twogether
Paper Technology Journal

24

ATMOS Premium Tissue I Energy efficiency – A challenge forthe paper industry I Voith Paper Environmental Solutions

Contents

4

Report4 Energy efficiency –		 A challenge for the paper industry

40 ahead07 –		 Vienna Remains the Venue for Board		 and Packaging Paper Producers

72 Voith celebrates its 140th anniversary –1867 - 2007

Interview
16 Voith Paper Environmental Solutions –		 A new future-oriented division

Technology
11 Reducing energy costs –		 A challenge in stock preparation

18 The anaerobic reactor –		 Setting new benchmarks in effluent
treatment, even with high lime content

22 Bowater Calhoun PM 4 rebuild –		 Realignment to more profitable markets

26 ATMOS Premium Tissue –		 35% energy savings and much lower
investment costs

18

29 Greater value-added through47

35 Process optimization, analysis andimproved cross-profile control

stabilization with PaperMiner –44 Developments in board production –		 A service which turns database ­				 Trends on the global carton market

		 information into know-how

47 Mondi Business Paper, Ruzomberok –36 Innovative drying technology enabling

		 PrintTech LBR dryer fabrics improve­efficiency

50 Graphic Packaging International –		 Promoting synergies through partnershipspeeds in excess of 2,000 m/min –		 HiDryer: the speed and quality module

38 Comprehensive know-how in pressing
technology –54 Preparing for tomorrow –		 The FeltView press felt analysis system

		 Designed for the future!

39 New Engineered “Diamond Edge”

57 NipcoFlex Calender –		 for dryer fabrics –		 A new means for crowning the finishing

		 Lasts up to three times as longprocess

60 High Technology on a Roll Part 2
63 New Thermal Spray Coating­production line started-up in China

Voith Group news
70 Voith Industrial Services,

66 Total Roll Management –		 fully integrated –		 The Ultimate Roll Service Concept		 The Münzing Chemie success story

68 Product finder –		 in Heilbronn

		 The Voith Paper offering, now online

71 Borçka hydro power plant inaugurated
		 by Turkish prime minister Erdoğan

R&D

71 Voith Turbo launches commercial
		 WinDrive production

32 First Anniversary of the Voith Paper
Technology Center (PTC) –		 Success through Innovation

34 New speed record on the Voith PTC
VPM 6 pilot paper machine –Regular features
3 Editorial
76 Imprint

		 Over 2,000 m/min with Single NipcoFlex
		 press

2

24 I 2007 I Voith Paper I twogether

EDITORIAL

Dr. Hans-Peter Sollinger
Member of the Corporate
Management Board Voith AG
and President of Voith Paper

Dear customers and other readers,nificantly reduce waste and effluent

papermaking process can be orches-

disposal costs with the additional

trated here for optimally harmonic

It is now twelve months since webonus of power generation. Thesedevelopment. Voith customers caninaugurated our Paper Technology

concepts were met with considerable

systematically develop their new

Center (PTC) in Heidenheim. This

interest not only in the paper industry,

products at our PTC and test their­edition of twogether magazine reports

but also in other water-intensive

market response before investingon the first year of R&D activities­sectors such as the brewery industry.

heavily in production facilities. Here

there, and we are proud to say thatagain, a key role is played by step

results achieved at the new PTC have

An important principle with thesechange innovations – new paper

exceeded our expectations.

innovations was to take a fresh look at

grades, and new paper and packag-

existing concepts, in order to finding applications.

During this time we have also devel-

really new solutions with advantages

oped our “step change” innovations,difficult to visualize at first sight.

on which we have been working for

As always, we only see a glimpse
here of our future challenges andseveral years, to market maturity.

Energy savings and cost reductions

opportunities. The ongoing challenge

Their first installations in practice with

were of course our primary innovation

however is creative innovation –our pilot-trial customers have met thegoals, and with ATMOS and Environ-and that is our calling.

highest demands. Detailed reports on

mental Solutions we have reached

two of these innovations are included

these goals. But overall savings poten­

Meanwhile, this twogether 24 editionin this issue.

tial throughout the papermaking pro-will doubtless provide you with stimu-

cess is still enormous. Cost savings,

lating reading.

One of them is ATMOS, an innovative

still our primary objective, can, how-production process for premium tis-ever, not be everything we want tosue. This saves 35% of energy costs

achieve with innovations.

and substantially reduces investment
costs, with the same or even better

Paper quality improvements are of

product quality than TAD tissue.

course an ongoing requirement of ourcustomers. The Voith PTC offers for

Our new “Environmental Solutions”

that ideal conditions. From chemicals

division has developed some innova-

to fabrics to automation concepts,

tive processes and systems that sig-

every single aspect of the complex

24 I 2007 I Voith Paper I twogether

On behalf of the Voith Paper team3

REPORT

Energy efficiency –A challenge for the paper industry

REPORTREPORT

Extreme droughts: a typical consequence of global warming due to high energy consumption

Globalisation opens up completely new opportunities tothose who can master the challenges. But the unprecedented
dynamics of the new global market are driven almost exclusively by finite fossil resources including above all coal,oil and gas. This headlong market development also has a big
drawback: energy prices are rising according to the law ofsupply and demand. Furthermore, global warming is having
an increasingly political impact worldwide – the exceptionally
mild winter in Europe, disastrous rainfall in the USA, extreme
drought in Australia... climate change is an international andpolitical long-runner.

Power tariffs in Europe, 1997-2007






" 
#




$ 
 % & 







6


 







 
 !
 '  (()

    

Primary energy needs worldwide







          

24 I 2007 I Voith Paper I twogether

REPORT

Renewable energy resources: the sooner the better!

The paper industry has taken the lead

Brussels summit conference lastconditions going forward. Even today

in improving energy efficiency andMarch, German Chancellor Angela

paper companies are increasingly

promoting industrial sustainability.

Merkel, as current president of the EU

having to pay for the liberalization ofPaper is made from naturally regener-

Commission, committed the member

the European energy market.

ating resources, bio-energy alreadystates to a climate protection pact. Its

covers much of the energy require-goals are ambitious: by the year 2020

At the beginning of 2002 German

ments, and production increases gogreenhouse gas emissions are to be

paper mills were charged 34 Euro per

hand in hand with steadily rising

reduced by 20%, while renewable

Megawatt hour, and by the end ofenergy efficiency. This is the path theenergy usage should be raised to2006 this had risen to 62 Euro. Gas

paper industry must continue to

20% and energy efficiency is to betariffs have more than doubled fromfollow in the future.

increased by 20%.

11.5 Euro/MWh at the beginning of

While energy shortages and the re-

The 27 EU states are free to devise

sulting price increases are a conse-

their own ways of reaching thesequence of globalization, they are also

goals. Given these ambitious targets

Global conditions are expected tobeing used as a political tool forthe energy-intensive paper industry

challenge the energy situation evencombating global warming. At thewill continue to face even tougher

more – declining resources andGas tariffs in Europe, 1997-2007

Crude oil price development 1996-2005

Global coal price development 1996-2005

1999 to 30 Euro/MWh at the end of














24 I 2007 I Voith Paper I twogether

*+0

/ -




          








-





*+,.


*+,- & '  (()



2006.


                  

7

REPORT

global warming know no frontiers.

more than in the previous year, andAccording to the latest UNO report

fuels are increasingly being procuredenergy consumption is likely to dou-

on the global market. However, theble over the next 25 years, about two

Chinese government is already in-thirds of which is attributable to thecluding alternative energy resources

developing countries alone.

in its economic planning. Renewableenergy utilization is to rise from 7 to

The USA still derives two thirds of its

15% by 2020 – mainly consisting ofenergy from oil, and causes abouthydropower.

one fifth of global CO2 emissions,closely followed by China.

Economic growth in India over thelast few years has not driven energy

The Bush administration has recently

consumption so high as in China, but

signalled its readiness to cooperate

India’s energy supply infrastructureswith international efforts against

are being improved now. Southglobal warming and the climatic con-

America and Russia, with their richsequences, and there is every indica-

natural resources of oil and gas, aretion that the United States is looking

well situated with regard to future

to innovative technologies as a solu-

economic growth.

tion. However, current US government funding to this end is much

The bottom line is: energy prices arelower than in the European Union.

rising and political conditions are increasingly ambiguous. Papermakers

China’s energy consumption is rising

can make the best of this situation

just as rapidly as its economic growth.

by using it as an incentive to optimize

Coal consumption as a primary en-

their processes with an eye on ener-

ergy source had already reachedgy, and thereby sustainably improve

2.14 billion tons p.a. in 2005, 10.6%

their profitability and competitiveness.

The EcoProcess:trend-setting for stock preparation

Voith is well versed in all aspects ofenergy. Whether in power generationor energy applications, Voith has always been on the front line of develChina’s Three Gorges Dam hydro project, one of the world’s biggest
and also involving Voith

opment with innovative solutions.
Voith is the right partner for the paperindustry because Voith not only offers
cost effective components that saveenergy, but also has the comprehensive expertise required for optimizing
the entire papermaking process. A lot
has already been achieved ‘twogether’in the past – for example, converting
newsprint production from energyintensive mechanical pulp to environmentally friendly and energy efficient
recovered paper.
One of Voith’s greatest strengths
undoubtedly lies in its comprehensive

8

24 I 2007 I Voith Paper I twogether

REPORT

The Single NipcoFlex press consumes
about 30 % less drive and vacuum power

papermaking know-how, with energy

cal progress with regard to energy

speed pumps the flows can be pre-efficient concepts covering the entire

savings. The verdict was clear: PM 2

cisely adjusted at all times to actual

papermaking process to guarantee

uses about 404 kWh per ton of paper

needs according to application. With

maximum production and depend-

less than PM 1 – which was signifi-these trend-setting principles Voith isable stability. Complete production

cantly optimized afterwards.

taking the decisive step from conven-line auditing ensures the best possible basis for this know how.

tional papermaking, to “EcoProcess”.
Voith not only pioneered energy
auditing on Kehl PM 1 and PM 2, by

A particularly effective energy-saving

Voith recently conducted an in-depth

focusing on the paper machinesdevice in this area is the EcoMizer.

energy audit of two paper machines

themselves, but is also breaking new

The EcoMizer is a hydrocyclone typeby measuring and evaluating overground in stock preparation. The

cleaner for the upper stock consis-

400 drives and associated line com-approach here is to interlink processtency range which requires signifi-

ponents. The partner for this pilot

stages more closely, exploit highcantly less pumping effort. For exam-

project was Koehler Paper in Kehl,

stock consistencies, and use mixing

ple, installing a series of EcoMizers inGermany, where two Voith paper

pumps and direct injection for rapidly

a German newsprint line has alreadymachines are operating. PM 1 ischanging stock consistency. This

paid off with annual energy cost sav-

13 years older than PM 2, which wasminimizes the number of pumps,

ings of 700,000 Euro.

built according to the One Platformvats and towers required and avoids

Concept. These machines make anunnecessary pressure changes.

Overall energy savings with the Eco-ideal pair to illustrate the technologi-

Through systematic use of variable

Process on an 800 t/d deinking line,

24 I 2007 I Voith Paper I twogether

9REPORT

Papervision – new solutions for the future(numerous patents registered)incorporating Eco Mizer, EcoDirect

Another effective component for fastand stability. While continuously

disperger and production regulation

paper machines is the Pro-Releaseworking to reduce operating and in-system, amount to 10%. This repre-

stabilizer. This not only stabilizes thevestment costs through innovative

sents a reduction in demand to a

web run in the first dryer group, but

and trend-setting solutions.

level of about 350 kWh/t. Further inno-

also has an energy-saving mechani-

vative technologies are also available

cal seal. High machine efficiency atfor significant additional savings.

high production speeds also saves
energy by drastically reducing web

The introduction of shoe presses inbreak frequency.

paper machine technology has alsobrought significant energy savings.

For board and packaging paper lines

In fact, much of the energy savings

the BoostDryer has a very favourable

on Kehl PM 2 compared with PM 1

effect on the energy balance. Boost-

are attributable to the shoe press nip

Dryer technology combines high dry-in the newer machine.

ing performance with improved paper
quality, for example, good strength

Meanwhile, Voith has made further

properties with less sizing. This saves

energy-saving progress with theenergy because less water has to beSingle NipcoFlex press. Utilizing only

evaporated in the afterdryer section.

Contact
Susanne Haase
Author/journalist
mail@susannehaase.de

one nip, this press concept requires
about 30% less drive power and vac-

To summarize: With the ongoing rise

uum energy at high dry contents.

in energy costs, future market success will belong to those who opti-

Suction roll drive power requirements

mize their production facilities forcan be significantly reduced by

maximum efficiency and minimum

installing SeaLencer sealing strips.

energy consumption. Voith is a com-Thanks to the resultant energy sav-mitted and competent partner to theings with this system, payback times

paper industry for the comprehensive

can be as low as 1-2 years.

optimization of productivity, quality

10

Dr Sören Köster
Voith Paper F & E
soeren.koester@voith.com

Dr Martin Staiger
Voith Paper F & E
martin.staiger@voith.com

24 I 2007 I Voith Paper I twogether




 









 



␩



()   ""  $*+%
  $*+%
,  $*+%
  $*+%














-   '     !
" # $ % &  '

TECHNOLOGY

$%

$%
*+%$

$%

*+%$

*+%$
*+

*+

*+



() *+!

Energy costs are steadily rising(source: VIK power tariff index)

Energy savings immediately reduce costs

Optimization measures bringvarious results

Reducing energy costs –A challenge in stock preparation
Energy costs, averaging 14% of overall costs in German paper
mills, are among the highest production expenditures in papermaking. The average cost per megawatt hour (MWh) in Germanyrose by more than 60% from 2005 to 2006. Against the backgroundof dwindling fossil fuel resources, and the slow development ofalternative energy sources, such drastic increases in energy prices
can also be expected in the future. Voith has long been taking
countermeasures against this trend by continually identifying energy savings and optimization possibilities, not only in systems as awhole, but also in individual operating modules.

In fact, Voith has already realizedenergy, and in many cases improve

numerous energy-saving concepts inperformance at the same time. The

recent installations, such as the Eco-specific energy consumption per ton

Process that can save up to 44 kWhof output can be reduced signifi-

per ton of production output in com-

cantly.

parison to conventional installations.
Such rebuild or retrofit measures are

24 I 2007 I Voith Paper I twogether

The following examples, focusing on

feasible not only on Voith stock prep-

the energy consumption of individual

aration systems, but also on equip-

stock preparation modules, show

ment from other manufacturers. The

how incremental modifications toenergy saving is recognized immedi-

machinery and systems can saveately on overall production costs.

11

TECHNOLOGY
S-helix with spoiler

Transport zone

Upper helix zone
(for vertical transportof the suspension)

Mechanically
active zone

Mechanically active zoneof helix (for defibering)&.".*   /!

Standard helix without spoiler
0  %.
1.) % .








  ,  (&.  ''!

Converting a standard helix into an S-helix reduces pulping time and improves pulping results

How to save energy ?

In a HC pulper, for example,

Nearly all types of helix can be modi-

hydrodynamically optimizing

fied with a hydrodynamically opti-

There are two basic energy-saving

the spoiler helix saves 15-20%

mized spoiler, a measure that short-principles: either take direct mea-energyens pulping time with the same orsures to reduce power consumption,better defibering results. In someor save energy indirectly by increas-

Energy input via the helical rotor incases, it has even been possible toing production output for the samea HC pulper efficiently defibers the

reduce the amount of deinking chem-

power consumption. The result infurnish at more than 15% consisten-icals, thus achieving further cost sav-

both cases is a reduction of specificcy, and at the same time shears off

ings. Another advantage is that theenergy consumption per ton of fin-ink particles from the fibers for more

stock consistency in HC pulpers canished stock.

effective deinking. The pulper vat andbe slightly increased. In general,

helix have to be specially designed

using an S-helix can save 15 to 20%

Energy-saving optimization often im-

for this purpose. A low rotor speed

specific pulping energy.

proves the technological parameters

ensures controlled circulation of theas well. This can be illustrated byhigh-viscosity suspension in the vat.

In screening machines, thedividing improvement measures into

Mechanical agitation and the addition

optimal combination of rotor

various categories:of specific deinking chemicals help

and basket design can saveto break down the suspension intofrom 5 - 30% of energy costs

Reduce specific energy consumption by lowering power con-individual fibers and to separate ink

sumption or by increasing production

particles from the fiber surfaces.

throughput for the same power
consumption.
Reduce power consumption

Optimally configuring a verticalscreen provides significant energy

Depending on furnish characteristics

cost savings, and usually increases

and defiberizing requirements, thethroughput capacity as well. The

while increasing production through-specific energy consumption can varywide range of Voith screening rotors

put or improving technological resultsfrom 18 to 50 kWh/t. Voith’s latest

and baskets enables custom-tailored– a double gain.

design advances in helix geometry

configurations for every application.

Optimally: Reduce power

have led to a spoiler contour on the

Energy cost savings usually go handconsumption, increase production

upper part of the helix – hence thein hand with the same or betterand improve technological results.

name S-helix.

screening results.

