover must pro-ments of that application. However, eachvide a homogeneous surface for the ap-

application has one common requirement-

plication of sizing or coating, reduce orabrasion resistance.

even eliminate sheet stealing and misting
while providing the correct nip conditions

Vic Shive
Servicevic.shive@voith.com

In the press section of a paper machine

to optimize sizing and coating applica-

the roll cover needs to provide consis-tion. In both the press and sizing/coating

17/04

46

Fig. 1: StratoSize.
Fig. 2: StratoCoat.
1

2

section of the paper machine the paper

StratoSize for puddle size press and film

run cycles 30% longer than the previous

maker is demanding longer run cycles

press applications

longest running covers. These lab resultswith predictable roll changing intervals to

StratoCoat for film and blade coatingwere confirmed by several field results ofeliminate unscheduled down time and re-applications.

Strato covers.

The new abrasion testing method is part

As noted previously, abrasion resistanceduce the costs associated with rollchanges.

of our entire testing process called

is important for the performance of press

Based on Voith Paper’s already proven

Process Simulation Testing which incor-roll covers. Improved abrasion resistancerubber cover product line our, Research

porates testing methods that simulate

results in covers that not only maintainand Development Department began anoperating conditions and provide excel-

their crown profile for longer but also, in

extensive program to produce a new se-lent correlation between lab results andthe case of drilled covers, have minimalries of products which improves the wear

cover behavior in a paper machine. Tradi-hole cupping. This can result in longer

properties of the cover while maintaining

tional abrasion testing methods are donetimes between grinds and improved press

the excellent paper quality attributed toat room temperature under dry condi-

performance.

the roll cover. Our search was not only

tions which do not provide an accurate

for a new and improved cover compound,correlation between lab results and actual

The improved performance of the Strato

but for a testing method that would accu-

cover wear in the machine. Our new abra-

series over competitors’ offerings has

rately predict the abrasion resistance ofsion testing is done under conditions

been demonstrated on a highly loaded

the cover in the paper machine. The re-similar to actual operating conditions injumbo press on a linerboard machine insult of our research and development wasorder to accurately predict results seen in

the Southern US. A large diameter, blindan abrasion testing method that more

operation.

drilled StratoPress cover was installed inclosely simulates machine conditions andthe first press mating against a “supera new series of covers called Strato:

The Strato Series of covers provides ex-

premium, super abrasion resistant” cover

StratoPress S and SR for demanding

tended run cycles while maintaining thefrom a competitor. Although the covers

suction press applications

excellent surface qualities of our existing

had the same geometry there was com-

StratoPress for demanding soft press

rubber covers. Using the results of ourpletely unequal performance. When theapplications (plain or blind drilled)abrasion testing, we were able to predict

covers were removed for grinding after a

17/04

Service

47

Fig. 3: Volume loss of several roll covers.
Fig. 4: Difference in roll diameter.
Fig. 5: Roughness value of several rubber
covers at installation and after the run cycle.
 Installation
 Removal
3

+0.04

7.5
Volume Loss (%)

4

+0.08

1.5

TopSize HPX

0
-0.04

5

5

1

-0.08
+0.08

2.5

0.5

+0.04
0

StratoTopSize
Size HPX

MagnaSize II

Standard
RubberStratoSize

0

0

-0.04
-0.08

Magna
SeriesHP
HPX
SeriesSeriesChange in Ra, mStratoSeries6 month run time it was found that the

our first major field trials of StratoSize.

during the run cycle as the surface char-competitor’s cover had four times more

Previously, TopSize HPX was the pre-acteristics of the cover are more stable.

wear than the StratoPress cover. Unlike

ferred cover at this mill due to its abra-

the competitor’s product, the StratoPresssion resistance and excellent sizing prop-

These product improvements are possi-

had little hole cupping.

erties. StratoSize has the same excellent

ble because of the formulation and manu-

sizing properties while maintaining thesefacture of the Strato Series cover. Not

properties over the run cycle.

only did we develop unique combinations

The improved durability and the consis-

and ratio of raw materials used to manu-

tent, efficient dewatering ability of theblind drilled StratoPress cover was seenFig. 4 shows the difference in roll diame-facture the cover, but we also optimizedin the machine performance.

ter versus target diameter between Strato-

each individual raw material used to pro-Size and TopSize HPX over similar runvide the desired physical and chemical

During this 6 month run the customer

periods on the above mentioned multi-

properties of the cover. The formulation

was able to set a new speed record forcoated paper machine.

of the cover compound is responsible forthe machine on 42lb. (205g/m 2)

surface wettability, surface tension, re-liner-

board of over 3000 fpm (915 m/min) for

Another property required for uniform

sistance to surface deposits, hydrophilic/four consecutive days.

coating and sizing application as well ashydrophobic sites and other cover char-stable sheet release is surface rough-acteristics. All of these characteristics

Lab results of abrasion testing comparing

ness. A rougher surface allows for easier

have an impact on the performance of thethe volume loss of StratoSize to TopSize

sheet release. Fig. 5 shows the rough-roll cover in the paper machine.

HPX showed a 46% decrease in volume

ness value of several rubber covers at in-loss. Fig. 3 shows the volume loss ofstallation and after the run cycle.

At Voith Paper we continuously use

several roll covers.

our process know-how and Research
The Strato series has a higher surface

and Development to bring new prod-

This increased resistance resulted inroughness which remains rougher duringucts to the market. The Strato Series

more uniform operating conditions on athe entire run cycle. This results in moreof rubber covers is our newest prod-large European graphic paper machineconsistent

uct line to meet the increased de-producing multi-coated paper in one ofsizing, and fewer operational changes

anduniform

coatingandmands of our customers.

17/04

48

17/04

49

Voith Process Solutions Seminar andVoith Paper Service opening ceremonies
in Kunshan and Dong Ying, China,
October 22 to 27, 2003

Wednesday, 2003-10-22
The event started with a banquet reception dinner in the evening
before the seminar. During this reception dinner, the technicaldiscussion and exchange of information between the customer andVoith team already began. All speakers, management membersof Voith in China as well as Mr. Ray Hall, Executive Vice President
Voith Paper Service and Member of the Management Board of Voith
Robert Kietaibl
Voith Paper Service Chinarobert.kietaibl@voith.com

Paper, Mr. Peter Huber, Senior Vice President Europe and Asia
of Voith Fabrics were attending this evening. All guests enjoyed arelaxed informative dinner including musical entertainment.

Thursday, 2003-10-23
Voith Process Solutions
Customer Seminar
More than 120 customers from 60 different paper mills in China, Korea and Japanattended the Voith Process Solutions
technical seminar in Kunshan end of
October 2003. Speakers from Voith Paper
China, Voith Paper Service Europe, Voith
Paper Liaoyang, Voith Paper Service
China, Voith Fabrics, Voith Paper Tail
Threading Group and Voith Paper Automa-tion gave an update on the latest developments and state of the art technology forthe paper industry.
The theme for the seminar was “Voith
Process Solutions”, a new service approach which evolves from the need oftoday’s papermaker to more efficiently
manage the entire papermaking process
to achieve lasting profitability. As part ofour Mill Service activities Voith Process
Solutions will combine all the process
knowledge and experience of the Voith
Group.

The Voith team has the capability of analyzing the entire paper making process
and recommending the most appropriate
solution for the customer. The paper
maker will get realistic recommendations
that will enhance productivity and quality,
while providing maximum return on investment.
The result of this 3 day event in Kunshan
was more than 110 customer requests
requiring follow up, confirmation of neworders and an overwhelming customer
response. More than 70% of all our cus-

17/04

50

tomers returned to us a feed back report
and we want to present some of thesewritten comments:
Shandong Rizhao SSYMB
Pulp & Paper Co., Ltd.
“I am impressed by your two service
centers. Voith is responsible to the customers and professional at services.
Well-equipped and can meet the maintenance demands for high speed paper
machines of the domestic market.”Guangzhou Paper Co., Ltd.
“The Voith Service Network covers moreareas than its competitors and theemployees are very professional. Good
impression, they can follow up for therequirements of customers very well.”
Sun Paper Share Co., Ltd.
“The advantage is that Voith Paper Service China can meet customer demands
in urgent cases.”
Daewoo Paper Mfg. Co., Ltd.
“For our company, which is 4 years in
production, the two Voith Service Centerswill provide good technical support. Voith
Paper Service has already successfully
provided one Super Calender roll coverfor us in a very short period. Until now
the performance of the roll cover is very
good. Thank you very much and I hopethat we will keep this cooperation partnership in the future and grow together.”On behalf of Voith we want to thank all
customers for their attendance and great
response to our technical seminar and weare already planning the next event in2004.

