twogether
Paper Technology Journal

22

Paper Technology Center inauguration I Holmen Paper –95 years of partnership I SAICA – new PM boosts capacity

CONTENTS

4

Report4 The new Voith Paper Technology
Center opens its doors –Paper Valley celebrates

11 Voith Paper Technology Center –A vision becomes reality
Interview with Ulrich Begemann

14 Partnership is the key to successInternational customer symposiumfor graphic grades

19

34 Holmen Paper Madrid“Peninsular” –New world record start-up speed
for newsprint machines

39 Ettringen PM 4 –19 Stora Enso Kabel SM 5 –Quality creates satisfaction

24 Thune screw presses for sludge –the innovative screw press designfor high torques

28 Voith Paper Vaassen –Wear-proofing for rotors and more...

32 From the idea to installation –Market launch of an innovative
pulp bale dewirer

68 TerraSpeed –the new generation of ceramic coatings
for press rolls

72 The Vantis family of elastic calendercovers

ProQuality rebuild “MyFuture44”

42 New fabric technology
for single tier drying

45 Klabin Brazil invests in a liquids
packaging board production line

46 UPM Kaipola –a Perfect Fit rebuild

Technology

34

Miscellaneous
76 Service Seminar in Finland –Record attendance

77 Excellent response
Reader opinion survey

50 SAICA boosting production
by another 400,000 tons –Two-million tons within reach

55 Working together andcommon goals
Interview with Francisco Carilla,
Project Director SAICA 4

56 Productos Familia, Columbia –Voith Group news
78 Voith Maxima® 40 CC –Crossing new frontiers in traction power

79 Voith Industrial Services
79 Voith Siemens Hydro
New contract in Germany

Expansion in Tissue

58 Atmos –Innovative technology for premium

Culturetissue production

80 Green turf, beautiful game

60 Faster quality tons on the reel –and lots of paper

Turbo-upgrade of Perlen Papier’s
LWC PM 4 “Pioneer”

64 Dresden Papier –optimized threading process cuts
threading time in half

Regular features
3 Editorial
84 Imprint

66 Higher output at Dresden Papierand enhanced product quality at thesame time2

22 I 2006 I Voith Paper I twogether

EDITORIAL

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

Key to the future

modules. Standardization is the pre-We, together with our Voith Paper

requisite to excellent start-up curves,

divisions, are doing our part to devel-

Where would the world be without

expressed by increased tonnage.

op solutions to reduce these costs.

papers, newspapers, toilet paper,

To standardize both process andTo find the perfect key for all thesebooks, just to name a few, would be

modules, we, Voith Paper, createdconcerns, we have to focus on inno-

unthinkable without it. Paper produc-

the One Platform Concept as well as

vations. This is exactly what we havetion developed rapidly and constantly

the completion and execution based

done with the creation of our Papertakes up new challenges. Just take aon the Process Line Package. With

Technology Center (PTC) in Heiden-

look at the development of machine

capabilities such as these we are able

heim. Everything that has an influence

speed and width. The fastest ma-

to offer our customer a single-sourceon quality, process efficiency andchines in the industry operate atsolution, reducing interfaces thereby

paper quality in papermaking is here

nearly 2,000 meters per minute andreducing risks and supporting ouravailable for research.

are more than 10 meters wide!

customer in consistently producing

paper? Items such as magazine

high-quality paper.
Despite its dynamic growth, the paper

For the first time, we can research
the entire paper production process –industry has been suffering from

We give our customers the opportunityfrom fiber to paper. Here, our cus-

unsatisfactory earnings and high cost

to streamline mill maintenance. Voith

tomers will have the possibility ofpressure. Old and unprofitable pro-Industrial Services together with Voith

developing and experimenting withduction lines have to be shut downPaper is here the competent partner,completely new machine concepts.

and up-to-date units have to copeusing all synergy effects and, there-

This research center is the dream ofwith increasing production costs.

fore, stabilizing the production line effi-

every papermaker and opens so far

Papermakers, and we also, know thatciency on a high level.

unknown opportunities!

reduced, but what is the key to make

Fiber and raw material costs are a

The Paper Technology Center isthis happen?

major concern for papermakers as

our key to the future. We have it in

the costs of operating must be

they represent a significant amount

our hands, and we will use it for

The solution to this challenge is theof the total cost. We have developed

a more successful business of our

key to the future for us. Both the cap-

solutions such as fiber loading tocustomers!

ital costs and the operating costs ofreduce these costs.

our customers must be lowered. We
can achieve this by standardizing the

The paper industry ranks among theentire production process and thefive most energy-intensive branches.

22 I 2006 I Voith Paper I twogether

on behalf of the Voith Paper Team

3

REPORT

The new Voith Paper Technology Center
opens its doors –Paper Valley celebrates

REPORTREPORT

Voith AG invested 75 million Euros in this futureoriented project. Why did the Heidenheim family
firm spend more on a single project than everbefore? The answer lies in a fundamental Voith
philosophy: faith in innovation, strict alignment
to customer needs and the independence of afamily business.

