Paper Technology Journal“Paper is my life!” – Hans Müller,a member of the Corporate Board ofManagement, has retired.
News from the Divisions:
Austrian papermaker banks on
Voith innovation.
Papresa doubles capacity –PM 6 went successfully on stream.
100 % Voith for Tissue.

20

The NipcoFlex shoe calender –Development and operating experience.
Paper Culture:
Paper kites – Magic, mythology andsport.

Contents

EDITORIAL
Foreword

1“Paper is my life!” –Hans Müller, a member of the Corporate Board of Management, has retired

2

Voith Paper New Organization Structure – Looking to the Future

6

NEWS FROM THE DIVISIONS
Austrian papermaker banks on Voith innovation –Experience and know-how: the key to dependable secondary fibre preparation

8

Fiber Systems in Japan – Customized solutions for small to medium size
stock preparation lines, too

12

Papresa doubles capacity – PM 6 went successfully on stream

16

Traun PM 3 – Special grades for exclusive demands

21

Varel PM 5 – Interview with Uwe Wollschläger,Managing Director Papier- und Kartonfabrik Varel

24

think in paper – Topping-out party at the new Paper Technology Center

27

Rebuilds with Voith – Improved quality, productivity and economy
for greater customer benefit

28

Rebuild of Braviken PM 52 – “After the rebuild we can now take on
any new newsprint machine”

32

Abitibi-Consolidated “Alma” – PM 14 conversion to coated paper

36

Krkonosske Papirny – first SpeedSizer in the Czech Republic

38

Unchallenged Market Leadership – More than 300 Voith shoe presses worldwide

40

BoostDryer – New higher-performance drying technology
for improved paper quality

44

100 % Voith for Tissue

48

The NipcoFlex shoe calender – Development and operating experience

52

Virtual Reference Grinding – An innovative method to re-condition
the Yankee Dryer in a Tissue Machine

57

Voith Customer Conference in Indonesia –Improving Productivity, Quality and Efficiency!

60

Stage-Gate ® at Voith Paper Fabrics –Greater customer benefit through faster product development

62

iCon – intelligent Control for stock preparation lines

64

Voith Paper Fabrics Customer symposium in China –On-the-spot reliability, knowledge and trust

68

PAPER CULTURE
Paper kites – Magic, mythology and sport

70

Title page – Colourful paper
dragons in the sky – a pleasurefor young and old in countless
civilisations across the world,both now and in the past.

1

Dear customers, Dear friends, Dear readers,
My almost 40 years of association with the pulp and paper industry and, in particular,
the cooperation with people from all over the world brought me a great deal ofsatisfaction and sustained friendships and can best be summarised by the words ofWilhelm von Humboldt:“In principle it is the relations with people that give life its real value.”
I am very grateful that so many influential people supported and fostered me in thebuild-up of my professional life. I never took that for granted and always endeavoured
to return the favour by, among other things, investing my time in the development ofyoung, talented people.
Hans Müller

My special recognition and my thanks go, of course, also to all of you and, in particular, to our customers and suppliers. The pulp and paper industry will, in my opinion,
remain an interesting and undoubtedly high-tech industry that will continue to play
an important role in the development of mankind. Communication is and remains animportant cornerstone in the bringing-together or globalisation of the different cultures. Whether printing, writing or packaging papers, most papers are, in the broadest
sense of the word, first a means of communication. Despite growing electronic communication, there is still a lot to discover in paper and its derivates.
Dr Sollinger, as the new Chairman of the Voith Paper Corporate Management Board,along with Mr Staudenmaier and Mr Nettesheim, has already taken over the destiny ofVoith Paper and – I am quite certain – together they will professionally and innovatively master the future. The combination of these three gentlemen is the right one at
the right time.
Thank you very much again for having given me the opportunity of leaving a small
mark on the ongoing development process of this fascinating industry.
I hope you will all remain favourably disposed to Voith.
Yours

2

“Paper is my life!” –Hans Müller, a member of the Corporate Boardof Management, has retired

In April, a formal ceremony was held in honour of Hans
Müller on the occasion of his retirement. He was a member of the
Corporate Board of Management of Voith AG for eleven years andChairman of the Executive Board of Voith Paper and Voith Fabrics.
Over 200 guests were present at the event. About a third of themwere customers from the paper industry, who had travelled fromevery corner of the world, from India to North America, to honour
and thank “Mr Paper”.

Hans Müller has worked in and influenced the paper industry for over 40
years. With him, the company has lost an
experienced specialist and expert in this
sector. Paper played a central role inHans Müller’s professional life. “Paper
cast its spell on me in my early childhood. I was born right next door to apaper mill, my father worked there andsometimes, at the weekend, he would
secretly take me with him into the mill”,
recounts Hans Müller. “Ever since thenpaper has been my passion, and I havenever escaped from its spell.”Hans Müller was born in Balsthal, Switzerland, on 6th January 1942. In 1966 hecompleted his studies in paper technology at the Fachhochschule in Munich as a
Diplom-Ingenieur (Masters degree in engineering). During the years that followed,
Hans Müller worked as a development
engineer at Consolidated Bathurst Ltd in
Canada. His next position was production
manager of Balsthal’s Niederbipp Paper
Mill, Switzerland. In 1971 Hans Müller
moved to Sulzer Escher Wyss in Ravensburg, where he worked as a start-up andproject engineer. In 1975, Hans Müller

3

4

20/05

was appointed head of sales in the Paperand Process Technology Division of
Sulzer Canada in Montreal. From 1980 to
1992 he first acted as Senior Vice President of Sales and Engineering and later
as President at Escher Wyss in Middletown/Ohio, USA. In 1992 Hans Müller returned to Sulzer Escher Wyss in Ravensburg as a member of the Management
Board and product manager for paper
technology. In 1993 he was elected President of the Management Board. In thecourse of the joint venture in the paper
technology sector together with what5

3

Fig. 1: View of the banquet hall at the“Konzerthaus” in Heidenheim.
Fig. 2: Hans Müller expresses his heartfelt
thanks.
12

was, at that time, J.M. Voith GmbH, Hans
Müller became President and CEO of thejoint venture in October 1994 with theformation of Voith Sulzer PapiertechnikGmbH. Since 1995 Hans Müller was amember of the Corporate Board of Management of today’s Voith AG and was
responsible for the Group divisions Voith
Paper and, since July 2000, also Voith
Fabrics.

another challenge. In addition to his previous responsibilities, he also assumed
presidency of the newly formed Groupdivision, Voith Fabrics. Further acquisitions, like Jagenberg and Finckh, followed. Hans Müller’s strategic goal wasalways to be able to offer the customer
the complete paper production processfrom a single source.
One year ago, Hans Müller launched a
final, future-oriented milestone on thecompany’s way to becoming a processsupplier, together with his colleague on
the board, Dr. Hans-Peter Sollinger: thePaper Technology Center PTC, a uniqueresearch and development centre worldwide for which Voith in Heidenheim hasinvested over EUR 50 million. With this, afoundation stone has been laid for a successful future at Voith Paper.

During the past decade, Hans Müller has
left an indelible mark on Voith Paper andplayed a decisive role in structuring it.
The successful merger of the two companies, Sulzer Escher Wyss and Voith, inthe field of paper technology, which was
carried out under the presidency of Hans
Müller, bears his signature. In 1999, when
Voith acquired the paper machine clothing business division of the British company Scapa, and thereby significantly
expanded its product range of paper machine clothing, Hans Müller took up yet
6“I look back on the eleven years at Voith
with a feeling of satisfaction. During theseyears we have achieved a great deal as ateam. Voith, as a family-owned company,
cultivates its own culture, which I had
the honour of experiencing over the past
years and consider to be extremely pleasant. For the future I wish that Voith willcontinue to remain independent as a family-owned business and that our customers from the paper industry may
profit from the innovations that the PTC
will produce. I am convinced that at Voith
the interests of the customer will be at
the forefront of everything that the company does”, were the words of Hans Müller.

7
Fig. 3: Setting the mood in music for Switzerland, Mr Müller’s homeland.
Fig. 4: Dr Rogowski thanks Marianne Müller
with a bouquet of flowers.
Fig. 5: Dr Michael Rogowski, Hans Müller,
Angela Voith and Dr Hermut Kormann enjoy awalkabout.
Fig. 6: A shadow play recalls Hans Müller’s life.
Fig. 7: Going-away present from the Corporate
Board of Management of Voith AG: Marianneand Hans Müller immediately take a seat in the
cocktail armchairs made of paper.

20/05

4

Extracts from the welcoming
speech given by Dr Hermut
Kormann, President and CEOof the Corporate Boardof Management of Voith AG“Thank you very much for accepting ourinvitation to the headquarters of ourcompany in the beautiful Swabian Alps.”“Don’t get this wrong: the alp horns thathave welcomed you here today arecertainly not typical instruments of theEastern Swabian Alps. The welcome was

Excerpts from the laudatory
speech by Dr Michael Rogowski,
Chairman of the Supervisory
Board of Voith AG and
President of the Shareholders’Committee of Voith“It is a great honour and pleasure
for me to give an official speech here for
Mr Müller.”“It is nice to see so many companions
here today, many of whom accompanied
Mr Müller over decades through his professional life. When I look through thehall, I see so many faces from old Sulzer20/05

a first homage, setting the mood forwonderful Switzerland, the homeland of
the Voithian to whom we are today
saying ‘Thank you’ and ‘Goodbye: Hans
Müller, our ‘Mr. Paper’, who, after having
worked for more than 40 years in thepaper industry, goes into well-earned
retirement.”“When I look around me, I see manywell-known and familiar faces from nearand far. That fills me with pride. It isa great honour for our company to playhost to so many customers and long-

Escher-Wyss times and, of course, many
Voithians. And it particularly pleases methat so many of our company’s customers have come here. The presence ofso many passionate papermakers is thebest evidence of the reputation that our‘Mr Paper’ has gained in the sector andthe standing he enjoys with you all.”“‘Paper is my life’ – it was with thesewords that Hans Müller once characterised himself and his relationship to his
work. They have long become a standard
quotation at Voith.
‘Paper is my life’ – there could not be abetter heading for over sixty years of life
with paper – more than forty of whichspent working in the paper industry.”“Looking back I can now say: It was a
lucky stroke for Voith when Hans Müller
joined us in 1994. He knew the sector
like the back of his hand far more thanstanding business partners. I would almost tend to say: The entire ‘Who is
Who’ of the paper sector is here with us
today.”“I am particularly pleased to also be able
to welcome a member of the Hanns Voith
family here today. It is a sign of thecloseness of our shareholders to theircompany that they do not wish to missoccasions like the one today to be present personally and to thank the persons
who have done so much for the Voith
company.”

anyone else. He was an expert and entrepreneur. His name stood for reliability
and trust.”“I am quite sure: Much of what Hans
Müller has done for Voith will have alasting effect and he will be given an
honourable place in the chronicle of ourcompany.”“Dear Mr Müller, you were and are afirst-class colleague! We all know that
the Voith Company would not be where it
is today without your service and yourcommitment. It only remains for me tosay a big and heartfelt ‘thank you’ foreverything that you have done for Voith.
For your commitment, your know-how,and the experience that you have madeavailable in your service to our company.
We wish you and your family all the best,happiness, good health and satisfaction
for the years ahead.”5Hans Müller – an institution in the paper industry,
and a pillar of strength

Dr Marietta Jass-Teichmann, Executive Managing Partnerof the Adolf Jass Paper Mill in Fulda, Hessen, Germany gave amoving thank-you speech – from the customer’s point of view –for Hans Müller’s farewell. A few exerpts follow.
“Dear guests,
That Voith can today supply a paper millwith all the machinery, equipment andauxiliary materials it needs is the ‘strategic’ face of Hans Müller. How have we as
customers, dear Mrs Müller, got to know
your husband personally?
It is not just PM 1 in Schwarza, that went
on stream on 12th February this year,that brought us together with Hans
Müller. Our first encounter was at theJass Company in Fulda in 1993, shortly
after you, Mr Müller, had taken up chairmanship of the Management Board of
Sulzer Escher Wyss GmbH in Ravensburg.
From the point of view of a paper machine manufacturer this was a period that
had little to offer at Jass. The last major
investment, the fundamental renewal andrebuild of PM 4 together with Sulzer
Escher Wyss, was completed successfully in 1991. The time was not yet ripe
for another major investment. Nevertheless, you took a whole day of time forus, and we appreciated it very much.
I remember with pleasure how we went
together with you for a meal after thetour of the mill, with your family and themembers of the management.
In 1997, you met our request to implement the fundamental renewal andexpansion of PM 3 in 1998, in the old

tradition again under the overall controlof Ravensburg.
Dear guests, how does a typical meetingwith Hans Müller go? First it should be
remembered: We have spoken and you,
Mr Müller, have listened. For you are agood listener. A man of few words. You
follow the teachings of Laozi: ‘True rulers
do not set great store by words.’ Instead,
you take note on a sheet of paper of allof the problems that your customers
have in order to persistently ensure that
one day each item can be crossed off.
To achieve this you are prepared to go
deeply into detail. In the end you personally check with the customer to see
whether the crossing-off, to show thatthe matter has been settled, is justified.
And another thing has also been noticed
by several of your customers. Sparks
may fly on a high-speed paper machine,
but in a meeting in the presence of Hans
Müller there is no dispute. Problems are
solved objectively.
And so Hans Müller is not only an institution in the paper industry, but also apillar of strength. A man who, throughsincerity and reliability, can convinceothers. One man – one word. In important questions you have stood beside us
even at weekends and on holiday. This iswhat I personally very much appreciate
about you.

Dr Marietta Jass-Teichmann,
Papierfabrik Adolf Jass,
Schwarza, Germany

Today we say – with a little nostalgia –a very hearty thank you. Thank you forwhat you have achieved for us, for thepaper industry. Thank you for yourexcellent and fruitful cooperation. I knowthat you are looking forward to the newchapter in your life. We wish you, yourwife and your family all the very best forthe coming years, good health and God’s
blessing. Perhaps now, back home inbeautiful Switzerland, you will regain‘das Wandern ist des Müllers Lust’ (hiking is the miller’s delight). And should
you ever have a yearning for the pleasantodour of warm paper, you will always be
most welcome to visit us in Fulda and
Schwarza!”
20/05

6

Voith Paper
New Organization Structure – Looking to the Future
In connection with the retirement of Hans Müller, a numberof changes have been made to the organization of Voith Paper.
Dr Hans-Peter Sollinger succeeded Hans Müller on 1st May 2005.
He took over the chairmanship of the new Corporate Board ofManagement of Voith Paper, the “Executive Board”. Together with
Bertram Staudenmaier and Norbert Nettesheim he, therefore, shares
the responsibility for Voith Paper.

Fiber Systems
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Paper Machines
Graphic Papers & Specialty Papers

Paper Machines
Board & Packaging Papers

Fabrics

7

The members of the Board of Management ofVoith Paper, Rudolf Estermann, Andreas Endters,
Dr Roland Münch, Kurt Brandauer,
Thomas Koller, Bertram Staudenmaier,
Dr Hans-Peter Sollinger, Norbert Nettesheim
and Dr Lothar Pfalzer (from left to right).

Within the Board of Management of Voith
Paper, the tasks are split between thesethree members: Dr Hans-Peter Sollinger
will focus on the divisions for systembusiness, which includes fiber systems,
graphic and specialty paper machines,
board & packaging paper machines, finishing and automation.
Bertram Staudenmaier will assume responsibility for the Voith Paper Fabrics
division (forming fabrics, wet felts anddryer fabrics for the paper industry) as
well as the Voith Paper Rolls division(rolls and covers, including roll service).
Norbert Nettesheim will be in charge ofFinances and Controlling.
Dr Hans-Peter Sollinger and Bertram
Staudenmaier have been appointed to the
Corporate Board of Management of Voith
AG. In future, Voith Paper will be represented by two members.
There are also organisational changes in
the new structure: the merger of Voith
Paper and Voith Fabrics. In the past,
Voith Fabrics was an independent division of Voith AG. As a worldwide leading
supplier of paper machine clothing, it is

Finishing

now a division of Voith Paper and goes
under the name of Voith Paper Fabrics.
Therefore, Fabrics will in future be integrated into Voith Paper, which will leadto closer cooperation and enable fasterstart-ups to the advantage of our customers. The previous Group name for
Voith Paper and Voith Fabrics, Voith
Paper Technology, will be discontinued.
The following seven division managers
will be members of the Voith Paper Boardof Management:
Dr Lothar Pfalzer – Fiber Systems,
Kurt Brandauer – Paper Machines Graphic and Specialty Papers,
Rudolf Estermann – Paper Machines Board & Packaging Papers,
Bertram Staudenmaier – Fabrics,
Thomas Koller – Finishing,
Andreas Endters – Rolls(formerly Service) andDr Roland Münch – Automation.
As a “collegial” management organisation, this successful concept with sevenclosely meshed divisions is geared to optimally networking the know-how and the

Rolls

Norbert Nettesheim, member of the Executive
Board of Voith Paper (Finances and Controlling);
Dr Hans-Peter Sollinger, Chairman of the
Executive Board of Voith Paper and member of
the Corporate Board of Management of Voith AG;
Bertram Staudenmaier, member of the Executive
Board of Voith Paper and member of the
Corporate Board of Management of Voith AG(from left to right).

business strategies of the individual divisions. The divisions share knowledge
and experience, the best practices andprocess solutions and, therefore, mutually support one another so as to be thebest in their field. As a leader in innovation and the only process and service
supplier in the paper industry, Voith
Paper is the competent partner for thecomplete range of products and services
for the enhancement of the paper production process.

Automation
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8

Austrian papermaker banks on
Voith innovation –Experience and know-how: the key to dependable
secondary fibre preparation
The Austrian paper group W. Hamburger AG, foundedby Wilhelm Hamburger, specializes in the production of high grade
corrugating medium and packaging papers.

Today the W. Hamburger Group has four

The overall system design capacity isPeter Meßmer

production plants in three countries:

1,500 t / 24 h handling a 100 % recovered

Fiber Systems
peter.messmer@voith.com● The parent company in Pitten, Austria

paper furnish. Included in the scope of● Papierfabrik Rieger in Trostberg,

supply for these three stock preparationlines were pulping, screening, fractiona-

Bavaria, Germany● Dunapack, Hungary andtion,● The new mill Papierfabrik Hamburger

thickening, refining, process water andcleaning,

dispersion,

flotation,

reject handling systems, plus a compre-

Spremberg in Germany.
This latest member of the Hamburger

hensive set of spare parts.