Friday, 2003-10-24
It was a day of information and celebration for the paper makers in North East
Asia. In addition to the technical seminar
our customers could get an impressionof the state of the art manufacturing
equipment and processes during theplant tours at Voith Fabrics Kunshan andVoith Paper Service Kunshan. The detailed presentation of the expansion ofVoith Fabrics Kunshan into the largest
press felt and forming plant in Asia wasanother high light during these exciting
events.
Opening Ceremonies Voith
Paper Service China – Kunshan
A further highlight of this 3 day event in
the Jiangsu Province was the opening
ceremony of the new service center in
Kunshan. More than 300 visitors – customers, vendors, contractors, official
representatives of the government andthe local authorities, co-workers andfriends from China and all over the world
celebrated with Voith Paper Service in

17/04

Kunshan. Included in the opening ceremony was a plant tour and a festive banquet lunch with traditional Chinese musical background.
Mr. Ray Hall, former Executive Vice President Voith Paper Service and Member ofthe board Management of Voith Paper
mentioned in his speech:“It is no accident that Voith Paper Service
is co-located here in Kunshan. On thissite, Voith Fabrics will soon break groundon a new expansion. Kunshan will become a significant resource center forthe paper industry, a further sign ofVoith’s commitment to this market and to
our customers. You see by this tangible
evidence of investment, our commitment
to the support of our customers and success of the paper industry in China andthe region North East Asia. No other supplier to the paper industry has made sucha commitment to this extent.”

Processexpertise
Enhancement
products
Spare
parts

Automation
expertise

Maintenanceexpertise
Diagnostic
expertise
Combined
Know how
Machineexpertise

Field
serviceexpertise

Rolls
Roll covers
Roll service

Felts andfabrics

51

Monday, 2003-10-27

Voith Paper Service China

Opening Ceremonies Voith
Paper Service China – Dong Ying
More than 100 visitors– customers, vendors, contractors, official representativesof the government and the local authorities, a delegation from Huatai Group andfriends from China and all over the world
celebrated with Voith Paper Service Dong
Ying in the Shandong Province. The plant
tour after the official opening ceremony
was very impressive to the paper makers
and visitors from the Shandong province.

365 days a year,
24 hours a day
The team of Voith Paper Service worked
endless hours in both service centers to
finalize the erection, installation and start
up of the equipment. Since June 2003
both facilities are fully operational andrunning with an excellent utilization rate.
Voith Paper Service is manufacturing rollcovers in Polyurethane, Composite andRubber for all applications in the paper
machine up to 15 meters length, 2 meters diameter and 80 tons.
In cooperation with the Voith Paper Service R&D centers in Europe and North
America Voith Paper Service China has
installed the most sophisticated manufacturing line for roll covers. The casting
equipment used to manufacture Polyurethane and Composite roll covers allows a 100% quality and process controlled manufacturing of Voith’s world
wide known High-Tec roll covers. Rubber

Shortly after its start up, Voith Paper Service Dong Ying developed into the centerfor grinding and mechanical roll service
for the paper industry in north China. The
expertise on grinding of high end rollcovers such as hard and soft calenderrolls and chilled iron rolls is well accepted. Short turn around times and high precision for the increasing demands of thepaper machines and all mechanical repairs including rotor refurbishment are in
the scope of capabilities of this wellequipped Voith Service center.

roll cover manufacturing is done using
the latest state of the art extruding technology on a unique set up of reversing
the extruder between two multifunctional
lathes, to enlarge production capacity
and have highest manufacturing flexibility.

Voith Paper Service China is operating 365 days a year, 24 hours a day,for our customers benefit!

Please feel free to send
us your inquiry, visit orcontact us at any time,either direct to our local
Technical Sales Manager
or our general email
address
service.china@voith.com

17/04

52

Voith Process Solutions –plant optimization by process analysis
Every papermaker and mill manager knows the importance of good plant efficiency and consistently high product quality. But it often takes a long time to get that far, and needs of lotof know-how and experience. Voith Paper’s vast experience andknow-how comes as part of the service package. Highly qualified
expert teams in all locations are ready to keep customers’ paper,
board and coating machines running properly and analyze all
Klaus Meier
Paper Machines Graphic
klaus.meier@voith.com

process conditions – irrespective of product grade.
Purpose of process analysis

After thorough process analysis, which
can be extended with various measure-

The operating behaviour of modern paper

ments, the results are evaluated. This ismachinery and production lines depends

where the diagnostics start. Based on

on a wide variety of process conditions,findings, the weaknesses and improve-

often very complex. Any faults or errors

ment possibilities are identified. After-in these processes can significantly re-wards,

duce efficiency and quality. The purpose

are worked out. By agreement with the

Kerst Aengeneyndt

of process analysis is to monitor all themill management, the best options are

Paper Machines Graphic
kerst.aengeneyndt@voith.com

operating parameters and conditions as athen selected and jointly implemented.

optimization

recommendations

basis for efficiency improvement measures right down the line, e.g. for better

This may involve anything from machine

runnability and printability.

adjustments and overhauls to additional
optimization components and training, orProcess analysis (Fig. 1) is thus very im-even a rebuild.

portant for:
1

Frank Opletal
Paper Machines Graphic
frank.opletal@voith.com● enhancing the overall efficiency;

Production process● ensuring consistently better product

Module 1 Productivity
Total efficiency elevation

quality.
Further modules are in course of preparation, such as for shutdown scheduling

Voith
Process
Solutions
Plant optimizationby process analysis

17/04

The Modules

Module 2 Product quality
Development of quality and increase of quality
stability in the individual production stages

and execution.

Voith process analysis uses modern
and structured analytical thinking
and problem solving methods

Each module is transparent thanks to a

Analysis – Diagnosis –Recommendation – Execution

systematic and well-proven procedure.

Further Modules are under preparation

53

Fig. 2: “Fanning” a high-pressure shower.

The improvements attained thereby are● Increasing the production rate by rais-

then checked and documented. In thising the operating speed and minimiz-

connection, various types of partnershiping break time.

Module 2: Product quality
Not only total quality, but, above all, consistently high quality is essential for suc-agreements can be agreed upon forreaching the customer’s goals by team-

As a renowned paper machinery manu-

cess in today’s markets. This demands

work with Voith Process Solutions.

facturer with decades of process experi-systematic discipline. Accordingly, theence in most of the paper mills world-

main tasks of this module are as follows:

wide, Voith Paper is predestined forModule 1: Productivity

detecting faults and errors (Fig. 2) and
Productivity is primarily improved by theenhancing efficiency by optimizing thefollowing parameters:

respective components.

● Quality data acquisition
and analysis● Printing results acquisition andanalysis● Reduction of shut down times whether
planned or unplanned● Reduction of broke amount2

In particular, Voith Paper has vast experi-● Evaluation of print comparisonsence in taking measures to reduce shut-● Paper fault analysis (Fig. 3)

down times.

● Complaints analysis.

Module 2: Product quality – Example paper defects analysis

3

Which quality group generates the highest loss?
Classification into different ranks organises the priority.
Quality group/Parameter

Loss/Month in Euro

Rank

Holes

38 658

1

Dirt

3 896

5

Doubling

4 539

4Blistering

3 764

6

Cuts

8 739

3

Size lumps

23 978

2

Slitter dust

2 997

7

341

0

2 844

8

Splice problems
Mottling

17/04

54

For analysing paper and print test sam-5

Target groups

ples, Voith uses the latest measuring

Voith’s comprehensive partnership withthe paper industry (Fig. 5) is upheld bytechnology and laboratory facilities in

Product-related

Voith Process Solutions – the trou-

teamwork with renowned printing firms.

Graphic grades

bleshooting optimizers.

Specialty grades

To meet such high demands, Voith Paper

Our teams of paper technology experts,
Board and packaging papers

uses highly sophisticated instrumenta-

plant engineers and chemical specialists

tion, mobile in part, incorporating the lat-

Tissuehave all spent years in the paper industry

est technical advances.

Carton board

worldwide – an unbeatable combinationof concentrated know-how and accumulated experience.

Typical example 1
Fig. 4 shows how the operating stability

nently exceeded! A double quality boost

and production output of a modern high-was thus attained. (It is apparent thatspeed newsprint machine were improved

quality benefited also.)

Typical example 2
Fig. 6 shows how one of the most pro-

after replacing a faulty pressure trans-

ductive copy paper machines was suc-ducer.

In the end, the key to such success lies

cessively optimized, thanks to process

in the experience and a systematic andanalysis right down the line from pulp

After eliminating the source of trouble,

analytical approach of the Voith Paper

production to roll packaging.

breaks decreased dramatically. And inon-siteparallel to these savings in down-time,pleased to tell you more about how thisVoith Process Solutions –the 1,600 m/min speed limit was perma-

concept can benefit your mill too.

Optimization always at your service!

optimization

team.

We’ll

be

Fig. 4: Production development and decreases
in number of breaks.
4

Fig. 6: Development of monthly average salable
production.