12

24 I 2007 I Voith Paper I twogether

TECHNOLOGY

Typical energy savings attainedby modifying vertical screen rotors

Conversion from/toEnergysavings in %Bump/MultiFoil rotor

approx. 30-40

Lobed/stepped rotor

approx. 10-15

Continuous foil/
MultiFoil rotor

approx. 5-10

C-bar screen basket

S-basketLobed rotor

Bump rotor

Contoured holed basket Contoured slotted basket

Stepped rotor

MultiFoil rotor

Screen basket and rotor portfolio (patented)

Screening technology has a long his-a worthwhile solution for outdated

Example (for a customer in Germany):

tory, not only at Voith. Numerous

production lines. Our extensive expe-

Rebuild of five Black Clawson

manufacturers have tried out various

rience with rebuilds have shown thatscreens from conventional bar typeconcepts, rotor and basket designs

in addition to significantly reducing

baskets to contoured baskets without

over the years. With regard to screen-power consumption, productionchanging production throughput or

ing results, energy consumption andthroughput increases and screening

screen hole diameter. This enabled

overall operating costs, the MultiFoil

efficiency are also improved in mosta 20 % reduction of rotor speed with-rotor combined with a C-bar basket iscases.

out affecting production output.

the best solution so far. In fact, theReducing the rotor speed saved 35%

quality thus attained by Voith remains

Before rebuilding screens, we always

unmatched by any other manufactur-

recommend carrying out a brief anal-

er. For difficult applications, above all

ysis to get an overview of optimiza-

Energy consumption reducedwith holed screening, best results aretion potential. We can then propose

by 20%, and screening quality

attained using a stepped rotor withdefinitive optimization measures andincreased

contoured holed or slotted baskets.

also provide a clear estimate of return

Problem 2: Poor screening quality

on investment.

due to high slot flow velocities.

Examples of screening

Solution: A basket with greater open

optimization solutions

area reduces mean throughflow

energy consumption.

This kind of rotor can also be classified as an energy saver.

velocity for more effective screening.

Rotors with continuous foils, or fastrunning, full-mantle designs such as

Energy consumption reduced

The best solution is the C-bar QE

the bump or lobed rotor, are seen

by 35%

basket, which has bars that are 20%

less and less on the market these

Problem 1: High screening power

narrower than the standard C-bardays because MultiFoil or stepped

consumption.

SE version.

Solution: By using fine-profile con-

While narrower bars give better

rotors are a better alternative. This
trend can be observed worldwide.

toured holed or slotted baskets, thescreening results, they also cause

Rebuilds, both for stock preparation

rotor speed required for cleaningslightly more fractionation. Also im-

and in the approach flow system, arethe screen surfaces can be reduced.

portant is the kind of furnish being

24 I 2007 I Voith Paper I twogether

13

TECHNOLOGY>   *  & "    *?␮'/!

( & @ -&
A& %@ D&.  -  @
A..@ '..
 % - @A..@    %










,



D& ) % G &   H H  "  #*+%$ !

Conversion package: C-bar screen basket/MultiFoil
rotor with belt pulley for speed adjustment (patented)

High-Toothed disperger fillings compared with milled-tooth ring fillings

screened, to prevent plugging of theenabled a 30% production increase

Numerous older dispergers have al-

screen basket surface.

of the paper machine.

ready been converted to modern

By increasing capacity, this measure

A complete success right down

the well-proven high-toothed casteither saves about 20% of specificthe line

fillings that are also used in the latest

energy costs or improves screening

Problem 4: A customer in Thailand

DX disperger series with direct

quality with otherwise unchanged

wanted to optimize the approach flow

heating.

parameters.

screen for greater throughput capac-

high-toothed fillings. These compriseThroughput capacity increased

ity, and the customer also required

Upgrading with high-toothed fillings

better paper quality.

instead of milled or cast fillings withby 20%, and bottleneck elimi-

low-profile teeth has always brought

natedSolution: Rebuilding the Black Claw-

improvements, whatever the applica-

Problem 3: Increase in paper machine

son screens by fitting MultiFoil rotors

tion, resulting in energy savings up

production cause higher rejects rates

with speed modification, and using

to 20%.

in the approach flow screens,

C-bar technology with slot widthand overloading of the last screening

reduction from 0.45 to 0.30 mm,

Furthermore, of all technological ad-

stage.

enabled:vances, our customers have benefit-● 47% less power consumption

ed most from those that address● stickies separation efficiency

product cleanliness. In several cases

Solution: Increase screen throughput
capacity by fitting the screen withimprovement from 25% to 63%

a MultiFoil rotor and a C-bar basket.

● overall stock loss reduction from

Example (for a customer in Germany):● 20% higher maximum throughput.

this also had a positive effect on
paper machine operation.

0.4% to 0.1%
Rebuilding Omega screens with

Voith dispergers with modern hightoothed fillings technology have

MultiFoil rotors and C-bar baskets

High-toothed disperger fillings

proved themselves in practice withincreased throughput of the final

save up to 20% energy andmaximum customer benefit. In team-screening stage by 20% with the

improve stock quality

work with our engineers and special-same slot width.

ized service technicians, Voith can
High-toothed disperger fillings save

tailor disperger fillings to the specific

By ensuring dependable operation of

up to 20% energy and improve stockneeds and circumstances of every

the first screening stage, this rebuild

quality.

customer.

14

24 I 2007 I Voith Paper I twogether

TECHNOLOGY

Accepts

Inlet

Energy savings with the

EcoMizer dilution modules can be

EcoMizer dilution concept on

retrofitted to practically all makes

cleaner systems

and types of cleaner. Rebuilding thecleaner is simple, and the payback

By upgrading with EcoMizer technol-

time is very short. Voith Paper hasogy, existing cleaners can be rejuve-

proven this so far in more than 100

nated.

applications with payback times ofless than one year in every case.

To uphold rotation and reverse flow

Our expert cleaner-service team willin the bottom of cleaner cones, agladly advise you and is always

retrofit with an EcoMizer provides aavailable for on-site analysis of yournew dilution module offering consid-

requirements.

erable advantages compared withconventional cleaner concepts:

Summary and conclusions● Greater reliability, particularly for

Rejects

furnishes with high tendency ofAgainst the background of today’s

thickening.

steadily rising energy costs, mill

● Lower overall overflow rates.

owners must pay greater attention● Fewer cleaner stages required

to the challenge of reducing power(two or three fewer in stock prepa-

and energy consumption. In otherration, and no more than fourwords, energy saving must become

required in the approach flowa priority.

Dilution
HCH5 cleaner with EcoMizer module
at cone bottom (patented)

system).
● Greater compactness and lower

The measures explained in this article

conventional deinking line total about

additional investment costs forare only some of the many possibili-

8.5%. For a deinking line with an out-

pumps, drives, piping and MCR

ties for reducing energy costs andput of 500 tons per day and a powersystems.

modernizing older production lines.

consumption of 175 MWh/day or

Apart from their technological advan-

61,250 MWh p.a. (350 days of opera-● About 30% savings on pumping
power requirements.

tages, the interesting new energytion), the power savings therefore● Sand separation possible at muchsaving solutions developed by Voithamount to 5,206 MWh p.a. At a tariff

higher stock consistencies up

can be implemented rapidly, system-of 70 € ($ 90)/MWh, this provides a

to 2.5%.

atically, cost-effectively and irrespec-

financial savings of 350,000 €tively of limited maintenance budgets.

($ 455,000) per year.

● Greater process layout flexibility,e.g. cleaners can be arranged upstream of flotation.

With the theoretical savings potential● Lower fiber losses thanks to higher

described here – 15% for an HC

contaminant concentration in thepulper, 35% for holed screening,

rejects, raising ash concentration

30% for slotted screening, 15% perthereby from about 40-50% todisperger and 30% per cleaner groupabout 60-70%.

– the overall power savings on a

24 I 2007 I Voith Paper I twogether

Contact
Werner Brettschneider
Fiber Systems
werner.brettschneider@voith.
com

15

INTERVIEW

Voith Paper Environmental Solutions –A new future-oriented division
Werner Geßler

The zero-effluent paper mill is no longer a fiction! Mills in theindustrialized nations currently use up to 20 cubic meters of freshwater per ton of paper produced, and a lot more in developing
countries. Innovative technologies are therefore in high demand forclarification and recycling mill effluent and to reduce fresh water
consumption. And that is a pre-eminent capability of the newly
founded Voith Paper Environmental Solutions (VPES) division withits more than 100 specialists worldwide. In this interview, VPES
manager Werner Geßler explains these new ecological and economical oriented technologies and environment-friendly concepts.

twogether: Apart from saving fresh-

Recovered paper is the biggest

water, the economical recycling ofsource of raw material for the paper

mill waste is one of the biggest

industry at more than 50 percent, andchallenges facing the paper industry.

thanks to Voith Paper Fiber Systems

How is Voith dealing with this chal-process technologies, the contami-

lenge?

nants in recovered paper are removed
very efficiently. In modern packaging

Geßler: We have always paid great

paper lines, for example, the rejects

attention to recycling technologies.

and residuals to be disposed range

Raw material
Stock preparation

Innovative system technologies
for the environmentally integrated paper mill – all from Voith
Paper Environmental Solutions

Pulper ropes
Power plant
Incineration

Rejects

Rejects and residuals
storage system

SludgeBiogasPaper machineInternal water treatment

Biosludge

Anaerobic effluent treatment

Freshwater

Aerobic effluent treatment

16

24 I 2007 I Voith Paper I twogether
Receiving watercourseINTERVIEWPaper industry facts and figures – advances in papermaking are driven by sustainability
Key paper industry figures

Sustainable development in the paper industry• Global forestry and paper industry output isworth around 750 billion Euro p.a.

Less water consumption

Better energy utilization• Freshwater consumption in the German paperindustry fell from 46 liters per kg of paper in1974 to 13 l/kg in 1996. Water consumption per
ton of chemical pulp produced fell by 75 percent
from 200 to 50 cubic meters.

• Since the nineteen-eighties there has been
greater use of waste materials (such as waste
liquor, bark and fiber residuals) in chemical
pulp production as fuel for energy generation.

• Worldwide paper production totals about
360 million tons from 8,800 mills.
• Global paper consumption averages 56 kg
per capita.
• Most of the world’s paper is produced in the EU(96 million t.p.a., of which 20 million t.p.a. inGermany) followed by the USA at 83 million
t.p.a.
• Modern paper machines run at speeds of up to
2,000 m/min and can produce up to 1,000 tonsof paper each day.

• German paper industry effluent fell in the same
period from 46 l/kg to 12 l/kg.
• The average water consumption today is about
10 liters per kg of paper. Depending on the furnish makeup and paper grade, this figure canbe reduced in future to 1-2 l/kg by means ofexternal water loop purification using anaerobic
biological methods and the “Lime Trap”.
Less CO2 emissions• From 1990 to 2000, paper mills worldwide
reduced their CO2 emissions per ton of paper
produced by 22 percent on average.

• In German mills alone, production waste inpaper production using recovered paper furnish
amounts to 1.4 million tons annually. It costs
more than 100 million Euros each year to dispose of this waste.
• Energy consumption fell from 820 kWh per tonof paper in 1955 to 295 kWh/t in 1998. This
was attributable above all to the introduction of
combined heat and power plants, greater use
of waste heat recovery systems, more efficientmechanical dewatering, energy-saving drive
systems, and higher machine efficiencies.

from 150 to 300 tons per day. And in

aerobic effluent treatment as detailed

production process and water treat-parallel to the rise in energy prices, ain this edition of twogether magazine.

ment systems. Our newly developed

new market has established itself for

The further expansion of our technol-“Lime Trap” technology efficiently

utilization of rejects and residuals as

ogy portfolio by innovations is ongoing.

controls this problem. That is an important requirement for recirculating

alternative fuel for generating heatand energy. The newly founded Voith

twogether: What are the customer

anaerobically purified, solid free andPaper Environmental Solutions divi-

benefits of transforming rejects anddecalcified waste water to replacesion in Ravensburg focuses precisely

residuals into alternative fuel?

freshwater.

on this need.
Geßler: Until 2005, paper mills in

twogether: Are there similar require-

twogether: Which technologies

Germany paid landfill fees of 30 toments in other industries?

does VPES use for realizing the envi-

50 Euros per ton of waste deposited.

ronmentally integrated paper mill

The new EU guideline eliminated that

Geßler: Waste and water recycling

concept?

low-cost solution. Disposal cost roseare global challenges affecting all

to 100-130 Euro per ton. Reutilizing

branches of industry. Since nearly allGeßler: Together with well-provenconditioned mill waste as alternative

the technologies we offer also have

B+G Material Handling technologies,

fuel not only eliminates these high dis-applications in other areas, we aim

and meri WSR subsystems – integrat-

posal costs, but can also benefit cus-right from the beginning to market

ed system modules for internal water

tomers through electricity generation.

our innovations throughout industry.

reuse of waste water, and preparation

twogether: Which concepts will VPES

With VPES we provide environmen-of sludge and rejects – form a solid

use for further closing water loops?

tally sustainable concepts for theloop treatment, the clarification andbasis for further development. This

paper mill, which conserve resources

technology portfolio is rounded off

Geßler: Deposits due to the high limeand generate savings for the cus-with an innovative technology for an-content in loopwater influence thetomer.

24 I 2007 I Voith Paper I twogether

17Technology

Mobile pilot reactor
on site at a corrugating board mill					 The anaerobic reactor –Setting new benchmarks in effluent treatment,						
even with high lime content
In the late nineties the European paper industry started significantly closing its water loops. Today, corrugating board machines aredesigned for about 4 to 6 m3 of effluent per ton of output, and someproduction lines operate with specific effluent quantities around3 m3/ton or less. This ongoing closing of water loops places new
demands on cleaning systems and process configurations, but also
opens up new optimization potential through overall analysis andgreater integration of peripheral effluent treatment in the process
as a whole. Voith Paper Environmental Solutions is already setting
new benchmarks with technical innovations in this area.

18

24 I 2007 I Voith Paper I twogether

Technology

Effluent treatment technology

Corrugating board mills already usedsludge treatment and disposal. And

in the paper industry has devel-

mainly UASB reactor technology

since the only air requirements are

oped through various phases­(Upflow Anaerobic Sludge Blanket)

for ­residual breakdown in the aerobic

at that time, when a specific effluent

stage, the resultant cost savings with

With greater use of recovered paper

quantity of 8 to 10 m3/ton was typical

today’s energy tariffs are enormousand an increasing content of dis-for this grade.

compared with a purely aerobic

solved organic substances, biological­system.

effluent treatment had to introduced

The further closing of water loops

on top of mechanical cleaning in theled to significant concentrations of all

In an airtight anaerobic reactor, theseventies. The first biological treat-

the substances contained in effluent.

dissolved organic substances (starch,ment plants were single-stage and

COD (Chemical Oxygen Demand)sugar, alcohol, etc.) are decomposed

purely aerobic. In other words: theconcentrations in raw effluent today

to form biogas with a high calorific­effluent was cleaned by micro-organ-

are around 6,000 to 10,000 mg/liter,value. This can be utilized on site inisms that needed air or oxygen forwith calcium concentrations ofa combined heat and power station

breaking down the dissolved organic

600 to 1,200 mg/liter peaking toto generate “green power”. The net

substances.

1,500 mg/liter or more.

result of saving sludge treatment andIn the eighties it was found that

Current state of effluent

aerobic treatment air costs, and2-stage aerobic treatment processes­treatment technology­generating power with biogas, is adisposal costs, drastically reducing

not only operate with greater stability,

rapid return on investment for the

but also are less susceptible toState-of-the-art today for highly­objectionable gas bubble formation.

­polluted effluent is 2-stage biologicalTo combat the increasing organic

treatment. In the compact high-Instead of UASB reactors, space-sav-

content in effluent, the next develop-­performance anaerobic stage (without

ing EGSB (Expanded Granular Sludge

ment phase was the introductionair) 85% of BOD5 (Biochemical Oxy-

Blanket) reactors are used today

of anaerobic reactors. These break

gen Demand) concentrations andfor the anaerobic stage. That results

down a lot of organic materials

75% of COD concentrations are ef-

in extremely compact installations.

­already in the first treatment stage.

ficiently broken down. The aerobic

The new R2S reactor is a further

stage only has to break down the re-development of EGSB reactor tech-sidual materials afterwards. By reduc-nology that meets the special

ing the amount of excess sludge, this­requirements of the paper industry

concept minimizes expenses forparticularly well.

24 I 2007 I Voith Paper I twogether­anaerobic stage.

19

Technology

Lime scaling on
sludge pellets

High calcium content is anotherAs a consequence, the anaerobic re-

The R2S reactor stays free ofchallenge to be met in effluent

actor performance declines so rapidly

deposits and blockages

treatment technology: it canthat it generally has to be shut down

seriously affect performanceand cleaned out. Not only does this

It is not possible in practice to entire-

due to scaling in the anaerobic

involve a production outage, but also

ly avoid problems due to erroneous

reactorthe reactor has to be refilled with new

drainage of surface-active substanc-active biomass.

es into effluent, such as oil, retention

Scaling due to high calcium content

agents and caustic soda. These prob-means that with large effluent quanti-

The R2S reactor has no scalinglems include weir blockage at theties, tons of lime mixed with biomass

problems­reactor head due to uncontrolled pel-are deposited in the anaerobic

let buoyancy. The necessary cleaning­reactor every day. Furthermore, theThe new R2S reactor solves thework at heights up to 30 m is notspherical anaerobic biomass sludge

problem of scaling that cannot beeasy – particularly a challenge for thepellets form around a limestone core

avoided by taking process technol-

personnel during the winter months.

up to 2 mm in diameter and can also

ogy and design measures.