Group is located in Spremberg’s “Schwar-

Roland Rauch

1

Meri Entsorgungstechnik
steffen.henkel@meri.de

The pulping system for the underliner

power station site in Lausitz/Brandenburg.

and backliner comprises a UniPulper,
Junkomat, Contaminex pulper detrasher,

Fiber Systems
roland.rauch@voith.com

Steffen Henkel

ze Pumpe” industrial zone on a former

In November 2003 Hamburger Spremberg

and ragger. For coarse screening, theordered from Voith Paper three separate

first two stages in each line are equipped

stock preparation lines for topliner, un-with disc screens (Turboseparators), withderliner and backliner, including approach

Combisorters as the final stage. Refining

flow screening and broke pulpers.

of the long fibres is undertaken in the
WEP

Topliner

PulpingMCMCcleaning screening

DeflakingRefining

LC Screening
cleaning

Underliner

IC
LC
Flotationscreening cleaning
Pulping

Dewatering

Dispersion

ScreeningMC
MC
Fractioncleaning screening ation

Backliner

20/05

PulpingMCMCcleaning screeningLC
cleaning

Dewatering Fractionation

Screening
Refining

9Fig. 1: Schematic layout of the 3-line stock
preparation system in Spremberg.
Fig. 2: Turboseparator coarse screening.
Fig. 3: Combisorter final stage screening.
Fig. 4: KS 900 cleaner installation with EcoMizer
technology.

underliner and backliner systems using

Compax compactor, Elephant thickener,

the stock preparation plant as well as

Voith TwinFlo double disc refiners.

Sedimator, Screenex and various convey-

supervising its erection and commission-ing equipment. The approach flows –ing.

Depending on the product – fluting, test-

critically important for sustainable highliner or white top testliner – the underlin-

product quality – have MultiScreens with

The underliner and topliner systems

er system can be fed with stock from

C-bar baskets. Voith also supplied Com-

started up in April 2005. Only a few days

brown or white recovered paper grades.

pactPulpers, a new generation of broke

after commissioning, high grade testliner

The white furnish is first cleaned using

pulpers under the paper machine.

stock was being pumped to the storage
chests. White top testliner production

EcoMizer technology and then deinked bystarted in June.

EcoCell flotation. This is followed by a DX

Likewise included in Voith’s scope ofdisc dispersion stage for efficient detach-supply was basic engineering for the con-ment of residual ink from the fibres, plus

trol and instrumentation systems, includ-

By choosing this state-of-the-art technol-

dirt speck and stickies reduction.

ing parameter listings, instrumentation

ogy, W. Hamburger AG has set anotherlayout and function planning for the com-

important milestone in its long and suc-plete stock preparation system.

cessful tradition of recycling. Voith Paper

Thickening is by Voith bagless disc filter

is proud to have partnered the company

and Thune screw press technology. Heretoo, Hamburger has opted for the mostThis engineering enabled the complex

advanced thickening equipment available

automated operation of the individual

today.

stock preparation lines to be efficiently

in this exacting project.

integrated together.

Reject handling by Meriventure partner with Voith Paper, was re-

In addition to the equipment and control

Since the new Technical Instruction on

sponsible for the entire reject handlingand instrumentation engineering, Voith

Municipal Waste came into force on

and water treatment systems, including

was also actively involved in engineering

01.06.2005, adequate reject handling has

Meri Entsorgungstechnik Munich, a joint-

2

3

4

20/05

10

Fig. 5: MultiFractor for fractionation.
Fig. 6: EcoCell flotation system.
Fig. 7: Bagless disc filter with HCH5 cleaner
plant on the right, also with EcoMizer technology.
Fig. 8: Part of the Voith stock preparation
system with Thune screw press (center).
5

6

become even more important in the paper

Light rejects from the drum screens andstalling a Meri metal separator and Lion

industry. Apart from the environmental

Combisorters pass via conveyors to ashredder at a later date. This provides forprotection aspects of reject handling,

Compax compactor where they are com-more stringent disposal demands in fu-

greater attention is now being paid to thepacted to the maximum possible dry con-ture.

costs in this area since only after correct

tent. The dewatered rejects are then fed

pre-treatment can rejects be incinerated

to the reject bunker via a third conveyor.

Solids are separated from sewer water inwithout further handling. To ensure cor-Thanks to their high dry content, the pre-the pulping zone by two Elephant discrect pre-treatment, the Hamburger Sprem-

treated rejects can then be transported

thickeners, with drainage exclusively byberg paper mill was partnered by Mericost-effectively for trouble-free disposal.

gravity.

The plant layout allows enough space

Coarse rejects from the screens and fromahead of the Compax compactor for in-

the HC, MC and LC cleaners are handled

Entsorgungstechnik.

7

8

20/05

11

HaraldGansterFig. 9: Principle of the MSA screen as installedin Spremberg’s approach flow systems.

Director,
Production andTechnology
W. Hamburger
AG

Fig. 10: Compax for compacting and dewatering
rejects.
Fig. 11: Sedimator for dewatering small, heavy
rejects.
9

Light rejects removal(deaeration)“We are extremely satisfied with theentire handling of this project, the suc-Covercess of which is very much attributable

Clamping bolt
Screen basket

to the Voith team. In delivering the comInlet

Rotor

plete stock preparation system including
approach flow screens and broke pulpers,

Bearing housing
Housing
Auxiliaries
connection plate
Lubrication
drainage tray

Accepts
Rejects

Voith has played a key role in the successful completion of our ambitious
project. We are very impressed by theirprofessional project management.”

by a Sedimator. This machine has beenbottles, stones, wet strength paper, met-

shredder. The trash can then be transport-

specially developed to remove small andal, wood, textiles and the like. Thanks to

ed by belt conveyor to the container toheavy rejects such as paper clips, glass,the large buffer storage capacity of thejoin the rejects from the Screenex units.

small stones and sand, metal and heavy

inlet hopper, the machine can handle

plastic particles from reject flows.

large amounts of rejects and flushing wa-

Theter. The dewatered heavy rejects from the

Spremberg and Meri Entsorgungstechnik

The pulper rejects are dewatered by two

two Screenex units are then transported

has resulted in a reject handling system

Screenex units. These machines are de-by belt conveyor to a disposal container.

that not only enables trouble-free dispos-

teamwork

between

Hamburger

al according to the new regulations, butsigned for draining the water out ofcoarse rejects from batch-operated pulp-

Enough space has also been allowed foralso a much more cost-effective rejecting systems. The Screenex can process a

the future to shred the pieces of ropetransport thanks to greater compactness

wide variety of rejects, including plastic,

trash after the rope cutter using a Lionand weight savings.

10

11

20/05

12

1

Fiber Systems in Japan –Customized solutions for small to medium size
stock preparation lines, too
Customer requirements, expectations and circumstances
in Japan are different from those in other countries. These differences range from printability demands right back through thepapermaking process to stock preparation. Demands on end product quality and on machine runnability are very high. Plant spacerequirements is a particularly important factor.

Andreas Sauer
Fiber Systems
andreas.sauer@voith.com

20/05

Due to the high population density andearthquake safety requirements in Japan,
building costs are also high, so that installation and maintenance access space
is usually restricted. In addition, normal
mass production solutions with large
paper production tonnages are not always

applicable. As against the average DIP
production of 200 - 400 t / 24 h in Japan,
the DIP output of many Japanese mills is
only about 50 -150 t / 24 h, and suchplants are still being planned and installed. Moreover, Japan has one of theworld’s highest domestic recycling quo-

13

Fig. 1: Each subsystem in the trial facility
can be individually tested.
Fig. 2: Trial dispersion system for thickening
and dispersion at temperatures up to 125 °C.

tas, which means different local printing
ink binders and ink speck sizes have tobe taken into account, too.

2

Voith Paper has been working closely together with Japanese customers for many
decades, helping to develop cost-effective and optimized concepts. For example, Voith Paper has introduced newtechnologies in Japan, such as the twoloop principle (pre- and postflotation).
The stock preparation lines commissioned in Japan for graphic grades andboard and packaging papers meet all expectations and are highly commended byVoith’s customers.
Voith IHI Paper Technology provides customers in Japan with the full range of
Voith Paper production plants, including
optimal machines and solutions for tissue stock preparation lines.

Significant orders in Japan
for Voith Fiber Systems● Complete bale feed systems with thelatest in automated bale dewiring
machinery. Due to the very high costof labour, maintenance-friendly plants
are particularly important in Japan.
● High consistency pulping systems for
OCC lines. These systems offer
customers better paper strength characteristics than conventional low
consistency pulping systems.
● Fiberizers to replace pulper detrashingmachines supplied by others. For thesame power consumption, production
and screenplate hole size, customers
report half the fibre losses, with higher
quality at the same time.

● HiPRO high consistency cleaningsystems for OCC, DIP and chemical
pulp plant. Customers report twice thescreen basket life in downstream
machines after replacing cleaners fromother suppliers.
● 250 rebuilds of screens supplied byothers. The successful MultiFoil rotor
and C-bar screen basket combination
has resulted in substantial powersavings, with better stickies removal at
the same time.
● Within a single year 10 rebuilds ofcompetition screens to Voith’s new
low profile screen technology.
MC slotted screen capacity then rose
threefold, with higher product quality
and lower power consumption.

● Disc filters (now with the patented
bagless segments) for OCC, TMP, DIP
and the wet end process. Within justfour years these machines are now so
successful that more of them are soldin Japan than any other make.
● 70% of all pre-, post- and filtrateflotation systems in Japan have beenordered from Voith IHI. EcoCell andthe improved MT II flotation technology have convinced customers for
production tonnages exceeding
50 t / 24 h.
● Repeat washer orders for DIP, OCC
and tissue lines. Compact Washer withimproved design.

20/05

14

Figs. 3a and 3b: Flotator development from
the MT (3a) to the MT II (3b).
Fig. 4: Overall losses and brightness gainin the primary stage of a pre-flotation system(70% ONP, 30% OMG, 15% ash, soap ascollecting agent).
3a

3b

4

58
56

Brightness ISO

54

MT II

52
MT
50
48
46

Fiber Systems customer trial
facility in Japan
Voith IHI Paper Technology serves customers and research institutes with a trial
facility for simulating machine and stock
behaviour under virtual mill conditions.
Many customers buy this service from
Voith, since it enables them to precisely
check out both positive and negative influences and effects, thus ensuring asound basis for their investment decisions.
All stock preparation subsystems areavailable in this test facility (Fig. 1), at
the heart of which is a dispersion system.
Both the high consistency discharge(chute) and pump operation for 3 bar
high-temperature dispersion can be run,e.g. for investigating freeness and dirt
speck development (Fig. 2). Many customers also use our facility for selecting
the correct screen slot width. For this,approximately two dozen screen baskets
are available for establishing the optimal

20/05

compromise between quality, fibre losses
and fractionation. Here, Voith also investigates other influences during the trial
work such as screen basket profile angle
and rotor speed.

The MT II Flotator:
specially designed for small to
medium production tonnages
Voith’s EcoCell flotation is a very flexible
process in many respects. Thanks to its
simple, modular design, the EcoCell flotation system can easily be expanded tocater for production increases. For difficult or slow flotation conditions the number of cells can also be suitably adjusted.
This and many other factors make the
EcoCell the most efficient and cost-effective flotation machine for production outputs exceeding 150 t / 24 h.
As mentioned, there are numerous millsin Japan with relatively small production

2 4 6 8 10 12 14 16 18
Overall losses (%) from ash balance

capacities between 50 and 150 t / 24 h.
For tissue production and filtrate flotation, compact machines are also needed.
The MT Flotator (Fig. 3a) has a capacityof 20 to 50 m 3. Developed mainly forhighly specialized customers, this machine achieves excellent quality levels.
Its design has now been completely revised for greater ease of maintenance.
The new MT II Flotator (Fig. 3b) offers
the following main benefits:● Adjustable air bubble spectrum and air
flow control.
● Greater collision probability between
air bubbles and ink specks –adjustable to suit requirements.
● Self-cleaning aeration system.
● Automatic foam overflow.
● Compact design for lower investment
costs and less space requirement.
● Improved quality results for the samedwelltime, or reduced size for the same
quality if this is already sufficient.

15

Fig. 5: The new Compact Washer.
Fig. 6: The maintenance-friendly headboxof the new Compact Washer.
5

6

The MT II Flotator ensures excellent
brightness development (Fig. 4) and low
losses in the smallest possible space. In
addition, its specific energy consumption
in this production area is the lowest of all
flotation concepts.

The Compact Washer:
specifically for small to medium
production tonnages
While washers are used in Europe exclusively for tissue and market pulp production, the machine is a favourite in Japanfor other purposes as well. For board andpackaging paper production from recovered fibres, it offers the advantages ofgreater product strength characteristics,
better drainage behaviour and fewer web
breaks on the paper machine. In DIP lines
the Compact Washer is used for improving brightness, dirt speck removal andmicrostickies reduction. Fluctuations in
ash content and freeness, due among

other reasons in Japan to the generally
small size of raw material storage capacities, invite new solutions based on intelligent control concepts. Here too, Voith
also offers customized solutions forsmall to medium size production lines.

practice (Figs. 5 and 6). Drainage in thismachine is by centrifugal force on agrooved roll, and by wire tension. Deashing is regulated by varying the inlet
stock consistency.

The Voith VarioSplit is a high-speed
washer with drainage by wire tension
around a smooth roll. By integrating two
headboxes and two drainage rolls into thesame machine, higher capacities are possible with only one unit. The machine
is very compact, and at normal stock
consistencies up to 1.3% very high deashing efficiencies are reached. The efficiency can be simply adjusted by altering
the wire speed.

The new Compact Washer offers the following benefits, all of which have been
confirmed in practice:For small to medium production systems,
and particularly for stock consistencies
between 1% and 4%, Voith Paper has onward developed an existing machine concept and the result, the Compact Washer,
has proved to be highly successful in● Lower operating costs thanks to longer
wire life.
● New improved headbox design:– Forced cross machine distribution
ensures better wire utilization for amore uniform wash effect.
– Modular headbox design for easierdismantling and cleaning.
● More maintenance-friendly thanks toeasier accessibility.
● Closed machine concept keeps thesurroundings clean.
● New tray design eliminates dead zones
and prevents deposits.

20/05

16

Papresa doubles capacity –PM 6 went successfully on stream
In the Basque town of Renteria, Spain, Papresa S.A.,
a manufacturer independent of large industrial groups, produces
170,000 t/year of newsprint on two paper machines, PM 4 and PM 5.
Elmar Engstler

80% of the production goes to the Spanish market, covering with it

Voith Paper Tolosa
elmar.engstler@voith.com

a market share of 20%. The remaining 20% of production is exported to neighbouring countries. With the start-up of the new PM 6
production line, the capacity of the paper mill has been more thandoubled, with the goal of increasing the Spanish market share to
30% and the export rate to 40%.

Norbert Peters
Voith Paper Krefeld
norbert.peters@voith.com

20/05

17

Fig. 1: Papresa S.A. in the Basque town ofRenteria, Spain.
Fig. 2: Operator Team PM 6, Management ofPapresa S.A., Management of Voith Paper S.A.,
Tolosa, Project Management Team of Voith Paper.
Fig. 3: Schematic PM 6.
1

2

The project, originally intended in 2002
as an extensive rebuild of PM 5, very
rapidly gained dynamic and Papresa decided to install a completely new production line, PM 6, on the site of the shutdown PM 3. The goal was, with a total investment of EUR 100 million, to increase
annual capacity for the production ofnewsprint in Renteria to 350,000 t/year.
Papresa ordered the turnkey production
line from Voith Paper S.A., Tolosa, which
was completed according to the ProcessLine Package concept. Besides the machine and the wet end process, the order
included almost all ancillary systems, theelectrical equipment and control system.
In addition, Voith Paper was entrustedwith the complete machine and plantengineering. The furnish, consisting of
100% recovered paper, is mostly prepared in two stock preparation systems,
which were supplied by Voith Paper S.A.,
Tolosa and put into operation in 1997
3 (DIP 2) and 2003 (DIP 3).

Paper machine
It is intended to produce 180,000 t/yearof newsprint on the new PM 6 with a wire
width of 5,900 mm and a design speed of
1,500 m/min. The maximum parent rolldiameter is 2,500 mm.
The production line is based on the Voith
One Platform Concept. This means that
only proven high-tech modules that havealready been deployed very successfullyin many machines world-wide were used.
This ensures, among other things, a fast
and trouble-free start-up and optimization of the production line.
The paper machine includes a headboxwith ModuleJet dilution water line andProfilmatic CD profile control, which isused on a DuoFormer TQv. This combination ensures that a uniformly controlled
CD basis weight profile is reached early
on in the process. This is followed by a
DuoCentri NipcoFlex Press, a CombiDuo20/05

18

LourdesMarquetFig. 4: PM 6 with an annual production capacityof 180,000 t of newsprint.

Technical
Director
Papresa S.A.

Fig. 5: Extract of 3-D plan Wet End Process.
Fig. 6: EcoSoft-Delta Calender.

4

Run dryer section, a 1x2-roll EcoSoft
Delta calender with CalTronic CD profile
control, which provides the web surface
values necessary for the required goodprintability even at moderate pressuresand temperatures and ensures optimal
runnability by uniform densification. A
MasterReel wind-up system ensures
excellent winding quality thanks to thedirectly measured linear load.

Finishing“We are extremely satisfied with thefast and troublefree start-up and optimisation of the production line.
Looking back, we can say that the decision to entrust Voith Paper with overall
responsibility was right. We operate amachine that has almost completely
reached the design data, but apparently
still has a lot of additional potential that
we will now utilise jointly step by step.”

5

In addition, two VariFlex M winders, one
Twister roll wrapping machine and theassociated transport units were delivered.
The winders are of the two-drum type ofthe latest generation. The roll-forming
drum systems have been specifically designed for newsprint, i.e. the first drum
6

20/05

19

has its own specially developed, flexible
Elastomer cover of the MultiDrive type,
and the second drum is a tungsten-carbide-coated steel roll. The rider roll, in
turn, has a soft MultiDrive cover.
Through this combination it is ensured
that the finished paper rolls are absolutely free of the disturbing creping wrinkles
that occur frequently on newsprint rolls

and that the cores are seated centrally inthe rolls – both are a prerequisite for optimal runnability of the rolls in the printing presses.
The roll handling system consists of amanually operated, rail-bound transport
car for the parent rolls and a roll wrapping system with upstream and downstream transport sections.
As far as the roll wrapping machine isconcerned, the customer has again decided on the installation of a spiral winding
principle based Twister.
The first Twister supplied to Papresa had
already proven successful. The new machine is a Twister 1 Line.
At this type the individual sections are
set up along a continuous conveyor belt
so that the rolls are wrapped “as theypass”, so to speak.
This makes the machine fast and also
protects the rolls because the ejection
and insertion, customary up to now, is nolonger required.