1600

6

1250

1800
v PM

1200

1000

Gross production

20

800

16

600

12

400

8

200
0

Breaks40Daily tons [80 g/m2]

1200
Number of breaks per day[m/min] [to]

1400
1150
1100
1050
1000
950
900
8.02

17/04

10.02

12.02

2.03

4.03

6.03

8.03

10.03

Service

55

Voith Process Solutions –North American case studies
As North American paper producers continue to faceeconomic pressures they are more often seeking improvement
through process optimization and low-capital investment projects
that deliver high financial returns. Instead of replacing or rebuilding entire machines, the customers pursue sectional improvements
to the equipment that they already have. In doing so, they areasking suppliers to be more innovative in approach to machineAlex Piquer

improvements.

Servicealex.piquer@voith.com

In its first full year of operation, Voith

problem. Voith Process Solutions provid-

Process Solutions North America has

ed an experienced paper maker and a di-worked successfully with customers andagnostic technician to observe operations

other Voith divisions to provide process

and investigate potential causes of the

optimization and complete solutions to abreaks.

variety of paper machine problems. The
results have produced significant eco-

Within a few days, the Process Solutions

nomic returns and process improvements

team determined that a large number ofallowing our customers to be more com-holes in the sheet were being caused bypetitive.

rubber being released from tubes recently installed in the cleaners. During the

The Process Solutions team is dedicatedvisit, the Voith team also made opera-

to helping Voith’s customers improve thetional recommendations that resulted inutilization of existing equipment andreduced draw between the former andidentify projects with the greatest eco-press. These findings and recommenda-

nomic impact on their business. The fol-tions reduced the holes in the sheet fromlowing cases are a few examples of the

250 to 2 per reel and the number ofresults achieved by this new group.

breaks on the machine from seven per
day to less than one. For a minimal service fee and no additional capital expen-

Improving Processes withditures, the mill was able to realize a sub-Low Investments

stantial in reduced waste and increased
production.

Voith
Process
Solutions
Plant optimizationby process analysis

At Norske Canada – Elk Falls, the newsNorth American
Case Studies

print machine began experiencing severe

Norm Facey, Vice President of the Elkrunnability issues and the mill was

Falls operation, praised the Voith Process

unable to determine the cause of the

Solutions effort saying: “They came in

17/04

56

Fig. 2: Approach Flow
problems.
Fig. 3: Approach Flow
modification.

1

ing flow characteristics, Tapio/TSO analy-

Peak List for Frequencies

Comments

0.379 psi at 8.375 Hz=>

1x Fan Pump

0.167 psi at 9.000 Hz=>

2x Screens

Process Solutions’ Paper Process Engi-

0.279 psi at 29.750 Hz=>

2x Secondary Fan Pumpneers performed the pulsation study uti-

0.137 psi at 58.250 Hz=>

7x Fan Pump

lizing a multi-channel spectrum analyzer

Pressure Variation (psi)Fig. 1: Pulsation
example.
Line Pressure 11.20 psi
Peak to Peak 3.11 psi
Overall Variation 27.7%

sis,

and

headboxmapping.

One

of

0.70

to assess the pressure variations at vari-

0.60

ous points in the stock system (Fig. 1).

0.50This type of analysis can identify mixing
0.40

problems, cavitation, and pulsations in-

0.30

duced by rotating machinery as well as

0.20

other flow related issues. Voith’s paper
testing laboratory tested finished paper

0.10

samples to identify periodic variations in

0.00
0

10

20

30

40
50 60
Frequency

70

80

90

100

the sheet and fiber orientation. The study
identified several areas in the approachflow system that were contributing to theand found a problem we did not evenchine-direction basis weight swings. The

basis weight instability being experienced

know existed. We were able to reduce

problem left the machine unable to meeton the machine (Fig. 2).

draw by 17 feet and got incredible

customer specifications for the mill’srunnability on the machine.”

most important product at an acceptable

The outcome of the analysis was a two

machine efficiency rate.

stage approach that included changes tothe existing approach flow piping system

The Voith Process Solutions team con-for short-term improvements as well as aducted a complete analysis of the stock

redesign of the entire piping system as a

A large LWC machine was experiencing

approach flow system including a pulsa-

capital project that would allow thesevere machine directions and cross-ma-

tion study, engineering review of the pip-machine to fully reach its expectations

Stock Approach Flow System(Fig. 3).
2

3

By implementing Voith’s recommendations the mill was able to improve basis
weight control significantly. This improvement allowed a reduction of 2 lbs.
per 3300 sq. ft. in the basis weighttarget. Improved operational efficiency
has resulted in additional savings for the
mill.

17/04

Service

57

Fig. 4: Suction Roll modification.

4

Fig. 5: ProcessPlot.

Cross Division Cooperation

vacuum zone to the existing suction box.

Innovative New Technologies

Working with the local Voith service
One of North America’s largest market

center, a competitor’s suction box wasVoith Process Solutions is now introduc-

pulp machines had been unable toredesigned

performanceing advanced diagnostic systems to fur-achieve its design production goals due(Fig. 4). The Springfield, Oregon Service

ther support customers in getting theto water rejection in the second nip. After

Center carried out the modifications andmost out of their equipment. Working

the mill and several suppliers had fo-

the mill re-installed the roll in the ma-

with the leading experts in process infor-

cused on trying to correct the problem

chine.

mation systems, Voith Process Solutions

toimprovethrough changes around the second

has developed the ProcessPlot systempress, the mill contracted Voith Process

Since installation of the modified roll, thewhich allows us analyze data gathered

Solutions to address the problem.

machine has increased speed by 300 fpm

through the paper mill’s data historianand is producing an additional 400 TPD.

and distributed control systems as neverThrough observation of machine opera-

The mill has also had the suction box for

before (Fig. 5). With ProcessPlot, Voith

tions and a series of diagnostic tests, thethe spare roll modified by Voith.

Process Solutions can assess and quantify process control issues that had previ-

Process Solutions specialists concluded
that the problem was due to inadequate

These examples and many others show

ously gone unnoticed. The unique value

water removal in the first press. Since

the ways that Voith Process Solutions isof ProcessPlot is to quantify economic

the first press had already been opti-

working with our customers to improve

opportunities on the machine and provide

mized, Process Solutions made the rec-productivity and quality over the life offinancial justification for recommended

ommendation of adding another highthe paper machine.

changes.

Mill Data –hundreds of variables

5
Customer Pulp and Paper Mill Site(local network)

Voith Process Solutions
Mirror Server

Selected key“Profit Opportunity”
Authorized Users

Step II
Presses(40% Cons)(20-25% Cons)(10-12%Cons)(.5- .75%)
Saveall(7% Moisture)

Max 30 - 40 TPH
Hot
Box

CAL
Reel

2ND
STKS

1ST
STKS

Blow
Box

Dryers

Pri
HB

Sec
HB

DRYERS
Stm
Box

Wdyd

Sweco (4)BiocideDefoamer
FOURDRINIER
PE
Tank
Couch
RepulperMWWSec Fib

DefoamerDry End
PulperWt.
Valve

Primary
Silo

Alum
Acid

Sec Screen Rejects

Alum
Acid

Couch
Pit

Sec
Bird
Screen

Ret
Aid

2

Ret
Aid
Primary (3)Bird
ScreenReject
Tank

MachineWhite Water

Size

Sec
Fiber

Cons

LD
Broke
35 Tons@ 4%

Sweetener

8

Baseline Calculator

Refiner3

Refiner

Cons

Acid
Tail
Scrn

Voith
Process
Solutions

77

RefinerRej
Scrn

OSIsoft
Consultants,
SoftwareRefiner

Pri Refined
7 Tons@4%

Tailing
Tank

Primary
Raw
14 Tons@ 4.5 %Sec Raw
5 Tons@ 4.5 %

4

Accepts

Acid

Refiner

Step IIICons

Accepts

Stock Dilution

Rejects to
Sewer
Silo
Makeup#4 HD
300 Tons@ 12 %

5#5 HD
225 Tons@ 12 % ConsCons

Refiner

Wt.
Valve

HD
Broke
75 Tons@12%

Wire Showers

Pri Mach
6 Tons@ 3.5 %Cons

Primary Accepts

REJ

Sec
Fan
Pump

Filt
WW
Chest

Wdyd
Tank

Steam

Rejects

Sec Silo

Acid

1

Primary
Fan
Pump

(1)

Flatbox
Seal Pit

BariumDispersant& Defoamer

Refiner

Vacuum Sump

Clarified
White
Water

The ProcessPlot programis used to analyze theselected Profit
Opportunities to deliver
potential solutions

6
BariumDispersant

Sec Mach
2 Tons@ 3.5 %

Cons

Refiner

Sec Refined
3 Tons@4%#1 HD
450 Tons@ 12 %#2 HD
450 Tons@ 12 %ConsCons

Step I
Establish a Baseline

Controls Freeness(length of Fiber)

Process Change Implementation
Using DOE Strategy

Identification of Missed Profit
Opportunities

17/04

58

DuoShake –continues to be successful

The DuoShake has proven its potential
and superiority on 70 paper machines
worldwide – in the meantime, from China
through Europe to North and South America. This extends over the entire bandwidth from low-speed machines to highspeed machines running at 1,200 m/min
as well as at basis weights from 18 g/m2
to 550 g/m 2.
Walter Blum
Voith Paper
walter.blum@voith.com

The advantage of the DuoShake over conventional shakes is mainly due to the factthat the DuoShake only transmits negligible centering and frictional forces to thefoundation. Other shakes on the market
do not have these advantages and support their shake rod force in the machinefoundation. This means that extensive
constructional measures are required totake up these forces. No special foundations are required for the DuoShake, except a steel base.
The operating principle of the DuoShakepermits shake frequencies that are notachievable with any conventional shake.