By taking systematic design mea-

have a limestone shell, known as theIt does this thanks to the inflow modesures at bottleneck points with a high“eggshell” effect. The results are onlyin the reaction zone, internal flow

throughput of gas, water and sludge,

too well known:

streaming, and systematic dwellor by using water flushing to assist

c Non-uniform fluidization of thezones. Lime sludge and pellets de­sludge throughput, scaling and block-activated by scaling can be removed

ages in the R2S reactor are prevented

without problem during operation.

and the circulating sludge is reacti-­pellet bed
c Undesirable deposits causing ­so-called “cold points”
c Formation of preferential flow­channels

By preventing deposits, the R2S­reactor’s newly designed flow path

The R2S reactor is flow-

ensures uniform processing over the

optimized for maximum spacedespite theoretically adequate bio-

entire reactor cross-section. Floating

utilization

mass content in the system.

sludge layers are systematicallyc Serious overload symptoms ­20vated in good time.

­removed separately from the system.

Another important feature of the

Design measures have been taken

R2S reactor is its innovative clog-free

to prevent air pocket formation at

charging system. This distributes

critical transition points, thus reduc-­incoming effluent uniformly over the

ing lime precipitation potential.

entire reactor cross-section area.

24 I 2007 I Voith Paper I twogether

Technology

Weir blockage at the­reactor head

The new R2S anaerobic
reactor (patented)

Full-size R2S anaerobic EGSB pilot reactor
ready for the first installation

As a result, the pellet bed is optimallytrials. The primary goal of these trials

fluidized and much more of theis to significantly raise the current

sludge is actively involved in thelimits on reactor capacity. With this­decomposition process. The reactor

mobile test facility, Voith Paper

performance is therefore optimized.

­Environmental Solutions enables

Optimal pellet bed fluidizing is also

­customers to carry out full-scale tests

assisted by external recirculation on

on site to assist their investment

top of the inherent internal recircula-­decision-making in borderline casestion. This ensures that even with verysuch as with low organic substancelow effluent inputs, hydraulic upflow

content.

is adequate irrespective of inflow.
Market launch of R2S reactor
Our mobile full-size pilot reactor

technology

for further optimizing R2S­technology is also available for

In March 2007 a leading internationalcustomer tests

supplier of corrugating board ordered
the first R2S reactor for its Italian mill.

A pilot reactor (30 m3) for 600 toThis reactor has a diameter of 9 m,

1,000 kg COD/day throughput,an overall height of 26 m and anhoused in one 40-foot container and­effective capacity of 1,320 m3. It will

two 20-foot containers, is in use

process 38,000 kg/day of COD efflu-

since May 2007 at a leading Germanent, and commissioning is scheduled

corrugating board mill for full-scale

for autumn 2007.

24 I 2007 I Voith Paper I twogether

Contact
Dieter Efinger
Voith Paper Environmental­Solutions
dieter.efinger@voith.com

21

TECHNOLOGY

Bowater Calhoun PM 4 rebuild –Realignment to more profitable markets
The declining demand for newsprint above all in North America isforcing papermakers to look for other ways of using their production lines. In many cases existing newsprint machines can beconverted for producing other grades. This is often a very attractive
option for increasing value-added – the secret of success in today’schanging markets.
Bowater Incorporated headquarteredconsumers of recycled newspapers

in Greenville, SC, USA, is one of theand magazines.

leading producers of coated papers,
specialty grades and newsprint.

In 2003, Bowater and Voith demon-

Bowater has approximately 7,600

strated their successful cooperation

employees and operates 12 pulp andwhen the Catawba PM 3 was con-

paper mills located in the Unitedverted from newsprint to LWC. This

States, Canada and South Korea. In

is the largest US machine conversion

North America, it also owns two con-so far.

verting facilities and 10 sawmills.

22

Bowater operates six recycling plants

Bowater’s Calhoun facility, built inand is one of the world’s largest

1954, is one of North America’s

24 I 2007 I Voith Paper I twogether

TECHNOLOGY

largest mills for paper from secondary

Adding more value is a key factor

dering, the uncoated paper alreadyfiber. The Calhoun mill is fully inte-

for success when market demand forhas excellent surface quality. Using a

grated on a site with five PMs in total,

your product decreases.

coating system could further improve

located next to the Hiawassee River,printing ink yield and type character

just upstream of the Tennessee River.

Bowater has long realized this, and,The product range includes news-

therefore, set clear targets for the

print, uncoated paper from secondary

PM 4 rebuild in Calhoun. Thesefiber and virgin pulp of own produc-

included precisely defined quality

tion.

requirements for the new product,Internal studies confirmed that Cal-

BowHybrid FS paper.

houn’s PM 4 offered the most prom-

Annual capacity:
Newsprint

resolution.
Perfect Fit rebuild scope

ising installed base for a successful
approx. 372,000 tpy

BowHybrid FS paper is a registeredand cost-effective rebuild. Voith’sSpecialty paper approx. 372,000 tpy

trademark of Bowater. FS stands forwell-proven Perfect Fit strategy turnedMarket pulp

Freesheet and Hybrid means that thisto be the optimal solution. Bowater’s

approx. 145,000 tpy

grade is made from mixed furnish

fiber base met all requirements for

Rebuild Objective:

comprising bleached chemical pulp

meeting paper quality demands.

BowHybrid FS paper production

and bleached TMP. BowHybrid FS
paper combines high strength andPaper machine 4, originally supplied

The declining newsprint demand inbulk with a relatively low basis weightby Beloit Corp. in 1958, has a

North America makes it attractive forof 60-74 g/m2 that, among otherwire width of 7,112 mm, and waspaper suppliers to convert theirbenefits, reduces mailing costs.

designed for an operating speed

newsprint machines to products inHence the marketing concept: “Highof 1,067 m/min and an output ofgreater demand and with more value-

bulk and lightweight with maximum

150,000 tons per year.

added. Whereas newsprint consump-strength”. It can be produced either

tion is declining, direct mailing, cata-in the coated or uncoated form, be-

To convert PM 4 from newsprint tologues and flyers are more promisingcause the hybrid furnish meets basic

the same tonnage of coated hybrid

markets with good outlook for future

requirements both for brightness andpaper, extensive upgrades were

demands.

improved opacity. With optimal calen-required. These upgrades included:

Calhoun PM 4 rebuild

24 I 2007 I Voith Paper I twogether

23

TECHNOLOGY

MasterJet II F headbox

Customer Comment
Mike Cresswell
Bowater Inc.
Technical AssistantPaper MillThe new DuoFormer D● Improved stock preparation line

aeration system was installed in the● New headbox

new Low Consistency line.

● Major modifications to existing
forming section● Press and dryer section upgrades

The wet end upgrade of the paper● New coater station, including

machine included replacement of thecoating kitchen“We are very pleased to have chosen

Wet end and press section

Beloit Concept III Converflo headbox● New after dryer section

with a state-of-the-art Voith Master-● Modification of the existingJet II F headbox with ModuleJet dilu-

calender.

tion water technology.

Voith as the equipment supplier for thegrade conversion rebuild of Bowater’s

In addition to the PM rebuild, Bowa-

The existing Beloit Belform top former

PM 4 at Calhoun, TN. The equipment opti-

ter also invested in a new bleaching

was replaced with Voith’s well-provenmally meets our requirements and theplant.

DuoFormer D. In addition, new foil

Voith commissioning personnel was very

24boxes, a new TriVac suction box as

knowledgeable. The start-up went very

Stock preparation

well as new ceramic bars were

well, and we have already been able to

In order to handle production for the

installed in the forming table. Withrun the machine at speeds and production

new hybrid paper grade, extensive

these changes, almost all elements inrates exceeding the guaranteed values.

upgrades were necessary to thecontact with the suspension / paper

Initial sheet quality parameters look goodstock preparation line for conversion

have been replaced.

and we continue to get very positive

to low consistency. These upgrades

feedback from customers regarding theincluded new Voith MSA and MSS

The press section configuration was

quality of our paper.”screens, new MultiSorters type MSM

optimized for shorter draws and im-

and a MultiDeflaker DF. For lowest

proved runnability. The granite rollgas content and, therefore, best

was replaced with a modern ceramic

paper quality, a new VoithVac de-roll. These modifications were de-

24 I 2007 I Voith Paper I twogether

TECHNOLOGY

signed to accommodate the installa-

ing calender and reel would not have

Within three weeks after start-up,

tion of a shoe press in the future.

to be relocated.

the 3-month production target was

Runnability was further improved bysurpassed, and within six weeks,

installing a BubbleMaster suction box

It was found that the existing calen-

the 12-month production milestonealong with Fibron tail threading equip-

der location could be maintained if

had been attained.

ment such as tail diverters and peel &eight dryer cylinders were removed

transfer foil units.

from the last dryer section and re-Continuing its high performance

placed by the SpeedSizer, CB turn

during the following months, the ma-

Pre-dryer section

system, air flotation dryers, scannerchine produced more than the bud-

Minor upgrades performed in theand the necessary paper rolls.

geted production levels on various

dryer section included converting

grades. In a very early stage nearly

one of the single tier groups into

The last two dryers from the existing

all performance criteria were fulfilled

a double tier section to increase

machine remained in their originalin close cooperation with the techno-

drying capacity.

position and became part of the newlogically well-versed customer.

after-dryer section. This now comCoating and after-dryer section

prises a combination of gas fired air

The produced sheet showed excel-

A challenging part of this rebuild,dryers with two dryer cylinders acting

lent printing quality from the begin-and a major key to success for Voith,

as “pull group” ahead of the calenderning, especially the coated paper

was to identify and deliver a very

and driven by Voith drives.

product that has been well received

economic solution by installing a
SpeedSizer in the existing machine.

by printers and advertising agencies
Calender rebuild and winder

alike. Furthermore, the market de-Extensive modifications were per-mand for this grade is continuously

The Perfect Fit rebuild solution, and,

formed to the existing 6 roll hard-nip

increasing.

therefore, the most cost effective,

calender, which was converted into

was to design the coater and dryera 4 roll calender utilizing fly rolls to

Once again, Voith’s “Perfect Fit”

section in such a way that the exist-

improve nip loading flexibility andrebuild strategy – single-source andeliminate the risk of wrinkles.

fully coordinated – has resulted incomplete customer satisfaction.

A new Voith GooseNeck parent roll
Voith Drive (patent pending)changing system was installed to im-This rebuild ensured a highly suc-prove turn-up efficiency.

cessful launch for the BowHybrid FS
paper marketing concept:

Results“High bulk and lightweight withmaximum strength”.

Hardly more than one year after signing the contract on June 3, 2005,
the paper machine was restarted onJune 29, 2006. Within a very shortperiod, PM 4 demonstrated its highContact
Martin Jauch
Paper Machines Graphic
martin.jauch@voith.com

potential and was ahead of the predicted start-up curve.

24 I 2007 I Voith Paper I twogether

25

TECHNOLOGYATMOS Premium Tissue –35 % energy savings and much lower investment costs
For more than 30 years, premium tissue was produced only by
the largest tissue paper producers, using Through Air Drying (TAD)
technology. Only they could afford the high capital investment
involved and the high production costs mainly attributable toenergy consumption. But the innovative Voith ATMOS technology
has changed this situation. ATMOS technology was developed at
the Voith Tissue Process Technology Center in São Paulo, Brazil
in close teamwork with Voith Paper Fabrics. Thanks to this development, premium tissue can be produced at much lower investment
and energy costs, also saving fiber and even using 100% recovered
paper furnish.

26

We first reported on Voith ATMOS

interdivisional synergies. The big(Advanced Tissue Molding System)

advantage of this technology is thattechnology for premium tissue pro-for premium tissue production it con-duction in twogether 22. This joint

sumes 35% less energy than TAD

achievement, involving innovationand the investment costs are much

input from various Voith Paper

lower. Depending on application, it

Divisions, shows once again how

also enables fiber savings and themuch customers benefit from ouruse of 100% recovered paper furnish.

24 I 2007 I Voith Paper I twogether

TECHNOLOGYATMOS tissue machineThis is how ATMOS tissue productionsures 3-dimensional sheet formation

developed dewatering fabric, named

technology works (see Fig. 1):

and carries the web all the way from

AtmosFlex (marked yellow), that is

the headbox to the yankee cylinder.

installed between the ATMOS roll and

The ATMOS module is located be-

the AtmosMax fabric.

tween the former and the yankee

A special vacuum roll, known as thecylinder. Formation is in the same

ATMOS roll, ensures maximum dewa-

Intimate contact between the web

way as with a conventional crescenttering. Water is mostly removed by

and AtmosFlex fabric is ensured byformer, but the felt is replaced by a

the airflow (vacuum) and, in addition,

an air-permeable AtmosBelt (marked

structured fabric known as Atmos-

optimally supported by intimate con-in red). This was specially developed

Max (marked blue in Fig. 1). This en-tact between the web and a newly

to withstand high tensile loading, andAtmosForm
AtmosMax
AtmosFlex
AtmosBelt  

    Fig. 1: The ATMOS
operating principle(patented)

24 I 2007 I Voith Paper I twogether  

27

TECHNOLOGY

Fig. 2: Sheet structure of conventional
tissue (top) compared with ATMOS (bottom)

Fig. 3: Sheet structure of TAD tissue (top)compared with ATMOS (bottom)

is located above the AtmosMax fab-

TAD, and ATMOS tissues. Figure 2

ric. Since it is not in contact with theclearly shows the 3-dimensional

web, the AtmosBelt has no influencestructure of ATMOS tissue comparedon paper quality.

with conventional tissue.

The ATMOS hood installed on the

As shown in Fig. 3, ATMOS technol-

top of the ATMOS module provides

ogy attains the same 3-dimensional

additional heat by blowing hot air

sheet structure at maximum volume

and steam. This results in a higher

as with TAD technology.

water temperature and lower viscosity accordingly, thus speeding up

ATMOS production lines can be

dewatering. The wet-shaping box indesigned in 2,800 mm single width

front of the ATMOS module intensifies

or 5,600 mm (double width). The

the structuring effect of the Atmos-

ATMOS module is also ideally suit-

Max fabric by vacuum application.

able for upgrading conventional
tissue machines. Both conventional

During web transfer to the yankee

and premium grade tissue can becylinder by a press roll, the Atmos-

produced on ATMOS lines.

Max fabric structure minimizes sheet
compression to enable premium

Depending on furnish quality, basis

quality tissue.

weight requirements and productContact
Rogério Berardi
Voith São Paulo, Brazil
rogerio.berardi@voith.com

specification, a double-width ATMOS
To ensure perfect sheet transfer andline with a 5,500 mm yankee cylinder

uniform adhesion to the yankee cylin-

and a 500 °C hood can produce up to

der surface, and for fine-tuned crep-

200 tons of tissue per day.

Thomas Scherb
Voith São Paulo, Brazil
thomas.scherb@voith.com

ing control with optimal runnability,
Voith and Bruckman Laboratories de-Further information and operating

veloped Magnos coating chemicals.

experience with the first ATMOS
tissue line will be reported in

Figures 2 and 3 show electron-micro-

subsequent editions of twogether

scope images of conventional tissue,

magazine.

28

Ademar Lippi Fernandes
Voith Paper Fabrics
lippi.fernandes@voith.com

24 I 2007 I Voith Paper I twogether

TECHNOLOGYGreater value-added
through improved cross-profile control
Everyone is talking about greater value-added these days, not only
top managers. A recent international survey by PriceWaterhouseCoopers among 17 paper industry leaders brought a clear verdict:the value-added chain must be further optimized. Voith Paper
Automation aims in this connection to reach the point where paper
machines automatically maintain optimal operation, thereby
increasing value-added. The benefits of automation innovations
are twofold: not only better paper quality, but also lower energy
consumption.