Process Line Package
That the PM 6, as mentioned above, isdesigned according to the “One Platform
Concept”, and is therefore a proven andsafe machine concept, was, however, notthe only criterion that made the Voith
offer so attractive for Papresa. Added tothis was the fact that Voith was prepared
to assume full responsibility for the newline to stand up from the very beginningfor the success of the process based on
the “Process Line Package Concept”, i.e.
from stock preparation to the finished,single roll.
That means that Papresa did not need tobother with interface problems, which
frequently provide the reason for arguments, whenever something does not“run the way it really should”. Project
handling has shown that this approach
was correct and that the idea of the“Process Line Package” followed by Voith
is a guarantee for success.
Voith Paper S.A., Tolosa supplied the following systems within the “Process Line
Package”:
20/05

20

Fig. 7: VariFlex M Winder.
Fig. 8: Twister 1 Line.
7● The entire wet end process with approach flow system, broke preparation,
fibre recovery and water systems● Vacuum system● Machine air system● Lubrication systems● Steam and condensate system● Compressed-air system(ropeless threading)● Mechanical drives● Electric drives● Electrical equipment (medium andlow-voltage distribution, MCCs)● Process control system.
Among the services within the “ProcessLine Package” that were provided for
Papresa are:
● The entire plant and machine engineering (basic and detail engineering),
beginning from the demands made on
the building and the crane systems up
8

to the engineering of systems thatwere purchased directly by thecustomer● The project management containing,among other things, the entire project
coordination and time scheduling● Installation● Training● Commissioning/start-up● Optimisation.
Papresa cared much about maintaining
the limits for noise emissions, as the milladjoins a residential area. This called for
detailed studies of the sources of noise inorder to determine the optimal arrangement of the equipment and the necessary
noise insulation. As a result of this, machine sections were then installed inside
the building that normally would havebeen installed outside, and special noise
insulation material was used on thebuilding.

Project handling
For Voith Paper S.A., Tolosa this order
was a great challenge in terms of sizeand scope of services. To achieve thegoals set, a consortium was formed withother Voith Paper companies.
Last but not least, the geographical proximity of Papresa and Voith Tolosa (about
half an hour by car) resulted in very closeand optimal cooperation between the
project teams, which meant that many
problems were detected at an early stage
and could be eliminated in advance,
which led to the first roll being wound up
at 1,250 m/min on 10th December 2004.
The paper was of saleable quality rightfrom the first roll.
In the remaining two weeks up to theChristmas shutdown, the machine wasfurther optimized and its speed was increased to 1,300 m/min. The technical director of Papresa, Mrs. Lourdes Marquet,then said how impressed and very satisfied she was about the troublefree andfast start-up of this complete production
line.

Currently, 4 months after start-up, themachine is being operated at the design
speed of 1,500 m/min and reached anaverage operating time efficiency of over
85%. The forecasted starting curve
could, therefore, be clearly exceeded.
20/05

21

Traun PM 3 –Special grades for exclusive demands
Trierenberg Holding Group – with the Traun andWattens mills in Austria, Olsany in the Czech Republic
and Tervakoski in Finland – is not only the world’s leading
producer and supplier of cigarette papers, filter envelope
and tipping papers, but also the leading processor ofthese grades.
Wolfgang Schuwerk
Paper Machines Graphics& Specialty
wolfgang.schuwerk@voith.com

Herbert Brandiser
Paper Machines Graphics& Specialty
herbert.brandiser@voith.com

1

20/05

22

AndreasWindischbauer

Fig. 1: Dr. Franz Feurstein GmbH, Traun,
Austria.

Chief Engineer
Dr. Franz
FeursteinGmbH

Fig. 3: Cigarette tipping papers also serve
another important purpose – Image.

“Voith optimally supported our project
team right from the early stages, thus
laying solid foundations for a successful
outcome. Years of experience in producing our high-quality products on PM 2,
paired with the latest technology andinnovations, has now led to our stateof-the-art PM 3.
Our management’s ambitious projectschedule was only met thanks to theoutstanding commitment and capabilityof all concerned. For me personally, thisonce again shows that despite all ouradvanced technology, the human factor
is the most important of all. In thisconnection I would like to thank onbehalf of the Feurstein team all our Voith
colleagues in the Traun PM 3 project.
The indispensable need of our customers to precisely reproduce the tipping paper qualities so far attained on
PM 2 was easily complied with after
start-up optimization. Meanwhile thishas been confirmed by the complete
approval of all customers, and we arealso very interested to see what the
new machine can do for us in the wayof new product developments. There isFig. 2: Traun PM 3.

Figs. 4 and 5: The character of a cigarettedepends on three different grades of paper.

Not everyone knows that a cigarette is ahigh-tech product. Apart from the tobacco quality itself, the paper grades in particular influence the taste, strength andbrand image of a cigarette. The porosityof the normally white cigarette paper andfilter envelope paper makes a cigarette“light” or “heavy”. The printed tipping paper gives the cigarette a certain image,and is perforated to admit exactly theamount of air defining its character.
The new PM 3 at Dr. Franz FeursteinGmbH in Traun mainly produces tipping
papers. These very lightweight grades,with basis weights from 28 to 40 g/m 2,
are afterwards rotogravure printed withthe cigarette’s exclusive image and perforated to ensure precisely the right ventilation characteristics. Small batches ofthin or “bible” printing papers are also
produced on PM 3.
This machine was jointly developed
based on Feurstein’s experience in tipping paper production and Voith’s specialized papermaking process know-how.
The primary focus was on product quality
and machine flexibility. Consistently highpaper quality is of paramount importancein cigarette-making machines. Furthermore, the paper must be as insensitive as
possible to humidity and temperaturefluctuations.

no doubt that this highly successfulcommissioning has enabled us to set
new product quality benchmarks. Our
new PM 3 is perfect proof that a powerful modern paper machine can provide
all the flexibility we need for our highly
specialized products.”
20/05

Quality first
Quality starts with stock preparation. To
this purpose the approach flow section
incorporates C-bar screens, EcoMizer
cleaners and a HydroMix for efficient water-stock mixing. The result is consistentproduct characteristics and fast stabilization after product changes – decisive for
optimal economy and market success.
Rectifier roll headboxes with ModuleJet
are well proven in the Trierenberg Group.
Also on the new PM 3, one of these headboxes ensures a uniform basis weightprofile in the machine and cross-machine
directions. And together with the dandy
roll, indispensable for these paper gradesin the fourdrinier section, it also guarantees excellent formation.
The press section includes a DuoCentri-I
press with separate pick-up, a conventional double-felted first nip, and a single-felted second nip. This is followed bya straight-through press enabling separate smoothness adjustment on the top
and bottom sides. Deflection compensation is assured by a newly developed selfloading single-zone Nipco-F1 roll.
A CombiDuoRun pre-dryer section withtransfer foil unit, DuoStabilizers and Ventistabilizers, enables a reduction of web
tension for optimal running at low basis
weights. Web threading is ropeless.
To ensure perfect printing, tipping papers
must have a very homogeneous smoothsurface, whether glossy or matt, that is
adequately absorbent. The unprinted side
must also meet all further processing
requirements, such as glue penetration
capacity and suitability for adhesion.
A Speedsizer between the pre-dryer andafter-dryer sections enables 2-sided coating at 1-5 g/m 2 per side. Airturn with
infra-red profiling and hot air dryer ensure contact-free drying prior to the next
process step.

23

2

Customer satisfaction –the key to success

Immediately after the two-tier after-dryer
section are two DeltaSoft calenders, withsingle or dual nip operation and ModuleTherm with caliper cross-profile control.
This ensures first-class calendering for awide variety of grades.

Technical data

The entire erection and all testing procedures went according to plan, with stockon wire on December 6, 2004, after nearly 5 1/2 months of erection and start-up
procedure, and round-the-clock production only 4 days later. After about three
weeks of start-up optimization, the firstsample rolls were produced in the last
week of December. By the end of January
2005, twenty out of the 75 different basepaper grades had been produced. Vicedirector Andreas Windischbauer, chiefengineer at Dr. Franz Feurstein GmbH andPM 3 project manager, was extremely
satisfied with the start-up results. Thanks
to the customer’s valuable teamwork
from an early stage, the testing and commissioning phase was relatively short.

Wind-up takes place on the new MasterReel with oscillation. The axial movementof the web prevents uneven reeling andlocal overstretching of the web. Thanks
to permanent line load measurement on
the reel drum and controlled nip load,
this system ensures excellent wind-up
quality. The parent rolls are cut on the
VariFlex M two-drum winder with shortest possible paper runs at speeds up to2,500 m/min.
For Trierenberg it goes without sayingthat the paper machine’s appearance
must match the high quality of its products. The unmistakable Voith design not
only appeals to papermakers, but at least
as much to Trierenberg’s customers.

Design width

5,950 mm

Design speed

1,000 m/min

Basis weight range

28-40 g/m 2

Production capacity

122 t/dayFurnishChemical pulp

tipping paper requirements – further proofof the successful teamwork between thecustomer, Voith and engineering partners.
Even happier than project manager
Andreas Windischbauer is Trierenberg
Group Chairman Ernst Brunbauer. Voith’s
initiative in identifying additional small
improvement possibilities and implementing them to the customer’s benefit
has fully confirmed his choice of Voith as
supplier: “The relations between Trierenberg and Voith are exemplary.”

The operating team on production line 3,
partly comprising experienced membersof the line 2 team, is well acquainted with

3

4

Cigarette paper

5

Tipping paper
Filter envelope paper

20/05

24

Varel PM 5 –Interview with Uwe Wollschläger, Managing Director
Papier- und Kartonfabrik Varel
At the end of 2004 Papier- und Kartonfabrik Varel in Friesland,
Germany, commissioned PM 5, their second paper machine for low basis
weight corrugating paper and testliner. This increased their total capacity
by 250,000 to 650,000 t.p.a. together with the other two board machines.

Trimmed width of PM 5 is 5,600 mm,

ble tier groups with 45 dryer cylinders inwith a design speed of 1,300 m/min andtotal, a SpeedSizer film press, a Master-

drying capacity of 850 t / 24 h. Supplied

Reel and a VariFlex M winder.

by Voith St. Pölten, Austria, this machine
was designed for a basis weight range of
75 to 120 g/m 2.

twogether magazine spoke with Uwe
Wollschläger, managing director Papier-

20/05

This paper machine has a DuoFormer

und Kartonfabrik Varel with responsibility

base with MasterJet M2 2-layer headbox,for production and the Varel PM 5 invest-

DuoCentri-NipcoFlex press section, a dry-ment project, about his company’s strate-

er section with combined single and dou-

gy and experience with Voith.

25

Fig. 1: Varel PM 5.
1

order to ensure a troublefree start-up andfast optimization. The perfect commissioning and a startup curve exceeding
our expectations, with no unpleasant surprises, fully confirmed our expectations.
Your PM 5 went smoothly on line on
December 21, 2004 and, since then, hasmainly been producing corrugating paper
and testliner at basis weights below
110 g/m 2. How is the market acceptanceof these new lightweight grades?
When did you first think about installing

missioning. Also included was key equip-

For the first six months of operation wea completely new corrugating paper andment for stock preparation and approach

only planned to produce corrugating

testliner line in Varel, and why?

flow sections. By ordering all this tech-paper on PM 5, but testliner production

nology from the same supplier, what

trials have already started. Based on dis-

Uwe Wollschläger: Our plans for a new

benefits did you gain during the projectperging, coloring and sizing results, we

paper machine started to take shape inand commissioning?

shall soon be able to produce very high2002, mainly because of the increasing

quality testliner.

demands by our customers for corrugat-

Our very ambitious budget could only be

ing paper lighter than 105 g/m 2. Sincecomplied with by choosing what we con-

We were surprised how well our light-

the existing PM 4 could only meet thesesidered to be the most cost-effective so-weight corrugating paper was accepted

demands at the expense of considerably

lution in each case. Maybe we could haveon the market, and how quickly we wereless output, we realized that only a newsaved more money by dividing orders

able to change from 100 g/m 2 to 90 g/m 2.

production line would solve the problem.

among more suppliers. But since our hu-

Clearly, we made this investment at the

man and technical resources are limited

right time, because the market is really

In mid May 2003 you placed an order

as a medium sized company, we needed amoving now. In the first 100 days of fullwith Voith for the entire line, from paper

strong partner like Voith. We decided to

production with our new PM 5, we evenmachine to winder including control

order the key components of this newprocessed several orders for 80 g/m 2

system, erection supervision and com-line from Voith, including the fabrics, incorrugating paper.
20/05

26

Fig. 2: Uwe Wollschläger: “Teamwork is
indispensable for sustainable success”.

Our rapid response to changes and inno-

2vations will safeguard our market positioning.
Due to saturation of the corrugating paper market, we now face a couple of difficult years. But the market continues togrow, and capacity increases will be possible again afterwards. In the meantime
we shall also develop further our secondary business of board and cardboard
production, because this market is subject to changing trends and cycles.
Business success depends on entrepreneurial know-how and making the rightdecisions at the right time. Nevertheless,every company also depends on market
developments. How do you think the
packaging paper market will develop in
central Europe?

In a highly competitive market including

PM 5 project is decisively attributable toa good many reputed suppliers, Papier-our team of experienced specialists andund Kartonfabrik Varel is remarkably

well-trained young employees, together

There is a limit to everything, but as I

successful as a small company. How dowith our consultants who have been part-

said before, we think the packaging paper

you explain this success?

nering us for years.

market will continue to grow. However,For many years our strategy has primarily

With your new PM 5 you have invested

as shown by this latest trend toward low-

focused on first-class product quality andin the future. Where will Papier-er basis weights, which should make cor-

immediate response to customer needs.

und Kartonfabrik Varel be in 2015?

rugating paper cheaper to produce and,

there will be new developments as well –therefore, more competitive. But in future,That demands great flexibility and excellent customer service. As a relatively

At the end of the next ten years we seegood surface printability will play an in-small privately owned company, we canourselves as a medium size German com-creasingly important role.

make decisions and realize customers

pany producing 650,000 t.p.a. or moresuggestions very quickly. And anotherof paper and board. We intend to go on

reason is our well-functioning teamwork,

developing with our customers and play

Many thanks for this interview,which, in my opinion, is indispensable for

an important role as corrugating paper

Mr Wollschläger, and all the best to you

sustainable success. The success of theand board supplier, not only in Europe.

and your team!

20/05

27

think in paper –Topping-out party
at the new Paper Technology Center

1

Only eight months after laying the foundation stone, the newPaper Technology Center in Heidenheim already had a roof over its
Anja Lehmann
Corporate Marketinganja.lehmann@voith.com

head by June 17, 2005. This state-of-the-art research facility investment underlines Voith Paper’s future-oriented innovation strategy.

guration. This new Voith Paper technology center – the world’s most modern –incorporates equipment as it were a complete graphic paper line for process modifications and analysis, ranging fromstock preparation to finished product.
The technical data of this facility are
equally impressive: with a design speedof 3,000 m/min or 180 km/h, 50 m ofpaper can be produced per second – fivetimes faster than the 100 m world sprint
record.

Karl Josef Böck, managing director Voith
Paper Heidenheim, thanked the architects, building contractors and everyone
else involved for their outstanding performance. Even the size of this impressivebuilding faced them with a considerable
challenge – 115 m long and 22 m high,with 850 tons of steel and about 8,000
cubic meters of concrete. That is about
150 times more concrete than for an average house.

Fig. 1: Construction work on the new Paper
Technology Center is progressing rapidly.
Fig. 2: Congratulations on a highly successful
topping-out (left to right):
Herbert Stahlhut, Glass GmbH building contractors; Jörg Wilhelm, project manager Voith Paper;
Josef Schuster, Schuster Engineering;Heinz-Jörg Hüper, Hüper Plan; Ulrich
Gönnenwein, Züblin GmbH; Ulrich Begemann,
R&D manager Voith Paper; Dieter Tegeder,
Glass GmbH; Karl Josef Böck, managing director
Voith Paper Heidenheim, Germany.
Fig. 3: Inside the new PM hall.

After completing the building so quickly,
paper machine installation can already goahead in July this year, ready for thescheduled commissioning in February
2006. To meet that deadline, all available
forces will be mobilized for on-time inau-

Fig. 4: The topping-out address was held byforeman Horst Steiner of Züblin GmbH, Germany.

2

With this Paper Technology Center,
Voith’s technology leadership will be further consolidated for meeting customer
needs even earlier, with innovative future-oriented solutions.
3

4

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28

Rebuilds with Voith –Improved quality, productivity and economy
for greater customer benefit
As one of the most capital-intensive industries worldwide,
the paper industry demands concentrated efforts to maximize
productivity and profitability. On the one hand this requires continuous advances in high-performance technology for cost-effective
raw material utilization. On the other hand, the commercial
viability of existing plants must be assured by quality and productivity enhancement measures, efficient maintenance, and compliIngolf Cedra
Paper Machines Graphic
ingolf.cedra@voith.com

ance with environmental protection regulations. All these aspects
are equally important for staying abreast of market competition.

Net global market growth of the paper industry is currently forecast at about 2.5%
per annum. But taking account of capacity replacement for old production lines,
the figure rises to about 3.5% p.a.

importance of upgrading existing lines
for increased productivity is very clear.
Voith meets this challenge by systematically developing custom-made rebuild
concepts for existing installations, focusing thereby on individual customer needsin order to ensure optimal benefit fromeach rebuild.

As shown in Fig. 1, this comprises newmill capacity plus increases through rebuilds and optimization measures. The

1 Capacity in million t.p.a.

High

400
375
350

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Unprofitable

Life
Cycle

Rebuilds

Rebuild

Optimizations

Shut down lines

Profitable

Low

200
2000

Break-even price line
= production costs + capital costsNew
installation

New installations

300
250

2

Invested capital, capital costs

2005
Year

2010

Low

Relative specific production costs

High

29

Fig. 1: Global paper industry capacity andinvestment developments.
Fig. 2: Market positioning.
Fig. 3: Operating earnings as a function of theratio of reinvestment capital to production line
depreciation.
Fig. 4: Rebuild project drivers.