6

22 I 2006 I Voith Paper I twogether

REPORT

The new Voith Paper Technology

Kormann, Chairman of the Board ofCenter (PTC) in Heidenheim was in-Voith AG, in his inauguration address.

augurated on May 11, 2006 in thepresence of about 700 international

At the heart of the PTC is the 75 me-guests.

ter long PM 6 pilot paper machine.
While the old test machine can only

“The Voith PTC breaks new
ground in customer-oriented
research and development.”

be run in start-up mode, this new one
is designed for record performancelevels at speeds up to 3,000 m/min(180 km/h!).

The new PTC uniquely combines theresearch areas fiber system technology and papermaking process
technology. “Ever since its foundingin 1867, Voith has been an outstandingly future-oriented and research-“Now we can realistically test
almost unlimited process
alternatives, ranging all theway from stock preparation
to print rolls.”

driven company”, said Baden-Württemberg minister-president GüntherThanks to its modular arrangement,

Oettinger in his inauguration address.

the new facility enables the testingand direct comparison of completely

This new research center now en-

different and of course completely

ables for the first time comprehensive

new production concepts. “Now wepapermaking process testing and op-

can realistically test almost unlimited

timization under realistic conditions –process alternatives, ranging all the

ranging from stock preparation to

way from stock preparation to print

machine configuration to end prod-rolls. That promotes innovation anduct, including automation systems

gives our customers added security

and fabrics. “The Voith PTC breaks

for their investment decision-making.

new ground in customer-oriented

The modular arrangement of the newresearch and development. Researchfacility cuts the needed time to about

can be conducted here on everything

one tenth”, said Ulrich Begemann,affecting paper quality and the pro-managing director Voith Paper Tech-duction process”, said Dr. Hermut

nology Center GmbH.

At the heart of this newPaper Technology Centeris the 75 meter long
PM 6 pilot paper machine.
Inauguration on May 11,2006 in the presenceof minister-president
Oettinger.

22 I 2006 I Voith Paper I twogether

7

REPORT

Overall view of the world’s most modern paper technology research center.

The various parts of the PM 6 test

The equipment incorporated in PM 6

facility are stored in the so-calledis also impressive: the latest Duo-

module station. Storage and retrieval

Former TQv version, tandem Nipco-

are masterfully handed by lifting out

Flex shoe press, and HiDryer. Apart

entire machine groups and replacingfrom the length of the dryer section,

them. The drying section is thethis test machine corresponds exactly

largest and heaviest at 600 tonnes.

with a production machine layout ex-

It is supported on rollers, and auto-

cept that it is only one meter wide as

matically moved into the correctagainst modern production machine

position according to press arrange-

widths of up to 11 meters. This differ-ment.

ence has no effect on the technologi-

Project manager Jörg Wilhelm
has everything under control.

cal validity of test results.
Until now it was not possible to influence stock characteristics in paper

Test operations are led jointly bymachine test facilities, but the newpapermakers, automation experts

PM 6 is equipped with a “fiberand paper engineers. Ideas can be

design” system allowing precise ad-developed, tested and realized here

justment of the stock characteristics

together with customers from allto paper product requirements. The

over the world. The test findings are

overall process optimization, possible

used either as a basis for rebuilds

here for the first time, is expected toon existing installations, or for newlead to further innovations.

paper machines.

8

22 I 2006 I Voith Paper I twogether

REPORT

The architectural highlight is clearly
the office complex. Designed to harmonize with papermaking themes,
it emanates the lines of a paper
machine wet end. It also houses thecontrol room, as well as conference
rooms and lounges for customers.
Several laboratories are incorporated
for assessing stock samples, finishedpaper, and printing results.
Heidenheim was chosen as PTC location due not only to the immediate
vicinity of existing research anddevelopment facilities but also to theimportance of continuous contact
with other departments such as
design and marketing. Our entrepre-

About 140 specialists work at the new PTC.

neurial foresight has paid off: the newPaper Technology Center – exempliThe new Paper Technology Center isPaper Technology Center lets us playfying record-breaking performance,

primarily intended for testing andan even greater role in technologicalfuture orientation and vision – was

implementing customized solutions.

and quality leadership. Here we shallchosen as one of the 365 locations

One way we do this is by integrating

make things possible that have only

nationwide promoting “Germany –in the Paper Technology Center

been dreamed of so far”.

the Land of Ideas”. This unique technology center not only enhances the

reputed companies such as BASF,
Omya, Siemens and Cargill who work

Architecturally, the new Paper Tech-

image of Heidenheim as Voith head-with Voith here on common research

nology Center comprises three build-quarters, but also turns it into a paper

projects.

ing tracts: the actual paper machineresearch center par excellence –hall, the office building largely adjoin-some people are already calling thising it, and the stock preparation zone.

Ostalb location “Paper Valley”!