$%& '

In practise, optimizing value-addedon Voith Paper as an overall systemmeans finding the best compromise

supplier highly competent to upgrade

between maximum production out-

your existing machinery with auto-

put, minimum use of resources, andmation systems. Voith is increasingly

highest product quality. And thatapproached in this connection for

depends on how important each of

optimizing paper machines, increas-

these three parameters is for theing their speed or reducing theircustomer concerned. Typically, moreenergy consumption.

than 50 percent of mill operating! ""#
  

  
 Typical operating costs in the paperindustry: more than 50 % attributable toenergy and raw materials costs

24 I 2007 I Voith Paper I twogether

costs are attributable to raw materials

One such solution offered by Voith(35 %) and energy (18 %). So this is

Paper Automation is OnQ Module-

clearly where the most effective

Therm, controlled by OnQ Profilmatic

action can be taken, for example bysoftware. Thanks to this technology

reducing energy consumption andthe sheet thickness can be kept

improving overall process cost-much more constant, with significant

efficiency with automation systems.

energy savings at the same time.
A good example is PM 18 in Ruzom-

Voith Paper Automation systems

berok / Slovakia, producing copying

cover all aspects of the papermaking

paper for Mondi SCP. Voith Paper

process. In terms of customer ben-Automation used OnQ ModuleTherm

efit, this means that you can depend

here to reduce the thickness devia-

29

TECHNOLOGY-Ruzomberok PM 18 – Thickness crossprofile readings on the calender

'(
'(
'(*

Basis weight

80 g/m2+*,Mean sheet thickness 104 μm

'(
'(#

'(#

'
)"  " Line force

28-34 N/mm

PM speed

1,250-1,400 m/min

Thanks to OnQ Profilmatic, the thickness cross-profile (2-sigma value) on PM 18
in Ruzomberok was significantly improved

tion, already low at 0.8 μm (2-sigma

cause different radial expansions ofslowly until the programmed quality

value), by 69 percent to 0.25 μm –the roll. These result in calender nip

requirements are reached within cer-about one hundredth the diameter ofline force variations that influence thetain tolerances. Using this strategy,

a human hair.

sheet thickness profile. Another way

energy consumption during theof varying the calender nip line force

commissioning of a hardnip calender

OnQ ModuleTherm directs an air jet,over the web width is by Nipcorect(in Ruzomberok) was reduced bywhich can be separately adjusted forroll, whose hydrostatic support ele-

about 70 kW. The resultant annual

each control zone, on to the calenderments exert different pressures insavings amount to about 600 MWhroll surface. The different surface

each zone along the roll. Both OnQor 40,000 Euro.

temperatures in the control zones

ModuleTherm and the Nipcorect rollare controlled by OnQ ProfilmaticThis control strategy – that optimizes

software. By coordinating individual

not only paper sheet quality but also

actuator adjustments in each zone,

profitability in terms of value-added –this software enables any desired

also applies to the OnQ Module-

thickness profile to be realized.

Steam blow box regulation system.
Whether on DuoCentri presses, Tan-

Each time an OnQ ModuleTherm is

dem NipcoFlex or Single NipcoFlex –commissioned, Voith focuses on en-

the innovative OnQ ModuleSteamergy savings. To this purpose, a newcontrol system guarantees a high dry

The efficient actuator control by
OnQ Profilmatic software enabled improved paper quality, and lower energy
consumption right down the line

solution has been developed where

content after the press. OnQ Module-

the actuator energy consumption is

Steam also optimizes the moisturemeasured and automatically reduced

cross-profile after the press for opti-

OnQ ModuleSteamMoisture

OnQ ModulePro
Moisture30

24 I 2007 I Voith Paper I twogether

TECHNOLOGY

3/20/2005 15:32:02
-
106
105
104
103
102
0

500

1000

1500

2000

2500

3000

3500

4000

4500

5000

5500

6000

6500 mmMax.:

104.41

Ziad.h.:104.00Min.:

103.932s:0.2070Priemer:

104.23Using OnQ ModuleTherm and Nipcorect roll, both controlled by OnQ Profilmatic software,cross-profile thickness deviations were greatly reduced (Ruzomberok)

mal transfer to the dryer section. To-

The optimized moisturizing system

reduce operating costs. An optimal

gether with the new control strategy,

saves energy afterwards in the dryer

compromise can thus be reached

OnQ ModuleSteam automaticallysection, and thanks to the better

automatically between maximum

reaches the best compromise be-paper quality, the web run is also

production output, minimal resources

tween optimal dry content and opti-

improved so that fewer breaks occur.

consumption, and highest productmal cross-profile. And a higher

OnQ ModulePro is, therefore, anotherquality. This can save mill owners

dryness after the press means signifi-

important tool for optimizing value-

30,000 to 200,000 Euro per CD

cantly less energy consumption foradded in papermaking. After installing

control system each year, without

drying, which increases value-added.

OnQ ModulePro on Rheinpapierrequiring any further production line

Hürth PM 1 newsprint machine ininvestments.

Another way of increasing value-add-

Germany, the quality improvement

ed by improving cross-profile control

was nearly 80 percent – on a paper

is the OnQ ModulePro nozzle mois-

machine that was particularly de-turizer system. This ensures an ideal

manding due to its high operating

humidity cross-profile using state-of-

speeds.

the-art nozzles and valves, and is
As shown by these examples, with

control software. An OnQ ModulePro

new automation concepts existing

regulating valve with stepless high-machines can now be optimized toprecision adjustment moisturizes therealize their full value-added poten-

web only as far as necessary to attaintial. These concepts not only optimize

the required humidity cross-profile.

paper quality, but also significantly

OnQ ModuleTherm
Thickness;) :likewise regulated by OnQ Profilmatic

Rudolf Münch
Automation
rudolf.muench@voith.com<)&<) :  = ! :")

24 I 2007 I Voith Paper I twogether

Contact

Energy consumption is reduced until therequested quality level is reached.
This means greater profitability in termsof value-added31

RESEARCH AND DEVELOPMENTFirst Anniversary of the Voith Paper Technology Center(PTC) – Success through Innovation
Over the last few years Voith has launched numerous innovative
products into the marketplace. The changing demands on researchand development have led to reviewing and in some cases modifying the entire papermaking process, from stock preparation tofinishing. There has thus been a radical change in R&D opportunities and challenges.
Voith met this trend by opening thearrangement. This features allow

Paper Technology Center (PTC) one

individual modules to be precisely

year ago. Unique features such as aarranged according to customer

fully integrated fiber design facility

demands.

and state of the art production loops,

32

enable testing at the highest operat-

Twelve months of experience haveing speeds and outputs. The mostconfirmed the correctness of thisoutstanding feature of the VPM 6 isconcept: all our customers are highly

however its modular machinery

impressed by the excellent practice

24 I 2007 I Voith Paper I twogether

RESEARCH AND DEVELOPMENT

conformity of paper production at the

The results achieved in terms of inno-

PTC. For the first time, development

vative developments are most en-work can be carried that would notcouraging indeed. That is why, start-

possible on conventional pilot facili-

ing with this issue, we will regularly

ties. Three different press modules –report on new product developments

Tandem NipcoFlex, Single NipcoFlex

which help to reduce investment

and DuoCentri NipcoFlex – as wellor production costs and / or improveas the HiDryer, were used during thepaper and board quality. In otherfirst 12 months at the PTC. This

words: innovations for the benefit ofenabled our customers to compare

our customers.

Contactmachine concepts on a one-to-one
basis for the first time. Finally, theThe following articles briefly summa-

most convincing evidence in support

rize some of these developments.

of the PTC concept can be found in

The contact person for further infor-

the numbers, the pilot facilities aremation is indicated at the end of eachfully booked until the end of 2007.

article.

24 I 2007 I Voith Paper I twogether

Ulrich Begemann
Voith Paper R & D
ulrich.begemann@voith.com

33

RESEARCH AND DEVELOPMENT

New speed record on the Voith PTC VPM 6 pilot paper
machine – Over 2,000 m/min with Single NipcoFlex press
The VPM 6 pilot paper machine with Single NipcoFlex press atVoith’s new Paper Technology Center has produced wood-free
paper at 2,092 m/min – exceeding the world record speed for thisgrade by more than 300 m/min. “This test result puts us far aheadof todays state of the art”, according to the Voith R&D team.

This speed record is all the more im-

cept for these trials, including forming

pressive because it was achieved

fabrics, press felts, press sleeves andwith only one press nip on a Single

dryer fabrics was carefully selected

NipcoFlex press. The current pro-by Voith experts for high speed andduction record is held by a paperhigh paper quality.

machine with two shoe-press nips.
An important advantage of this press
Targeted development by Voith Paper

concept is the closed web run, which

Fabrics helped to achieve this speed

ensures that even at the most critical

record by optimally adapting thepoints, such as in the first dryerpress fabrics to the machine technol-group, web transfer at this record

ogy. Meanwhile, these press felts

speed is no problem. Finally, thehave been successfully introduced toquality of the paper produced withthe market. The entire clothing con-15% filler is impressive, with excel-

Contact
Daniel Gronych
Voith Paper R & D
daniel.gronych@voith.com

lent formation, strength characteristics and surface properties.

34

24 I 2007 I Voith Paper I twogether

RESEARCH AND DEVELOPMENT

Voith data analysis experts– Voith Tools– DataMining– OnView etc.

Optimization potential
10%
20%
70%

Mill
know-how

Customer– Technological problem– Database (offline)

PaperMiner

Voith technologies– Process know-how

Process analysis
Technological know-how
Optimization recommendations

Conventional PaperMiner
Voith
optimization

Process optimization, analysis and stabilization
with PaperMiner – a service which turns database
information into know-how
PaperMiner is a new Voith development that incorporates numerous
useful services. It enables all the data collected during papermaking and finishing to be analyzed by various methods. However,this was not the only reason for developing PaperMiner: we want togive Voith customers the opportunity to turn all this data into new
know-how in order to enhance their profitability.
This is a matter of process optimiza-

analyzed and utilized. PaperMinertion, detailed analysis for a deeper

evaluates ongoing process data using

insight, and stabilization of all steps

various algorithms, and supplies

in the papermaking sequence. A sin-papermaking experts with hidden

gle figure is enough to give some idea

correlations between process steps.

of the data volume involved: more

PaperMiner enables a much morethan 6,000 readings are continuously

comprehensive process analysis thantaken and stored during the paper-

was previously possible, allowing

making process, some of them within

Voith experts to propose measures

fractions of a second. In other words,

for more efficient and trouble-freea Voith paper machine today incorpo-

papermaking.

rates more control system circuits
than a modern jetliner.

Voith engineers regard PaperMiner asa way to exploit the last ten percent

Instead of leaving all this valuableof optimization potential that cannot

data idle, it should be systematicallybe utilized by conventional methods.

24 I 2007 I Voith Paper I twogether

Contact
Dr Rainer Schmachtel
Voith Paper R & D
rainer.schmachtel@voith.com

35

RESEARCH AND DEVELOPMENT

2,400
with HiDryer
2,200
2,200 m/min

Speed [m/min]

2,000
1,800

1,900 m/min

1,600

Newsprint

1,400
1,200
Wood-free grades
1,000
800
1980

1985

1990

1995

2000

2005

2010

New speed record prospects – with the HiDryer

HiDryer – Impingement drying directly
after the press (patent pending)Innovative drying technology enabling speedsin excess of 2,000 m/min –HiDryer: the speed and quality module
One of the main goals of paper machine development has always
been higher production speeds. Impressive advances have been
made in this respect thanks to improved press technology, optimized felts for high solids content, and efficient stabilizers in thedryer section for reducing draws. But breaking the “speed barrier”
of 2,000 m/min is only possible if the web already has a high solids
content before entering the dryer section. And this is exactly what
the Voith HiDryer makes possible. It is in fact a breakthrough development for wide and high-speed paper machines making themmore profitable in the future.

36

As proven with the Hürth PM 1 news-

To attain speeds significantly higher

print machine, high quality newsprint

than 2,000 m/min high web strength

can be produced at speeds in excess

at the first dryer is required. Theof 2,000 m/min. Further speed in-

HiDryer ensures this by drying thecreases are however limited by the

web with high-performance impinge-

initial wet strength of the web, which

ment hoods to give it the necessary

dictates the maximum web tension

strength before entering the dryerthat the wet paper can withstandsection. In this way the HiDryer en-

after the press section. Excellent ma-

ables speeds 200 m/min higher thanchine runnability requires adequate

with conventional technology, thus

tension in order to release the web

making modern paper machinesfrom the smooth dryers.

more productive and more profitable.

24 I 2007 I Voith Paper I twogether

Web tension: 1st press Ð 1st dryer roll [%]RESEARCH AND DEVELOPMENT

2,240 m/min
2,030 m/min
1,815 m/min
1,600 m/min

48

50

52

54

56

58

60

62

Dry content after 1st dryer roll [%]HiDryer facility at the Voith Paper
Technology Center (PTC)

High-speed test results with the HiDryer

Efficient contact-free drying is en-

to adequate vacuum, the web is fixed

concept are outstanding. All paper

sured by using impingement hoods

rapidly and dependably to the dryer

characteristics affected by dry con-similar to those used for tissue pro-fabric and held on the HiDryer rolls

tent or web tension after the press

duction. Important here is that pureduring drying. Since fabric deflection

can be improved with the HiDryer –impingement airflow is applied but nois eliminated even under high vacu-

for example the bulk of wood-freethrough-air drying. The advantages ofum, constant clearance from thegrades or the plybond strength andfull web support, well proven in single

drying hood is ensured. This is im-

porosity of wood containing grades.

tier dryer sections, are also utilized byportant, because even the smallest

All other paper characteristics such

the HiDryer. The web is guided safely

clearance deviations can cause

as opacity or optical properties re-and reliably by large suction rolls with

undesirable moisture cross-profile

main unchanged within the normal

stabilizers while at the same time

variations.

range according to grade.

ensuring an adequate drying surface
area. Particularly important is that for

The HiDryer was intensively tested forany impingement drying directly after

more than two years on the pilot

the press, the web has to be trans-

paper machines in Heidenheim withferred over its full width to the first

great success, and is available at thedryer, because this is the first pos-

Voith Paper Technology Center (PTC)

sible location for the takeoff doctor.

for customer trials. Test results have

Here again, the large suction roll con-confirmed the great potential of the

cept is well proven. There are no

HiDryer as a commercially viable

excess pressure pulses on take-up

drying concept. The offset printing

points, because no paper guide rolls

results on paper produced at speeds

are needed with this concept. Thanksof well over 2,200 m/min with this

24 I 2007 I Voith Paper I twogether

ContactRoland Mayer
Voith Paper R & D
roland.mayer@voith.com

37

Vacuum pump power consumption [%]RESEARCH AND DEVELOPMENT

Reduction 20%
100
90
80
70
60
50
40
Top Felt 1
Bottom Felt 1
Top Felt 2
without FeltView
with FeltView

FeltView, an effective tool for press optimization(patent pending)

Energy savings potential with FeltView

Comprehensive know-how in pressing technology –The FeltView press felt analysis system
Voith FeltView provides a unique way of visualizing the interactions
between felt status, conditioning devices and moisture crossprofile in the press. Results can be used for improving the moisturecross-profile and service life, and for significantly reducing energy
consumption.

In a best case scenario energy

quality management systems via theprocess transparency in the press

savings of up to 20 percent can beuniversal OPC industrial communica-

section, FeltView enhances drainage

achieved through the vacuum sys-

tion standard. Initial operating experi-

stability and minimizes production

tem. The FeltView system provides

ence with FeltView has allowed previ-

costs due to wear and tear.

online traverse measurements of felt

ously hidden potential for optimal felt

moisture content, permeability andconditioning to be uncovered. Felt-

temperature in all felt positions, thus

View-based felt management means

enabling felt condition analysis andconditioning precisely according to

optimization at full production speed.

felt condition. This not only saves

The measuring head, traversing in themoney and energy, but also increases

cross-machine direction, gently con-process stability thanks to systemati-tacts the felt at fixed time intervals

cally planned felt conditioning. As an

and takes continuous measurements

added benefit, press felt performance

during each cycle. The readings are

fault analysis is greatly simplified.

displayed in the OnView portal and

FeltView is a step forward in day-to-

can be linked into all process andday troubleshooting. By increasing

38

Contact
Ralf Pfifferling
Paper Machines Graphic
ralf.pfifferling@voith.com

Dr Oliver Kaufmann
Automation R & D
oliver.kaufmann@voith.com

24 I 2007 I Voith Paper I twogether

RESEARCH AND DEVELOPMENT

Diamond Edge for Edge Wear Resistance.
Colour: Black, Width: 25-30 mm.
Position: On the edge in contact with guide spade(patent pending)

The heavy and solid Guide Spade is marginal adjustable and results
in severe edge wear

New Engineered “Diamond Edge” for dryer fabrics –Lasts up to three times as long
Paper machine dryer screens have to operate under extreme
conditions, due to mechanical forces, thermal influences andchemical effects. It is often the edges of dryer fabrics that are
the most vulnerable.

Voith Paper Fabrics has developed a

Following intensive manufacturing

breakthrough engineered dryer fabrictrials, dryer fabrics with the newedge technology. Extensive techno-engineered edge technology were

logical research based on advanced

supplied and successfully trialed onhigh tech materials currently used incommercial paper machines thatspecialist applications, including thehave a particular history of fabricaerospace industry, led to a solution

edge damage.

which satisfies the requirements set
out above and in addition provides

The results surpassed customer ex-

optimal resistance to abrasion.

pectations. In one example the dryer

Contact
Antony Morton
Fabrics R & D
antony.morton@voith.com

fabric achieved a 300% improvement
in running life when compared tostandard fabrics. Positive customer
feedback is generating multiple re-Cheong Fatt Lam
Fabrics Operations Ipohcheong_fatt.lam@voith.com

peat orders and further interest in themarket.

24 I 2007 I Voith Paper I twogether

39

REPORTahead07 – Vienna Remains theVenue for Board and Packaging
Paper Producers“High Tech – Human Touch” – that was the motto of the
fourth ahead Customer Conference taking place inVienna from May 9 to 11, 2007. Around this topic, about
450 participants from 30 countries all over the world
enjoyed a superb conference program. In this connection, man and machine turned out to be a highly interesting combination. The more you want to get out of a top
machine, the more you depend on human factors.

40

24 I 2007 I Voith Paper I twogether

REPORT

In the beginning was the lightThree blocks full of partnership,

Wednesday, May 9, 2007

performance and innovations

Semper Depot

Thursday, May 10, 2007
Hilton Hotel Conference Center

Built as a storage space for the stage
scenery used at the Viennese the-The two conference days were the-aters, the Semper Depot has beenmatically divided into three blocks –the perfect setting for the opening

the topic of “partnership” wasscene of the fourth ahead Customer

handled first.