Rebuilds are a worthwhile
investment
The profitability of a rebuild project depends on competition in the respective
market segment (e.g. copying paper).
Fig. 2 is taken from a JP Management
Consulting study comparing the market
positioning of various different production lines (plotted in grey). The specificproduction costs and capital investment
needs can be typified as a function of individual requirements per paper grade.
This serves for determining the relative
market positioning of each line.
New installations are typically the mostcompetitive due to technical advances inpaper technology and productivity, thus
setting quality and cost benchmarks accordingly. For long-term viability, existing lines must, therefore, be upgraded bytaking suitable rebuild measures. In manycases their relative market positioning
can even be raised to the level of new installations, but with far less expenses.
Assuming that product quality complies

with market demands, the resultant increase in productivity significantly improves their cost-effectiveness. Conversely, the relative market positioning of anew production line declines during its
lifetime due to technical outdating. Fromthe life cycle management point of view,
today’s new installations are, therefore,
the rebuild candidates of tomorrow.
In 2002 a cost-effectiveness analysis of
9 global papermaking groups establishedthat operating earnings are closely related to investment behaviour as a ratio of
reinvestment capital to depreciation ontechnical installations (Fig. 3). Ongoingreinvestments in production lines to stayabreast of technology are, therefore,
indispensable for market success in thepaper industry.

Rebuild project drivers
The purpose of rebuild projects is to improve and maintain longterm a respective
market position of the line concerned.

The primary focus thereby is on productivity, quality, safety/reliability and environmental aspects, as well as production
costs (Fig. 4). For optimal benefit fromrebuild projects, simultaneous accountmust be taken of all these parametersin connection with overall project costs(total cost of ownership including costs
arising during shut down, construction
costs, peripheral and other costs).

Meeting customer requirements
For maximum customer satisfaction with
optimal rebuild solutions, sixteen selected operators of technically outdated
graphic paper machines were systematically interviewed by Voith engineers(Fig. 5). The primary goals of numerous
rebuild projects are higher efficiency andhigher operating speed while retaining oreven improving product quality. The mainemphasis for reaching both these goals is
on rebuild measures in the press or dryer
section. Quality improvement measures
mainly include runnability increase for

3

4
25

Productivity

Product quality

Operating profit [%]20
R2 = 0.82

15

Project success

10
5

50

70

90

110

130

150

Safety and environment

Production costs

Ratio of reinvestment to assets depreciation [%]

20/05

30

Fig. 5: Machine operator opinion –the primary drivers and goals of rebuild projects.
Fig. 6: Voith rebuild concepts.
Fig. 7: Braviken PM 52 rebuild concept.
Fig. 8: DuoFormer C rebuild concept to
DuoFormer TQb.
Optimization and rebuild measures by priorityed– Vibrations– Reliability– Maintenance and operation– SafetyS

Custom made solutions
Braviken PM 52
In tune with customer requirements,
Voith has developed rebuild concepts forvarious typical goals. All rebuild measures are however focused on the opti7

Together with Holmen Paper AB, a rebuild concept was developed for Braviken
PM 52 (Voith, installed 1985) incorporat-

Braviken PM 52: project goals and rebuild concept
Efficiency
Web break number

Operating speed
1,525

1,585 m/min

Web break time

Quality
Basis weightcross-profile
Formation

ProRelease+ _MasterJet II headbox

Web stabilizers in the dryer section

with ModuleJet

Ropeless threading

DuoFormer C

DuoFormer TQb

ProEfficiency

ProSpeed

ProQuality

20/05

ic

ro

Following the reports on successful rebuild projects in earlier editions of
twogether Magazine (such as Ruzomberok PM 18 and Schongau PM 9), theBraviken PM 52 rebuild is reviewed here
as latest example (see also separate article on page 32).

ie

nc

m

en

t

y

on
ir
nv
E
ro
P

ty

mal solution for maximum customer benefit in each case (Fig. 6).

liprinting presses or processing machinery. The wire section takes priority in thisconnection, followed by the headbox.
Printability improvement measures (sheet
structure and two-sidedness) are mainly
taken in the wire and press sections.
Other optimization opportunities mainly
include vibrations and individual equipment reliability.

pe– Wire section– Headbox– Press section– Dryer section

ff

Perfect Fit

ua– Press section– Dryer section– Calender– Wire section

Other

Q

– Dryer section– Wire and press
section– Coating line

Quality
Roll profile
Web defects
Printability
Dimensional stability

6

E

ro

Operating speedroP

Efficiency
Web break number
Web break time
Rejects volume
…

P

P

5

ing ProSpeed, ProQuality and ProEfficiency goals. Fig. 7 explains these goals
and their attainment.
This joint concept mainly focused on developing an upgraded former for PM 52
machine, which even prior to rebuild operated above the original design speed of
1,500 m/min. The wire section included a
DuoFormer C roll-former with weak points
in sheet quality. Apart from wire run, theformer was improved by adding a D-section with flexible bars as already wellproven in the DuoFormer TQv (Fig. 8).
Thanks to the new headbox and the rebuilt former, newsprint quality, at a pro-

DuoFormer C, prior to rebuild

After rebuild to DuoFormer TQb

8

31

Fig. 9: Quality improvement by rebuilding
headbox and former.
Fig. 10: Customer orientation, custom made,perfect fit, partnership.

0.50

0.37%
0.41

0.40

Rebuild PM 52-37.8%

0.30
0.23%
Pre-rebuild

after rebuild

duction speed in excess of 1,550 m/min,– was significantly improved (Fig. 9).
Four months after recommissioning, all
the project goals have clearly been met,so that this 20 year old paper machine
can now hold its own well in thenewsprint market.

Voith – the right partner
Voith is dedicated to meeting the needsof the paper industry as a project partnerand process technology supplier. In orderto fulfil specific customer requirements
at all times, a specialist team has been
formed for rebuild projects. This team is
responsible for concept development andproject handling to ensure the optimal“perfect fit” rebuild solution in each case(Fig. 10). To that purpose, the specialists
normally involved later on are already included in the project well before order

Customerinquiry

Site analysis
or preliminary
studyTechnical/
technology
concept

Pre-rebuild
Time

0.53

0.20

10

Oven-dryness profile – HMX colour chart
CD 2

0.60

after rebuild

9

Ambertec formation norm [g/m 2]

Fig. 11: Typical rebuild phases before and after
receipt of order.

Machine width

placement. This ensures a smooth transition from the proposal phase to orderprocessing.

Once the rebuild concept has been established, the proposal and specification areprepared as a basis for order placing.

Shown on the left in Fig. 11 are the typical phases of a rebuild project prior toorder placement. After requirements havefirst been clarified with the customer, thecondition of the line is carefully investigated on site. Priority is always given inthis connection to the re-usability ofrolls, auxiliary equipment and other machinery components. If the entire plant
periphery (stock preparation, media, logistics, etc.) has to be included in the
project, the necessary data is gathered
for preliminary studies, which may also
include feasibility studies. Afterwards,
the optimal “perfect fit” concept is developed with the customer to meet his productivity and quality targets. These targets define the technology concept, thatfirst has to be confirmed by quality comparisons, pilot trials and printing tests.

After receipt of order, the order processing phase continues until handover andcontractual fulfilment (Fig. 11 on the right).

ProposalReceiptof orderEngineering
anddesignA well-proven solution for complex rebuild projects is to delegate the entire
responsibility to a single contractor for
optimal coordination of all interfaces.
In this connection, the Voith Process Line
Package (PLP) was described in twogether 18.
The latest joint project successes confirm
that Voith’s rebuild philosophy is correct.
By taking into account all the complex
needs of rebuild projects, with specificmeasures and adjustments in the proposal and order processing phases, the focus is always on customer benefit frombeginning to end.

Manufacturing
andprocurement

Erectionandcommissioning

Production
start-up

Upgrade

11

20/05

32

Rebuild of Braviken PM 52 –“After the rebuild we can now take on any
new newsprint machine”

With this statement, Rikard Wallin, mill manager inBraviken, sums up the success of this rebuild (see comments).
In the face of competition in the marketplace, rebuilds of existingproduction lines have developed into an attractive alternative tothe buying of new machines. Rising demands on the quality andAlbrecht Weberrunnability of machines can be sustainably improved by this.

Paper Machines Graphic
albrecht.weber@voith.com

Taking Braviken PM 52 as the current example, it is shown how
a good “old” machine can be made to run even better.

In December 2003, Voith was commissioned by Holmen Paper to rebuild thewet end and dry end of PM 52 at their
Braviken, Sweden, location.
Dirk Thomas
Paper Machines Graphic
dirk.thomas@voith.com

20/05

The goal of the rebuild was to further
improve productivity and the quality ofthe machine and to raise the average

speed from the previous 1,525 m/min to
1,585 m/min with continuously increasing runnability.
The heart of the rebuild was a completely
new MasterJet headbox with ModuleJetdilution water control and new HC/LC
lines at the wet end as well as a new

33

1

2

Fig. 1: Holmen Paper in Braviken, Sweden.
Fig. 2: DuoFormer TQb.

drainage section for the DuoFormer. In
the area of the press section the press
hydraulics and the control system wererenewed. The dryer section was equippedwith ProRelease Plus Stabilizer boxes in
the 1st dryer group and, in addition, withstabilizers between the DuoRun dryer
groups. Furthermore, the two-tier area ofthe dryer section was equipped withthreading doctors, enabling ropelessthreading. The increased speed range
also called for the replacement of all fabric rolls in the dryer section.
The selected rebuild concept, above all in
the DuoFormer, was to contain the latest

technology, with as few modifications as
possible to the web run and framing.
Different methods had to be applied. The
forming suction box was integrated in avery small space into the top wire and theentire drainage section was optimized
with strip arrangements in the bottom
wire. Not to be forgotten is the MasterJet
20/05

34

3

headbox which, when optimally placedand equipped with the Profilmatic M control system, contributes to the good running of the paper machine.
Well-conceived and balanced project andshutdown planning also made a contribution that enabled the installation work to
be completed one day ahead of schedule.
DuoFormer C, prior to rebuild

After rebuild to DuoFormer TQb

5
1,000

before rebuild

In summary it can be said that the startup expenditure corresponded to approx.
60% of that of a new paper machine. The
large scope of supply on components andservices could only be handled by a supplier with overall project responsibility.
It was only through mutual support by
the engineers of the automation, design,
rebuild

after rebuild

1,560
1,540
Machine speed [m/min]

800
Production [t/day]

4

This in turn made it possible to start up
the machine 3 days earlier than had been
agreed in the contract. The start-up itself
took place in a very short period of only
2 days and placed high demands on theentire team, as the machine drive wasrebuilt at the same time and a new DCS
with S7 control system was used for the
NipcoFlex press and the reel.

1,500

600

1,460

400

1,420

200
0

1,380
1.1.0520/05

8.1.05 15.1.05 22.1.05 29.1.05 5.2.05 12.2.05

35

Fig. 3: The rebuilt PM 52 at Braviken.
Fig. 4: Drainage section in DuoFormer
before and after rebuild.
Fig. 5: Start-up curves
Production
Machine speed.
Fig. 6: Beta Formation.
Fig. 7: Porosity.

It was especially pleasing that just a few
hours after start-up we were able tobegin with the optimization trials for theformer setting.

optimization and start-up teams during
installation, sometimes working in shifts,
that this goal could be reached together
in a spirit of partnership with the customer.

The new technological concept demandedthat the optimal setting of the drainage
elements is found quickly.

The result is particularly pleasing. Thevery stable running of the machine,which began shortly after start-up, allowed the transition to a calm and concentrated optimization phase. This camenot unexpected, because now the numerous trials performed prior to the start ofthe project were confirmed. This is also
one of the main reasons why almost allof the warranty parameters could bereached shortly after start-up.

PM 52 produces newsprint in the basis
weight range of 40 to 48,8 g/m 2 on a wire
width of 9,300 mm from 65% TMP and
35% DIP. The quality of the CD profiles
and those of formation as well as fiber
orientation within the warranty limits impressed the customer.
Voith Paper and Holmen Paper have enjoyed trustful relations in a spirit of partnership for many years. This is also reflected in the 3 production lines at theBraviken location, that were all suppliedby Voith and rank among the most reliable and fastest in the world.

Productivity and machine speed speak forthemselves and objectively confirm thesuccess (Fig. 5).
Particularly noteworthy is the fact thatthe paper machine achieved an average
speed of over 1,540 m/min (1,525 m/min
prior to the rebuild) with about one totwo sheet breaks per day after only one
week.
6

7
450
0.53
0.50
0.41
0.40

0.30

0.20

Porosity Bendtsen [ml/min]

Ambertec Formation norm [g/m 2]

0.60

400

393

405

350

RikardWallinMill Manager,
Holmen Paper
Braviken“We are very satisfied with the rebuild
done by Voith. The MasterJet headbox
and the DuoFormer TQ forming unit
have brought our 20-year-old PM 52
up to the front line again in terms of
quality. The quality of the paper inrespect to profile and formation cannow, after the rebuild, take on any
new newsprint machine.
Through the use of ropeless tail threading and new fabric rolls, the sheet
break times have been reduced and the
speed increased. In this way we havebeen able to achieve additional productivity, which we need in order to remaincompetitive. And, as the icing on thecake, our working environment has
become safer.
The cooperation between Voith andBraviken worked very well, and for me
this project is a further link in the close
collaboration between Braviken undVoith.”

300
250
200

before rebuild

after rebuild

before rebuild

after rebuild

20/05

36

1

Abitibi-Consolidated “Alma” –PM 14 conversion to coated paper
This rebuild at the Alma mill, Canada, was entrusted
to Voith by Abitibi-Consolidated (ACI), a global leader in newsprint
and uncoated groundwood papers as well as a major producerof wood products, with approximately 14,000 employees in Canada,
the U.S.A., the U.K., South Korea, China and Thailand.

Sammy Di Re
Paper Machines Graphic
sammy.dire@voith.com

20/05

ACI enjoyed such success with the previ-

When fully optimized, PM 14 will produce

ous conversion of Beaupré (Quebec) PM 1

230,000 t.p.a. of “Equal Offset” at a

to high-bright coated paper, that the mar-paper machine speed of 1,100 m/min.

ket demand for this product (named

The conversion from newsprint to coated“Equal Offset”) is steadily rising. With that

paper production entailed major process

in mind, ACI decided to significantly in-changes. In addition to the PM rebuild,crease the production capacity of thisthe project included an increase in TMP

grade. An analysis concluded that the best

capacity, a new peroxide bleach plant, ancandidate for a rebuild was PM 14 news-

increase in secondary paper treatment

print machine in the Alma mill, Quebec.

and modifications to the finishing section

37

Fig. 1: The converted PM 14.
Fig. 2: Abitibi-Consolidated, Alma mill, Quebec,
Canada.

Gratien
GirardProject andproduction
manager
AbitibiConsolidated(ACI)
2

and shipping logistics. The total project

The TRC transfer roll coater was supplied“Thanks to the support received fromcost was about 200 million Canadian dollars.

by Voith-IHI (Japan). This “film-transfer”

the Voith group, the ACI-Alma team wascoating technology had been successfully

able to meet all performance goals of

The former was originally a hybrid withapplied in Beaupré and thus was a natural

the Equal Offset project.

BelForm top former (forming shoe). For

choice for the Alma project. After coat-better formation and two-sidedness con-ing, the sheet run goes over a new con-

The sheet quality level surpasses thetrol, the latter was converted to a Voith

tactless Airturn device and an IR dryer.

objectives set for the project. More

DuoFormer D (opposing multi-blade for-importantly, we received high praisemer). The three straight-through presses

PM 14 previously incorporated two multi-

from our customers for the excellent

were replaced with a new Centri-Nipco-hard-nip A-frame calenders. The newprint quality. And, with respect toFlex press + straight-through 3rd press.

calender incorporates four rolls in a new

PM operating speed, we already expect

The Centri-NipcoFlex ensures very good

L-frame, the existing rolls and hydraulics

to achieve the design speed shortly.

sheet dryness before the first open draw.

being reutilized. The sheet run ends at

The straight-through 3rd press allows

the new TR 125 reel.

two-sidedness control in smoothness.

We are confident that we will surpass
all the expectations of our investors.”

In addition to the PM rebuild, Voith also
The dryer section rebuild pays particularsupplied three MultiSorter broke screensattention to sheet support and highto treat the coated broke, and two disk

about seven weeks later on June 1. All

dryness ahead of the on-line coater. To

filters to recover the fibers from thethe quality and quantity targets of this re-accomplish this, the pre-dryer section

PM white water.

build were attained in full. At an average
operating speed of 1,125 m/min, the con-

was fitted with sheet support boxes (ProRelease, DuoStabilizer and VentiStabi-

The order was awarded in January 2003.

verted machine produces coated paper

lizer). Here again, the mechanical compo-

Rebuild work started on April 11, 2004

with a basis weight range of 59-74 g/m 2

nents had to be modified.

and start-up was accomplished only

and uncoated paper at 49-74 g/m 2.
20/05

38

Krkonosske Papirny –first SpeedSizer in the Czech Republic
After extensive project activity and intensive rebuild
preparations both on the part of Krkonosske Papirny (KRPA) andVoith Paper with the consortium partner ABB Cellier (rebuildof color kitchen), the time had come at last: The active phase of
installation and start-up of the rebuild on and around PM 6 in
Hostinné was finished with the “preliminary take-over-protocol”
and finally successfully concluded with the signing of the “final
Ulrike Haupt

acceptance-protocol” on 27 January 2005.

Paper Machines Graphic
ulrike.haupt@voith.com

1

Fig. 1: Start-up team.
Fig. 2: Upper course of the River Elbe in
Hostinné.
Fig. 3: The new SpeedSizer.

20/05

After proof had already been provided forthe troublefree production of writing paper and the required test run for “greaseproof paper” (suitable for food-wrapping
purposes), the last contractual acceptance test run for CF paper was successfully carried out on 26 January 2005.

front) in a basis weight range of 30 to
80 g/m 2. These grades are finishprocessed for the final consumer in thecompany’s own finishing department andprinting shop. This form of vertical diversification ensures KRPA, above all, close
contact with the final customer.

This success was the result of intensive
cooperation between KRPA and Voith
Paper. All phases of the rebuild project
were marked by mutual trust and clear
orientation toward goals.

PM 6 was installed in 1984, with themain supply coming from the Soviet
Union. Within the past 20 years a numberof modernization measures have beentaken on PM 6. In the course of these,
Voith supplied a new approach flow system and a new headbox in 1996.