“Here we shall make things
possible that have only been
dreamed of so far.”

The machine hall is of course themost impressive feature of all:
115 m long, 42 m wide overall, andThe Heidenheim research center in its

up to 28 m high.

futuristic new building, therefore, hasa clear assignment: to promote paper

Constructing the new PTC required

industry profitability and productivity

900 tonnes of reinforcing steel, 9,800

worldwide through innovations andcubic metres of concrete, and nearlysystematic process optimization.

1,400 prefabricated concrete sec-

Or as enthusiastically formulated bytions – about the same as would be

Dr. Hans-Peter Sollinger: “The newneeded for building 150 houses!

22 I 2006 I Voith Paper I twogether

Contact
Stefanie Weber
Public Relations
Corporate Marketings.weber@voith.com

9

WELCOMING ADDRESS

Günther H. Oettinger

Dr. Hermut Kormann

Dr. Hans-Peter Sollinger

Minister-President

Chairman of the Board of Voith AG

President of Voith Paper

I heartily congratulate Voith AG andToday is a big day not only for Voith

Now we have it: the key to the future.

all its people on the inauguration of

but also for Heidenheim and theToday is the beginning of a new era in

Heidenheim’s new Paper Technology

entire East-Württemberg region. With

paper technology research. The new

Research Center, which sets a mile-

the inauguration of Voith’s Paper

Paper Technology Center is a dreamstone in global leadership. By invest-

Technology Center, the heart ofcome true for every papermaker, anding about 75 million Euros in thisPaper Valley starts to beat. For this is

for us it opens new frontiers. Here we

project, you have once again shown

where the paper of the future will be

can show our customers the future

the decisive entrepreneurial commit-

developed; this is where new frontiers

already today. And for the first time,

ment traditionally characterizing Voith

will be crossed in paper machine

our paper technology research can

as a venerable family business.

technology. The future innovations

delve into every detail of the entire

born in Paper Valley will be acclaimed

papermaking process.

Baden-Württemberg

This exemplary company stands forby papermakers worldwide.
This globally unique paper technology

the values and quality dedication thathave brought Baden-Württemberg to

I am delighted that we have so quick-research center is well timed for Voith.

the forefront in our Land of Ideas, as

ly realized this epoch-making projectIt allows us to tackle the challenges ofshown by the 400 patents annuallyright here in Heidenheim, where

the paper industry with developments

registered by Voith. Baden-Württem-

Voith has always been at home. And I

to further improve papermaking cost-berg’s leadership lies in the commit-

strongly believe in the power of inno-

effectiveness by saving energy, reduc-ment of companies like Voith AG tovation: Voith has written technologi-

ing water consumption and making

superiority on the global market.

cal history time and again in our longmore efficient use of fibers. It will also

And the new PTC, internationally ac-

tradition as an independent family

enable paper quality improvements

claimed in expert circles, will ensurecompany. The new Paper Technology

with still greater benefits both for end

that we uphold our lead in industrial

Center will play a decisive role in as-

users and finishing plants. The de-performance, research and develop-

suring not only the future of Voith but

mands of our customers today forment.

also the future of our customers.

new and better papermaking solutions
are higher than ever before.This Paper
Technology Center will help us tomeet those demands in our role as
pathfinder for the paper industry.

10

22 I 2006 I Voith Paper I twogether

INTERVIEW

Voith Paper Technology Center –A vision becomes reality

Interview with Ulrich Begemann,

twogether: How was the PTC idea

Begemann: To succeed in our busi-

Managing Director Voith Paper

born?

ness, we must respond to market
needs immediately. For this our R&D

Technology Center GmbH
Begemann: Our customers’ require-people have to be in continuous

ments have changed a lot over thecontact not only with customers but

last few years; to book orders today,

also with their design and marketing

we have to offer an overall concept

colleagues among many othermeeting their needs in full. Cost-

departments. And all of them are ineffectiveness, productivity and highHeidenheim. Another point is that not

quality play a key role thereby.

everyone likes changing workplaces,
and we might have lost some good

And this naturally makes higher de-people if that had been necessary.

mands on our research capabilities.
To assess the overall effect of inno-

twogether: How will Heidenheim

vations, we must reproduce thebenefit from the new R&D center?

papermaking process as realisticallyas possible right from stock prepara-

Begemann: Big research institutes

tion to paper finishing. This has notwork today in networks, and thisbeen possible anywhere in the worldoften attracts new businesses. The

until now. Voith saw in good timetransfer of Voith Paper Fabrics R&D

the opportunities opened up by thesefrom Pfullingen to Heidenheim is amarket charges and energetically

typical example. As another benefit,

realized the PTC vision with creative

this also safeguards jobs in Heiden-

enthusiasm.

heim, where the Voith Paper Technology Center GmbH employs about

22 I 2006 I Voith Paper I twogether

twogether: How long ago was that?

140 people.