Conference. Every third year, Voith
Paper invites its customers, partners,

How is it possible that one customer

but also universities, research facili-reaches top performance while theties and the trade press to Vienna toother one remains on an average

inform them about the newest devel-

level with the same equipment? In his

opments in the board and packaging

opening speech, Rudolf Estermann,

paper industry. The event is, of

Executive Vice President – Board &course, perfectly suited as a platform

Packaging, discussed this question

to foster friendships and develop newfrom several points of view. Sincebusiness relationships.

Voith delivers the same high quality to
all its customers, it seem to be the

The spectacular and abstract opening

human factors like cooperation, part-show – a performance combining

nership, trust, and social influences

light effects and music composedthat make the difference. But also

specifically for the occasion – canhard facts, such as resource plan-

hardly be put into words. At least, itning, technological consultation andhelped to show the guests that an

the uncompromising dedication of

established mechanical engineer canboth partners, play an important role.

also be modern and daring. After
this brilliant beginning, Dr Hermut

Many interesting papers on the topic

Kormann, CEO of Voith AG, gave aof “partnership” were presented

welcome speech to the guests.

during the first half of the conference

Even the six buffet stations were inday. Lars Mallasch, Vice President –line with the conference theme.

Project Execution, for instance, talked

Under the keyword “High Tech”, forabout the increasing complexity,

instance, the guests were able todemanding a higher degree of profes-

have a look at “molecular cuisine”.

sionality in project handling. A paper

Spectacular opening showmachine may comprise more than
70,000 individual components and up
to 4,700 inputs/outputs must function

as senior project manager Helmut

perfectly. Competence, know-how

Riesenberger informed the audience.

and working often under enormous

That is why Voith founded the Projecttime pressure are the name of theManagement Institute several years

game for the technical and financial

ago. This tailor-made training oppor-

success of a project.

tunity is also accessible to Voith’scustomers.

The growing complexity of machines

24 I 2007 I Voith Paper I twogether

also requires increasingly higher qual-

Voith Process Solutions, PerfectFit,

ifications of the project managers,

Process Line Package and Total Roll

41

REPORT

Top performance for a success-To ensure its technology leadership in

ful future

the long run, Voith is highly dedicatedto research and development activi-

Technology is one of the most crucial

ties. Dr Manfred Feichtinger, Vice

issues for Voith. It is Voith’s commit-

President – Process Development,

ment to tackle its tasks in a system-

Board & Packaging, presented theatic, realistic and ambitious manner.

various Voith Paper research facilities,

Jean-Yves Nouazé, Vice President –as well as the innovation strategy ofProcess Technology, confirmed what

“Secure – Build up – Create”, which

Erich Brunnauer, Senior Vice Presi-

is indispensable for such revolution-

dent, had pointed out in the begin-ary solutions as the BoostDryer.

ning of his presentation: Never let thecustomer down. Technology can also

The paper industry is on the verge

help to reduce risks. Board technolo-of entering the world of interactive

gist Dr Torsten Paul told the interest-

training. Using EduCAT (Educational

Management are only some of theed audience how this works with theComputer Assisted Training), themost important services and con-

help of various tools, databases, on-customer will be able to simulate thecepts that Voith Paper offers to thesite visits, etc.

use of a real paper machine.

leader, it is Voith’s top priority to find

When it comes to the runnability of

The highlight of the first conference

correct and perfectly tuned concepts

the paper machine, a smooth and

day was a high-level panel discus-

meeting the customers’ specificcross-divisional cooperation is of vitalsion. Moderated by Hannelore Veit –requirements.

importance. Voith Paper is the only

Anchorwoman of the Austrian Broad-

paper industry. Being a technology

supplier who is able to develop andcasting Services (ORF) –, Carol

The financial sector has also been

perfectly tune both paper machine

Roberts (International Paper, USA),discussed. According to Helmut

and clothing. The advantages of thisDr Jan Klingele (Klingele Papierwerke,

Sieder, Vice President – Commercial

unique cooperation have been dis-Germany), Jose Manuel Barroso

Sales, Board & Packaging, tailor-

cussed in three presentations. Cloth-(SAICA, Spain) and Ming Chung Liu

made finance solutions are undoubt-

ing design, felt and wire cleaning, as(Nine Dragons Paper, China) dis-

edly one of the tasks of a technology

well as web stabilizing are an insepa-

cussed together with Rudolf Ester-leader.

rable triad at Voith.

mann.

Interesting talks about technical solutions

42

High-level panel discussion

24 I 2007 I Voith Paper I twogether

REPORT

Aperitif on the castle grounds

Closing dinner at the Orangerie of Schönbrunn Castle

An evening with the Emperor
Innovation is what counts

board and packaging paper industry

Whereas the first evening has offered

Friday, May 11, 2007

is particularly affected by high inci-

an extraordinary and modern program,

Hilton Hotel Conference Center

dental expenses with regard to en-

the closing dinner at the Orangerie ofergy, waste water and the discharging

Schönbrunn Castle offered everything

The guest speaker coming from Paris,of residuals. However, there is a huge

one may expect from a spring eve-

Gérard Caron, the “High Priest” ofpotential in this field. Optimized sub-ning in Vienna. After taking the aperi-

design, took the participants on ansystems are always a success, rang-

tif on the castle grounds, the guests

interesting and – at the same time –ing from energy procurement throughtook their seats at two 80-meter longamusing journey through the world of

the reduction of discharging costs

banquet tables to enjoy an imperial

packaging design. Based on selectedto the integration of the complete

dinner just like in the times of the Aus-

examples from Japan, USA andpapermill. Voith Paper Environmental

tro-Hungarian monarchy. Not even theEurope, he showed the development

Solutions makes it possible and of-Emperor himself would have been able

and dependency of packaging design

fers all the technologies and compo-

to organize a more pleasant evening.

on our ever-changing way of life.

nents required from one source.
What remains is the memory of three

Smart solution must not necessarily

The list of innovations was continued

wonderful days in Vienna, with inter-be large. Voith has developed a wideby Martin von Pawelsz, Area Sales

esting papers, innovative ideas,

range of “Product Solutions”. These

Manager of Voith Paper Finishing. He

two delicious dinner evenings and –small but mighty products guarantee

presented the youngest sibling, thehopefully – thousands of ideas for the

maximum performance and several of

new VariSprint winder, reaching wind-

years to follow.

them were presented by Martin Hub-ing speeds of up to 3,000 m/min.

Contact

mayer as part of the “Performance”
block in the morning of the second

The closing presentations of the con-conference day.

ference were reserved for the new
products of Voith Paper Automation.

One of the highlights of this second

Voith DriveCommand, Formation

day was the presentation of the new

Sensor and EnergyProfiler are brand-

field of Voith Paper Fiber Systems.

new products that have been devel-

Managing Director Lucas Menke pre-oped partly in a cross-divisional man-sented the extensive portfolio of Voith

ner and that will exceed the industry’s

Paper Environmental Solutions. The

expectations.

24 I 2007 I Voith Paper I twogether

Helena Pirttilahti-Feichtinger
Marketing Paper Machines
Board and Packaging
helena.pirttilahti-feichtinger@
voith.com
Christian Schrofler
Marketing Paper Machines
Board and Packaging
christian.schrofler@voith.com

43

TECHNOLOGY

NipcoFlex
calender inoperation

Developments in board production –Trends on the global carton market
About 42 million tons of folding boxboard are produced worldwide
every year. Growth rates are 2-2.5% p.a. in Europe and America andabout 8-10% p.a. in Asia, where annual production currently totals
around 10 million tons. Folding boxboard production in China rose
20% last year to about 3.5 million tons per annum.
The trend in liquid carton (LPB) pro-

Different machine concepts

duction is also rising. With a volume

in Europe and Asiaof 3 million tons per year and annual
growth of 5-6 %, China and South

Folding boxboard is typically pro-

America are currently the fastest

duced in Europe on multilayer four-

growing markets.

drinier machines with MG cylinder,
thickness control being ensured by a44

It is clear from these growth figures

hard-nip calender located ahead ofthat particularly China is investing

the coater. Depending on the smooth-in new machinery, while production

ness and gloss requirements, a

expansion in Europe is mainly

soft-nip calender may be used after

through rebuilds and machinery

double or triple coating. Asian ma-

optimization.

chine concepts primarily differ with

24 I 2007 I Voith Paper I twogether

TECHNOLOGY

regard to calendering technology,

are based on the NipcoFlex press,

rial consumption. Up to 10% higher

because in these countries there are

installed so successfully by Voith on

specific volume can be expected

practically no folding boxboard ma-more than 300 machines so far. Nip-

while reducing raw material con-chines with MG cylinder. Instead, thecoFlex calenders enable long dwell

sumption for the middle layer andbase board is usually pre-calenderedtimes and low line forces thanks toincreasing cost-effectivenesswith heated hard-nip calenders.

a press shoe that follows the contour

accordingly.

All grades of coated board, therefore,of the heated backup roll.

have to be post-calendered, forwhich soft-nip calenders are used.

DynaCoat –A particular advantage of this con-the new coater concept

cept is that speed increases do not
This difference between European

affect the NipcoFlex calender, be-After Voith acquired the coatingand Asian concepts naturally affects

cause the required dwell time canspecialist Jagenberg Streichtechnik,

the finished board quality. European

be set with the nip length.

the overlapping and widely scatteredfolding boxboard exhibits the bestproduct portfolios had to be unified

smoothness/volume ratio, which

This volume-retentive calenderingand reorganized. This has resulted

cannot be attained either with hard or

technology enables comparable

in the new DynaCoat product family,

soft nip calenders. While the smooth-board quality at significantly higher

comprising the AT and C coater

ness of Asian folding boxboard isoperating speeds and lower stock

types.

comparable with European products,

consumption. Rebuilds of various

the specific volume is lower because

kinds have shown that with the same

The DynaCoat C combines thesmoothness is achieved by heavy

dryer section length, capacity in-advantages of all previous Combi-

calendering and thicker coating, bothcreases of 10 to 60 percent are pos-Blade and GL coater versions. It isof which negatively affect board

sible without sacrificing board quality.

based on the larger DynaCoat AT, but

volume.

optimized for smaller web widths
Compared with new production lines(up to 6 m) and slower speeds (up to

in Asia, most of which so far embody

800 m/min) and, therefore, predes-

pre-calendering with a hard-nip cal-tined for use in boxboard machines.

The design concept and main com-ender, the NipcoFlex calender mainly

The first application will be for aponents of the NipcoFlex calender

offers savings potential in raw mate-rebuild in China.

Scheme of NipcoFlex calenderComparison between MG cylinderand NipcoFlex calender

NipcoFlex calender technology

PPS S-10 [␮m]6
5
4

Uncoated
MG cylinder

32
1

CoatedNipcoFlex
calender01.70 1.75 1.80 1.85 1.90 1.95 2.00
Bulk [cm3/g]

24 I 2007 I Voith Paper I twogether

45

TECHNOLOGYThis new product family offers theshaker neutralizes reaction forces andpaper machines, the latest DuoShakefollowing advantages (amongst

enables significantly higher shaking

with 600 Nm energy enables trouble-

others):frequencies than conventional ma-

free breast roll shaking.

● No blade beam heating or coolingchines. Much better formation is,required.
● Modern safety concept, also en-

therefore, attainable even at higher

This opens up new application fields,

operating speeds.

such as for rebuilding existing lines

abling excellent coater accessibility
and process monitoring.
● Optimally user-friendly maintenance and cleaning.

with heavy steel rolls weighing up toFurthermore, the hydrostatic support

12 tons. One of the first applications

principle eliminates almost all fric-of the new DuoShake 600 will be fortional and eccentricity forces acting

a large rebuild in America.

● Compact standardized control sys-on the foundations. No extensive

tem concept, pre-wired and tested

structural measures are. Therefore,

in the work shops. The pneumatic

required.

and hydraulic switchgear valves aremachine-mounted.

Thanks again to various intelligent
Shaking may be required on one or

and innovative products, Voith Paper

more layers of multilayer board andis now able to meet the highest board

outdated coaters; same dimensions

carton grades. The DuoShake is ideal

quality requirements by intervening

as the CombiBlade coater.

for this purpose, because it requires

at decisive points of the production

no concrete foundations and can beprocess.

● Minimal rebuild times for replacing

DuoShake –installed on a steel platform. Breast

significant improvement ofrolls on overhead fourdriniers can,multilayer board quality

therefore, be shaken without causing
undue vibrations.

DuoShake installations are alreadywell proven on more than 100 paper

Not long ago this shaker’s big brothermachines worldwide. Thanks to its

was introduced: the DuoShake 600.

operating principle, this breast roll

Designed for heavy rolls on large

DynaCoat AT

46

Summary

Contact
Christian Schrofler
Marketing Paper Machines
Board and Packaging
christian.schrofler@voith.com

DuoShake (patented)

24 I 2007 I Voith Paper I twogether

TECHNOLOGYPeter Demcak and Franz Aigner,
Ruzomberok, with Ladislav Vargic ofVoith Paper Fabrics (left to right)

Mondi Business Paper, Ruzomberok –PrintTech LBR dryer fabrics improve efficiency
Papermakers are always trying to find ways of cutting energy costs
and optimizing fabric performance. To this end Mondi Business
Paper invested in 2003 in rebuilding their PM 18 in Ruzomberok.
The rebuild mainly involved installing a new Voith Single NipcoFlex
shoe press, plus DuoStabilisers and VentilStabilisers in the dryer
section to improve web run and air circulation. Voith Paper Fabrics
also cooperated with the customer to optimize the dryer section
capacity and fabrics. Today this 6,500 mm wide paper machine
produces 335,000 tons per year of copying paper at 1,500 m/min
on average, using exclusively spiral dryer fabrics throughout thedryer section.

24 I 2007 I Voith Paper I twogether

47

TECHNOLOGY

The levelling process shown on the rightincreases the contact surface area andresistance to abrasion

Ruzomberok, a town with 35,000 in-ditions, hood air conditions, hoodand less risk in marking high quality

habitants in the hilly Zilinas region

supply and exhaust air, pocket airflow

paper grades.

of Slovakia, has been involved in

conditions, and web shrinkage. After

papermaking since the seventeenth

shutdown, the machine and fabrics

Following the successful use of Print-

century. Mondi Paper is one of thewere then examined in detail toTech LBR spiral fabrics in the second

region’s biggest employers and oper-

determine improvement potential.

and fourth single-tier dryer group

ates Slovakia’s largest pulp and(TopDuoRun) in May 2005, Voith

paper mill. In 2004, when various

The study of the dryer section showed

Paper Fabrics spiral fabrics were in-dryer fabrics of different makes anda high specific steam consumption

stalled throughout the PM 18 dryer

designs were in use, Mondi assignedof 1.33 to 1.39 kg of steam/kg ofsection. The measurements carried

Voith Paper Fabrics with efficiency

evaporated moisture. Pocket mois-

out in 2006 showed improved drying

analysis of the rebuilt dryer section.

ture content amounted to 700 g/kg,

rates, and reduced specific steam

thus reducing the evaporation rate.

consumptions of 1.18 to 1.19 kg/kg.

The goals were as follows: improve

A higher evaporation rate with lower

drying efficiency, solve the web run

Spiral fabrics with low air permeabil-steam consumption brings energy

problems, and optimize fabrics

ity normally have elliptical spirals.

cost savings, adding value from theperformance throughout the dryer

As a result the web is only supported

dryer fabrics.

section.

on a few small contact points, which
can cause marking and non-uniform

Improved drying

Improved web run

drying. Voith Paper Fabrics, therefore,
developed the levelling process for

The dryer section showed high read-

The following analyses were carried

the PrintTech LBR spiral fabric withings for inflowing air (negative values)

out in two days: drying efficiency,

low air permeability. This increaseson the wet side and high readings forheat transfer (steam, cylinder surface

the contact surface area on the web

outflowing air (positive values) on theand web temperatures), pocket con-side, resulting in more uniform drying

dry side at the web edge. This airflow

PrintTech LBR spiral fabricEnergy savings achieved by replacing all dryer fabrics with PrintTech LBR

48

Date

Steam used
(kg steam/kg evaporated moisture)

Evaporation rate(kg/hr/m2)

29.04.04

1.33

24.25

21.04.05

1.39

23.06

22.03.06
PrintTech LBR on 70 % of positions

1.19

26.92

24.10.06
PrintTech LBR on 100 % of positions

1.18

27.15

24 I 2007 I Voith Paper I twogether

TECHNOLOGY

+2.3

+1.3

-2.2

+0.5

-1.2

+0.3

-2.7

+0.4

-1.5

Imbalanced pocket airflows

imbalance in the pockets was due

systems may have to be adjusted oc-

to using different fabric designs ofcasionally to prevent premature wear

various makes with different air per-and tear of the fabrics. Paper debris

meabilities. Ideally, the airflow values

from tail threading can accumulate,should be about the same on both

dry out and cause wear stripes to thesides.

fabric.

At the beginning of 2006 the dryer

The levelling process improves resis-

fabrics in this section were replacedtance to wear because more material

with fabrics of the same permeability

is at the fabric surface. PrintTech LBR(200 cfm) to ensure optimal ventila-

spiral fabrics have an extremely hightion and uniform airflow conditions.

specific cross-sectional area of

Subsequent measurements showed

42.55 mm2 per 100 mm fabric width.

lower inflowing and outflowing air-This results in a stronger fabricflows, resulting in more stable web

and seams to improve resistance torun with less sheet breaks.

damage.