KRPA is a company that is now in private
hands. A total of four production facilities
operate in the Czech Republic and in Slovakia. Three paper machines, two fairly
small coating machines and a series ofother paper processing machines operate
at the headquarters in Hostinné. It is located at the foot of the Riesengebirge,
with the upper reaches of the River Elbemeandering through the premises.
In Hostinné, KRPA produces graphic,greaseproof and CF paper grades (coated

To continue to be competitive in the global marketplace in the future, KRPA decided in 2003 to replace the old sizepress with a modern film press of the
SpeedSizer type. This decision to invest
demonstrated KRPA’s entrepreneurial
vision.
The overall concept, which Voith Paper
was able to carry through in the courseof the negotiations in the face of exten-

39

2

sive competition, is based on the following scope of supply and services:
SpeedSizer, web run, Airturn, hot-air dryer, basic engineering/overall concept air
system + steam and condensate system,
the respective associated control modules, rebuild of the coating color kitchen(including agitator mixing tank, digesterfor Meypro film coating and workstationfor SpeedSizer, including the integrationof automation into the existing ABB
DCS). Installation and start-up supervision as well as the training of the operating personnel by Voith Paper and its
consortium partners rounded off the
package. Spare and wear parts were additionally included in the scope of supply.
The following goals were associated withthe rebuild measures:

3

To increase the production capacity of
PM 6 by 20%, to provide for on-line
application of the CF layer for the production of duplicating papers and to significantly expand the range by greaseproof
papers (KH Pack) with the possibility ofapplying different application fluids to the
top side and bottom side. It was also intended to achieve savings in the metering
rates of the application fluids.
In particular the possibility of now being
able to produce CF paper on-line in thepaper machine and no longer, as up tonow, to run over the air knives at a separate coating machine makes for a considerable improvement in the utilization of
the entire paper mill. It saves re-reelingand the capacity of the air knives freed
can be utilized for other coating tasks, resulting in another increase in effectivityof the entire plant.

With the results achieved up to now thedemanding goals of the project can be
met or even exceeded.
20/05

40

Unchallenged Market Leadership –More than 300 Voith shoe presses worldwide
Shoe presses offer numerous advantages in paper andboard production, both with regard to quality and quantity. Thanks
to product innovations and reliability, Voith is the unchallenged
market leader for shoe presses, with a 60 percent share of installations worldwide.

Thomas Augscheller

Shoe press technology

depends on how well the shoe press is

Paper Machines Graphic
thomas.augscheller@voith.com

applications

integrated, which is decisive for compliance with the required process and quali-First introduced years ago, shoe presses

ty parameters. The basic development

are now well established in the paper in-goal was, however, well matured high-dustry. Nearly all modern paper andperformance shoe press modules andboard production lines of every type arepress roll sleeves for the highest de-equipped with shoe press technology. A

mands and production outputs.

shoe press is basically a module com-

20/05

prising two press rolls, one with press

The first Voith FlexoNip press was com-shoe and soft sleeve, and the other as

missioned in 1984 in Austria. It was fol-mating roll. The success of this concept

lowed by 46 more shoe presses of the41Fig. 1: Shoe press sales development.
 Pulp Calender Tissue Packaging paper Board Graphic grades
NipcoFlex press No. 300 sold to Aracruz Guaiba!

1

320
Number of installations

280
240
200
160
120
80
40
0

83 84 85 86 87 88 89 91 92 93 94 95 96 97 98 99 00 01 02 03 04 05 06

As shown in Fig. 1, shoe presses wereBrazil. As part of a chemical pulp dewa-

originally installed in packaging paper

tering machine rebuild, it plays a key

machines. With ongoing technical androle in boosting production output frompaper technology developments, the con-400,000 to 430,000 t.p.a. of eucalyptus

cept was extended to new applications

pulp. This press will be delivered withand performance classes. This led in

QualiFlex roll sleeves and is the second

1994 to the first NipcoFlex shoe press in-

NipcoFlex shoe press ordered by Aracruz

stallation for graphic paper production.

Celulose – a sure sign of their confidence

Considerable success with these gradesin this well-proven technology. It is due

was achieved through compact press

for commissioning by the end of 2005.

concept integration, and development of
the Tandem-NipcoFlex press section, in-

NipcoFlex presses with web widths rang-

corporating full web support and excel-

ing from 2,600 to 10,600 mm and operat-same type that are still giving excellent

lent drainage performance for high out-

ing speeds of 50 to 1,912 m/min are inservice. Another successful product was

puts. With the systematic development ofservice worldwide to the full satisfaction

the Sulzer Escher-Wyss Intensa press forfurther applications, shoe presses wereof their users. In order to stay one step

improving paper machine runability andalso used for board und tissue produc-

ahead of ongoing customer needs, a spe-

production output. Thirty such shoetion and in chemical pulp dewatering ma-

cial NipcoFlex test unit is already under-presses were installed in total. Whenchines. In 2003 a NipcoFlex shoe press

going trial runs at continuous speeds ofVoith and Sulzer joined forces in 1994,

was applied for the first time outside theup to 3,000 m/min. NipcoFlex presses

the best press technologies developed bypress section, in the form of the Nipco-offer customers important advantages

each company were combined into theFlex shoe calender.

both with regard to production output
and product quality. Already 60% of all

NipcoFlex shoe press. More than 230
NipcoFlex presses have been sold world-

The 300th Voith NipcoFlex shoe press

shoe press users worldwide believe inwide since then.

was sold to Aracruz Celulose in Guaiba,

the Voith NipcoFlex shoe press, the most
20/05

42

2

3

Press sleeve
Internal support bar
Pneumatic hosereliable and well-tried technology on thehold it against the exterior doctor blade

market.

(Fig. 2). This support beam is brought
into the operating position pneumatically,
and is designed to have a stabilizing and

System optimization –damping effect on sleeve operation with-

Voith FlexDocout scraping the cooling oil film off its
surface.

As a process solution provider, Voith is

Mini-NipcoFlex press – a newmember of the Voith press family
Target: New, small NipcoFlex module(Ø 770 mm)
Suitable for almost all kinds of machines andrebuilds:
UpkeepReplacement of press rolls
Improvement
Increase of dryness andproduction output
New PMs
First Nip in DuoCentri press
concept

concerned not only with machinery im-

The efficiency and simplicity of the Voith

provements, but also with process tech-

FlexDoc system go hand in hand. In addi-

nology development for enhancing prod-tion to the water drained centrifugally

uct quality. The complete removal of

from the press roll sleeve, a lot of water

water collected in the press roll sleeve,is also removed by the doctor blade

whether blind-drilled or grooved, prior to(Fig. 3). The advantages for the machine

Efficient rebuild solution –nip re-entry is decisive for efficient web

operator are self-evident: efficient sleeve

Mini-NipcoFlex

drainage. This ensures the high water re-drainage increases the nip water storage

moval rate required for a good moisturecapacity and enables a higher dryness.

Shoe presses are practically a must today

cross-profile.

This reduces web break frequencies andfor all new paper machines. This technol-

Technical data
500 kN/m at 4,500 mm paper width

increases productivity. The success ofogy started however as an ideal rebuild

Due to the roll sleeve flexibility, however,this system is confirmed by 139 refer-solution for increasing existing papera conventional doctor system is not pos-ence installations and highly satisfied

machine performance. Shoe presses are

sible. Voith recognized this problem at anproduction managers worldwide. Voith

now used for the majority of rebuilds, but

early stage, and solved it by installing aalso retrofits this technology to shoe

limits are often set in such cases by roll

flexible support beam inside the sleeve topresses supplied by others.

diameters and weights. To solve this

20/05

4

43

5

6

49

Dryness [%]

48
47
46
45
44
100

150

200

problem, Voith has added a new member

Since the existing mating roll often limits

to the NipcoFlex shoe press family: thethe maximum possible line load, Voith

Mini-NipcoFlex press (Fig. 4). Despite its

has also developed a Mini-NipcoFlex

very small roll diameter of only 770 mm,

module that also includes a mating roll.

this new shoe press has an extremelyThis enables full exploitation of the avail-high performance of up to 500 kN/m line

able line load capacity. A typical applica-

load with a web width of 4,500 mm.

tion is shown in Fig. 5, representing
an ideal solution for increasing the out-

The Mini-NipcoFlex press is an ideal re-put of a 6,000 mm web width machine bybuild solution for small to medium size

approximately 8 %.

machines, e.g. as replacement for an existing roll pair in the third nip of a com-

If the machine output is limited by thepact press. Freestanding press versions

dryer section, about 2 % more dryness

are also possible, however, with the shoeafter the press is required for a produc-press roll at the bottom. The shoe press

tion increase of this order. In the exam-advantages of longer nip dwell time andple shown here (Fig. 6), this higher

adjustable line load profile can of course

dryness and production increase can be

be fully exploited here as well. Further-achieved by increasing the line load in

more, typical felt life in a shoe press isthe third nip to 350 kN/m with a Mini-

much longer than in a roll press.

NipcoFlex press and suitable shoe geom-

250
300
350
400
Line load 3rd nip [kN/m]

450

500

550

Fig. 2: FlexDoc doctor on a shoe press.
Fig. 3: Operating principle of the Voith FlexDoc.
– Misting ahead of doctor– High water removal – dewatering of void
volume and sleeve surface– No water before re-entering the press nip.
Fig. 4: Rounding off the product range –Mini-NipcoFlex.
Fig. 5: Typical application of a Mini-NipcoFlex
module.
– For example: customer (woodfree paper
grades) requires e.g. 8-10 % more output– Solution: Mini-NFP module (with mating roll)
Increase of dryness ~ 2 %– Max. line load: with Mini-NFP much higher
than with roll press.
Fig. 6: Attainable dryness increase with a
Mini-NipcoFlex press.
Woodfree grades, 70-80 g/m 2 (15 % fillers)Current status:
Duo-Centri II press
Web width: 6,000 mm
v = 650 m/min
Line load = 70/86/117 kN/m

etry – a worthwhile rebuild investmentthat soon pays dividends!

20/05

44

BoostDryer –New higher-performance drying technology
for improved paper quality
Maximizing production is the driving force in today’s paperindustry. In this connection the dryer section is often a bottleneckfor rebuilds due to space restrictions, so that more efficient drying
technology is indispensable. Apart from increasing production,
optimizing product quality is also a challenge – both with regard to
sheet strength and surface finish.
Christoph Haase
Paper Machines
Board & Packaging
christoph.haase@voith.com

This article presents a new drying tech-

The paper runs directly on the drying

nology that meets production maximiza-cylinder, which is heated by saturated

tion requirements both quantitatively andsteam at a pressure of 6-12 bar above

qualitatively. It is ideally suitable foratmosphere. Contacting the paper on theboard and packaging paper production,

outside are a fine wire, a coarse meshand combines two processes – conden-

wire and a steel belt. The belt, fabrics andsation and press drying – by incorporat-

paper are held against the heated cylinder

ing a drying cylinder and a pressure

surface by water pressure. The same wa-

hood. The positive effects of press drying

ter cools the fabrics and the belt.

have already been demonstrated by anumber of studies, and are now proven

Water vapour from the paper condenses

by this new drying technology.

in the cooled mesh of the wires and on
the surface of the steel belt. The conden-

Apart from explaining the new process,sate and the very small amount of water

this article also shows how it can be in-vapour remaining in the mesh are trans-

corporated in the dryer section.

ported out of the pressure hood with thefabrics. After leaving the hood, the condensate evaporates.

Process
The BoostDryer process attains far higher
Drying takes place on a specially de-drying rates than conventional systems,

signed cylinder, whose outer periphery isthanks to the pressure hood, whichpressurized by water that also serves for

greatly improves the heat transfer coeffi-

cooling. The water temperature is be-

cient due to better paper contact with thetween 60 and 90 °C.

cylinder surface. Another reason is thatthe special cylinder design enables more

Water pressure, ranging from 0.5 toefficient heat flow.

5 bar, is generated in a hood that enclos-

20/05

es three quarters of the drying cylinder

As a further benefit of this drying process,periphery.

the paper strength is improved by com-

45

Fig. 1: BoostDryer layout.
Fig. 2: The BoostDryer process.
Fig. 3: Comparison of various drying
technologies.
Fig. 4: Static prototype test results.
 Machine dried BoostDryer laboratory unit
12

Cooling water

Steel belt

Coarse fabricFine layer
Paper

Heated cylinder

Static test resultspression due to pressurizing. By soften-

With regard to pressure, the contact

ing the hemicelluloses and lignin, fiberpressure between the paper and the heat-bonding is also improved.

ed surfaces is no more than 0.07 bar for

BoostDryer

conventional cylinder dryers, as against

were first carried out using a static pro-

0.5-5.0 bar at the BoostDryer.

totype. Paper samples (corrugating medi-

The parameters of the BoostDryer processprocess

simulation

trialsum, 120 g/m 2) were laid on a heatedlie between those of impulse drying andconventional cylinder drying. This means

The necessary dwell time for the required

plate, and a fine wire, coarse-mesh wirethat drying is more gentle than withdryness, in other words the total contact

and impermeable belt were placed on top

impulse drying. Fig. 3 compares the sur-time between the paper and the heatedof the sample. The entire package wasface temperatures of various drying tech-surfaces, is attained in the BoostDryer

pressed against the heated plate by anologies.

with only 6-8 dryer cylinders.

second plate.

3

4

50

30
20

140
Conventional cylinder drying
Surface temperature 80-150 °C

Relative strength [%]Dwell time [s]40

BoostDryer
Surface temperature 120-160 °C
Impulse drying
Surface temperature
200-400 °C

10

120

100

80
1

2

3

4

5
Pressure [bar]

50

100

Breaking length

SCT

Burst strength

20/05

46

Fig. 5: BoostDryer prototype.
Fig. 6: BoostDryer prototype drying rates.
 Conventional (Tappi)
 Latest BoostDryer results (April 2005)
5
125
Average drying rates [kg/m 2h]

129 kg/m 2h

114 kg/m 2h

100
75
50

41 kg/m 2h

45 kg/m 2h

25

7 bar

10 barSteam pressure [bar]Fig. 4 compares test results on conven-rates, values are based on the contact

to the hood pressure, and also the dwell

tionally dried paper samples with thosesurface size.

time. The highest strength was attainedwith complete BoostDryer application

using the BoostDryer process. The breaking length increases by 20%, SCT by

The results with testliner show an aver-

23% and burst strength by as much as

age drying rate of 114 kg/m 2h at a steam

49%.

pressure of 7 bar, and 129 kg/m 2h at a

The surface temperature also has an in-steam pressure of 10 bar.

fluence on sheet strength. Moreover, theafter the press section.

sheet side in contact with the cylinder

In view of these promising results, Voith
developed a dynamic prototype to evalu-

The test parameters were varied as follows:

ate the BoostDryer process during con-Basis weighttinuous operation.

Steam pressure

4-10 bar

Hood pressure

0.5-3 bar90-260 g/m 2

surface is smoothed. The results are similar to those with a Yankee cylinder.
Voith is currently investigating theseresults in more detail by carrying out ex-

Dynamic trials

Tests were also done with various dwell

tensive trials, prior to a pilot installation

times, different kind of fabrics and differ-in a paper mill.

The first prototype (Fig. 5) was installed

ent freeness. The results were astonish-after the press section in the Voith VPM 5

ing – drying rates of 100-150 kg/m 2h at

paper machine test facility. An infra-red

all settings. In other words, the process

Future prospects

dryer was also installed, in order to run

is not only stable, but also at a very highfor the BoostDryer

tests at different ingoing dryness.

level. In fact, drying rates lower than
100 kg/m 2h hardly seem possible!

Figs. 7-9 show BoostDryer application
possibilities in packaging paper machines

Significantly higher drying rates wereattained than with conventional drying

Strength characteristics also improved,

according to the current state of technol-(Fig. 6). In order to compare drying

mainly because of sheet compression due

ogy. Thanks to the high drying rates, a

20/05

6

47

Fig. 7: Replacement of two dryer groups by
one BoostDryer unit.
Fig. 8: Given adequate strength and smoothness
gain, possible elimination of size press andcalender?
Fig. 9: Significant possible reduction of machine
length.

single BoostDryer unit comprising three7

cylinders with a diameter of 3 m can replace two conventional dryer groups.
This reduces the length of the dry section
from 97 m to 87 m.
Voith envisages not only using the BoostDryer for drying alone, but also developing this process for other purposes aswell. With adequate strength improvement, it would, for example, be possible
to use the BoostDryer instead of a sizepress. Furthermore, the surface smooth-8

ing effect of the BoostDryer may eveneliminate the need for calendering.
Due to these benefits, a good deal of theafterdryer section may no longer be required, thereby reducing the overall
length of the dryer section to 45 m.

Advantages of the BoostDryer
process
The BoostDryer process enables extreme-

9

ly high drying rates. This reduces spacerequirements for new machinery, or allows substantial production increases forrebuilds with limited available space.
The paper strength is increased thanks tocompression under the hood, and the
sheet side contacting the cylinder surface
is smoothed. The heating medium issteam, available at low cost in all paper
mills.
20/05

48

1

100 % Voith for Tissue
Tissue is fascinating! It is an indispensable product wellknown in the consumer’s everyday life – at home or away. Innovative tissue producers have developed differentiated products
and tuned tissue properties to increase consumer benefits:
Wet strength in kitchen towels absorbing many times their weightin water, softness and strength for reliable bathroom tissue, softness also in facials, and also napkins, diapers, etc.
Thomas Scherb
Voith São Paulo, Brazil
thomas.scherb@voith.com

Intensive product development and mar-havior is very much regionalized so thatketing has avoided tissue becoming a

producers and machine suppliers must

pure commodity like their family mem-take care of each region individually:bers from the graphic papers and board

Markets growing in quantity or quality,& packing grades. It is a growing market,

conventional products transforming into

driven by classical factors like economic

quality products and quality products intoand population growth as well as by qual-premium goods, growing markets for

Christian Münch

ity improvement and increasing con-bathroom tissue or paper towels, single

Voith São Paulo, Brazil
christian.muench@voith.com

sumer awareness of the usefulness ofor multiply, recycled or virgin fiber, inthese high tech products. Consumer be-brands or private label.

20/05

49

Fig. 1: Tissue World in Nizza –100 % Voith for Tissue.
Fig. 2: Tissue-pilot machine at the Process
Technology Center at São Paulo, Brazil.

Voith has decided to regionally expand its
activities in this lively market. The prerequisites are promising. Voith is an experienced player in tissue, is known as
innovative and provides a unique worldwide structure.
Voith has been in the market since thefirst tissue machines have been built andis covering customer needs from stock
preparation to finishing. Voith is market
leader for tissue machines in SouthAmerica, tissue machines developed andproduced under Voith license are runningsuccessfully under record conditions in
the whole world. Tissue is a substantial
Voith business sector and amounted to
120 Mio. Euro turnover in the last fiscal
year.