Begemann: We first had the PTC idea

twogether: Why is the Heidenheim

in 1999.

region called “Paper Valley”?

twogether: Why did you finally decideBegemann: Because here we haveon Heidenheim as a location?

the world’s best paper industry

11

INTERVIEW

research center by far. For the firstfrom a deeper insight into the entire

twogether: In what respects was yourtime we can now conduct full-scale

papermaking process.

PTC project team so outstanding?

cess, integrating all its key disciplines

twogether: What problems did you

Begemann: Enthusiasm for an unusu-

because Voith Paper Fabrics works

have to tackle while realizing thisal project, fast decision-making, thehere with our cooperation partners

project?

ability to plan untrodden paths intests on the entire papermaking pro-detail, and an excellent team spirit at

BASF, Siemens, OMYA and Cargill.
Begemann: Since this is a paper tech-

all times, even under time stress.

twogether: How do you work withnology research center, not muchthese four cooperation partners in theof the project was standard practice,

twogether: What are you particularly

new PTC?

and a good many solutions had toproud of in this project? What is yourbe worked out as we went along.

personal highlight?

Begemann: On the one hand they are

For us these were more of an exciting

free to carry out their own tests here,

challenge than problems, however.

Begemann: Actually there are twohighlights. One of them is the combi-

and on the other hand we shall work
together on joint projects such as

twogether: What motivated you tonation of our new PM 6 test machine

investigating the effects of chemical

carry on when things got tough, aswith a “fiber design” facility. This en-additives on the papermaking

they certainly did sometimes?

ables customers for the first time tovary their stock characteristics andprocess.
Begemann: We knew right from thesee the effects on the finished paper

twogether: How will Voith’s partners

beginning that putting our PTC visionstraight away. The other highlight isbenefit from the new PTC?

into practice was the right decision –the modularity of the PM 6 test facil-in fact the only way to stay abreast

ity, which enables entire paper ma-

Begemann: Our partners have aof market needs. It was really fantas-

chine sections to be exchanged in astate-of-the-art paper machine test

tic to see the dream coming true

very short time. That gives our cus-facility at their disposal. Thanks to

before our eyes, and that’s what kept

tomers the possibility of developing

this and through cooperation with us

us going through all the weeks andand testing completely new machine

and Voith customers, they benefit

months of hard labour.

concepts.

1222 I 2006 I Voith Paper I twogether

INTERVIEW
twogether: Did you have any ideas

Begemann: We now will focus more

Begemann: I’m sure he would bethat could not be put into practiceon our R&D work, and shall work harddelighted to see that Voith still finds

yet?

on making everything run smoothly

innovations so important and perhaps

in the PTC. That is quite a challenge,

even more decisive: that we are stillrather like running a paper mill.

investing in innovation. Because all

Begemann: No, we managed toreach all our goals so far. The next

those years ago, his strategy was tothing will be to put our customers’

twogether: How will Voith customers

stay ahead through a creative andideas into practice here.

profit from the PTC?

open attitude to innovation. It was

twogether: Building the new PTC

Begemann: All papermakers have

was Voith’s biggest investment togoals for perfecting their production

date. How will it pay off?

processes and products, and natu-

twogether: How would you summa-

not by chance that he was called the“inventor from the Swabian Jura”.

rally for getting the most out of their

rize the new R&D center in only three

Begemann: To continue with organic

raw materials. Now for the first timewords?

growth as planned, Voith needs toin the history of papermaking, ourdevelop innovations benefiting ourcustomers can test under realistic

Begemann: Innovation, realness,customers significantly. Such innova-

conditions production processes that

customer-benefit.

tions generally consist of completely

are completely different to their own.

new products and processes, andtwogether: How do you visualize thewe need the PTC to prove to our

They get results rapidly and can takecustomers that they work.

them home with them.

twogether: You have taken the first

twogether: What do you think Johann

customers enthusiastically put theirstep by opening the new PTC. What

Matthäus Voith would have thought

visions into practice with Voith. And

will you do with it now?

of the new PTC?

I am sure that will soon be the case.

future of the PTC?
Begemann: As a place where our

The spectacular unveiling of the new Paper Technology Center on the evening of May 10, 2006.

22 I 2006 I Voith Paper I twogether

13

REPORT

Partnershipis the key to successInternational Customer Conference on Graphic Papers
This year’s Voith Paper customer conference in Ulm Congress
Center, entitled “Life Cycle Partnership”, was attended bymore than 550 guests from all over the world. The expert
discussions of topical themes at this first-class conference
soon showed very clearly that for sustainable success intoday’s tough global market, trusty partnership between
paper machine suppliers and papermakers is indispensable.

14

22 I 2006 I Voith Paper I twogether

REPORT
The symposium was expertly moderated
by Alexander Wassermann,
Senior Vice President Sales and Marketing
Paper Machines Graphic.