17/04

Through this, distinctly measurable improvements in formation can be reachedeven at very high machine speeds.
The shake characteristic number is calculated with the following formula:
Frequency 2 x stroke
Machine speed
It has been found that, as a rule, the best
results are reached at shake characteristic numbers from approx. 3,000 to 4,000.
If a frequency of 280 strokes/minute anda stroke of 14 mm are now taken as abasis for a shake, this results, at a machine speed of v = 300 m/min, in a shakecharacteristic number of 3,659. However,if the machine speed is raised to v =1,000 m/min, this results in a shake characteristic number of only 1,098, which
has hardly any influence on formation.
With the DuoShake an excellent value atmuch higher shake frequencies isreached even at higher machine speeds.
At a shake frequency of, for example,

59

Fig. 1: Performance diagram – stroke.
Fig. 3:
Coating base 1
Coating base 2
News
Envelope
Decor paper 1
Decor paper 2
Label

Fig. 2: Performance diagram –shake characteristic number.
Shaken mass:
2,000 kg
3,000 kg
4,000 kg
5,000 kg
Drive moment:
12Stroke [mm]25150 Nm250 Nm.

Abb. 4: DuoShake in use.

n2 x s
Shake characteristic number SKZ = v
wire
6000

3

5000

20

Formation Ambertec norm. [ g/m2]
1.3
1.1

4000
0.9

15

without DuoShake

3000
0.7

10

2000

5
0
150 200

with DuoShake
0.5

1000

300
400
500
Shake frequency n [min-1]

600

530 strokes/minute and a constant strokeof 14 mm, and at a machine speed of
1,000 m/min, a shake characteristic number of 3,933 is still achieved, of course
without disturbing reaction forces.
The latest generation of the DuoShake isequipped with a hydrostatically supported
carriage. This contributes considerably tothe reduction of wear.

The technical principle
The DuoShake operates on the physicalcenter-of-gravity principle. Several masses moved in a system maintain theircommon center of gravity. In a gear unit
housing, masses are arranged in such a
way that the mass center of gravity canmove only in the breast roll axis. If the
shake masses are rotating, the breast roll
responds with a counter movement. The
inertia forces remain in the moving system and are transmitted only via theshake rod.

0
200
400
600
800
1000
Production speed vwire [m/min]

1200

The stroke length is determined by theaddition of the shake mass forces. Adjustment is made by changing the angle
between the rotating pairs of masses.
The performance diagram (Figs. 1 and 2)
shows the operating range of the DuoShake taking into consideration the maximum rod force of 50 kN. Below the limit
curves, any combination of stroke andfrequency is possible.
As Fig. 4 shows, the fact that the DuoShake generates no interfering forces ofreaction makes it possible to install the
DuoShake on the top-wire framing.
Evaluations made by many different customers have shown that, with the DuoShake, formation can be improved evenat higher PM speeds thanks to the muchhigher shake characteristic numbers. In
addition, the DuoShake reduces the tensile ratio l/q by up to 0.5, which is indispensable especially for good dimensional
stability. The DuoShake is, therefore, an

17/04

0.3

1

1.5
2
2.5
Tensile Ratio MD/CD [-]3

economic alternative for formation improvement and a must whenever a low
tensile ratio l/q is required. In many cases it is even used in addition to a DuoFormer D in order to achieve optimal formation at a low tensile ratio l/q.
For trial purposes, a rental shake is always available at our Düren location,
which can in most cases be used by thecustomer for tests at short notice. Before
purchasing, each customer can test theeffects on his machine and on his special
products under simplified, but realistic
conditions without great expense andcan convince himself of the tremendous
advantages and possibilities of the DuoShake.

460

Eric Arseneault
Voith Fabrics
eric.arseneault@voith.com

Voith Fabrics’ PrintFlex P –development of a new press fabric concept for
improved surface uniformity and sheet dryness
Surface Uniformity

viding a high ‘pressing uniformity’ for thepress fabric.

The surface characteristics of a press

John Fox
Voith Fabrics
john.fox@voith.com

fabric are influenced by three main com-

In order to better understand and quanti-

ponents: batt fiber size, the fiber locking

fy press fabric surface uniformity, anprocess and the base cloth components

evaluation method has been developed byused. By far the greatest impact comes

Voith Fabrics. The testing method isfrom the batt fiber size. For graphic paper

based on a numerical analysis of com-

applications, batt fiber size will typicallypressed contact points of the press fabric.

be in the range of 6.7 dtex (fine) –The two values of importance are the

44 dtex (coarse).

ASN (average size number) and the FIN(fiber indentation number).

In general, the coarser fibers are used inHans Ragvald
Voith Fabrics
hans.ragvald@voith.com

17/04

the intermediate structure while the finer

The finer fibers offer great potential for

fibers are used on the surface to be inproviding a high uniformity, but they

contact with the sheet. The finer fibers

have a negative influence on the wear rate

will have the greatest influence for pro-and porosity loss of a press fabric.

Fabrics

61

Fig. 1: ASN for press fabrics with different
surface properties.
Fig. 2: ASN index comparison for press fabrics
having different surface properties.
 New
 After running
Fig. 4: After press dryness results for different
batt structures – VPM4.

55
50
45
40
3.3 dtex

5 dtex

11 dtex

Fig. 5: Permeability of press fabrics
New – VPM4.
3

55

60
50

50

40

45

FIN

2

60

ASN (Average size number)

1

ASN (Average size number)

Fig. 3: FIN index comparison for press fabrics
having different surface properties.
 New
 After running

40

20

35
30

17 dtex30

10PrintFlex P

6.7 dtex
surface0PrintFlex P

6.7 dtex
surfacePrintFlex P, forms stage 2 of Voith

Figs. 2 and 3 show the comparison ofgave almost 10 % less weight loss. The

Fabrics ‘4-stage platform’ for pressing.

ASN and FIN between new and used fabric.

benefits of this can be seen from the case

PrintFlex P is composed of a surface

study shown in Fig. 9.

made of fine batt fiber, layered with engi-

Analysis of the fabric permeabilities

neered resin components. It provides anshowed that the PrintFlex P retained overextremely high degree of pressing unifor-

33 % of more of its original permeability

mity, with excellent wear resistance.

after use, compared to the ‘standard’ de-Dryness/Rewet

sign. It is important to also note that de-Initial evaluations of PrintFlex P were car-Figs. 2 and 3 show the comparison ofspite the application of the engineered

ried out on the VPM4 pilot machine inresults between a ‘standard’ press fabric,

resin components, the PrintFlex P design

Heidenheim, Germany, to investigate thewith a fine 6.7 dtex surface, and Print-

was manufactured to the same level ofinfluence of fabric surface properties on

Flex P.

starting permeability as the ‘standard’sheet dryness and sheet quality. An SC

design.

magazine furnish was used for the tests.

It can be observed that the PrintFlex P

Three different sets of press fabrics hav-

has an ASN number almost 10 % lower

Mechanical abrasion tests have also

ing different surface properties were test-

than the ‘standard’ fabric. The FIN index,

demonstrated the high wear resistant

ed: a ‘fine’ (3.3 dtex), ‘coarse’ (17 dtex)

shows over 40 % improvement for Print-

properties of PrintFlex P. Again, com-and PrintFlex P.

Flex P over the ‘standard’ fabric surface.

pared to the ‘standard’ design, PrintFlex P

4

5

58
57
56
55
54
53
52

Dryness values were taken after the sec-

70
Fabric permeability, cfm

Dryness after 2nd press

59

60

ond press (Fig. 4). PrintFlex P provided

50

the highest dryness values of over 55 %.

40
30

Another important aspect to consider is20

the permeability of the press fabrics. The

10

PrintFlex P had a permeability of 58 cfm,

0Very finebattMediumbatt

PrintFlex P

Very finebattMediumbatt

PrintFlex P

the ‘medium batt’ fabric 63 cfm, whilstthe ‘very fine’ fabric only 18 cfm (Fig. 5).

17/04

62

Fig. 6: Base paper
PPS roughness results – VPM4.
Fig. 7: SC Paper
PPS roughness results – VPM4.
Fig. 8: Missing dots (%) – VPM4.

6

7

6

1.25

PPS (microns)5
PPS (microns)

8

1.50

4
3
2

1.00
0.75
0.50

1

0.25

0

0
Very finebattMediumbatt

PrintFlex P

Very finebattMediumbatt

Missing dot area, top side (%)

Fig. 9-12: PrintFlex demonstrates superior
printability compared to standard press fabric.