Less risk of fabric damage

Experience and know-how

Fabric damage can be due to various

Voith Paper Fabrics utilizes the paper-

causes. Sometimes paper debris

making know-how of all Voith Paper

gets caught between the fabric anddivisions, and combines it with appli-

machine parts, causing local stresscations technology know-how topeaks that lead to fabric tearing.

optimize drying section efficiency and

The sealing strips on the web control

dryer fabric performance.

24 I 2007 I Voith Paper I twogether

Contact
Ladislav Vargic
Fabrics
ladislav.vargic@voith.com

49

TECHNOLOGY

Graphic Packaging International –Promoting synergies through partnership
The three-year partnership between Graphic Packaging
International and Voith Paper Fabrics has paid off in production
gains for this leading maker of coated board. Superior teamwork –led by the mill’s award-winning machine superintendent
Jay Martin – has been a key success factor.

50

24 I 2007 I Voith Paper I twogether

TECHNOLOGY

Graphic Packaging International in

Derek Hutchison, vice president andMacon, Georgia is a leading supplier

resident manager. “Natural gas goesof coated board for beverage pack-into everything we buy to make coat-aging and folding cartons. Along withed board. We’ve done a really goodsister mills in Louisiana, Michigan

job of offsetting inflation.”and Sweden, the Macon mill supplies
coated board to the company’s con-

In fact, the mill has set records oververting facilities, which in turn provide

the past three years in every categoryfinished packaging for some of theit measures: safety, quality, produc-world’s largest consumer producttion, cost per ton, and financial

companies.

performance. Hutchison credits thissuccess to Paper Machine Super-

The company can be credited withintendent John “Jay” Martin, along

innovative packaging designs, includ-with Martin’s efficient team of manag-

ing the fridge vendor, microwavableers and operators, and value-added

cartons and Z-Flute® (zero flute).

suppliers like Voith Paper Fabrics.

The management team at Graphic

Award-winning machine

Packaging Macon takes pride in the

superintendent

mill’s outstanding safety record, quality production output and operating

Jay Martin, who joined Graphic Pack-efficiency.

aging in 1993, was named the “2007
Brookshire Moore Superintendent“Inflation has been a huge challengeof the Year.” This prestigious industry

for this industry and for this mill,” said

award was presented at PIMA’s

Graphic Packaging International
in Macon, Georgia, is a leading
global supplier of coated board

Jay Martin wasrecently honored
as the 2007
Brookshire Moore
Superintendent of
the Year

24 I 2007 I Voith Paper I twogether

51

TECHNOLOGY(Left to right)
Wes White, Brian Garnett and Don
Miller of Voith Paper Fabrics with
Jay Martin and Derek Hutchison ofGraphic Packaging International

National Awards Ceremony in March

fix the problem. We’ve knocked downson. “This has enabled us to really

2007. In addition, Martin is also amany of those obstacles.”increase operating efficienc.”

Fraternity, which recognizes individu-

According to Hutchison, Martin is not

Engineered surface enhance-

als for their contribution to the ad-

one to accept traditional paradigms.

ments through systematic fabricvancement of papermaking science“Jay is constantly seeking opportuni-

designand technology.

ties to speed up, improve quality andmember of the Couch Pit University

train operators. He gets others in-Graphic Packaging Macon was one

Martin is a seasoned machine super-volved as well, like the people in theof the first mills to work with Voith inintendent who is willing to take calcu-

field and engineers at Voith.”the early stages of a new, engineered

lated risks in testing new technolo-

paper surface enhancement. Macongies. The mill has benefited greatly

Voith has a significant share of form-

was interested because of thefrom his ability to think beyond theing, press and dryer fabrics on thesmoothness that could be achieved

obvious solutions and create newmill’s two machines, as well as atwhile maintaining the dewatering

ways of utilizing technology andGraphic Packaging’s Louisiana andcapacity and permeability attributes

increasing productivity.

Michigan locations. Graphic Packag-of a press fabric.

ing’s Macon mill has been an ideal“Machines aren’t designed to break,partner in the development of new

The product trial on No. 1 paper

they’re designed to run,” Jay Martin

fabric technologies.

machine’s second press top fabricsaid. “I challenge my operators toproved successful, but the mill want-push the limits. When we encounter“With our current contract and rela-ed to take it a step further. They were

obstacles that prevent us from run-tionship with Voith, we have thelooking to improve sheet quality andning faster, it’s my job to recognize

flexibility to collaborate closely, makesheet bulk, as well as gain productiv-

that. That’s when I’ll go to Derek, anddesign changes, and then trial fabrics

ity. Martin worked with Voith’s Bob

we work through what is needed toon the paper machine,” said Hutchi-

Crook in R&D and Brian Garnett,

52

24 I 2007 I Voith Paper I twogether

TECHNOLOGY

Press Fabric Sales/Service represen-for Voith, these fabrics have improved

tative, to develop a modified press

drainage, speed and smoothness

fabric for a smoother paper surface.

because of better fiber support. They

Graphic Packaging’s Macon mill has

The new fabric has performed very

have also proven to have a long life;

seen a 10% increase in tons per day

well and is now the standard felt

the MultiForm GP ran on No. 2 paper

over the last few years with minimalon this machine. A seam can bemachine’s top position for a fullcapital investment. These production

applied to the permeable structure,

363 days, a record for the mill.

gains can be largely attributed towhich enhances safety during

Teamwork pays off

operating efficiencies, training andinstallation.

Dryer fabric efficiency

fabrics innovations.

“We’re really stepping up with ad-

In 2006, Voith Paper Fabrics began

Says Hutchison: “We give Voith a lot

vancements brought about by thistalking with Graphic Packaging aboutof credit for the fabric designs. The

new surface technology,” said Martin.

energy savings that can be gained

team is really focused on perfor-“The goal for us is smoothness, so

through advanced dryer fabrics ap-

mance and finding ways to offset

anything we can do to increase

plication and better air handling. The

inflation through process changes

smoothness and not hurt bulk is whatmill agreed to try a conversion fromand innovations. The forming fabric

we shoot for. This had really helped

woven dryer fabrics to Voith’s Multi-

designs and the wet felts we’re

us to gain bulk and reduce weight.”

Tech LAY link design. A full set of

running today have basically madefabrics was installed on No. 2 paper

No. 1 paper machine a new machine.

machine during the annual outage.

We’re able to get the board quality

The development work done jointly
by Voith Paper Fabrics and Graphic

attributes we need and not sacrifice

Packaging will soon lead to the future

Upon startup, the machine immedi-

speed. It’s really been a good rela-introduction of engineered surface

ately achieved a significant gain intionship.”enhancements to the entire paper

drying efficiency.

industry.
The Macon management team appreMulti-layer forming fabrics

ciates the value-added ideas that
Voith has brought to the relationship.

As in the press section, the Macon

The mill also benefits from the hands-

mill has also seen improvements

on approach of the sales and techni-brought about by new fabric innova-

cal teams.

Contact

tions in forming. The MultiForm GP
and other multi-layer designs fromDon Miller, Voith’s Dryer Fabrics

Voith have performed well, even as

Sales/Service representative, is amachine speeds continue to increase.

constant presence in the mill, running

According to Wes White, Forming

weekly diagnostics to measure

Fabrics Sales/Service representative

machine performance.

24 I 2007 I Voith Paper I twogether

Brian Garnett
Fabrics
brian.garnett@voith.com

53

TECHNOLOGYThe VariTop winder at UPM Schongau (patented)

Preparing for tomorrow – Designed for the future!
Today we often find that what seemed impossible in the past isalready reality. Even wide fast-running paper machines meanwhile
rely on a single winder for their entire output. At the UPM Schongau
mill, for example, a Voith VariTop single-drum winder handles paperof 6 meters width, produced on PM 9 which is running at speeds up
to 1,700 m/min.
The high demands met by this Vari-

to 3,000 m/min for the VariTop in

Top are particularly impressive in view

Schongau.

of the fact that while the paper ma-

54chine operates at constant speed,

To ensure dependably trouble-free

the winder has to change four roll

winder operation, all components

sets per parent roll. This intermittent

must be of the highest quality, andoperating mode places high demands

a modular automation concept ison the machine dynamics and re-required. Dividing the highly complex

quires a high operating speed of up

automation system into clearly

24 I 2007 I Voith Paper I twogether

TECHNOLOGY

VariTop winding stations
operating at 3,000 m/min

organized and easily controllable

papermaking line. The Voith VariTop

ware and software components are

modules is the primary requirement inlikewise takes into account all these

now arranged systematically on

modern machine control technology.

requirements, based on the automa-hierarchically structured automation

Furthermore, comprehensive andtion systems incorporated in the well-levels, with clearly defined horizontal

dependable diagnostics functions areproven Voith One Platform Concept.

and vertical interlinks.

most of the sensors and actuators

The Voith VariTop winder has been

Extended diagnostic is enabled bymust be automatically checkable for

equipped with a completely revised

the E/A groups used. In combination

faultless operation. In addition, it isautomation system in order to ensurewith the Voith Library for PCS7, alldesirable have the automation struc-

optimal dependability and high pro-components can thus be thoroughly

ture harmonized within the whole

ductivity accordingly. Both the hard-

checked for correct operation.

indispensable today. This means that

Automation levels for the finishing process

Finishing process
OnView Taragon DB OnView

Mill Service Router

Voith Service

Level 3Intranet

Customer VPN via Voith
firewall Internet firewall

Calender CalTronic
Roll calculation /NipcoLogic
CD / MD control
NipcoSet

Winder VariTronic
Set and order management
Unit position calculation
Winding curves
High speed trending

Gateway

Printer

Voith
Intranet

TGG
Trending
Analysis

Twister RollTronic
Order management
Data / Statistics
Label printing
Status / Roll tracking

Warehouse

Paper machine

Level 2

Gateway
WinCC/PCS7

WinCC/PCS7

WinCC/PCS7

WinCC/PCS7
Machine visualization
Machine operation
Alarming

Level 1
Simatic S7-400
DP/DP Coupler

Simatic S7-400 F

Simatic S7-400

Simatic S7-400 F
DP/DP Coupler

Simatic S7-400
Profibus/DP

Level 0ET 200 ET 200 Motor Converter

ET 200 ET 200 ET 200 ET 200
Failsafe

24 I 2007 I Voith Paper I twogether

Control panel
MP

ET 200 ET 200 Control panel ET 200 Motor
Failsafe
MP

Scanner Robots Scale

ET 200
Failsafe

Barcodeprinter55

TECHNOLOGY

Without exception, all actuators andbased on the extensive data volume

Since – due to rapid technologicalsensors are completely interlinked toavailable, dependable and trouble-

progress in this sector – automation

enable full exploitation of the control

free operation is ensured.

system components normally have asystem diagnostics capabilities. Even

shorter useful lifetime than the ma-

the VariTop’s extremely precise posi-

Indispensable for the new VariTopchine itself, upgrading must be en-tioning and control functions, suchautomation concept was modular

abled by allowing for replacement in

as knife positioning to one tenth of aarrangement of the hardware andthe future with more advanced andmillimeter, are directly linked with thesoftware components. Each compo-

higher-performance automation com-paper machine control system. Whilenent must fulfil its purpose perfectly,

ponents. By optimally exploiting on-

computing is done by the process

but also has a clearly defined inter-going improvements in automation

technology software modules, theface for horizontal and vertical net-technology, the VariTop can staysensors and actuators are controlledworking. Interactions between theabreast of future demands for a longand monitored by the SPS.

components must be excluded, andtime to come.

no communication partner must be
The user control interface is based onallowed to interfere with the timing

Thanks to its modularity and hierar-

the familiar WinCC system, with ad-

and data throughput rate of the com-

chical networking, the present Vari-ditional software modules enabling

munication network. Meeting theseTop automation concept is optimallycomputing and monitoring tasks thatkey requirements has not only en-

prepared for the future. In view of

go beyond the standard ones. All theabled practically trouble-free auto-

today’s rapid advances in automation

complex machine functions are, there-mation, but also forms the basis fortechnology, this is the only way offore, visualized comprehensively, and,future upgrade concepts.

ensuring the longest possible payback on investment.

VariTop slitter section(patented)

Contact
Volker Schölzke
Finishingvolker.schoelzke@voith.com

56

24 I 2007 I Voith Paper I twogether

TECHNOLOGY

NipcoFlex calender incoater SM 1 at Koehler
Kehl

NipcoFlex Calender –a new means for crowning the finishing process
In spring 2006, Voith Paper successfully equipped two machinesat the same time with NipcoFlex extended nip calenders: one at
Weyerhaeuser Longview in Washington State in the U.S. for the
production of liquid packaging board, and the other at Koehler Kehl
in Germany for thermal paper. Before describing these two projects
in further detail, one reason for this success should be mentioned
and dealt with first, namely the Paper Technology Center, Finishing.
PTC Finishingsummer of 2006. Now it is possible inthree stacks to calender paper or board

24 I 2007 I Voith Paper I twogether

The basis of successful projects ison one or both sides with hard, soft, or

the determination of the expected im-

shoe calender nips in any combination.

provements in terms of product qual-

Since the beginning of 2002, a consid-

ity and/or product costs. Along witherable number of tests of various

and as a complement to the Paper

grades have been performed, fromTechnology Center (PTC) in Heiden-

thin graphic papers with no more thanheim, Voith Paper has also commis-

40 g/m2 basis weight all the way tosioned a new combined calender inboards with a thickness of 800 μm.

57





 

 


 
 !
 !

 "

 "

 
 

 
  

Combi-pilot calender at the PTC-Finishing          

TECHNOLOGY    

   

Smoothing the top and bottom side ofliquid packaging board

In terms of technology, the NipcoFlex

Another issue that had to be resolvedson, Voith recommended and in-calender nearly always proves advan-

was whether the back side can bestalled a soft nip calender instead of

tageous in the tests. In addition, thebetter calendered with a hard or aa hard nip calender.

investment decision must also makesoft nip. The figure above shows re-sense economically. Two examples

sults from the pilot calender. It illus-

In addition to the improved quality,that meet these requirements aretrates how the individual processing

Weyerhaeuser Longview was soondescribed in the following.

steps affect the specific bulk and theable to realize further advantages:

Bendtsen macro-roughness on the

The number of dry end sheet breaks

Weyerhaeuser Longview –top and bottom side: In the first hardthus decreased remarkably, and afrom calender trials to successcalender nip, the roughness of thequicker web threading was possible.

paper bottom side that is in contact

Moreover, the project is meeting theWeyerhaeuser Longview wanted towith the moderately heated roll de-desired basis weight reduction plan.

replace its two wet stacks (multiple

creases by almost 50%. Subsequent-Overall, Weyerhaeuser now has aroll calenders with water doctors)

ly, in the NipcoFlex calender, thiswider operating window and canwith a modern calendering concept,

paper side touches the soft Qualiflex

provide better quality and higher stiff-

consisting of a two-roll calender for

sleeve, and the surface quality im-

ness without additional cost. The

the processing of the back side andproves only marginally. The rough-other option is to provide board withfor CD-profiling, and an extended nipness of the top side decreases by

the same stiffness as before the con-calender for the smoothing of the top

about the same amount in the hardversion, but with lower basis weight.

side. The main goals were to improve

nip and then considerably in thethe correlation between surface qual-

NipcoFlex calender to about only

Koehler Kehl –ity and bulk and to increase produc-

25% of the initial value. What is inter-

success off the beaten tracktivity by means of a higher operating

esting here is the development of the

speed.

bulk. A loss of 8% occurs in the hard

During the production of thermal

nip, while in the following extended

paper, calendering is an essential, but

The first tests aimed to determine thenip almost no additional reduction

often also a very limited process. Be-

operating windows for three grades

occurs at all. This again confirms thecause a pre-reaction of the pressure-of liquid packaging board. The goal

advantage of the NipcoFlex calender;

and temperature-sensitive coating

was to optimize the start-up curvethat is, it yields a soft and smooth

has to be avoided under all circum-

and achieve the objectives as soon

surface while preserving bulk to thestances, the coated paper can only

as possible after the rebuild. Using

greatest extent possible. Thus, thebe smoothened to a degree of quality

DoE-software (DoE= design of experi-development of the bulk significantly

just short of allowing this reaction toments), the specifications have been

depends on the calendering method

occur. This quality is usually alreadymet with the least possible expense.

chosen in the first step. For this rea-

the minimum that the market requires.