Worldwide Structures for Tissue
The Center of Competence for tissue con-2tinues to be at the Voith São Paulo facility. Here, 2,000 people are employed ofProcess Technology Centermachine, stock preparation, water treat-

which 1,000 work in the paper division

for Tissue

ment as well as wet and dry end laborato-with more than 50 specialists for tissue.

ries. In the last year, Voith Paper invest-

Tissue machines are already being sup-Voith Paper installed the Process Tech-ed in a fiber design plant (fractionation,

plied by São Paulo and in future will also

nology Center Tissue in São Paulo infiber curling, etc.) linked to the actual

come from our system suppliers in Italy,

1994 to allow tissue producers to verify

stock preparation system. It is now pos-

Spain, China, Japan and India. Voith

the compatibility of their processes andsible to run trials comprising the entire

Paper at Ravensburg, Germany, will cov-

raw materials with newly to be acquired

tissue process, from the fiber to the final

er the European, Asian and African mar-equipment.

paper on the reel, aiming at fiber quality

kets. Additionally, 27 service centers, op-

improvement, higher machine efficiency

erating world wide, are taking care of our

The Tissue facility in the Process Tech-customers’ everyday needs.

nology Center consists of a tissue pilot

and better tissue paper quality.

20/05

50

Fig. 3: TissueFlex configuration.
Fig. 4: Voith winder for Tissue.
Fig. 5: Voith Tissue PM.

Innovation for Tissue…
…has always been one of Voith’s main
focuses. For paper production the Janus
calender, NipcoFlex press, Sirius reel
were major milestones of innovation.
TissueFlex and Super Soft Tissue Package for handfeel and bulk increase are thelatest Voith contributions to the tissue industry and were developed at the Process
Technology Center for Tissue.
4

3

vesting 30 Mio. Euro over the next 5 years

ing technologies but also in new products

into the Process Technology Center for Tis-for conventional technologies. Voith Paper

sue and its tissue research. Additionally,

Fabrics is very close to its customers andwe expect innovation to be driven by syn-is working closely with the Process Tech-ergies from developments in the graphic

nology Center for Tissue to reach the am-

paper and P&B divisions. Here, Voith isbitious R&D goals.

already investing 150 Mio. Euro yearly
and is considered a leader in innovation.
Stock Preparation for Tissue
Fabrics for Tissue
Voith Fiber Systems in Appleton, WisconThe Fabrics Division of Voith has been

sin/USA is the worldwide Center of Com-acting in the tissue market for overpetence for stock preparation systems

Today, the market is still waiting for a

20 years. Over 30 people are involved inand fiber processing techniques relating

new machine concept to produce premi-

the tissue section at Voith Paper Fabrics,

to tissue. They offer an environmentallyum tissue paper at commercial speedswith a team in the Americas and one infriendly process which features low in-with less capital investment and energy

the European Region, calling only on tis-vestment and operating costs while pro-consumption than TAD machines. Voith

sue mills and their corporate headquar-

ducing a tissue product that completely

will present a new and innovative solu-

ters. Voith Paper Fabrics has approxi-

meets the needs of the customer. Thetion in the not so far future. Anothermately 25% of the global tissue clothing

portfolio covers recovered and virginfocus point is the elimination of speed

market and a share of over 50% in sever-fiber preparation, water, sludge andlimitations to operate tissue machines

al leading countries. The company is con-reject treatment as well as water manage-

beyond the 2,000 m/min that are so com-sidered the leader in innovative fabricment. Key products are the Kneading Dis-

mon for decades now. Voith will be in-products, especially in Through Air Dry-

perger and high consistency refiner to in-

20/05

51

5

fluence fiber properties, EcoMizer Clean-

are essential for a high-quality end prod-wide and operating at 1,500 m/min, anders, MSS pressure screens with MultiFoil

uct. The quality and dependability ofreaches the VariSoft II concept with up

rotors and C-bar slot baskets, EcoDirectthese services is supported by Voith

to 4 unwind stands, maximal 7,500 mm

dispersion and EcoCell flotation technolo-

Paper’s continual investment in the latest

wide and designed for 2,200 m/min. Sup-gy for effective removal of ink specks

technology and techniques. The Voith

ply may also include calender, edge em-and stickies, the VarioSplit washer for re-

TCS Group recently introduced the Virtual

bossing station, shaft puller and auto-

moval of ash and fines, and iConBleach

Reference Grinding technology (see arti-

matic core handling.

control for reliable pulp brightness levelcle on page 57), a breakthrough thatwith low chemical consumption.

changes the way Yankee grinding services are performed, with dramatic time-

100 % Voith for Tissuesavings and significantly improved stanCylinder Service for Tissue

dards of accuracy.

Stock preparation, paper machine, fabrics, automation, yankee cylinder service,
combiners, various enhancement compo-

Voith Paper’s Tissue Cylinder Service(TCS) Group is the recognised leader inWinder Technology for Tissue

nents, service, PTC for Tissue – this isVoith, 100% in tissue, and covering theon-site reconditioning, maintenance, andcondition-assessment of Yankee Dryers.

Voith has been building winders for theentire tissue production process! New

We provide support to tissue producers

tissue industry for over 100 years andstructures and intensified R&D activities.

worldwide with safety inspections, mea-

has the perfect technology to solve theDuring the Tissue World exhibition insurement & diagnostic services as well

winding problems posed by tissue grades

Nice we had a first opportunity to explain

as mechanical repair.

made of different furnish, multiplies,

our expansion plans to our customers.

smooth or embossed. The Voith winder

So far, their feedback was enthusiastic.

The Yankee Dryer is the heart of a tissue

portfolio begins with a basic concept with

The tissue teams at Voith are so as well.

machine – its condition and performance2 unwind stands, maximal 3,000 mm

Good luck to everybody!
20/05

52

The NipcoFlex shoe calender –Development and operating experience
Based on excellent results with the shoe press, Voith
Paper started developing the shoe calender in the early nineties.
The foundations were laid and several patents were taken out,
but the market situation soon demanded concentration on theJanus calender. Development work on the shoe calender started
again in 2000, and in December 2001 the NipcoFlex calender
test facility was commissioned.
Dr. Jörg Rheims
Finishingjoerg.rheims@voith.com

Basic design andoperating principle

Dr. Rüdiger Kurtz
Paper Machines Graphic
ruediger.kurtz@voith.com

1

The NipcoFlex calender comprises a heated Flexitherm roll pressing against a
NipcoFlex roll with soft cover and rigid
concave shoe (Fig. 1). Between the
NipcoFlex sleeve and Flexitherm roll thepaper is calendered on the side in contact
with the latter. Important for wide-nip
calendering are above all the QualiFlex
Cal sleeve with its special characteristics(surface smoothness, hardness, thermal
capacity and mechanical strength), andthe shoe itself (nip length, MD line force
profile, lubricating system between sleeveand shoe).
2 Moisture and temperature gradient calendering
Nip pressure reduction, while preserving bulk
Contour calendering by NipcoFlex calender– Soft sleeve adapts to macro surface structure– Mainly micro roughness improved (PPS)– Macro roughness (Bendtsen) improved lesssignificantly

20/05

The principle of shoe calendering isbased on the effects of moisture andtemperature gradients (Fig. 2). The longer
nip has a greater influence on calendering, which is further enhanced by thehigh temperature. This allows a significant reduction of line force and, therefore, the required pressure and enables
the desired volume retention.

The NipcoFlex calender
test unit
The NipcoFlex calender test unit shown in
Fig. 3 is completed with a humidifier(steam or water) in front of the nip. In
3

53

1,55
1,60
bulk [cm3/g]

200
1,50

1,65

combination with the second stack, online pre-calendering or post-calendering(reverse sheet side) with hard or softrolls is also possible.

Since December 2001 numerous tests
have been carried out over a wide rangeof basis weights, from folding boxboard
at 370 g/m 2 down to graphic paper at
40 g/m 2.

The NipcoFlex calenderfor board and packaging paper

uncoated

3.0
2.0
1.0
1.70

coated
1.80
1.90
bulk [cm3/g]

250
temperature [°C]

PPS S-10 [m]

4.0

7

2.00

190
40

300

120

250 °Cm
N/

m

150 °C0yankeereference

10

Bendtsen [ml/min]

m
N/m
100

m
m
N/

PPS S10: 5.30
Bendtsen: 500
60
80
100
linear load [N/mm]

400

4

N
00

/m

m

1,55
1,60
bulk [cm3/g]

1,65

At 130 mm nip length (Fig. 5), however,the bulk changes significantly also withtemperature. Furthermore, shoe calendering results exceed those at the reference
point over a wide range. If the calender
nip length is further increased to 250 mm(Fig. 6), these results are hardly improved because, due to the long dwelltime, temperature has a greater effectthan linear load.
As a further comparison between the
NipcoFlex calender and Yankee cylinder
with white lined chipboard, Fig. 7 shows
the relation between micro-roughness ofFig. 1: The NipcoFlex calendering principle.
Fig. 2: Surface quality improvement with
NipcoFlex calender.
Fig. 3: NipcoFlex calender test unit.
Abb. 4: NipcoFlex calender, nip length 40 mm,
precalendered with hard nip, white lined chipboard.
Fig. 5: Nip length 130 mm.
Fig. 6: Nip length 250 mm.
Fig. 7: Folding boxboard:
Yankee cylinder versus NipcoFlex calender.
Fig. 8: Operating window for liquid board:
comparison between soft calender and NipcoFlex
calender.
250

Soft nip calender:
targets not met

230

210

500

6

ls = 250 mm
precalendered

200
1,50

1,65

Using the shortest 40 mm shoe (Fig. 4),
temperature variations have no effect oncalendering results. Compared with thereference point, a higher bulk than with a
Yankee cylinder is only attained at low
linear loads. This nip is clearly too shortfor the relatively heavy board, and results
are similar to those with a soft calender.

In many board machines volume retention is achieved by calendering with a
Yankee cylinder, which however has the
drawback of restricted operating conditions with regard to production speed
and output. In the end, the principle of

5.0

1,55
1,60
bulk [cm3/g]

NipcoFlex calender in comparison to the Yankee cylinder
Nip length is a very important parameterin shoe calendering, because it determines how long the pressure, temperature and humidification take effect.
Figs. 4, 5 and 6 show calendering results on uncoated white lined chipboard –WLC (basis weight about 370 g/m 2) withnip lengths of 40, 130 and 250 mm. The
continuous lines in these diagrams show
the relation between macro-roughness(Bendtsen) and specific bulk at temperatures of 150 °C (blue) and 250 °C (red)with linear load variation from 100 to 400
N/mm. The dotted lines show this relation at constant linear load and varying
temperature. Overall, these curves define
the operating range at these calender settings.

Nip lengths can be varied between 40 and
250 mm, the shorter nips mainly being
used for graphic grades and the longer
nips for carton.

Yankee dryer
NipcoFlex
calender250 °C

gentle bulk-retaining calendering leads tothe wide-nip or shoe calender.

The NipcoFlex calender test unit can be
operated at speeds of up to 1,500 m/min,line forces of up to 1,200 N/mm andmaximum roll surface temperatures up toaround 260 °C.

6.0

300

0

250 °C400

yankee 150 °C
reference

600

temperature [°C]

200
1,50

500

5

ls = 130 mm
precalendered

40

300

600
Bendtsen [ml/min]

400

150 °C

4yankeereference
100 N/mm

500

ls = 40 mm
precalendered
400 N/mm

Bendtsen [ml/min]

600

230

210
190
100

8
NipcoFlex calender:
meets all targets
bending
resist.: 365
bulk: 1.660
PPS S10: 5.30
Bendtsen: 500
150
200
250
linear load [N/mm]

300

20/05

10

500

Raw paper
Softnip calender
400
NFC
Soft and shoe nip
300 same correlation
macro roughness – bulk

PPS S-10 (mean TS+BS) [m]9

Bendtsen (mean TS+BS) [ml/min]

54

200
100
1.16

1.20

1.24
1.28
bulk [cm3/g]

1.32

1.36

5.5

3.5
1.16

Shoe calender:
PPS 1 m lower
at the same bulk level

1.20

1.24
1.28
bulk [cm3/g]

1.32

Fig. 9 shows Bendtsen macro-roughness
plotted over specific bulk. Here there ispractically no difference between the twocalendering methods. But referred to PPS
S-10 micro-roughness (Fig. 10), there isa very clear difference: bulk with the
Steam box

Heated roll

Rebuild of White Lined Chipboard Machine
width: 4.8 m, speed: 750 m/min
Scope
NipcoFlex shoe press
NipcoFlex shoe calender (at 250 °C), Sirius reelTarget
1. step: increase production ~ 35.000 t/a (20%)
2. step: replace Yankee cylinder (approx. 25%)
February 2004:
production restart after rebuild BM 3

13

20/05

1.36

Figs. 9 and 10 compare results for 2sided calendered copy paper (80 g/m 2).

12

Fig. 9: NipcoFlex calendering of copy paper(80 g/m 2 ): macro-roughness.
Fig. 10: NipcoFlex calendering of copy paper(80 g/m 2 ): micro-roughness.
Fig. 11: StoraEnso Baienfurt BM 3 project.

4.5

NipcoFlex calender incomparison to the soft calender
Soft calenders are used for grades suchas copy paper or matt coated wood-free
papers. Here NipcoFlex calendering offers
the advantage of a possibly higher bulk,
with savings in fibers and lower operating costs accordingly.

NipcoFlex calendering incomparison to the soft calenderFig. 8 shows this comparison based on
test data with liquid packaging board. Using a process optimization software, therespective operating window was determined each time. In the present case nooperating window remains with soft-calendering: surface quality requirements
are fulfilled, but the bulk is inadequate.
With the NipcoFlex calender, however, allrequirements are exceeded within the yellow range.
Project

6.5

Shoe calender:

Raw paperbulk 0.06 cm3/g higher
Softnip calender at the same PPS level
NFC

The NipcoFlex calenderfor graphic grades

the board surface (PPS S-10) and bulk
before and after coating. The NipcoFlex
calender attains the same PPS level as
the Yankee cylinder, but with up to 4 %more bulk and at 40 % higher speed. Thiseffectively eliminates the bottleneckcaused by the Yankee cylinder.

11

7.5

Edge insulation
belt

NipcoFlex roll
Edge coolingFig. 12: NipcoFlex calender.
Fig. 13: StoraEnso Baienfurt BM 3.

NipcoFlex calender is 5 % or 0.06 cm 3/g
higher at the same PPS value, whilesmoothness improves by about 1 µm or
20 % at the same bulk.
NipcoFlex calendering in comparison to the Janus calender
The Janus calender is currently used forgraphic grades with high demands on
surface quality, such as SC or LWC papers. Based on this technology, demands
for still better surface quality and higher
production speeds can only be met byfurther increasing the number of nips.
However, this is unreasonable both technologically and with regard to investment
and operating costs. Here again, theNipcoFlex calender might be the answer.
In order to equal the calendering performance of multiple-nip Janus technology
with a single NipcoFlex calender nip per
sheet side, short nips with high line
forces and/or high roll surface temperatures (well over 200 °C) are required. This
reaches the maximum sleeve loading limits, and while tests so far have shown thepotential of NipcoFlex calendering technology, they have also revealed its current limitations. Voith Paper, therefore,
has a lot of development and optimization
work to do in the near future.

55

Fig. 14: Design data of the Baienfurt BM 3
NipcoFlex calender.

Design speed

850 m/minFig. 15: NipcoFlex calender in Baienfurt BM 3.

Heated roll surface temperature

250 °C in operation

Line force

max. 500 N/mm

Nip length

190 mm(130, 250 mm possible)

Shoe tilt (load change at in- and outgoing side)+/- 20 %NipcoFlex calender in practice –operating experience at
StoraEnso Baienfurt, BM 3
NipcoFlex calender technology
Fig. 11 summarizes the decisive goals of
this rebuild, particularly with regard to
the planned 25 % production increase in
future by completely replacing the Yankee cylinder with a shoe calender.
In this rebuilt board machine (Fig. 13)
the NipcoFlex calender is not located in
the relatively damp board production
process zone, where the Yankee cylinder
is currently situated, but directly in frontof the coating machine where the web
has a much higher dryness.
Fig. 12 shows the detailed layout of the
NipcoFlex calender. The top roll is inductively heated to a surface temperaturereaching 250 °C during operation. The
NipcoFlex bottom roll enables shoechanges for nip length variation. Since
calendering is online, both rolls have tobe driven.

The NipcoFlex calender shoe is, therefore, retracted from the bottom roll
periphery, and the roll edges are cooledby compressed air and cold water nozzles.
Board surface quality is improved by asteam blow box located in front of the nip
above the web. The steam condensation
increases surface smoothness.
The rolls and NipcoFlex roll sleeve arechanged in the same way as with shoepresses.
Fig. 14 summarizes the main design andoperating parameters of this machine.
Three different nip lengths are available
for optimizing board quality. A 190 mm
nip was used at start-up, because thatgave the best results in the previous pilot
tests.

14

Fig. 15 shows the NipcoFlex calender inoperation on board machine BM 3 inBaienfurt.
Operating experience
Commissioning followed an optimization
plan based on experience with the pilot
machine. Fig. 16 summarizes the first
operating results immediately after startup, showing the quality and printability
data for 215 g/m 2 folding boxboard.
All the positive pilot test results wereconfirmed without exception during commercial operation.
With the rebuild, two important changes
were decisive for the board structure in
the z-direction and for the surface quality:● Drainage through a double-felted shoepress with downstream offset press
15

To prevent roll sleeve melting due to thehigh temperature of the top roll at theedge zones outside the board web, directcontact is avoided by changing the operating mode compared with shoe presses.

NipcoFlex calender
20/05

56

16

Required technological standard Before rebuild w. Yankee/grade 1

After rebuild w. NFC/grade 1

BW total [g/m 2]

220

215

Speed [m/min]

440

470

Bulk [cm 3/g]

1,48 +/- 3 %= (+)

Mean bending Stiffness [mNm]

9,6 - 10,7=

PPS roughness [µm]1,3 - 1,6

= (+)

Printability

mottle free, good gloss andbrightness= (+)

instead of conventional individualpresses (but still one press less intotal)● NipcoFlex calendering through a longhigh-temperature nip, without using
the Yankee cylinder.
It, therefore, had to be determined
whether the board structure was changed
enough to affect subsequent processes(coating, printing), or whether the difference in surface quality and z-direction
structure was only marginal.