PrintFlex P

7
6
5
4
3
2
1
0
Very finebattMediumbatt

PrintFlex P

to the end user. Finished paper quality

The paper was then submitted for miss-issues, such as missing dots, can often

ing dots evaluation (Fig. 8). As expected,

Depending on the application, the surface

be linked to the surface characteristics ofthe ‘medium batt’ fabric had the highest

characteristics of the press fabric can

the press fabrics used. Base and finishedarea of missing dots. PrintFlex P gave an

have a variable degree of influence on

sheet properties were evaluated during

improvement of over 30 % against this,paper properties. In shoe press systems,

the pilot machine trials. PrintFlex P gavewitha long-nip residence time will positively

improved PPS results for both the baseagainst the ‘very fine’ fabric.

affect dewatering dynamics, but can also

and finished paper (Figs. 6 and 7). The

generate some negative sheet quality

results also confirmed the clear correla-

From a comparison of standard press

issues. The effect of the press fabric sur-tion between the press fabric surface

fabrics and PrintFlex P (Fig. 9), results

face properties on paper quality has

characteristics and paper smoothness.

taken from paper made in commercial tri-

Sheet Quality

gained a lot of attention in recent years,

measurable

benefits

also

seen

als has confirmed that a reduced fiber

especially with single- and tandem-shoe

Understanding the influence of the press

impression within the press nip (Fig. 10),

press configurations.

fabric on finished paper properties has

contributes directly to a smoother sheet

become an essential segment of Voithsurface profile (Fig. 11) and a significant

It is also important to investigate theFabrics’ continued research and develop-

improvement in measured printability

influence of the fabric properties beyond

ment work.

(Fig. 12).

9

10

17/04

11

63

CS I: Press fabric wear improvement ongraphic paper application.
13

CS II: Sheet smoothness improvement
on fine paper application.
CS III: Sheet smoothness improvement
on linerboard application.
Fig. 13: Press Fabric incorporating PrintFlex
technology.

I

II

III

Case Study I

Case Study II

Case Study III

PrintFlex P press fabricPrintFlex P press fabricPrintFlex P press fabric board

graphic paper applicationgraphic paper applicationand packaging application

1,700 m/min, 100 % recycled newsprint,

1,050 m/min, fine paper, 4th press.

675 m/min, linerboard, 3rd top/3rd bot-

3rd press (shoe press).

● Improved sheet smoothness by 26 %tom LNP 315 kN/m.

● Improved wear resistance. Weight loss
reduced by 43.5 % when compared tostandard structures.
● Consistent water removal throughout
life.
● Standard design on this position.

when compared to standard structure● Improved sheet smoothness (Emveco)(new).
● Improved sheet smoothness by 6 %by 24 %.
● Speed increase without maximizing

when compared to standard structure

steam.

(after mid life).
● Translates into significant reduction inConclusion

two-sidedness.
Asdemonstrated,

technologicallyad-vanced press fabric systems are truly
capable of facing the challenges imposedby modern paper making in terms of efficiency and quality.
The test results indicate that PrintFlex P
12can be used effectively as an important
tool to improve sheet properties and wear
resistance.
The findings also open the door for further research and development work in
the area of press fabric surface uniformity using resin based components.

17/04

64

Reliability beyond Equipment“ahead 2004 – The International Customer Conference
for the Board and Packaging Paper Industry.
“Reliability beyond Equipment” – under
this title Voith Paper invites customers
from all over the world to take part in the“ahead meeting being held in the conference city of Vienna from May 5 to May 7,
2004.
In the modern surroundings of the New
Conference Center Vienna, Voith will present, together with international guest
speakers, innovative process technolo-

17/04

gies, trendsetting reference projects aswell as trends for board and packaging
papers. In addition, an exciting supporting program in a relaxed atmosphere will
stimulate exchange of information andexperience.
For more information, please visit our
website:www.ahead.voithpaper.com

65

P

A

PE

R CU

R
LT U

E

Japanese Paper Blossoms Anew
Once upon a time there was a beautiful princess … Japanese legends
usually start that way too. The princess descended from heaven and taught
the Japanese people in the Kansai region the art of Washi making. Very soon
it turned out that it was the Goddess of Paper herself who had chosen thismethod of introducing “Wa Shi” – literally translated “Japanese Paper” – to theworld. Until this very day, Washi has remained a legendary paper in the true
sense of the word. It is as much part of the Western world’s traditional imageof Japan as Geisha, Samurai and Harakiri.
However, the craft that celebrates this
one thousand five hundred year old legend is threatened with extinction. In thecraft workshops it is almost always oldpeople that one sees working the bamboo
skimming screens. Many of the best papermakers, honoured and promoted by
the government as “living art treasures”,
have already reached the age of 80 or beyond. So far, the business acumen of afew enthusiasts has saved this tradition
from vanishing completely, and, at the
moment, Japan is even undergoing a distinct Washi renaissance.

Japanese paper is a much soughtafter product, particularly because of its
high quality. German book illustrator
Veronika Schäpers, who studied the artof papermaking for some years in Japan,
explains:“No chemical additives are used in the
production process. In traditional European rag paper the fibres are short andthick, whereas in Japanese Washi paper
they are long and thin. The papermakers
can thus produce outstandingly strong,tear-resistant paper.” In addition, a different skimming process is used. The

fibres are arranged more uniformly in one
direction and the paper’s surface issmoother.
Top-quality Washi is very popular among
artists, particularly book printers, lithographers and painters. The Japanese wood
engraver Katsushika Hokusai acquired
world fame with his Washi Paper prints
of mount Fuji. The Hamburg artist Horst
Janssen too, whom experts have extolled
as the “Albrecht Dürer of the 20th century”, also preferred to use high-quality
paper from Japan for his masterpieces.

17/04

66

1
Fig. 1: Boiling
vessel: Kozo branches
are steamed overboiling water to makethe bark easier toremove.
Fig. 2: Soaking thefibre strands in riverwater.
Fig. 3: Dried fibres infront of a farmhouse.
Fig. 4: Peasant
women at work witha bamboo screen.
2

Making Washi involves a lot of timeand effort – and is, as a consequence,very expensive. The best fibres are extracted from the inner bark of the mulberry tree (Japanese Kozo), Gampi plants
and the Mitsumata bush. The branches
are collected in the winter, after theleaves have fallen, and are then sawn into
1 metre long sections and steamed above
large vessels filled with boiling water.
The bark is removed and soaked in waterfor one day, contaminants are separated
off and the white fibres are dried. To
make them soft, they are soaked in water
again for many hours and later boiled
with potash. After washing out the lye,
the last dark pinholes are separated fromthe fibres – a task that is entrusted inJapan to female workers.
The fibre strands are then spread out ona cherrywood board and beaten with abroad wooden stick. After another washing phase the purified fibres are stirred
into water and sheets of paper arescooped out one by one with the aid ofbamboo screens. Only the skilled craftsman has the knack of plunging the screen

17/04

3

67

4

repeatedly into the paper suspension in aparticular rhythm, so that the fibres are
distributed uniformly.
One of the secrets of Washi production isadding Neri to the paste. This viscousroot sap from the Japanese hibiscus
plant links the paper fibres together, improves sheet formation and permits wet
sheets to be stacked. The sheets are
dried by pressing and then individuallybrushed on to Gingko wood boards. During the drying process it is this wood thatgives paper its special gloss, an effectthat becomes stronger as the paper ages.
Washi is never bleached unless by exposure to natural sunlight. The fibres get
their colour solely from the washing andcleaning processes.
Papermaking by this method is a burdensome task. Those involved have to workin a constant stooped or standing position for many hours with their hands inicy water. To master each step in theprocess, budding papermakers need fourto six years of training. Although wholesalers have to pay as much as 80 Eurofor one single sheet of this paper, theemployees hardly ever earn more than 8Euro per hour. This is one of the reasons
why traditional Japanese small-scale craft
trades have had difficulty for some years
in recruiting young people – despite a lotof advertising for this profession throughjob centres and the visits to schools bymaster papermakers, and despite exhibitions in museums and even theme parks
on the subject of papermaking.

mainly used for wood etchings. Several
famous painters, for example Taikan
Yokoyama, order large-format Washi
sheets from Echizen. They use them for
Sumi-e (watercolour paintings) and calligraphy. The museum in Imadate, whichis also located in the Echizen region, contains the world’s largest hand-skimmed
sheet of paper: 7.1 x 4.3 meters – over
30 square metres of Washi in a single
piece.

In many regions the traditional papermakers have had to become highly specialized in order to outperform industrial
products and locate market niches. In the
Gifu Prefecture, for example, the emphasis is on “Amime” paper: This networkstyle Washi is created by water jets perforating the fibres on the bamboo screen.
This paper is mainly used for decorative
purposes.