58

24 I 2007 I Voith Paper I twogether   #$  $

TECHNOLOGY

PPSvs. bulk

Bekk
vs. bulk

Bekk
vs. PPS

Surfacestructure

Reactionof coating

Print
quality

2 rolls
soft – hard

o

+

+

-

-

-

2 rolls
soft – soft

-

-

-

o

o

o

NipcoFlex
calender

+

o

o

++

++

++

++ best+ goodo moderate- worst result

Comparison of calender concepts
for thermo papers

Applying conventional means an

machine is operating at a speed far

additional increase is, therefore,

exceeding 1,000 m/min. A further

impossible or extremely expensive,

main requirement of the customer

All in all, the NipcoFlex shoe calenderfor example, by further improving

was the trouble-free closing of thehas successfully proven its potential

the already costly coating pigment.

calender nip when producing a thinin these applications. Thanks to the

Additional steps

graphic paper at full operating speed.

cooperation between Voith Paper’s

For this reason, Koehler Kehl first or-

In addition, the cross profile of thedivisions, both projects have been

dered the conversion of the soft nip

paper should vary only within narrowcompleted with exceptional success.

calender into a calender with two soft

bounds, and the sleeves must be de-Both machines are working withoutrolls from Voith. Soon it became ap-

signed for high durability despite theproblems and to the full satisfaction

parent that a shoe calender allowed

high pressure in the calendering nip.

of our customers. In addition to thefor a further, significant improvement

From the start, all challenges haveconsiderable increase in quality, bothof quality due to its contour-adapted

been taken care of, and the customer

customers were able to realize signifi-

calendering process. The table shows

expectations have been satisfied tocant improvements in terms of cost

a comparison of the different calen-

the fullest extent. The conversion

structure.

dering types. A conventional soft nip

indeed yielded positive effects bothIn the summer of 2007, the next chal-

yields fairly good lab test data, but inin terms of quality and production

lenge will be the commissioning ofterms of the more practical charac-

costs. The combination with the cur-the second NipcoFlex calender withteristics such as surface structure

tain coater installed by Voith in 1999

Koehler Kehl offering an even higher(evaluated visually), pre-reaction ofespecially results in a beneficial pro-production speed. Thanks to our pre-the coating layer, and printing quality,

cess layout, which in turn creates avious experiences we are sure we will

the NipcoFlex calender yields thewider operating window. This pro-be prepared to face this task. In addi-

best results by far.

vides Koehler Kehl with the possibilitytion, reducing operating costs will

to further develop its products andcontinue to be our aim, and Voith will

Thus, it only made sense that after

offer its customers more tailor-madeachieve this with the further develop-

the successful tests Koehler Kehl was

solutions.

ment of the Qualiflex calenderable to make a quick decision andsleeves we manufacture.

placed an order with Voith for the in-

The most obvious proof for the suc-stallation of a NipcoFlex calender.

cess of the project is the fact that

To ensure that these technologicaleven during the summer of 2006,

advantages prove valuable under the

Koehler Kehl also commissioned

tough, real conditions of daily pro-

Voith Paper to install a NipcoFlex

duction, several technical challenges

calender in the second coating

had to be solved. For example, themachine.

24 I 2007 I Voith Paper I twogether

Contact
Dr. Jörg Rheims
Finishingjoerg.rheims@voith.com

59

TECHNOLOGYHigh Technology on a Roll Part 2
Ceramics, polymers, elastomers and advanced composite materials
have experienced considerable growth in paper machinery
applications. In twogether 23 the first part of this article reported
on Voith research activities in this area. This second part now
examines the subject in greater depth.
R&D Locations

technology and, finally, intensive
prototype and field testing.

The R&D Centers of Voith Paper Rolls
are located in Wimpassing, Austria,

Modelling

and at the Research Triangle Park in
North Carolina, USA.

In many R&D projects the first step isa theoretical model of the problem.

R&D Projects

This approach can help to better define the project goal or to shorten the

The R&D activities of Voith Paper

practical development time.

Rolls are coordinated on a projectbasis, with cross-divisional projects

One example for better understand-with other Voith Paper Divisions.

ing roll cover contact is a sophisticat-

Global teams collaborate worldwide

ed computer program (“NipMaster”)

and meet the needs of market-driventhat was developed to predict the be-

projects.

haviour of our unique elastomer andcomposite materials when subjected

Finite Element Model of shear stresses
in a roll cover60

All Voith Paper projects are accom-

to paper machine nip conditions. This

plished by the Stage Gate Process.

computer program accurately ana-

The development of roll covers or

lyzes various conditions found in pa-

coatings is focussed on material sci-

per machine operations. Therefore,

ence. Typical R&D steps for roll cover

this tool can predict stresses, strains,development may include, modelling,

temperatures, heat fluxes, damping,material development, material test-

and optimal flow rates for coolinging, development of manufacturing(and analyze whether such cooling is

The R&D team in Raleigh, USA

Developing new materials to meetcustomer requirements

24 I 2007 I Voith Paper I twogether

TECHNOLOGY

needed). The capability to rapidly andrial that can tackle the demands.

viscoelastic materials is a criticalaccurately analyze these variables inState-of-the-art materials such as

property that governs the maximum

the cross-machine direction for mat-nanofillers and newly developed fiber

allowable load and speed of a covering covers of any property is uniqueand particle reinforcements are used

and, therefore, influences its safe op-

in the industry. This program canfor our latest innovations in the areas

eration and ageing. In general, data ispredict failure modes of various rollof press section, coating and finishing.

measured at various temperatures,covers under a variety of conditions

frequencies and deformation levels,(depending on temperature, stress,

An example from the coating/sizing

with a variety of time-dependent

strain, etc.). It can be used, for exam-

area is the development of StratoSize

functions (harmonic oscillation, step

ple, to optimize the shape of the cov-

and StratoCoat covers. These highly

pulses, etc.). The data is acquired byers (crown) to obtain uniform paper

sophisticated compositions are opti-

computers running software that uti-

properties, to avoid vibrations, or tomized to maintain the ground shapelize transform techniques to analyze

analyze dewatering.

of the cover. The development goal

the data. Currently several high tech-

was the minimization of cover wear

nology devices are available at our

For the analysis of paper dewatering

under operating conditions. Special

R&D facilities to test the temperature-

not only the press nip geometry or

filler combinations with adaptation of

dependent, frequency-dependent andthe roll cover surface but also thethe elastic matrix to suit those fillers

de-formation-dependent properties ofinfluence of the fabric is of prime im-

resulted in an exceptional increase inpolymers used in roll covers.

portance. Due to this fact the R&D

abrasion resistance of this new covergroups of Voith Paper Fabrics andseries. The performances of the cov-

Voith Paper Rolls are working closely

ers for the coating process were test-

together in order to integrate theed on the pilot coating unit in Voith

Seeking optimal manufacturing meth-highly specialized simulation for fab-

Paper Heidenheim.

ods of different materials requires arics into an overall calculation toolmodel for the press.

Manufacturing technology

continuous development of our manMaterial testing

ufacturing technology. A team ofengineers is continuously working onMaterial development

The measurement of dynamic me-

modifications and development of

chanical data is essential for develop-

new processes for new materials.

Once the customer requirement has

ment of roll covers for the paper in-

been properly analyzed, our material

dustry. This is required because heat

These engineers use their broad

scientists start to develop the mate-generation (by internal hysteresis) of

experience in cover manufacturing

Material testing

24 I 2007 I Voith Paper I twogether

Mixing head of a casting machinefor roll covers

Filament Winding

61

TECHNOLOGY

The development of exclusive/unique

Outlook

manufacturing technology allows
The challenges of a fast developing

unique product design.

paper production technology and thePrototype testing/field trials

trend to more efficiency and speed
will be met in the future only with a

Since reliability of covers and coat-highly customer oriented, market andings is essential for acceptance in thetechnology driven R&D organization.

paper industry, durability and loadRoll-cover test standability of the covers are tested on

For this purpose new scientists andcustom-designed roll test rigs. In

technicians have been hired to in-these test runs, the covers are run tocrease the expertise and focus of ourtheir limits, thus enabling Voith Paper

R&D activities. Voith Paper Rolls R&D

Rolls engineers to precisely define

will also focus on new technologies

the allowable stress, strain, speed

in the areas of real-time sensing andand temperature of our covers in

automation, and development of new

operation.

materials as well as new processdevelopments.

also for the technology transfers to

In these pilot units as well as in the

all external manufacturing sites

new Paper Technology Center, thearound the world.

newest roll covers are available forpaper mills to run paper technology

Contact

Voith Paper Rolls invests continuous-trials. The final test runs before

ly in new manufacturing technologies.

market introduction are performed inAmong these new technologies are

selected field trials together withe.g. a new Filament Winding Equip-

customers and R&D personnel.

Dr Norbert Gamsjäger
Rolls
norbert.gamsjaeger@voith.com

ment for manufacturing composite
rolls, the latest thermal spray equip-

The introduction of our products toment, and new proprietary processes

the market is accomplished in thethat were introduced to establish

last Stage Gate step with intensive

higher process reliability and better

involvement of Marketing, Productquality control.

Management and Sales.

Dr José Rodal
Rolls
jose.rodal@voith.com

Chronology of innovation

1987
SuperTop

1984
Kernethane
HT/KT

62

1993
TopTec Serie
TopCoat HP
TopSize HP
1988
TopRock

1997
AqualisDewatering
Technology
PolyDyne

1995
CeraLease
AST cohesive
bonding system
PolyDyne SR II

1998
G2000

1999
Safir
Rubin
CalTek
T-Master
Magna Serie

2003
Vantis S
CeraLease SDe
StratoSize
StratoCoat

2002
CenterSupported Roll
TopSize HPX
TopCoat HPX

2005
VRG

2004
Vantis SC
StratoPress

2006
Vantis M
TerraSpeed
Solar Generation
EndurAII
PikoClean NG

2007
SkyLineCarboTec
3DG
NipMaster
NipSense

24 I 2007 I Voith Paper I twogether

TECHNOLOGYNew Thermal Spray Coating production line
started-up in China
In February 2007, Voith Paper Rolls China started up successfullya state-of-the-art thermal spray coating production line for rolls anddryer cylinders at its Dongying plant in Shandong province.
In May 2003 Voith started to serve

With the realization of the recent im-

Asian papermakers with high-end rollportant strategic investment in Febru-

covers, mechanical roll services andary 2007, Voith is now in the position

regrindings out of Kunshan plant,

to serve Asian papermakers withlocated in Jiangsu province, andhigh-end thermal spray coatings andDongying plant. Since start-up of theshortest turnaround in manufacturing

two service centers in China a teamtimes.

of 150 members manufactured more

24 I 2007 I Voith Paper I twogether

than 1,200 rolls covers and ground

The thermal spray coating investment

more than 2,000 rolls for the Asian

has been realized in close coopera-

paper industry. Continuous invest-

tion with European technology spe-ment in new equipment and technol-

cialists and machine suppliers. Thus

ogy to offer new value added to thea modern and efficient production

Asian papermakers is one of Voithline, based on latest developments inPaper Rolls China’s core businesscoating technology, which fulfils in

strategies.

addition highest work environment

63

TECHNOLOGY

Grindingof a CeraCal Plusroll cover

ThermalCoating

protection and safety standards, has

papermaker’s needs for rolls with

been successfully realized. Bothsuperior running performance, com-

Plasma coating for ceramic covers

pared to non-coated rolls, for differ-and the HVOF coating process forent paper machine application posi-

metal alloys coatings are now avail-tions. For suction rolls in the wire

able in Dongying.

and press section, extremely wear
resistant CeraVac coatings offer a

The thermal spray coating production

significant increase in running time.

line is designed for rolls with a maximum face length of 14 m. The project

TerraSpeed for center press rolls is

included a building extension of

the latest generation of ceramic

500 m2 manufacturing area plus

coatings, which lead to uniform sheet

200 m2 laboratory and office space.

release and a lower draw. Thus

Additionally, the roll grinding capacity

sheet breaks can be reduced signifi-

was increased by a new grinder andcantly.

a second crane was installed.
High wear resistance CeraVent coat-64

Voith is now offering out of its Dongy-

ings are leading to a significant

ing plant a wide range of thermal

increase in running time for grooved

spray coatings that are matching thepress rolls.

24 I 2007 I Voith Paper I twogether

TECHNOLOGYThe Donying team –competence forhigh-quality roll covers
and roll service

CeraGuide Plusroll coverIn the dryer section CearDry and Cera-

coatings are only examples out ofin May and June 2007. Several dryer

Guide Plus coatings with superior

the thermal spray coating portfolio

cylinders were coated with CeraDryanti-sticky properties are significantly

offered by Voith in China.

Plus and have been delivered toreducing fine fiber sticking on dryer

customers.

cylinder surface, thus better paper

Since start-up of the new thermal

sheet release and decrease in draw

spray coating production line, several

With the successful realization of thecan be realized.

important orders have already been

thermal spray coating production linedelivered to customers. In March

Voith Paper Rolls China has enlarged

CeraCal Plus thermal spray coatings

2007 one CeraGuide Plus roll for APP

its cover portfolio and again proves

for the hard rolls of soft calender,

Dagang PM 3 and in April 2007 one

its commitment to be the competentmulti-nip calender, and super calen-

10 m face length CeraCal Plus coverand reliable partner for high-end rollder, with their superior wear resis-

for APP Dagang PM 3 Janus calendercovers and services for the Asiantance properties, offer low surface

were manufactured. This is the first

paper industry.

roughness values during the entire

roll out of a package order of four

running time. The need for roll change

CeraCal Plus coatings for APP Da-

and re-grounds is decreasing, andgang. Tjiwi Kimia, Indonesia, (PM 11)

the running efficiency of paper

and another Chinese paper producer

machines and off-line calenders is,placed orders for TerraSpeed ceramic

therefore, significantly increasing.

coatings for their press rolls. These

The above mentioned thermal spray

TerraSpeed coatings were delivered

24 I 2007 I Voith Paper I twogether

Contact
Stefan Dette
Rolls
stefan.dette@voith.com

65

TECHNOLOGY

Total Roll Management –The Ultimate Roll Service Concept
The performance and reliability of rolls have a huge impact on
paper quality and mill profitability. The Voith Total Roll Management(TRM) concept is the ultimate tool for all papermakers to achieve
the best roll performance and reliability.

       











Voith Total Roll Management is aare engaged in the whole papermak-

comprehensive program that takes

ing process: fiber systems, graphic

care of all the needs of the rolls. It is

paper machines, board & packaging

based on deep cooperation and long-machines, fabrics, finishing and auto-

term goals. With this partnership, youmation. The combined know-how of

get measurable results and bring sig-

all these groups results in a truly

nificant contribution to your bottom

comprehensive expertise throughoutline profit, today and into the future.

the entire papermaking process.

Voith personnel have tremendous

TRM Portfolio

Case study 1 result:Greater than 50% reduction in downtime
due to roll problems

know-how around the complete rollsystems, and they are dedicated toRoll Systems

everything related to rolls.

Voith Paper Rolls manufactures all
types of rolls using the highest quality 

!
" 

"
"


  

#$%
#$%
#$%Case study 2 result:– Reduction in annual roll spending– 3% increase in machine efficiency

66

Voith Paper Rolls was the first to in-material combined with accurate andtroduce the Total Roll Management

precise manufacturing procedures.

concept. You can rest assured we are

Each roll is custom engineered withthe most experienced partner in thethe latest design concepts, which

industry, and our case study resultsmeans they are optimized for eachspeak for themselves.

application.

What makes Voith Paper Rolls

Roll Covers

the Best Partner for You?

Voith has a complete portfolio of rollcovers and coatings. Starting from

Within the TRM partnership, Voith

the wire section to the winder, Voith

Paper Rolls will be your single point

has roll covers specially designed forof contact, working closely together

each position. Voith covers are top-with mill’s specialists to achive elimi-

rated in the industry, and the quality

nation of roll problems. Voith will stayis well proven through many years of– next to the internal specialist of thereliable service. Voith will recommend

Rolls company – closely connected

and fine tune the best cover for eachwith other Voith Paper experts, whichroll position.

24 I 2007 I Voith Paper I twogether

TECHNOLOGY

Roll Service

Voith also coordinates transportation

Voith services all types of rolls, re-of the rolls. Our roll tracking system,

gardless of original manufacturer.

called SØNAR, is a unique software

Total Roll Management enables mill

Periodically, rolls have to be com-

program that makes roll tracking very

personnel to focus more time on thepletely reconditioned to the original

simple. It supports the entire TRM

core business of papermaking, while

specification. If needed, Voith canconcept.

getting the industry’s best expertise

also perform engineering upgrades.
Every solution is tailor made for theon maintaining and optimizing rolls.
Implementation Steps

specific need, striving for maximum
results for the cost.

Summary

With the TRM concept, the total responsibility for rolls is turned over toAfter the machine survey or reviews

Voith Paper Rolls.

of rolls histories, e.g. past problems,Field Service

difficulties, roll change intervals or roll

Voith has roll service centers around

Voith Paper Rolls can also provide

grinding frequencies, are completed,

the world. We are there for you

Field Service from the wet end sec-various technical support tools are

24 hours a day, 365 days a year.

tion to the winder. For example, dryer

available to further optimize the paper

cylinders can be balanced in yourmachine operation.

paper machine in their own bearings;

We will take care of everything related
to your rolls to ensure, that roll issues

this leads to highest balancing results

The next step, after analyzing thewill disappear and you can rely on

and helps you reduce shut down

data, is to present the findings andyour rolls everyday.

time. Our Rollchange Teams are wellrecommendations to the mill. The

known for shortest reaction times

final step involves collaboration be-

and very quick rollchanges. That

tween the mill and Voith Paper Rolls

helps you to keep downtimes to ain formulating the implementation

minimum.

plan.