This question can be answered in part bycomparing the SEM (scanning electron
microscope) photographs taken in three
production phases (Fig. 17) – with individual presses and Yankee cylinder prior
to rebuild, with shoe press and Yankee
cylinder after rebuild, and finally withshoe press and NipcoFlex calender after
rebuild.
As shown in these pictures, there are
only minimal differences in the z-direction web structure. Moreover the excellent printing results prove that the effectof these differences is negligible.

Summary and future prospects
The tests carried out by Voith Paper overthe last three years show great potential
for the NipcoFlex calender.
The world’s first wide-nip calender forfolding boxboard production started
commercial operation on February 1,
2004 in board machine BM 3 at Stora
Enso Baienfurt/Germany. Fig. 18 summarizes the operating experience and advantages so far with this NipcoFlex calender.
In the second quarter 2006 Voith Paper
will start up a NipcoFlex calender at
Weyerhaeuser Longview (USA) for liquid
packaging board production. In the same
year further machines already ordered
will be installed, also for graphic grades.

Fig. 16: Post-commissioning operating
experience.
Fig. 17: SEM analysis of Yankee roll andNipcoFlex calendering results.
Fig. 18: Production benefits and future
potential.

17

Before rebuild withold press and Yankee

Quality targets with shoe calendering after
first production runs fulfilled and printability
as brilliant as before rebuild
Efficiency and runability as good as expected

After rebuild with
new NipcoFlex press
and Yankee

After rebuild with
NipcoFlex press andnew NipcoFlex calender

20/05

Speed increase without lack in quality
possible
Rebuild target to increase production by
further 25% and replacement of Yankee seems
reasonable
NipcoFlex calendering fulfills productdevelopment and rebuild objective

18

57

1

Virtual Reference Grinding –An innovative method to re-condition the Yankee
Dryer in a Tissue Machine
The Yankee dryer in a tissue machine is an unique, multi-functional
component. It is backing the press rolls, it is a sheet carrier, a large drying
cylinder and a creping surface all in one. The Yankee is the central, mostcritical and most expensive part in any conventional tissue machine.

Sjaak Melkert
Servicesjaak.melkert@voith.com

Fig. 1: VRG system.

The condition of the Yankee dryer, and inparticular the Yankee surface, is criticalto the operational performance of the tissue machine.
Re-grinding the Yankee dryer, to re-condition the surface and re-establish thedryer crown, has become a routine maintenance operation carried out by specialists, usually at intervals between 12 and36 months, depending on the operating
conditions. Any necessary maintenanceof the Yankee results in machine downtime, as it can only be performed ‘onsite’ and ‘in-machine’. Similarly, regrind-ing of the Yankee normally requires amajor shut-down of the tissue machine.
In co-operation with the German Fraunhofer Institute, the Voith Paper Cylinder
Service group has developed an innovative technology named “Virtual Reference
Grinding”, abbreviated to “VRG”, to regrind the Yankee dryer. VRG is a verysmall, but powerful dual head grinder,
which is mounted directly onto the existing creping or skinning doctor holder. To
install this grinder, almost no paper machine components need to be disassembled (Figs. 1 and 2).
20/05

58

Fig. 2: Installed grinder.
Fig. 3: Helix surface measurement.
Fig. 4: Measurement system.
Fig. 5: 2-D carpet-view of cylinder surface.
Fig. 6: 3-D surface representation.
2

3

VRG technology uses, as a reference, aspring steel wire spanned equidistant to
the main axis of the dryer, and incorporates on-board laser systems to continuously measure both the distance to the
Yankee surface and to the reference wire.
Indexing sensors and electronic levelsensors continuously record the positionof the measurement unit, which is freely
moving on the doctor holder, in relation
to the dryer (Fig. 4).

The surface description, in helix format,
is mathematically processed into a grid
matrix system, taking into account andcorrecting all movements of the measurement/grinding unit. The grid density canbe as small as 10 x 10 mm, very accurately displaying the topography of theentire dryer surface. Typical measurement accuracy is within a band width of
20-30 µm.

5
Scanning

xr
xt
0

20/05

Goniometer
Wire

Triangulation
rt

rs

x2

x1

xs
0

Any conventional grinding technology
uses a geometrical reference plane. Thiscan either be the grinding bed itself, or
any straight plane (reference point) incorporated into the grinder. The shape of
this so called reference is copied ortransferred onto the roll or cylinder to be
ground, often (as required) in the shapeof a ‘crown-profile’, or camber. In orderto maintain accuracy on these geometrically functioning grinders, the grinding

The system can display the Yankee surface in 2-dimensional carpet-view, or inreal-time 3-D visualisations, which allow
for in depth investigations into dryer
wear patterns and their correlation to
production related problems. A stand-

The Yankee surface is measured in ahelix, collecting up to 1,000,000 data
points from each sensor, simultaneously(Fig. 3).

4

alone visualisation software package provides further valuable information for ongoing optimisation of the Yankee within
the overall production process (Figs. 5
and 6).

6

59

Fig. 7: Grinding head.
Fig. 8: Force controlling the grinding process.
Fig. 9: 2-D carpet-view of a finished cylinder.
Fig. 10: Centerline run-out (TIR) achieved.
7

8

9

Fs/2
Fs

Ps
F

FR
Pz
F s = F±FR

bed needs to be very accurately machined
and must be sturdy and heavy, to maintain form stability.
VRG grinding technology is unique andfundamentally different. Grinding is notaccomplished through a geometrical coupling between the grinder and the rollor dryer, but through a force-coupling.
Material will be removed only where necessary (Fig. 8).
Following collection of the surface topography data, the grinding cycle uses thesurface description in the form of anelectronic grinding protocol to control
the forces applied to the grinding wheels,10

and thus the abrasive powers. This isaccomplished using very fast acting hydraulics, whilst the actual applied grinding forces are further measured continuously. Grinding forces up to 1000 N are
applied within a reaction time of lessthan 20 milliseconds. During the grinding
process the control computer simulates,in the background, material removal andthe expected form and shape of the dryer,
in real-time, to prevent over-cutting of
the surface.
Only the required grinding forces in relation to the out-of-profile condition of thedryer are applied and controlled. The
grinding equipment can, therefore, be extremely light-weight, and its actual movement accuracy is not important.
With VRG technology, Yankees can be reconditioned in a fraction of time whencompared to conventional grinding technology. Usually, no ancillary machinecomponents need to be removed for thegrinder installation. Down time and othermill cost savings are, therefore, considerable.

VRG is now proven as an extremely powerful machine tool capable of taking theguesswork out of the reconditioning ofYankee and MG cylinders, and can besummarised as follows:● Compact, lightweight equipment thatcan be easily shipped/air freighted.
● No need to disassemble paper machinecomponents to facilitate installation of
VRG grinding unit.
● Reduced installation, set-up and equipment removal times.
● Cylinder re-grinding can be performedmuch faster and more accurately thatany previously available grinding
technology.
● Due to VRG system accuracy, only
the absolute minimum of material isremoved to achieve Yankee profile,
thereby ensuring optimum asset
preservation (Figs. 9 and 10).
● 3-D data acquisition via system computer creates a comprehensive pictureof entire Yankee surface providing avaluable database for on-goingtracking of Yankee condition andperformance.
20/05

60

Voith Customer Conferencein Indonesia
Improving Productivity, Quality and Efficiency!
Indonesia, as one of the largest paper production
countries in Asia with an installed annual production capacity of
about 10 million tons of pulp, board and paper, was chosen forcustomer conference in Jakarta and Surabaya in March 2005.

Robert Kietaibl
Voith Paper Service Asia
robert.kietaibl@voith.com

Siegfried Wauer
Voith Paper Jakarta
siegfried.wauer@voith.com

20/05

Voith Paper Jakarta, Voith Paper Service
Indonesia, Voith Paper Fabrics, Voith
Paper Tail Threading Group and Krieger
presented products, services and solutions for improving productivity, quality
and efficiency. Customers from Indonesia
and Malaysia were invited to attend theseseminar days to listen to and discusswith experts of the various Voith Paper
Divisions from Asia and Europe.
The events started on the evening ofMarch 2nd with a reception dinner at theGran Melia Hotel in Jakarta, which was
the opportunity for guests and Voith specialists to begin their discussions. 150
dedicated papermakers from different countries exchanged their experience and shared
their input during this casual evening.

On March 3rd, the series of papers was
opened by Mr. Siegfried Wauer, Managing Director of Voith Paper Indonesia and
Mr. Robert Kietaibl, Senior Vice President
Voith Paper Service Asia, giving the audience an update of the current organization and product portfolio of Voith Paper,
Voith Paper Service and Voith Paper
Fabrics in Indonesia.
The technical experts from Voith in Asiaand the invited speakers from overseas
created high interest with their presentations and many questions were discussed
in the forum at the end of each presentation. It was hardly enough time to respond to all questions to specific topics
during the conference sessions. Groups,
therefore gathered during coffee and61Fig. 3: Speakers (from left to right):
Bertinus Tirtadihardja, Head of Paper Machine
Division, Jakarta; Michael Cartmel, Vice President –Asia/Pacific Sales, Fabrics; Hans Peter Schoepping,
Sales Manager, Krieger; Robert Kietaibl, SeniorVice President Asia, Service; Beth Rooney, Business
Development Manager, Tail Threading; Siegfried
Wauer, Managing Director for PT. Voith Paper,
Jakarta; Thomas Holzer, Regional Sales Manager
SEA, Service; Michel Beltzung, Vice President
Product Management Roll Covers, Service; Thomas
Jap, Head of Fiber Systems Division, Jakarta.

Fig. 1: Discussions amongst several guests.
Fig. 2: Evening event with Karaoke Show.
1

2

3

Mr Wong Kam Choi

Mr Alpin Wu

Mr Ramli Sirait“I was pleased to be invited to the Voith
Paper Customer Day. Several of the presentations were of specific interest tome. One of the drying cylinders on the
MNI machine needs grinding and theability to do this work at site would be agreat benefit to us because of the saving
in down time. Other topics like rollcovers, fabric cleaning and tail threading
are all subjects of high interest in ourmill.”“It has proved to be very beneficial for us
to have the Voith Paper Service Center
located here in Indonesia near to our two
Pindo Deli mills. This allows a rapid
response to our requirements. The conference was very informative with the update on the wide scope of Voith Paper’s
services and products. I was interested
in the details of several topics, includingroll covers, on-site cylinder spraying andModern Drying Concept.”“The conference gave me a better understanding of a number of technical subjects and was a good update on Voith’s
products and services. In particular I wasinterested to have information about the
DuoCleaner as well as the new developments of Voith Paper Fabrics. Roll coverlife time was discussed and is an
important subject at our operation at
Perawang.”lunch breaks to continue and work on
custom made solutions for the different
requests. The displayed roll cover samples gave customers insight into the
products manufactured in the Voith Service Centers in Indonesia and China.
50 contact requests on the seminar organization team for a visit by a Voith expert
to discuss specific customer questions,will be followed up in the near future. The
high interest created by the Voith teamduring this seminar was also reflected in
the fact that over 80 % of the guests
handed in the seminar feed back form,
giving us their comments and input for
future events.

with a traditional Indonesian dinner andfirst class entertainment. Some of thecustomers still could not stop work andcontinued to discuss paper making topics
where others enjoyed their time withkaraoke singing on the stage.

The Voith seminar organization team
meanwhile was working already behindthe scenes to move all the equipment toSurabaya for the next stop, were thesame seminar was held just a few days
later, on March 8th, at the Marriott Hotelin Surabaya.

Production Manager,
Malaysian Newsprint Industries

After a hard working day, all guests andVoith staff could finally enjoy an evening

Deputy Director of Engineering Division, Pindo DeliPulp and Paper Mills

A successful event ended late in theevening after intense communication between paper making experts from all over
the world. Satisfied customers left Gran
Melia Hotel on March 4th to plant tour to
our newly establish Stock Preparation
Service Center of Voith Paper Indonesia
in Jakarta, to get an overview of our rotor
restauration competence and to our Voith
Service Center in Karawang for an updateon the latest state-of-the-art roll coverproduction.

Deputy General Manager,
IKPP Perawang, Paper Mill 2

The event in this region was again very
successful with 72 customers and Voith
experts, many follow up requests fromthe visitors and very positive commentsin the returned seminar feed back forms
from our guests.
A big thank you to the South East Asian
paper makers for participating on thisVoith Conference. We are looking forward
meeting all of you again in Indonesia.
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62

Stage-Gate® at Voith Paper Fabrics –Greater customer benefit through fasterproduct development
As a world leader in paper machine fabrics, Voith Paper
Arved Westerkamp
Voith Paper Fabrics
arved.westerkamp@voith.com

Fabrics works in a global product development environment. These
activities are centrally managed by the R&D/Technology Center inPfullingen, Germany, where our basic research and process development is also located.

During restructuring of the Voith Paper
Fabrics R&D/Technology organization, avery effective customer-oriented development process was introduced. This enables flexible compliance with customer
requirements and the systematic development of Voith Paper products in teamwork.

Due to the complexity of manufacturing
technology, our forming wires, press
felts, dryer fabrics and transfer/smoothing belts are developed in close teamwork with the respective Voith production
plants for each sales region worldwide,
centrally coordinated in Pfullingen.

The result is a solid know-how basis,
that, together with basic research activities, makes a valuable contribution to thedevelopment of future-oriented manufacturing technologies.

Introduction of theStage-Gate® project management system

Thanks to clearly defined responsibilities
in the development fields of forming,pressing, drying, materials and process
technology, product development transparency and focusing have greatly improved. By integrating sales and marketing activities at an early stage in development projects and joining forces with all
the Voith Paper divisions, we can now
concentrate much more intensively on
customer needs.
By highlighting specific customer problems, cooperation with our applications
specialists for all the various paper
grades enables us to develop innovative
solutions more rapidly.

After extensive studies, the Stage-Gate ®
project management system was globally
introduced in the Voith Paper Fabrics
R&D/Technology organization for the following reasons:● It enables the central managementof development projects, involving
several locations worldwide● Systematic resource management● Portfolio management can be more
efficiently structured for meetingcustomer needs and developing newtechnologies● Product development is integrated in
the overall business process● Joint projects within Voith Paper cancontrolled and managed more efficiently.

In the next phase, the overall system wasestablished and employee training andsystem introduction was started.

The Stage-Gate® process
The Stage-Gate ® process is a phased
product development model, each stageof which is handled as a ‘mini-project’embedded in the overall project structure. This not only enables optimal resource allocation among parallel projects,
but also the efficient monitoring of intermediate goals and definition of break-off
criteria.
In contrast to the conventional milestoneplan, there is much more emphasis thereby on setting gates as hard, clearly defined limits. Only if the respective gatekeeper gives the go-ahead, can the project be continued. In case of a ‘kill’ decision, the project is immediately terminated. If it is decided to redirect the project,
the next gate cannot be passed until thishas been done.

Structure of theStage-Gate® process
As indicated by its name, the Stage-Gate ®
process is made up of stages (project
phases) and gates.

20/05

63

Schematic flow chart of the Stage-Gate ® process,with typical integration of various responsibilities
during the course of a development project.

Stage 0
Idea
Generation

Stage 1Preliminary
Investigation

Gate 1
Gentlescreening

Stage 2
Detailed
Study

Gate 2Heavy
screening

Stage 3Development

Gate 3Retain only
most promisingprojects

Stage 4
Full Scale
Market Test

Gate 4
Release formarket test

Stage 5MarketIntroduction

Gate 5
Release formarket launch

R&D-Management

Gate 6
Review
results,
terminateproject

R&D-Specialists
Business Development
Marketing
Manufacturing
Finance, ControllingStages
The first stage is idea generation, akind of brainstorming phase where ideas
are collected and structured.
Then comes the preliminary investigation stage, where rough estimates are
made of technical feasibility, the project
costs and timeframe involved, and thepotential market volume.
This is followed by the detailed study
stage, involving a thorough investigationof all factors including the market situation, technical and technological solutions, financial analysis, etc.

product launch, followed by revalidation
after assessing the experience gained
thereby.

the “backroom boys”, but handled as
actual business processes.

Gates
These five or six project phases are separated by gates, where decisions are madeby the respective gatekeepers according
to defined criteria. Only three decisions
are possible:

Customer benefits

Go: continue the development project.
Kill: terminate the project immediately
while safeguarding all findings and knowhow gained so far.
Redirect: do not continue the project until after realignment.

The subsequent development stage covers product and process development aswell as prototyping and the definition of
production goals.

Interdisciplinary project
structure

After that comes the full-scale market
test stage, which is critical for projectsuccess. With close customer involvement, the respective product or technology thereby undergoes product pre-launch
trials to test for market acceptance andmanufacturing dependability. Based on
test results and customer feedback, thedecision is then taken whether to go intofull production or not.

One of the main advantages of thisstaged development process is that theright specialists are engaged at the righttime under the supervision of each respective project manager. The philosophyof a sole project manager, often applied
to small development projects, is replaced
here by task distribution among the respective experts according to responsibility for each project phase.

Finally, the market introduction stage
involves a systematic and widely based

In line with the latest findings, development projects are no longer reserved for

Including customer requirements at an
early stage in the selection process is an
important step toward interdisciplinary,customer-oriented product development.
Well structured decision-making during
the course of the defined project sequence enables reproducible, resourceoptimized development.
Factually based decisions also help the
project team members to concentrate on
goal attainment rather than emotional
considerations.
By embedding Voith Paper Fabrics inVoith Paper, the volume of joint projects
and activities has risen steeply. The common controlling system for development
projects strengthens our systematic approach, and enables us to cooperate
more closely and efficiently thanks to ananalogous project structure on all sides.

Stage-Gate is a registered trademark of
STAGE-GATE Inc., Ancaster (Ontario, Canada).

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64

iCon –
intelligent Control for stock preparation lines
The technological trend in stock preparation lines today
is increasingly toward continuous production, with fewer vatsaccordingly. In this connection Voith has developed the EcoProcesssystem concept (Fig. 1), which enables enormous savings in investment and operating costs.