Of course, it was not a Goddess but
Korean monks who took the art of papermaking to Japan. The Japanese Emperors
invited the first monks over from the
Korean peninsula in the 5th century, because they wished to distribute Buddha’stranscripts on paper all over the country.
The common people were encouraged to
grow mulberry trees to ensure an adequate supply of raw material. In theeighth century the Japanese began to refine the Korean technology when they
discovered Gampi as a raw material, aplant indigenous to Japan. Gampi fibres
are noted for their exceptional finenessand natural viscosity. With the aid of thisHosho paper is particularly thick andsoft. In the Echizen region this grade wasused to produce Japan’s first national
paper money, because it does not shrink
and is resistant to tearing. Nowadays it is

17/04

68

5
6

7

Fig. 5: Bundled
Washi paper.
Fig. 6: The fibre
strands are spread ona cherrywood board.
Fig. 7: A papermakerskimming off a paper
sheet with a bamboo
screen.
Fig. 8: Finishing
Washi paper withplant dyes.
Fig. 9: Ibe-Washi.
8material, Japan’s own paper culture began to thrive and shook off the once predominant Chinese and Korean influence.
During the Heian period (794-1185) alarge paper mill was established in Kyoto,
then the Imperial capital of Japan, tomake paper for public use. The paper millalso dyed paper and trained papermakers,
so that the craft spread rapidly all overthe country. With its abundant forestsand clear mountain streams, the Japanese environment was extremely suitable
for the production of top-quality paper.
Very soon Washi was also used for correspondence, keeping records, Zen poetry(Japanese Haiku) and wood engravings.
In the 17th century Japan's strong but
flexible and translucent paper started topenetrate many aspects of daily life:
Washi was used to cover the sliding wallsof Tatami rooms, and also for lampshades, umbrellas, bags, flags, masks
and blinds.
At a very early stage, paper was used asa ritual material in numerous Shinto and

17/04

69

9

During the Edo period (1603-1868) farmers had to pay tribute to their feudal lordsin the form of rice in the summer and paper in the winter. The aristocrats usedsuch paper for private correspondence
but also as toilet paper. Paper used by
the farmers for their own purposes was
impregnated with the sap of the Khaki
plant to make waterproof shoes and raincapes for field work.
Until recently papermaking wasstill a secondary occupation for someJapanese peasant farmers. Of course,
their sheets were not as perfect as those
produced by professional papermakers,
but it was these little flaws in particularthat gave their paper a special charm. It

is uneven and far from smooth, and its fibres of varying thickness make it a distinct natural product with an “ecologicaltouch”.
In the 1980s, the Japanese Naoaki Sakamoto came up with the idea to revive thisrural tradition of papermaking. In remotevillages he found several farmers who
used to skim off paper by hand. Some
had still kept their original equipment, including very old screens, in the attic. A
genuine stroke of luck: Sakamoto, inTokyo known as “Paper Nao”, was able toconvince such farmers to make “ordinary” Washi paper for him. On the islandof Shikoku, for example, there lived anold couple whose families had made Senkashi paper for many generations. The
Korean Buddhist Senka had brought thiscraft to Japan, and it is one of the mostoriginal Japanese papers of all. Althoughalso produced in other regions of Japan,
its thickness, shape and colour had gradually changed. Only this one remaining
old couple still knew how genuine Senkashi paper should look and how to make it.

Nao finishes the farmers’ Washi with natural plant dyes applied to the paper withbroad paintbrush strokes. Interior decorators like to use this Washi grade as aluxury tapestry or wall decor in the designer restaurants of Tokyo and Osaka,
where the atmosphere has to accord withthe perfect presentation of the meal. A
large Washi sheet dyed by hand can easily cost 150 Euro.
However, this high price is not a deterrent to many Japanese customers, because in the past 10 years Japan has
become more conscious of its origins.
The reason: while catching up with andeven outperforming Western industrial
economies, Japan tended to neglect its
own roots. The recession that followed
the stock exchange crash in 1991 triggered off a resurgence of old traditionsand values. Japanese handicraft has now
become one of these much sought-aftervalues, a trend that has helped JapaneseWashi to experience a new, if modest
boom.
Martin Fritz

17/04

Photos: Naoaki Sakamoto, Tokyo

Buddhist religious ceremonies. It became
the symbol of purity and a spiritual
meaning was attributed to it. Even today
in Japan, paper ornaments and strips are
regarded as the bearers of glad tidings.
They often flutter on shrines and temples.
The art of paper folding (Origami) was
also born at this time.

70

Startup highlights in 2002/2003

Fiber Systems
Stock preparation systems andsub-systems for graphic papers
Hindustan Newsprint, Kerala,
India.
Chadha Papers, Bilaspur, India.
Murli Agro Papers, Nagpur, India.
Paper Corea, Kunsan, Korea.
Mudanjiang Hengfeng Paper,
Hengfeng, China.
Shandong Huatai Paper, Huatai,
China.
Stora Enso, Langerbrugge,
Belgium.
UPM Shotton, Shotton,
United Kingdom.
UPM Schongau, Schongau,
Germany.
Minfeng Special Paper,
Minfeng, China.
Ripasa, Americana, Brazil.
Daishowa America, Pt. Angeles,
USA.
Bear Island, Ashland, Canada.
Bowater, Catawba, USA.
Abitibi-Consolidated, Alma,
Canada.
UPM-Kymmene, Miramichi,
Canada.
Abitibi-Consolidated,
Baie Comeau, Canada.
Ponderay Newsprint, Usk, USA.
Stock preparation systems
and sub-systems for board andpackaging papers
SCA Packaging Switzerland,
Oftringen, Switzerland.
Kappa Kraftliner, Loevholmen,
Sweden.
Wuxi Long Chen Paper, Jiangsu,
China.
PCE, Manaus, Brazil.
Adami, Cacador, Brazil.
Shandong Bohui Industrial,
Bohui, China.
Thai Kraft, Wangsala, Thailand.

17/04

United Pulp and Paper, Calumpit,
Philippines.
PCA, Tomahawk, USA.
Weyerhaeuser, Springfield, USA.
Stock preparation systems andsub-systems for tissue papers
Sepac, Mallet, Brazil.
Kimberly-Clark, Lima, Peru.
Georgia-Pacific, Muskogee, USA.
Canoinhas, Canoinhas, Brazil.

Paper machines
Graphic papers
Shandong Huatai Paper Group,
Shandong, China.
Minfeng Special Paper, Jiaxing,
China.
Mudanjiang Hengfeng Paper
Group, Henfeng, China.
Calik Group Turkmenistan, Yaslik,
Turkmenistan.
Sichuan Jinfeng Spike Paper
Products, Chengdu, China.
Security Papers, Karachi,
Pakistan.
Board and packaging papers
Shandong Bohui Papermaking
Group, China.
Ibema-Cia Brasileira de Papel,
Turvo Mill, Brazil.
TissueGuangxi Guitang Group, Guigang
TM 1, China.
Guangxi Guitang Group, Guigang
TM 2, China.
Kriepa Hygienepapier, Kriebethal,
Germany.
SCA Tissue North America,
Barton, USA.
Installation and rebuilds
UPM Shotton Paper Company,
Shotton, United Kingdom.
Neusiedler-SCP, Ruzomberok
Mill, Slovakia.

Stora Enso, Veitsiluoto Mill,Kemi, Finland.
Stora Enso, Kotka Mill,
Finland.
Tamil Nadu Newsprint andPapers, Tamil Nadu, India.
Holmen Paper, Braviken Paper
Mill, Sweden.
Papierfabrik Palm, Eltmann Mill,
Germany.
SCA Graphic Sundsvall,
Ortviken Paper Mill, Sweden.
UPM-Kymmene Group, Rauma
Mill, Finland.
Stora Enso Publication Paper,
Kabel Mill, Germany.
UPM-Kymmene Papier,Schwedt Mill, Germany.
Solikamskbumprom Solikamsk,
Russia.
Lecta, Usine de Condat Le Lardin,
France.
Sappi Ehingen, Germany.
Stora Enso North America,
Duluth Mill, USA.
Bowater, Catawba Mill, USA.
Myllikoski, Ettringen Mill,
Germany.
Lecta (Torraspapel), Fabrica
Motril, Spain.
Norske Skog Tasman, Kawerau,
New Zealand.
Neusiedler, Dunjavaros Mill,
Hungary.
Neusiedler, Kematen Mill,
Austria.
Stora Enso North America,
Kimberly Mill, USA.
Stora Enso North America,
Biron Mill, USA.
Bear Island Paper, Ashland, USA.
Bowater, Catawba, USA.
Kishu Paper, Japan.
Nippon Paper, Komatsushima
Mill, Japan.
Nippon Paper, Shiraoi Mill,Japan.
Tokiwa Paper, Owariasahi,
Japan.