Implementation Steps

Contact
Jin KimRolls
jin.kim@voith.com

Jochen Honold
Rolls
jochen.honold@voith.com

24 I 2007 I Voith Paper I twogether

67

TECHNOLOGY

Product finder – The Voith Paper offering, now online“Products & Applications” gives an overview of our entire offering.
Find out what our products and services can do for you, check out
our references, and get to know our customized “Perfect Fit”
rebuild concept. You can also explore the future with us – take atour of our Paper Technology Center and discover how your dreamof tomorrow’s paper can already exist today.

Voith Paper

Products & Applications

Product finder

New plants
Rebuilds

Want to know what LWC paper is ormuch as you like. You’ll see a detailed

Servicehow MD control works? Need infor-

listing of all Voith products, or you

References

mation on CeraLease or optimal felt-

can get the same results with our full-ing for your press section? No prob-

text search engine 2.

Product finderHome
Perfect Fit

Research&Development

The Paper Technology Center

lem. Just call up the new online list-

New world record – successful start-up at
Huatai Paper already five months after start oferectioning of Voith Paper products at www.

The example on the right shows

voithpaper.com/products. It tells

Product finder results for Voith roll

you immediately everything you wantcovers in the press section of LWC

to know about our products as wellpaper machines 3. Just run theas paper grades, papermaking tech-mouse over a product name to see a

nologies, and components such as

short “Tooltip” description 4.

Note for U.S. residents

rolls or automation systems.
Click on the respective product to getUsing the three panels Paper grades,

detailed information on all its applica-

Processes and Components 1, youtions and benefits.

can narrow down your search as

68

24 I 2007 I Voith Paper I twogether

TECHNOLOGY

Voith Paper

Products & Applications

Current

e-Business

Detailed information

Jobs & Careers

To give you some idea of what to expect inHome

Voith Group

Product finder
Products A-Z

DeutschVoith Drive system:

Voith Drive

Back to search

As a first impression we have put together

Voith Drive is the integrated solution for an innovative drive which replaces the
traditional arrangement of cardan shaft, gear unit, coupling and motor. The motors
are simply mounted on the front or drive side, and they drive the rolls clearancefree and without any intermediate mechanical drive components. In this way, thegear casing and all mechanical drive components become superfluous.

ProEfficiency
ProQuality
ProSpeed
ProEnvironment
Optimization targets

the future, this page shows the innovativesome general product information andpictures. And the small graphic shows you

Your Problem:• Oil leakages of the gear train in the dryer section.
• High costs for maintenance of the gear train in the dryer section.
• Energy costs that are too high.
• Complex and cost-intensive spare parts purchasing for existing motors and gear
units.

our optimization goals in developing thisproduct for you. If you want to know more,
you can download our brochures to get

Our Solution:
The Voith Drive direct drive convinces by reliable operation because no additional
components such as gear units and cardan shafts are required. Compact installation
because the Voith Drive is mounted directly on the roll or cylinder journal and therefore,
extensive adapting of the surroundings is no longer required.

detailed data on each product, its applications, special features, and benefits.

Literature
Perfect Fit
Product sheet

Your Benefit:• Lowering of energy consumption of about 5%.
• Reduced maintenance as gear train, gear units and cardan shafts are not required.
• Reduction of noise emission.
• Limited spare parts keeping.
• Improved environmental balance as no central oil lubrication system is required.

And, it goes without saying that we haveopen ears for all your questions: eachproduct page shows the respective contact
partner.

Contact
Diethelm Beisiegel
Phone: +49 7321 37 2966
Diethelm.Beisiegel@Voith.com

Product finder
Products A-Z

Product finder
1 Paper grades

2

3

Search for

Reset allProcesses

Components

Graphical papers

Process automation

Machine clothing

Board & Packaging

Stock preparation

Specialty papers

Wet End Process

Optimization
Rolls

Tissue papers

Paper machine

Roll covers

Finishing

Automation

Environmental Solutions

Tail threading

Newsprint

Headbox

SC paperWire section

LWC paper

Press section

CWF paper

Drying

UWF paper

Coating & sizing

LWC paper – Press section – Roll covers
BlackStone S
AqualisSearch result: 21 products
CeraForm

CeraVac

CeraVent

DrillPress

DrillPress HD

G2000

MagnaPress II

MagnaPress II R

MagnaRock I

MagnaRock II

MagnaRock II R

PolyDyne

SolarFlow

SolarPress

StratoPress

StratoPress S

TerraSpeed

TopPress

TopRock

24 I 2007 I Voith Paper I twogether

Polyurethane cover for suction press rolls

469NEWS FROM THE VOITH GROUP
Customers in focus:
Münzing Chemie can now
concentrate its core activities
on business processes withdirect customer relations.

Voith Industrial Services, fully integrated –The Münzing Chemie success story in Heilbronn
It couldn’t be simpler – and it couldn’t be better! In future Münzing

company. Maintenance task planning,

Chemie can focus exclusively on its core activities: product devel-supervision and documentation are

opment, purchasing, production and marketing. Voith Industrial

facilitated by “maint-CATS” software

Services takes over all other peripheral or internal services such

(Maintenance Control and Tracking

as production logistics, maintenance and facility management.

System), thanks to which Hörmann

All input of the Voith companies involved is grouped together underEngineering solved the complex“Integrated Services”.

Münzing challenge in only four weeks.
VIHC compiled among others importroutines for the numerous databases

This is a pilot project both for Münzing

logistics partner. “We make sure thatand files, and was able to take overand Voith, because such outsourcing

all the media and raw materials re-most of the relevant data semi-auto-

has never been implemented to suchquired are ready at the right time atmatically. The customer placed spe-an extent before in the chemical

the right place, in the right quality

cial emphasis on the service andindustry. The VIZ integrated services

and in the right amount”, says Frankrepair workflow and on transparent

include preventive maintenance,

Hüther, head of the VISI Chemical &reporting between Voith and Münzing:

upkeep and repair of all production

Refinery business unit. Within the“Our service and repair procedures

facilities, other auxiliaries, and thecomplex framework of Facility Man-

were already in order previously, but

entire piping network – including

agement services, Voith also takeswith the comprehensive integration

150 pumps of various types. Also all

over additional tasks such as securityof additional functions and system-

the production media supply systems

and fire protection, cleaning, postal,

atic digital linking, we can exploit

such as power, gas, water, and steam

and telephone services.

substantial cost-saving and quality

including the respective plant. Voithpotential in future”, summarizes

people fill each product batch com-

This integrated service package ismanaging director Michael Münzing.

pleted at the Münzing plant into therounded off by the process and“If I ever had to make such a decisionright drums, and prepare all the nec-

applications experts of Hörmann En-

again, I would certainly choose theessary documents for our external

gineering – a Voith Industrial Services

same solution and the same partner”.

70

24 I 2007 I Voith Paper I twogether

NEWS FROM THE VOITH GROUP

Hydro Power Plant Borçka at Çoruh riverin the north of Turkey

At the push of a button: Turkish Prime
Minister Recep Tayyip Erdoğan starts
operation of hydro power plant Borçka

Borçka hydro power plantinaugurated by Turkish prime
minister Erdoğan

Voith Turbo launches
commercial
WinDrive production
Higher grid stability with lower
investment costs
The Voith WinDrive concept for windpowered generators has reachedcommercial maturity. Using a Voith
variable-speed hydrodynamic drive,
this new technology eliminates theneed for frequency converters in wind

Turkish Prime Minister Recep Tayyip Erdoğan inaugurated thepower plants. EU Energy Ltd./DeWind

Borçka hydro power plant in the northern part of the country.

(GB/D) is the first customer to benefit
from WinDrive. The first wind turbine

The 300 MW power plant on the

Borçka has been realized under awith WinDrive started up punctuallyÇoruh river has been built by national

bilateral agreement between Austria

at the beginning of 2007 on the Cux-

utility DSI State Hydraulic Works. The

and Turkey. It will be the penultimate

haven, Germany, test site. Commer-

plant is equipped with two Francis

power plant in the Çoruh basin,

cial production has now started main-

turbines from Voith Siemens Hydro,

north-east of the Black Sea, built by

ly for wind park applications in Northproducing 1,039 GWh worth of

DSI. The consortium consisted ofAmerica.

energy per year. The order value wasAndritz VA Tech Hydro, Verbundplan

around 26 million Euro.

(PÖYRY), Strabag, Voith Siemens

WinDrive technology enables conver-Hydro Austria and local Turkish

sion of a variable input speed into a

partners.

constant output speed. The wind

According to the Prime Minister in his

turbine rotor can, therefore, rotate atinauguration statement, hydro poweris Turkey’s most important energy

Voith Siemens Hydro Power Genera-

optimal speed depending on windresource. “Today, its share is 36 per-tion is a Group Division of Voith and –velocity, squall-induced peaks arecent of the Turkish energy mix. If thewith a workforce of around 2,500 em-

efficiently smoothed out, and windnecessary measures are not takenployees and an order intake of aroundforce related shutdowns are no longer

immediately, energy shortage could€ 720 million in the past businessnecessary. By allowing the use of

be a trouble for all of us. Therefore,

year – Voith Siemens Hydro Powersynchronous generators, WinDrive

we are taking precautions rapidly”,

Generation belongs to the world-wide

will have a significant grid-stabilizing

he emphasized. He affirmed to further

leading companies for hydro power

effect with high-powered wind gen-

support hydro power generation.

equipment.

erators in future.

24 I 2007 I Voith Paper I twogether

71

REPORT

Voith celebrates its 140th anniversary –1867- 2007
Voith, still a family-owned company, is 140 years old this year but
as young and dynamic as ever. Founded in 1867 with 30 employees,
Voith now employs 34,000 people worldwide, and holds 10,000
active patents to which 400 new ones are added each year. Orderintake exceeds four billion Euros, and Voith continues to expand asa successful global player.
The official birth date of this future

and the new railway line to Ulm, inworld star was August 6, 1867.

the kingdom of Württemberg”.

On that day Johann Matthäus Voith
handed over the original business toAfter graduating in mechanics andhis son Friedrich, according to theirmachine-building at Stuttgart poly-

agreement drawn up at the beginningtechnic, Friedrich Voith spent severalof the year. Against payment of ayears with the renowned Swiss engi-“life annuity of fifteen thousand sevenneering works Escher-Wyss Zurichhundred and sixty one gulden” fordesigning waterwheels, water tur-

Johann Matthäus and Friedrich Voith

his father, Friedrich Voith acquired abines and paper machines. He had

Top: The Heidenheim works in 1880

“locksmith’s workshop, including

ambitious goals, and was confident

all machines, tools and inventories,

of reaching them based on thelocated on the southern outskirts offoundations his father had laid. This

Heidenheim between the river Brenz

is reflected in the name he gave his

72

24 I 2007 I Voith Paper I twogether

REPORT

company: J.M. Voith Engineering

wrote technological history. It enabled

Works.

for the first time high-quality groundwood production in large enoughThose were times of headlong growth.

quantities for industrial papermaking.

The industrial revolution was in fullswing, bringing radical changes

In 1870 Voith began turbine produc-

throughout Europe as new technolo-tion, and in 1873 built its first Francis

gies increasingly took over from tradi-

turbine. This embodied a revolution-

tional handicrafts. Turbines replaced

ary improvement to the original Amer-waterwheels, and to satisfy the insa-

ican invention, by applying movabletiable hunger of the fast new printing

wicket gates to decisively extend thepresses, paper was no longer madeapplication range. In 1881 Voith deliv-

from rags alone but increasingly fromered its first complete paper machine,

groundwood pulp.

with a wire width of 2.35 m.

In 1869 Voith registered its first patent for
a wood grinder. This one dates back to1891. On the right is Voith’s first FrancisTurbine, built in 1873.
Top: Voith apprentices in 1913

In 1869 Voith registered its first

When J.M. Voith celebrated its silver

patent for a wood grinder withjubilee in 1892, the Heidenheim works

toothed loading rack. Known as theemployed 330 people. Ten years later“Raffineur” (refiner), this machine

this had risen to more than 1,000,

24 I 2007 I Voith Paper I twogether

Layout drawing of Voith’s first paper
machine in 1881 for the Raithelhuber millin Gemmrigheim, Germany

73

REPORT

ensued for Voith after the war ended
in 1918. Sales stagnated in plantengineering, paper machinery andwater turbines alike. It was paramountfor the company to regain confidence
among customers abroad.
In order to open up additional market
areas where best use could be madeDIWA drive package for city transit
buses

Voith Retarder power brake forcommercial vehiclesof the company’s pre-eminent turbomachinery know-how and experience, Voith embarked upon the development and production of hydrodynamic couplings, transmissions
and related components for vehicles

making Voith the second largest

thus avoiding the otherwise restrictive

and stationary machinery. With great

machine-building company after

customs barriers applying at thatcommitment and perseverance, Voith

Esslingen locomotive works.

time.

then built up its third pillar business,the power transmission systems, in

In 1903 Voith received an order for

Outbreak of the First World War in

addition to papermaking technology

the world’s largest water turbines at1914 abruptly ended this internationaland hydropower machinery.

that time, twelve 12,000 HP Francis

expansion for the time being. But

turbines for Niagara Falls power plant

Friedrich Voith, who had transformed

In 1926 development work started onin the USA. International businessthe original locksmith business into a

the Voith Schneider propeller based

expansion led in the same year to theglobally reputed company, wason designs by Viennese engineer

founding of Voith St. Pölten in Lower

spared that trauma. He died in 1913

Ernst Schneider. This marine propul-

Austria, the company’s first plant

aged 73 years, and was succeededsion and steering system for ferries,

abroad. This provided a platform forby his sons Walther, Hermann andtugs and similar special-purpose

market expansion into Eastern

Hanns Voith. Following the collapse

vessels enables incredible manoeu-

Europe and even Southwest Asia,of the German empire, difficult times

vrability in all directions.

Voith Water Tractor with Voith Schneider®
propellers

74

Voith Francis turbines for Itaipu, the world’s biggest
power station in Brazil

The WinDrive opens up
new markets

24 I 2007 I Voith Paper I twogether

REPORT

In 1934 the first Voith Turbo trans-

therefore, non-wearing brake fortaken as only an indication of what is

mission was installed in a diesel-trucks and other large commercial

to come.

hydraulic rail bus. This opened up avehicles that is now a matter-of-very lucrative business field: hydro-

course contribution to road safety.

dynamic transmissions and braking

Sophisticated technology for increasingly complex systems and applica-

systems for diesel powered track

On the occasion of the company

tions demands professional service

vehicles. Thanks to the ongoing suc-centenary in 1967 Voith was able toand maintenance. Voith, therefore,cess of this Voith speciality, the firstdraw a very impressive balance.

embarked upon the 21st century

Voith mainline freight locomotive was

Since its founding, Voith had soldwith a fourth pillar business: Voithdelivered in 2006 after only 500 days

17,000 water turbines, 850 paper andIndustrial Services. This new division

including development, design andboard machines, 22,000 gear drives,complements our production-orient-production.

1,550 Voith Schneider propellers,

ed activities and is recording strong

16,500 turbo-drives, 400,000 turbo

business growth. At the same time,

From 1939 to 1945 the Second World

couplings, and 25,000 DIWA auto-

however, our flow of innovations for

War once again curtailed international

matic transmissions.

Voith’s traditional markets of papermaking and board production, hydro-business relations and activities.
But Hanns Voith, who after the deaths

These imposing figures include nu-

power, and safer and faster mobility,of his elder brothers Walther andmerous world records. The fastest

is by no means exhausted. On the

Hermann steadfastly held to theirand widest newsprint machines, forcontrary, as noted by Voith AG Board

chosen course as of 1947, soon

example, and the most powerful tur-

Chairman Hermut Kormann:

restored contacts with long-standingbines for the world’s largest hydro-

Voith customers both in Europe andpower plants. But Voith has no need

“Our latest projects in tidal poweroverseas.

to boast and does not rest on its lau-

technology, the WinDrive wind turbine

rels: each new record is regarded as

drive system, the Voith Maxima loco-

In 1950 Voith Power Transmissiona challenge to break it again as soon

motive, and the Voith Paper Technol-

Systems started producing automaticas possible. What counts above all

ogy Center not only highlight ourdifferential torque converter transmis-

for Voith is customer benefit and sat-engineering capabilities but also set

sions (Diwabus) for city transit buses.

isfaction. This review of some epoch-

benchmarks in profitable new tech-This was followed in 1968 by themaking technological milestones overnologies to drive the future growth ofVoith Retarder, a hydrodynamic and,the last 140 years can, therefore, be

our company”.
Voith – Engineered reliability.

Maxima, the world’s most powerful
single-engine dieselhydraulic locomotive

24 I 2007 I Voith Paper I twogether

The new Voith Paper Technology Center in Heidenheim

75

Newsmagazine for theinternational clientele,
partners and friends ofVoith Paper“twogether” is published twice annuallyin German, English, Chinese, Russian and
Finnish. Contributions by independent
authors do not necessarily reflect theopinion of the publisher. Please address
all correspondence and inquiries to theeditor.
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
88212 Ravensburg, Germany
wolfgang.moehle@voith.com
http://www.voithpaper.com
Design, layout and typesetting:
Manfred Schindler Werbeagentur
P.O. Box 1243, D-73402 Aalen
www.msw.deIssue 24, July 2007

Copyright 7/2007: No part of thispublication may be reproduced or copied
by any means whatsoever without theexpress permission of the editor.

Printed on chlorine-free bleached paper manufactured with Voith Paper machinery.

Voith Paper