Trade press conference

informal get-together. Greeted by

overview. They were presented with a

Tuesday May 9, 2006

Kurt Brandauer, Executive Vice Presi-

systematic concept of presentations

dent Graphic Paper Machines, andcentering around the interests ofAt the international press dialogue,

Bertram Staudenmaier, Member ofVoith customers themselves: eachmeanwhile established as a tradition-

the Corporate Management Board

session was focused on upholding

al kick-off to these conferences,and Executive Vice President of Voith

their sustainable success in today’s

Voith Paper’s exciting new develop-

Paper, everyone gathered for a cock-fast-moving paper markets.

ments were released to the public.

tail reception with dinner buffet.

Voith Paper president Dr. Hans-Peter

The conference schedule was well

Sollinger and members of the corpo-

While savouring international cuisine

designed to hold their attention,

rate management discussed the Lifeand wines in this relaxed atmosphere,by dividing the Life Cycle Partnership

Cycle Partnership principle with re-some lively discussions ensued bothconcept into four paper machine

porters, and revealed some secrets

between old business friends andrelated phases: Grow – Improve –of our latest innovations. Interest was

new acquaintances. It must be very

Reposition – Sustain.

principally focused of course on the

seldom that so many key representa-

imminent opening of our new Paper

tives of the paper industry worldwide

Our slogan “Voith Paper – a perfect

Technology Center (PTC).

have such an opportunity to meetpartner at any time” aptly illuminates

together.

the concept of Life Cycle Partnership,

Get-together evening
Tuesday May 9, 2006
After very long journeys in somewhich is indispensable for optimal
Conference sessions:customer support in all markets. Such

Life Cycle Partnershippartnership with the supplier enables

Wednesday May 10, 2006

mutual identification of the mostcases, the 550 invited guests repre-

profitable solution for the customer insenting 189 companies in 31 coun-

Punctually at 9 a.m. all 550 partici-

all phases of the paper production

tries on four continents were heartily

pants met again at the congressline life cycle.

welcomed on the first evening at ancenter for the official welcome andTrade press dialogue with the Voith Paper Board and management members.

22 I 2006 I Voith Paper I twogether

15

REPORT

Prior to the four phases we added

the future challenges facing the paper

Spectacular gala evening in theanother one: “Consult” – because

industry, and how Voith Paper is al-

Donauhalle, with live video

success already depends on sorting

ready teaming up with customers andtransmission from Heidenheim

out the best ideas before starting on

strategic partners to work out appro-

project development. And Voith

priate solutions.

Paper as a truly experienced partneris invaluable at this stage.

This gala evening in the festively
decked auditorium was staged as aDr. Hans-Peter Sollinger vividly

spectacular journey through the vari-demonstrated in his presentation how

ous epochs of papermaking history.

The presentations given by our cus-

Voith Paper will put the key to the

The technological milestones marked

tomers authentically confirmed that

future in customers’ hands. Further

in this impressive show were accom-

Voith Paper is certainly following theto the now familiar One Platform

panied down the ages by gourmet

right strategy with Life Cycle Partner-

Concept – modular overall solutions

delights from China, Japan, theship. Some customers joined Voith

for all papermaking processes and for

Arabian-Moorish world and Spain,

speakers on the platform to explain

all grades – Voith Paper now takes

including Gutenberg’s times and the

how well their partnership with Voith

another big step into the future withindustrial revolution. Star of the show

Paper had paid off in their various

customers. “And the key to the future

at all times was of course paper itself.

projects. During question time after-

is our strength to be innovative”,

wards, our guests received clear

summed up Dr. Sollinger as an intro-

At 10 p.m. the excitement rose toanswers from Voith Paper experts on

duction to the new Paper Technology

fever pitch when our host in Ulm,

many interesting points. The entire

Center.

Dr. Sollinger, interrupted this journeyconference was moderated extremely

through time by returning to the here-capably and in an entertaining man-Indeed, the new PTC opens up un-

and-now. He invited the gala audi-

ner by Alexander Wassermann,limited possibilities for Voith Paper

ence of more than 650 guests to takeSenior Vice President Sales andcustomers to turn our common

a trip into the future of papermaking:Marketing Paper Machines.

visions into reality (see page 4).

to Heidenheim in Paper Valley –just in time to witness “live in Heiden-

Later on in the afternoon, our enthu-

With this vision statement, the pro-heim” the PTC unveiling ceremony.

siastic audience were shown Voith

ceedings concluded to resounding

Dr. Hermut Kormann, Chairman ofPaper’s vision of the future. Ulrich

applause and with high spirits in

the Board of Voith AG, was conjured

Begemann, Managing Director Voith

anticipation of the gala evening to

on screen in Ulm by video link,

Paper Technology Center, explained

follow.

together with Ulrich Begemann,

Question time in the Ulm congress center auditorium.

16

22 I 2006 I Voith Paper I twogether

Dances from the Arabian-Moorish epoch.

Managing Director Voith Paper Tech-birth of Paper Valley. And throughnology Center, and 1,200 jubilant

Paper Valley a veritable flood ofVoith people with guests against theinnovations will soon be flowing!”.

background of the veiled PTC.