Kaysersberg Packaging, Kunheim,
France.
SAPPI, Tugela Mill, Mandeni,South Africa.
Kappa Zülpich Papier, Zülpich,Germany.
Mayr-Melnhof, Neuss,
Germany.
ABB Figeholm, Figeholm,
Sweden.
Shindaeyang Paper, Ansan Mill,
Korea.
Korea Export Packing Industrial,
Pusan, Korea.
Koa Kogyo, Fuji, Japan.
Nippon Paperboard, Soka Mill,Japan.
Hokuyo Paper, Eniwa, Japan.
Adami, Cascador Mill,
Brazil.
Inpa-Ind. De Embalagens
Santana, Pirapetinga, Brazil.
Papel Caisas e Embalagens/PCE,
Amazonas, Brazil.
MD Papéis, São Paulo, Brazil.
Ripasa Americana, São Paulo,
Brazil.
Riau Andalan Pulp & Paper,
Kerinci, Indonesia.
Owens Corning Veil Netherlands,
Apeldoorn, Netherlands.
Papierfabrik Wattens, Wattens,
Austria.
Papierfabrik Schoeller & Hoesch,Gernsbach, Germany.
Security Paper Printing & Minting
Corporation Davlat Belgisi,
Tashkent, Uzbekistan.
Radece papir, Radece, Slovenia.
Arjo Wiggins, Fort William Mill,
United Kingdom.
Crane, Tumba, Sweden.
Neusiedler Ybbstal, Kematen,
Austria.
Neusiedler Szolnok Papirgyar,
Dunaujvaros, Hungary.
Ahlstrom Osnabrück, Osnabrück,
Germany.
OP papirna, Czech Republic.

71

Dresden Papier, Heidenau,
Germany.
AO Solikamskbumprom,
Russia.
Norske Skogindustrier,
Saubrugs, Norway.
Haindl Papier, Schwedt,
Germany.
Hansol, Korea.
Mundanjiang Henfeng Paper
Group, China.
Cartiere Sarego Valchiampo,
Italy.
W. Hamburger, Pitten, Austria.
Mondialcarta, Lucca, Italy.
Cartiera di Cadidavid, Italy.
Cartiera di Ferrara, Italy.
Cartiera di Tolentino, Italy.
Papelera de la Alqueria, Alqueria
de Aznar(Alicante), Spain.
Assi Domain, Frövi, Sweden.
Kartonfabrik Buchmann, Rinnthal,
Germany.
Indústria de Comércio de Papeis ePlástico/Citroplast; São Paulo,
Brazil.
Oji Paper, Saga, Japan.
Oji Board, Nayoro PM3, Japan.
Papresa, Renteria, Spain.
Zanders Feinpapiere, BergischGladbach, Germany.
Papirnica Vevce, Ljubljana,
Slovenia.
VPH Veiligheitspapierfabriek,
Ugchelen, Netherlands.
Papierfabrik Louisenthal, Gmund,
Germany.
Zhejiang Papermaking ResearchInstitute, Hangzhou, China.
Papeles Norske Skog Bio Bio
PM1, Concepción, Chile.
Bahia Sul Celulose, Mucuri,
Brazil.
Votorantim Celulose e Papel PM2,
Jacareí, Brazil.
Votorantim Celulose e Papel,
Piracicaba, Brazil.
Cia. Suzano de Papel e Celulose
PM8, Suzano, Brazil.

PCE – Papel, Caixas e Embalagem,
Manaus, Brazil.
Citroplast Ind. E Com de Papéis e
Plásticos, Andradina, Brazil.
Amcor Cartonboard, Petrie,
Australia.
Cia. Suzano de Papel e Celulose
PM 6, Suzano, Brazil.
Papeles Industriales, Santiago,
Chile.
Klabin Kimberly PM 4,
Mogi das Cruzes, Brazil.
Coating technology
Minfeng Special Paper, Jiaxing,
China.
Mudanjiang Hengfeng Paper
Group, Hengfeng, China.
Calik Group Turkestan, Yaslik,
Turkestan.
Neusiedler, Ruzomberok Mill,
Slovakia.
Stora Enso, Veitsiluoto Mill,Kemi, Finland.
Stora Enso, Kotka Mill,
Finland.
Tamil Nadu Newsprint andPapers, Tamil Nadu, India.
Lecta, Usine de Condat Le Lardin,
France.
Bowater, Catawba Mill, USA.
Lecta (Torraspapel), Fabrica
Motril, Spain.
Arjo Wiggins Papiers Couchés,Usine de Bessé-sur-Braye,
France.
Gruppo Marchi, Toscolano,
Italy.
Nippon Paper, Ishinomaki Mill,Japan.
Hokuetsu Paper, Ichikawa Mill,Japan.
Usine de Condat, Le Lardin,
France.
Hansol, Korea.
Jinfeng PM 3, China.
Shandong Bohui Industry,
Huatai, China.
Mitsubishi Paper, Japan.

Winding technology
Shandong Huatai Paper Group,
Shandong, China.
Neusiedler-SCP, Ruzomberok
Mill, Slovakia.
Stora Enso, Veitsiluoto Mill,Kemi, Finland.
Sappi, Ehingen, Germany.
Bowater, Catawba Mill, USA.
M-real Zanders, Werk Gohrsmühle, Bergisch Gladbach,
Germany.
Papresa, Renteria,
Spain.
W. Hamburger, Pitten,
Austria.

FinishingJanus Concept
Bowater, Catawba Mill, USA.
Ecosoft calender
Ibema-Cia Brasileira de Papel,
Turvo Mill, Brazil.
Ripasa Cellulose e Papel,
Ripasa, Brazil (2).
Shandong Huatai Paper Paper
Group, Shandong, China.
Shandong Bohui Papermaking
Group, China.
Stora Enso, Kotka Mill,
Finland.
Stora Enso, Veitsiluoto Mill,Kemi, Finland.
Minfeng Special Paper, Jiaxing,
China.
Neusiedler-SCP, Ruzomberok
Mill, Slovakia.
Papeteries des Vosges,
France.
Shenzhen Wander Color Printing& Packaging, China.
GAP Insaat Yatirim ve Disticaret,
Turkestan.
NipcoFlex calender
Stora Enso, Baienfurt,
Germany.

Calenders
Bowater, Catawba Mill, USA.
Neusiedler-SCP, Ruzomberok
Mill, Slovakia.
Stora Enso, Kotka Mill, Finland.
Minfeng Special Paper, Jiaxing,
China.
Shandong Bohui Papermaking
Group, China.
Maanshan Paper Mill, Maanshan,
China.
Ibema-Cia Brasileira de Papel,
Turvo Mill, Brazil.
Zhejiang Yongtai Paper, Fuyang,
China.
Cartiera di Carbonera, Italy.
Kishu Paper, Osaka CM 1, Japan.
Chung Loong, China.
Huatai, China.
Twister / Roll Handling
Shandong Huatai Paper Group,
Shandong, China.
Roll cutting machines
Gojo Paper, Fuji, Japan.
StoraEnso, Veitsiluoto Mill, Kemi,
Finland.
Shandong Bohui Papermaking
Group, China.
Sichuan Jinfeng Innovation
Industry, Taiwan.
Smurfit, Papeterie de la Seine,
Nanterre, France.
W. Hamburger, Pitten, Austria.
Minfeng Special Paper, Jiaxing,
China.
Neusiedler-SCP, Ruzomberok
Mill, Slovakia.
Cartiere del Polesine, Italy.
Shandong Huatai Paper, Paper
Group, Shandong, China (2).
Ripasa Cellulose e Papel,
Brazil.
Chung Loong, China.
Sichuan Jinfeng Innovation
Industry, China.
GAP Insaat Yatirim ve Disticaret,
Turkestan.

17/04

72

Recent large orders

Fiber Systems
Stock preparation systems andsub-systems for graphic papers
LEIPA Georg Leinfelder, Schwedt,
Germany.
Stora Enso, Maxau, Germany.
Feinpapierfabrik Dr. Franz
Feurstein, Traun, Austria.
Stora Enso, Veitsiluoto,
Finland.
Neusiedler-SCP, Ruzomberok,
Slovakia.
VIPAP VIDEM KRSKO, Krsko,
Slovenia.
Papresa, Renteria, Spanien.
Suzano de Papel e Celulose (B8),
Suzano, Brazil.
Suzano de Papel e Celulose (B6),
Suzano, Brazil.
Gold East Paper, Dagang,
China.
Steinbeis Temming Papier,Glückstadt, Germany.
Hebei Pan Asia Long-Teng Paper,
Shitaxilu, China.
Renova, Spain.
Stora Enso North America,
Port Hawkesbury, Canada.
Daishowa Paper Mfg.,
Port Angeles, USA.
Abitibi-Consolidated, Alma,
Canada.
Great Lakes Pulp, Menominee,
USA.
UPM- Kymmene, Miramichi,
Canada.
Abitibi-Consolidated, Alma,
Canada.