Dr. Boris Reinholdt
Voith Paper Automation
boris.reinholdt@voith.com

For maximum benefit, the EcoProcess

To cover such higher-ranking control

depends on systematic plant automationneeds in stock preparation lines, Voith

with higher-ranking control strategies. All

Paper Automation developed the iConthese higher-ranking systems work on

product family. iCon stands for intelligent

the same principle: they supply a produc-

Control, and incorporates all the control

tion automation system with setpoint

and regulation tools beyond basic au-

inputs for various control parameters, totomation of a stock preparation line.

keep plant operation as near as possible

20/05

to the technical and technological opti-

The modular iCon product family offers

mum. EcoProcess can also be retrofitted

hardware and software solutions withto increase the productivity of existing

associated services for simplifying stock

deinking lines.

preparation line operation, improving

65Fig. 1: From conventional process to
EcoProcess.
Fig. 2: Structure of the iCon product family.

reliability and minimizing costs (e.g. for1

bleach chemicals). Investment costs forthese intelligent systems are very quickly
amortized: according to Helmut Berger,
production manager at WEPA Giershagen, deinking line upgrading saved
30% oxidative and about 40% reductive
bleaching costs, with an investment payback time of less than two years.

MP

MP

MP

MP = Mixer pump

2
iConView

System structure

iConAlarm

iConTrend

iConReport

iConPlot

iConQuality

iCon is mainly divided into three inter-

iConBrightlinked areas:● iConControl is the platform under

iConControl

which all controls and the information

iConBleachsystem run. It communicates directly

iConSensor

with the process control system.

iConBleach

iConSensor iConSensor● iConQuality incorporates all thecontrol systems for improving stock
quality and at the same time
optimizing process operating costs.

MP MP

MP

MP

MP = Mixer pump

● iConView covers all the communication and information systems
required for stock preparation line

large quantities of data are read in frominterface, and is unaware that anothercontrol (Fig. 2).

the process control system, and thesystem is operating in the background.

requisite setpoints are fed back to the

All necessary inputs and outputs are con-deinking process. This OPC and web

tinuously provided by the database, thus

technology ensures seamless integration

enabling for example visualization on thein practically all process control systems,

form of freely configurable graphics. Viairrespective of manufacturer.

an ethernet link, the PC can access theiConControl
The MS Windows based iConControl
platform comprises a high-end industrial

process control system OPC server to

PC with standard OPC interface to the

The user operates the system from aread and write process data and vari-

process control system. Via this interface

browser window on the process control

ables.
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66

iCon OSPCS7 process control system
OS 2

OS 1

OS 3

3

ClientModem

iCon Server
– Web
– DB
– OPC

Server

AS 1

Modem

Voith service
laptopiConView

Redundant server

AS 2

AS 3

Sensors

iConView thus supplies plant operators,

operation can be limited to specific user

engineers and management not only withgroups.

The Voith iConView system is installed on

online process information, but also with

the iConControl platform to ensure basic

historical data. The only limit to the time

An iConView reporting system is alsofunctionality of the individual quality con-span of such data is the system storage

available optionally. By compressing thetrol modules. The large quantities of datacapacity, which can however be expanded

vast array of data, this enables documen-are stored in compressed form in a data-

to take account of increasing data vol-tation both chronologically (by shift, day,base developed by Voith Paper Automa-umes during the course of time. This

week, month and year) and according totion. This system forms the basis for var-enables for example data and parameterproduct grade. The form of reporting isious modules providing interactive datacomparisons over several months or evenagreed in advance with the customer.

interchange with the iConView system.

years. The iConView module is therefore
an ideal decision-making tool both forWith ongoing automation of the paper-

engineers and management (Fig. 4).

iConBright and iConBleachdata is increasing rapidly. On the one

Process data can be displayed in various

Brightness, one of the most important

hand this enables increasingly precise

forms depending on requirements – such

paper quality criteria, can be improved byanalysis, but on the other hand such a

as individual values, bar or column charts,

stock bleaching. The online brightness

flood of information can hardly be evalu-

trends, or X-Y diagrams – not only on in-measuring sensors installed by most pa-

ated manually. This is where the iConView

dividual client PCs via web browser, but

per mills in recent years supply the nec-

system plays a decisive role in drawing

also per intranet throughout the paper

essary data for Voith Paper Automation’s

the right conclusions and taking the rightmill’s process control system. By allocat-

intelligent bleach control system. By re-action.

ing the respective access rights, system

ducing the bleached stock brightness

making process, the volume of process

20/05

67
4
Fig. 3: iCon product integration in the processcontrol system environment.
Fig. 4: iConTrend display.
Fig. 5: iConBright – mimic diagram for brightness control.
Fig. 6: iConSensor – sensor calibration.

5

6

fluctuation, this significantly improves

iConBleach modules to optimize bleach-laboratory data system. The deviations

the finished stock quality and also brings

ing chemical costs, the technologicalbetween online and laboratory measure-considerable cost savings.

weighting of each bleaching stage, dead-ments can thus be determined and dis-times, and other factors (Fig. 5).

played, as a basis for recalibrating the

Each iConBleach system comprises several modules according to customer

online sensors whenever required (Fig. 6).
iConSensor

requirements. The main system module,

The iConBright and iConSensor modules

iConBleach, regulates the brightness gain

The iConSensor module is a so-called

can be activated by a grade selection pro-

per bleaching stage and determines thesoft sensor for various quality criteria

gram so that the respective grade only

dosing of bleach chemicals and additives.

sensors in the stock preparation line.

has to be set and activated at one point

An internal model-based controller (IMC)

By linking various internal and externalin the program. The respective setpoints

takes into account the long deadtimes

sensor signals, the display precision isand parameters are then adjusted auto-andmatically in the iCon modules.

bleaching

improved. In future this will enable theprocess as well as the upstream andinclusion of additional quality criteria sig-

downstream process values.

nals in the Voith iCon control system.

nonlinearities

of

the

Summary

Furthermore, various sensor calibration
Two or more iConBleach modules are

curves for different grades can be stored

Voith Paper Automation’s new iCon prod-

linked with a higher-ranking iConBrightand selected according to need.

uct family offers a comprehensive pack-module, thanks to which only one set-age of tools and modules not only giving

point for brightness at the end of theAnother advantage is that the central cali-users a better overview and control of thestock preparation line has to be entered.

bration not only saves time, but also

stock preparation process, but also pay-

This module coordinates the individual

enables automated interrogation of aing off quickly thanks to short ROI times.

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68

1

Voith Paper Fabrics
Customer symposium in China –On-the-spot reliability, knowledge and trust
In March this year Voith Paper Fabrics invited leading
papermakers in China and the Far East to an Asian customer
symposium entitled “Voith Paper Fabrics Kunshan – bringing
Chris Chenreliability, knowledge and trust closer to you”.

Voith Paper Fabrics China
chris.chen@voith.com

Linked with the inauguration of theKunshan plant extension, this event took
place from March 16 to 18, 2005 in
Kunshan, China.
Kunshan is about one hour to the west of
Shanghai in Jiangsu province, at theheart of a rapidly growing papermaking

region. The Kunshan plant, where former
wires and press felts are made, has been
supplying Asian paper mills for morethan seven years with high quality products.
Almost 150 customers from more thansixty paper mills met in Kunshan to hear
2

20/05

69

Fig. 1: Bob Burke opening the inauguration
ceremony.
Fig. 2: The attentive audience at the customer
symposium.
Fig. 3: Simultaneous translation services werein great demand.
Fig. 4: Dr Hermut Kormann greeting the guests.
Fig. 5: The Voith management delegation on its
way to the new production facility.
3

4

about Voith’s latest innovations in papermaking technology. Voith has always attached great importance to dependable
partnership with Asian customers. Thiswas emphasized once again by the presence of a high-level Voith management
delegation including Dr Hermut Kormann,
President and CEO Corporate Board ofManagement of Voith AG, Hans Müller,
formerly President and CEO Voith Paper,and Bertram Staudenmaier, new memberof the Voith Paper Executive Board withresponsibility for the Fabrics and Rolls
divisions.

China. Afterwards the various Voith Paper
technologies and their application possibilities were explained by specialists andillustrated by references. This was followed by a panel discussion, and it became quite clear that innovative high-end
technology is rapidly gaining ground in
the Asian papermaking industries, whose
further expansion still depends on an ongoing partnership with Voith. This partnership is solidly based on reliability,
knowledge and trust, and is being steadily consolidated by on-the-spot customer
contact.

The symposium was officially opened on
Wednesday March 16 in the evening by
Bob Burke, Senior Vice President of Voith
Paper Fabrics Asia/Pacific division. He
cordially welcomed the participants to
Kunshan and thanked them for attending.
During the ensuing banquet they wereentertained with jazz and a magician in alight-hearted atmosphere ideal for making new contacts and meeting oldfriends.

On Friday March 18, guests and participants attended the official inauguration of
the new Kunshan plant extension. Voith
is now in the position to manufacture locally the entire range of dependable press
felting from the Voith Paper Fabrics portfolio, thanks not least to a new production shop with high-tech facilities.

On Thursday the first day of the seminarstarted with a welcome address by Hans
Müller, who outlined the Voith organisation in Asia and gave an interesting
overview of Voith’s development in

Before attending the inauguration ceremony at this new Voith Paper Fabrics
plant, the guests of honour visited theneighbouring Voith Paper Rolls plant
opened in summer 2003.
Bob Burke greeted the guests at the inauguration before their tour of the new VP

5Fabrics plant. The official opening ceremony started at 9:58, a lucky number in
China.
After the official opening, the ceremonycontinued in traditional Chinese stylewith a lion dance as good omen or “fengshui”. When the red ribbon had been ceremoniously cut, welcoming addresses
were held by Dr Hermut Kormann, Bob
Burke and official representatives of theChinese government.
Dr Hermut Kormann got to the point in
his speech: “This Kunshan plant is our
new baby, whom we welcome withparental pride into the Voith family. Insuch a big strong family, the new member stands excellent chances of a long,prosperous and happy life!”
This successful two-day symposium willcertainly improve relations between Asian
papermakers and Voith Paper even further. Kunshan is the first Voith Group
location where former wires and press
felts are produced under the same roof
as roll sleeves, not to mention the rollservicing also offered here. This outstandingly successful teamwork continues to set an example worldwide for thesynergies between Voith Paper divisions.
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Paper kites –Magic, mythology and sport
Everyone knows those brightly coloured shapes in thesky that dance in the wind to the delighted gaze of children.
Whether on beaches or hillsides, in Asia, North and South America
or Europe, playing about with the air currents is a well-known andpopular pursuit. From the earliest days, mankind has yearned to fly.
The first and very ancient flying machine that enabled man toreach up into the air above, though still attached to the earth bya cord, was the kite.

1

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Fig. 1: Kite flying in China in the 19th century.
Fig. 2: Medieval ‘wind sock’ – similar to the kiteand made of pergamin paper and material.
Fig. 3: A colourful street-scene in Tokyo during
the Japanese New Year Festival two centuries ago.
3

2

But it is still very difficult to trace the origins of the kite, if at all. The first mention
we have of kites as flying objects is from
China, at least two and a half thousand
years ago. The latest finds, from Indonesia, suggest that the first kites could haveexisted even earlier. The first kites from
China that we know of were made fromlittle bamboo sticks and silk, which was
expensive even in those days. But tospread any further, the kite had to wait
for the invention of paper. Paper wascheaper to come by and easy to work andideal for decoration with symbols appliedin paint and other media.
Originally, there was a close link between
kites and religion and mythology. People
saw kites as some kind of messenger ofthe gods. They hoped that these flying
objects would carry their wishes andrequests, for good weather or fertility
perhaps, to the gods. Even today, kites
figure in countless folk celebrations,which can trace their origins back tomythological and religious traditions.
It is probable that the use of kites spreadout from China into the Pacific region.
Some experts think that, over 1,200 years
ago, Buddhist monks brought kite flying
to Japan via Indonesia whereas according
to other theories, kite flying reachedJapan and Korea along with the sale ofpaper. More recently, the view has developed that kites originated independentlyof each other in a variety of countries.
These messengers of the gods all developed and adapted differently in their various homes – Burma, Korea, Indonesia,
Melanesia and Polynesia – and acquired

their own key roles in religious ceremonies.
Sometimes, more worldly uses for kites
have been found. According to Japanesetradition, Kaniko Kinsuke, a mythologicalbandit, flew about on a man-sized kitewhile stealing the gold leaf from the dolphins decorating the towers of a palace.
But he did not have long to enjoy the
fruits of his daredevil banditry. Alongwith all his family, Kaniko Kinsuke was
executed in short order.
Then, well over a thousand years ago,kites started to be used for pleasure. Thiswas when China introduced the ‘Day of
the Kite’, a festival held on the 9th day of
the 9th month. And in some Asian countries there is still a popular form of duelling game whereby fragments of glass
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Fig. 4: Giant kite battles. The history of theseenormous kites, which are flown at the Hammamatsu Festival, goes back centuries. The battles
have become so popular since the 19th century
that lots of kite teams converge on Hammamatsu.
The traditional kite Edo Dako is fashioned frombamboo and robust Mino paper.

Fig. 5: Yakko – a servant kite from Japan. It iscalled Yakko (servant) because it was forbidden
to depict the Samurai – only the lower classes
could be shown.

Fig. 6: Traditional kites at the Wau Festival –Wau Bulan, Wau Jala Budi or Wau Kuching,
for the Malays, what really counts is the choice ofthe right paper and the form of the frame, not theactual flying skill.

are attached to the cord and are used totry and bring down an opponent’s kite.
There are festivals held in many part ofIndia for fighting kites fashioned fromsilk paper. In Japan and Korea, whenfamilies celebrate the birth of a boy, kitebattles can be part of this special ‘Boy’s
Festival’. Thailand, too, has a special
relationship with kite flying. There, kites
used to be an element of magic and folklore. In the past, kites made with paper
stretched on a frame were flown at monsoon time as an exhortation to the winds
to bring good weather, and the presentday festivals that have grown from thisare an obvious continuation of this kiteflying tradition.

kite, were very popular in the Roman era
and in the Middle Ages for use as pennants at festivals.

kites could also have their military uses.
According to tradition, the General ordered his men to construct a large number of kites and fit them with devices
made of bamboo that buzzed loudly in thewind. The General used these kites to terrify the opposing army in the night. The
enemy thought they were being attacked
by evil spirits and fled in a terrible panic.
This was not the only military use for the
kite. During the First World War, kites
were used for air surveillance. In theSecond World War, a kite, nick-namedthe ‘Gibson Girl’, was a regular part ofsea rescue equipment for flight crews
who were forced to ditch in the sea.

In the 13th century, in the Marco Poloera, merchants brought kites from Asia
into Europe. In the 16th century, kites ofa grander variety were brought to Europe
by English, Dutch and Portuguese merchants trading in the Far East. Brightly
coloured and decorated ‘wind socks’
made of paper, and so a primitive form of
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For centuries, Europeans mainly thoughtof kite flying as a game for children. And
yet, when adults discover the child within
them, childish games can become a pleasure for every age. The kite continues todevelop, even today. There are literally
hundreds of different types. Although kiteenthusiasts are tending more and more
to prefer modern, more robust materials,
the traditional paper kite remains a firm
favourite. It doesn’t take much effort tomake a kite from ordinary wrapping paperor newspaper and a flour-based paste.
More demanding kite makers choose
tear-resistant pergamin paper.
Given the wide range of uses a kite canhave, it is not very surprising that it has
also been used for military purposes. For
many centuries, soldiers have repeatedly
made use of kites. More than 2,000 years
ago, General Huan Theng discovered that

Since the time of Leonardo da Vinci(1452-1519), the kite has been used timeand again for scientific purposes. Leonardo was the towering figure of the Middle
Ages who thought through the problemsof air travel scientifically. A very wellknown kite experiment was conductedby the American Benjamin Franklin, whoused a kite in 1752 to prove that light-

Fig. 7: Chula & Pakpao – Battle of the Sexes inThailand. The battle kites made from paper andbamboo embody the male and female principles.
At festivals, two smaller female Pakpao’s(85 x 70 cm) fly against one male Chula (250 x
190 cm). The aim of the battle is to ensnare
the opposing kite by means of hooks fixed tothe cord.

Fig. 8: The Chinese centipede. The centipede isactually a chain of lots of interlinked kites plus athree-dimensional head. The long line of kites
makes for an impressive sight as it snakes aboutacross the sky.

Fig. 9 : Korean fighting kite – this is in the typical rectangular form with a central hole. The
framework covered with paper is made from split
bamboo canes.

ning was an electrical phenomenon (Fig.
below). During a heavy storm, he flew arhomboidal kite to which a metal rod was
attached which acted together with thewet cord of the kite as a lightning conductor. Since the end of the 19th century,kites have been used to carry meteorological instruments. Finally, one of themore significant aspects of kite flying has
been its influence on the development of
the earliest flying machines.

Early in the history of flying machines,
different covering materials were being
tried out, whereas paper, a tried and tested material, is still in use by kite enthusiasts. A whole range of different grades
and types of paper are used to cover kite
frames – from simple wrapping paperand other tear-resistant types to thefinest silk papers. Quite a number of kitemakers swear by their own particular way
of pretreating the paper before it isstretched over the frame. A common
method is carefully to crumple the paper
up beforehand, then rub it and finallysmooth it out again. As with banknotes,
which pass through many hands, thistreatment is thought to increase theelasticity of paper. According to an old
English method, it is advisable to lay the
paper between two damp cloths before
fixing it on the frame.

accomplished designs of kite-making
artists. And for enthusiasts of the many
types – two-dimensional, box-shaped,
steerable, V-shaped or arched kites andor even interlinked kites – there arecountless clubs and associations, especially in America and Europe. In Asia,
however, kite flying still retains a social
aspect. In Japan, for example, whole villages may build kites communally – andthese can be enormous. Probably thelargest, measuring 14.5 by 11 metres,
are flown at the Hoshuba Festival. Suchmonsters take fifty people to get theminto the sky.
Werner Jany

There is quite a distance between a simple piece of paper stuck on wooden
sticks, which children the world over love
to see fluttering in the sky, and the
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Photos: Deutsches Museum München, a.o.

73

Newsmagazine for theinternational clientele,
partners and friends ofVoith Paper

Published by:Voith Paper Holding GmbH & Co. KG
Editor:Dr. Wolfgang Möhle, Corporate Marketing
Voith Paper Holding GmbH & Co. KG
Tel. (++49) 07 51 83 37 00
Fax (++49) 07 51 83 30 00
Escher-Wyss-Straße 25, D-88212 Ravensburg
wolfgang.moehle@voith.com
http://www.voithpaper.com

Design, layout and typesetting:
Manfred Schindler Werbeagentur
P.O. Box 1243, D-73402 Aalen
www.msw.de
Copyright 7/2005: No part of this publication
may be reproduced or copied by any means
whatsoever without the express permissionof the editor.
Issue 20, July 2005.

7/2005 MA Printed on chlorine-free bleached paper manufactured with Voith Paper machinery.

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