With these historic words Dr. Hermut
Kormann summarized the epoch-

Grand finale at the gala evening: the“Paper Diary Song”.

Amid outbreaks of spontaneous ap-

making significance of the new Paper

plause in Heidenheim and Ulm, allTechnology Center.

our guests in both places were able
to witness the spectacular unveiling.

A large PTC key was then handed

A particular highlight of this event

over symbolically to Dr. Kormann as

was the specially composed “Paper“Key to the Future”. And that was

Diary Song”, poetically telling thethe end of the show in Heidenheim –story of paper and its importancebut in Ulm we all sat back to enjoy

for mankind and our cultural future

our gala dessert...

around the globe.
...until another surprise at 11 p.m.

22 I 2006 I Voith Paper I twogether“Today is a big day for Voith andwhen Dr. Kormann and Ulrich

Heidenheim: we are witnessing theBegemann suddenly appeared on

17

REPORT
Chinese acrobatics
from the birth of papermaking.

stage to greet us all in person. Thenfollowed the culminating highlightof the evening: Dr. Kormann handed
over his “Key to the Future” to
Dr. Sollinger, who proudly held it aloft
and announced “Here it is everyone!
We have it!”. After this moving “keyscene”, Dr. Hans-Peter Sollinger
passed on the key to Ulrich Begemann – now in charge of PTC operations – ready for opening the doors
next day to an inaugural tour by ourguests.
In this way “The Key to the Future”
was symbolically handed over to ourcustomers; for it is they, who in partnership with Voith will make the new
PTC a center of innovation meetingthe future needs of the entire paperindustry.
It goes without saying that after enjoying such a successful symposium
and exciting gala evening, our guests
retired in eager anticipation of thePaper Technology Center inauguration and tour on the following day.

Contact
Anja Lehmann
Marketing Paper Machines
Graphic
anja.lehmann@voith.com

18

22 I 2006 I Voith Paper I twogether

TECHNOLOGY

The paper quality is
not only confirmed bya visual control, butalso by the printers’
judgement: It’s firstclass!

Stora Enso Kabel OLC 5 – Quality creates satisfaction
The Stora Enso mill Kabel is one of the most modern and efficient
production sites of the Stora Enso Group. This was accomplishedby a consistent development of the OLC 5.
The start-up of the offline coater was

ed by two JetFlows, which werein 1980. The quality measurement

delivered by Voith as well.

system was replaced for the first timein 1988. In order to increase the oper-

Market requirements andating speed and to improve the run-existing old technology forced

nability, the applicator roll coaters

modernization

with blades were changed in pairs
step by step. In fall 1999, the two

In 2005 Stora Enso intended to equip

pre-coaters were equipped with Voith

its Hagen Kabel mill with a new

SpeedCoaters for one-sided coating.

quality control system because their
existing system was outdated. At that

22 I 2006 I Voith Paper I twogether

In 2001, the OLC 5 applicator rolltime the CD profile control has beencoaters for top coating were extend-done manually. Beside that techno-

19

TECHNOLOGY

JetFlow F
with 76 OnQ ModuleCoat
actuators

Winding

OnQ Scanner● Basis weight● Moisture● Temperature

Coating concept OLC 5

logical aspect the modernization was

Additionally, Stora Enso requested

Because different applicators are in-also the response to an increasingthat the new system will perfectly fit

stalled in the OLC 5 with the Speed-

market volume for rotogravure print-

into the existing coating concept.

Coater for primary coating and theing and a trend to wider rolls. At the

Furthermore, they set value on a con-

JetFlow F BladeCoater for the top

PM 5 and the SM 5, high quality

tinuous service support by high-classcoat, the mechanical effects of thecoated wood-containing paper forexperts over the whole life span ofapplicators were included together

offset and rotogravure as well as

the quality control system. In all thesewith the theoretical analysis in thecoated cut-size offset is produced.

mentioned points the concept of

specification of the ideal actuator

It is mainly used for magazines, cata-Voith Paper for the modernization ofwidth.

logues, flyers and advertisements,

the OLC 5 convinced management,

but also for school books, calendars

papermakers as well as C&I engi-

and business reports.

neers of Stora Enso.