17/04

Stock preparation systems
and sub-systems for board andpackaging papers
Emin Leydier, Nogent-sur-Seine,France.
Cheng Loong Corp., Shanghai,
China.
Cheng Loong Corp., Ta Yuan,
Taiwan.
W. Hamburger, Pitten,
Austria.
W. Hamburger, Spremberg,
Germany.
SCA Packaging Switzerland,
Oftringen, Switzerland.
Changjiang Paper, Jiangjin,
China.
SCA Packaging Munksund, Pitea,
Sweden.
Companhia de Celulose e Papel
do Parana, Curitiba, Brazil.
Conpel, Paraiba, Brazil.
Klabin, Guamipirim, Brazil.
Citroplast, Andradina, Brazil.
Irani, Vargem Bonita, Brazil.
AZBK Arkhangelskiy ZellyuloznoBumazhny, Novodvinsk,
Russia.
Ningbo Chonghua Paper Corp.,
Zhejiang, China.
Papier- und Kartonfabrik Varel,
Varel, Germany.
Adolf Jass Schwarza, Schwarza,
Germany.
PCA, Tomahawk, USA.
Stock preparation systems andsub-systems for tissue papers
Georgia-Pacific, Clatskanie, USA.
J.D. Irving, Saint John, Canada.

Paper machines
Graphic papers
LEIPA Georg Leinfelder, Schwedt,
Germany.
Stora Enso Magazine Paper,
Maxau Wolfsheck Mill,
Germany.
N.N., China.
N.N., China.
Feinpapierfabrik Dr. Franz
Feuerstein, Traun, Austria.
Papresa, Renteria,
Spain.
Shandong Binzhou Filter Paper
Industry, Binzhou, China.
Board and packaging papers
Shanghai Cheng Loong
Corporation, Shanghai, China.
Papier- u. Kartonfabrik Varel,
Varel, Germany.
Emin Leydier, Nogent-sur Seine,France.
Papierfabrik Adolf Jass, Rudolstadt-Schwarza, Germany.
TissueSwedish Tissue, Kisa, Sweden.
Dewatering machine
Jiang Lin, China.
Veracel Celulose Eunápolis,
Bahia, Brazil.
Installation and rebuilds
Holmen Paper, Braviken Paper
Mill, PM 52, Sweden.
Krkonosske Papirny, Hostinne,
Czech Republic.

Olsanske Papirny, Olsany,
Czech Republic.
Holmen Paper, Braviken Paper
Mill (PM 51), Sweden.
Crown Van Gelder, Velsen,
Netherlands.
Panasia, Mentakab, Malaysia.
Papierfabrik August Köhler,
Oberkirch, Germany.
Abitibi Consolidated, Alma,
Canada.
N.N., MI, USA.
Arkhangelsk Pulp and Paper Mill(APPM), Russia.
Stora Enso Packaging Boards,
Baienfurt Mill, Germany.
W. Hamburger, Pitten, Austria.
Union Industrial de Papel,
La Pobla de Claramunt, Spain.
Cascades Boxboard Group,
Toronto Mill, Canada.
Amcor Cartonboard, Petrie Mill,
Australia.
Cocelpa Celulose do Parana,
Curitiba, Brazil.
Papel Caisas e Embalagens/PCE,
Amazonas, Brazil.
Cia Suzano de Papel e Celulose,São Paulo, Brazil.
Abitibi-Consolidated, Alma
Division, Quebec, Canada.
Ledesma, Jujuy, Argentina.
Companhia Melhoramentos,
São Paulo, Brazil.
Papeles Industriales, Santiago,
Chile.
Cenibra Celulose Nipo-Brasileira,
Minas Gerais, Brazil.
Mondi Kraft, Richards Bay Mill,South Africa.

73

Bahia Sul Celulose, Bahia,
Brazil.
Carl Macher, Brunnenthal,
Germany.
Banque de France, Vic-Le-Comte,
France.
Dresden Papier, Heidenau,
Germany.
OP papirna, Czech Republic.
Kunshan Banknote Paper Mill,
Kunshan, China.
Baoding Banknote Paper Mill,
Baoding, China.
Chengdu Banknote Paper Mill,
Chengdu, China.
Mead Westvaco Corporation,
Chillicothe, OH, USA.
Guangzhou Paper Company,
Guangzhou, China.
Changjiang Paper, Jiangyin,
Jiangsu, China.
Mercer International, Landquart,
Switzerland.
International Paper, Quinnesec,
Mi, USA.
Andhra Pradesh Paper Mills,
Secunderabad, India.
Jefferson Smurfit Group, Wrexen,
Diemelstadt, Germany.
Coating technology
Cascades Boxboard Group,
Toronto, Canada.
Cascades Fine Paper Group,
Saint Jerome, Canada.
LEIPA Georg Leinfelder,
Schwedt, Germany.
N.N., China.
Feinpapierfabrik Dr. Franz
Feurstein, Traun, Austria.

Krkonosske Papirny, Hostinne,
Czech Republic.
Papierfabrik August Köhler,
Oberkirch, Germany.
Foshan Huafeng Paper, Foshan,
China.
Ningbo Zhonghua Paper, Ningbo,
China.
Groupe CMCP, Kenitra,
Morocco.
Obeikan Industrial Investment
Group, Riyadh, Saudi Arabia.
Winding technology
LEIPA Georg Leinfelder, Schwedt,
Germany.
Stora Enso Magazine Paper,
Maxau Wolfsheck Mill,
Germany.
N.N., China.
N.N., China.
Feinpapierfabrik Dr. Franz
Feurstein, Traun, Austria.
Papresa, Renteria, Spain.
Norske Skogsindustrier Follum
Mill, Hønefoss, Norway.
Sappi Ehingen, Germany.
M-real Zanders, Werk Gohrsmühle, Bergisch Gladbach,
Germany.
W. Hamburger, Pitten, Austria.

FinishingJanus Concept
LEIPA Georg Leinfelder,
Schwedt, Germany.
Stora Enso Magazine Paper,
Maxau Wolfsheck Mill,
Germany.

Gold East Paper (Jiangsu),
Dagang, China (2).
Ecosoft calender
Nenan New Century Hengxing
Paper, Suixian, China.
Feinpapierfabrik Dr. Franz
Feurstein, Traun, Austria.
Papresa, Renteria,
Spain.
Zhangqiu Huashi Paper,
Zhangqiu, China.
Shenzhen Wander Color Printing& Packaging, China.
Guangzhou Paper, Guangzhou,
China.
Zhejiang Rongfeng Paper,
Ronfeng, China.
NipcoFlex calender
Stora Enso Packaging Boards,
Baienfurt Mill, Germany.
CalendersHenan New Century Hengxing
Paper, Suixian, China.
Gold East Paper (Jiangsu),
Dagang, China.
Shandong Huazhong Paper
Industry, Zaozhuang, China.
LEIPA Georg Leinfelder,
Schwedt, Germany.
Shanghai Chung Loong Paper,
Shanghai, China.
Zhangqiu Huashi Paper,
Zhangqiu, China.
Twister / Roll Handling
Papresa, Renteria,
Spain.

LEIPA Georg Leinfelder,
Schwedt, Germany.
Dresden Papier, Heidenau,
Germany.
Roll cutting machines
Stora Enso Magazine Paper, Maxau
Wolfsheck Mill, Germany.
Gold East Paper (Jiangsu), Dagang,
China (2).
Papierfabrik Adolf Jass, Schwarza,
Germany.
Feinpapierfabrik Dr. Franz Feurstein,
Traun, Austria.
Papier- u. Kartonfabrik Varel,
Varel, Germany.
AO Kondopoga, Kondopoga, Karelia.
Emin Leydier, Nogent-sur Seine,France.
LEIPA Georg Leinfelder,
Schwedt, Germany (3).
Ningbo Zhonghua Paper, Ningbo,
China (2).
Papresa, Renteria, Spain (2).
International Paper, Jay, USA.
Guangzhou Paper, Guangzhou,
China (2).
Shanghai Chung Loong Paper,
Shanghai, China.
GAP Insaat Yatirim ve Disticaret,
Turkestan.
Parent reel cart
Papresa, Renteria, Spain.
LEIPA Georg Leinfelder, Schwedt,
Germany.
Gold East Paper (Jiangsu), Dagang,
China.
Guangzhou Paper, Guangzhou,
China.

17/04

Newsmagazine for theinternational clientele,
partners and friends ofVoith Paper Technology

Published by:Voith Paper Holding GmbH & Co. KG
Editor:Dr. Wolfgang Möhle, Corporate Marketing,
Voith Paper Holding GmbH & Co. KG,
Tel. (++49) 73 21 37 64 05
Fax (++49) 73 21 37 70 08
P.O. Box 1970, D-89509 Heidenheim
wolfgang.moehle@voith.com
http://www.voithpaper.com
Editorial coordinator:
Manfred Schindler, D-73434 Aalen
Design, layout and typesetting:
MSW, P.O. Box 1243, D-73402 Aalen
Copyright 2/2004:
No part of this publication may be
reproduced or copied by any means
whatsoever without the express
permission of the editor.
Issue 17, February 2004.

2/2004/27 MA Printed on chlorine-free bleached paper manufactured with Voith Paper Technology machinery.

Paper Technology Journal“twogether” is published twice annuallyin German, English, Chinese and Finnish.
Contributions by independent authors do
not necessarily reflect the opinion of the
publisher. Please address all correspondence
and inquiries to the editor.