“Perfect fit” solution
The result was a custom-made OnQWith the new quality control system,

Systematic approach forapplication solution for the OLC 5,

Stora Enso intends to meet the mar-excellent results

focussing on the specific customer

ket challenges and to improve its
competitiveness.

requirements with a clear defined ROI
To get a deep insight Voith special-by means of a quality improvement.

ists analysed first of all the whole
OnQuality fulfilled Stora Enso’s

process. By using a Fourier analysis

The two SpeedCoaters for pre-coat-high demandsof the CD-profiles the ideal actuator

ing were equipped with the OnQ

width was determined and the ex-

ModuleSpeed system with 38 actua-

Stora Enso was looking for an auto-

pected CD-profile deduced. This wastors each (200 mm actuator width)

mation partner who was able to fulfill

the basis for Voith to guarantee Stora

whereas both of the JetFlow F blade

the following project requirements:

Enso specific 2-sigma values. Addi-

coaters were retrofitted with the OnQ● state-of-the-art sensor technology

tionally, a simulation of the start-up

ModuleCoat system with 76 actua-● a convincing control strategy

curve of the OLC 5 was done to pre-tors (100 mm actuator width). The● a reliable design of frames anddict the settling time. Based on thispreceding evaluation showed that inanalysis, the concepts for the MD-

this case a shorter actuator width

controls were configured as well.

with 75 mm would only have led to aactuators● and best cost-efficiency ratio.

20

22 I 2006 I Voith Paper I twogether

TECHNOLOGY

SpeedCoater with
38 OnQ ModuleSpeed actuators

OnQ Scanner● Basis weight● Moisture● Temperature● Optional sensor

Unwinding

FFT analysis of coat weight CD profiles

marginal profile improvement. Bothactuator systems are controlled by
the well proven Profilmatic control
software. The quality control concept
was topped by the coordinatedspeed change control and a special
start-up control for the OLC 5.

The frequency analysis of the coat weight profiles breaks down the measured, typical coatweight CD profiles into the intrinsic harmonic
fluctuations and determines their proportions in
the overall profile. An optimum actuator width
can be determined according to the frequencies
occurring in the CD profiles. The phase shift
between the operating points of the actuatorsand the sinusoidal fluctuations is important to
the effect of the actuators.

Furthermore, the existing scanners
were replaced by five new OnQ Scanners. The sealed scanner structure
and air purge help stabilize the beamPresuming that the phase shifts of all profile
fluctuations are evenly distributed, three times
the actuator width can be used as an average tocalculate the minimum controllable frequency.

temperature to prevent contaminants

compressed air.

The initial measured profile and the number of
databoxes are decisive for determination of thetheoretical potential for improvement. At least
3 databoxes should be measured for each actuator width. Furthermore, the chosen actuator
width determines the possible improvements.

The first OnQ Scanner was installed

1.5

directly after the unwind. It measures

1.0
0.5

from entering the mechanical andelectronic components. The highaccuracy at the OLC 5 is further enhanced with flushing the sensors withbasis weight, moisture and tempera-zone widthzone width
effectRegarding the overall variance in the paper, thisis composed of the CD profile fluctuations, theMD fluctuations and a remaining fluctuation. The
remaining fluctuation includes all high frequencies, which cannot be regulated by CD or MD
control. In a profile with a large number of
databoxes, the proportion of the remaining fluctuations is higher than in a profile with a low
number of databoxes. The reason for this is thata low number of databoxes acts as a data filter.
A high number of databoxes reveals high-frequency fluctuations in the analysis. The numberof databoxes is a decisive factor in the examination of the potential improvement percentage.
For this reason, it is appropriate to relate thepotential improvements for all considerations toa previously defined number of databoxes andnumber of actuators.

1,5
1,0
0,5

zone
width
effectzone
widtheffectzone
widthture of the base paper and offers op-

0.0
-0.5

tional space for an additional sensor.

-1.0

The other four OnQ scanners are

-1.5

-1,5

Phase equivalence between the operating
point of the actuators and the sinusoidal
fluctuation: Only 2 actuator widths are
required to compensate the frequency.

90° phase shift: 4 actuator widths are
required to compensate the frequency.

placed after the coaters and the subsequent dryer section respectively.
They are each equipped with a basis
weight sensor based on krypton, an

22 I 2006 I Voith Paper I twogether

effect

0,0
-0,5

zone
width

-1,0

effecteffect21

TECHNOLOGY

Predicted Profile with CD Control
8

7.5

7
0

50

100

150

200

250

CD Databoxes
Predicted CD Profile
Original CD Profile

Predicted CD profile to determine the room for improvement
at the OLC 5.

The OnQ Scanners incorporate sturdy box-frame constructionthat provides inherent dimensional stability.

infrared transmission moisture sensor

direct moisture measurement without

The automapping algorithm of theas well as a temperature sensor. Alla separate basis weight sensor com-

Profilmatic control software continu-

sensors use CAN Bus technology forpensation. The simultaneous mea-

ously aligns the measured data of thehigh-resolution measurements.

surement of all four channels is done

profile with the respective actuatorby beam split techniques.

position. This ensures uniform coat-

The basis weight sensor with Krypton

ing. The “mapping model” adapts tosource is based on solid-state silicon

The OnQ Quality Control System istechnology. Its high signal-to-noise

supplemented by a control package,

ratio allows fast, precise profile mea-

which is especially aligned to theFirst-class results at all

surements. Furthermore it allows

needs of the Kabel mill. The combi-

four coaters

web flutter detection as the measure-nation of coating unit, Profilmatic

ment cone gets larger when the web

control software and dedicated

The improvements after the installa-

moves towards the transmitter.

actuator system of the OnQ Module-tion of the new quality control system

A x-y-z measurement compensation

Speed and the OnQ ModuleCoat

at the OLC 5 are really significant.

is possible as well.

respectively ensures that the high

The reduction of the 2-sigma varia-

requirements regarding the paper

tions is even better than predicted.

quality can be fulfilled.

The primary improvement appeared

DynaComp dynamic standardizationcompensates for dirt accumulation at

the measured modification.

at the coating profiles which resulted

the end of each traversing (typically

The OnQ ModuleSpeed actuator isafter every second traversing). There-

the centerpiece of the SpeedCoaterby, the standardization cycle can bewhile the OnQ ModuleCoat is

Furthermore the settling times of theretarded up to 12 hours and the mea-

designed for blade coaters and is

OLC 5 after a sheet break are nowa-

suring carriage is outside the web forequipped with a second direct posi-days a lot shorter as before the in-a shorter time.

tion measurement in addition to thestallation as the modern OnQ Quality

encoder.

Control System enables flat profiles

The infrared moisture measurement isin better moisture CD profiles as well.

within ten minutes after start-up. By

a fast and precise same-spot mea-

The additional position response via

improving the paper quality in thissurement with four channels for direct

LVDT (linear variable differential

way, the Stora Enso mill Kabel wasmoisture and fibre weight measure-transformer) provides absolute safety

able to significantly improve the cus-ment. The used technology allows a

to protect the profile ledge.

tomers’ satisfaction due to:22

22 I 2006 I Voith Paper I twogether

TECHNOLOGY

0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
2-9-2005
End of installation

2-10-2005
11:15 amStarting up with thesame functions as theolder system

2-10-2005
5:40 pm
Scanning with coatedpaper

2-11-2005
7:00 am
Saleable paper andstart of optimisation
phase

After finishing the assembly phase the whole project was realized within only three days.

● fewer coating defects

the described process analyses in the● better gloss profile

calculation of the ROI and the quality● improved flatness

parameters as well as in the assess-● uniform moisture content

ment of the results. It was also pos-

● better printability.

sible to achieve an optimum adjust-0
Coater 1

Coater 2

No Control

Coater 3

Coater 4

June 2005
July 2005
August 2005

Comparison of the monthly average valuesof the 2-sigma profile fluctuations of the coatweight from the parent roll reports (threemonths prior and after the installation).

Customer Comment
Andreas GenzManaging Director
Stora Enso Hagen
Kabel

ment of the mechanical components
The Stora Enso example shows that aof the CD profile actuators of themodernization of the QCS means

OLC 5, so that the installation of themuch more than just to keep a plant

control unit could be conducted as aalive. For Stora Enso Hagen Kabel

complete unit on the existing coater“We deliver high quality coated wood-

the realization of this project is an-

beams.

containing paper for offset and rotogravure as well as coated cut-size offset.

other step to consolidate and even to
The entire scope of supply for theWith the new OnQ Quality Control System

OLC 5 with measuring frames, asso-

by Voith Paper we had a significant

Customer benefits from

ciated sensors, MD controls, actua-

improvement of the paper quality. Our

teamwork of the Voith Paper

tors, Profilmatic CD profile control

customers are highly satisfied today

divisionssoftware and the subsequent service

because the quality constancy, the sur-were provided exclusively by Voith

face properties as well as the printability

The assessment of the project also

Paper. The advantage for the cus-of the paper fulfills highest demands.”

reveals the strength of Voith Paper:

tomer was to have a competent auto-

the combination of the knowledge ofmation partner at all times, in all mat-

Voith Paper technicians regarding theters regarding the project and without

coating process with automation

go-betweens.

extend their market position.

know-how permitted a “perfect fit”
solution to be implemented and the

To ensure that the results remain as

project to be completed with secured

perfect as they are now, specialists

funding and deadlines for Stora Enso.

from Voith Paper will support theservice and maintenance team on

The paper technicians were involvedsite for the entire life cycle of thefrom the beginning of the project withmachine.

22 I 2006 I Voith Paper I twogether

Contact
Friedrich Schröder
Automation
friedrich.schroeder@voith.com

Jürgen Frank
Automation
juergen.frank@voith.com

23

TECHNOLOGY

Thune screw presses for sludge –the innovative screw press design for high dry contents
In almost every pulp and paper mill sludge is generated and has
to be taken care of. Squeezing out as much liquid as possible
before final disposal is of utmost importance in order to fulfil
environmental legislation within economically reasonable limits.
Voith now has an advanced screw press specially designed forsludge dewatering in its product portfolio.

24

22 I 2006 I Voith Paper I twogether

TECHNOLOGY

New revolutionary design

lower than the same size Thune pulp

Thune screw press for sludge

presses. And the dewatering per
On starting design work for the Thune

screen area must be higher than forscrew press for sludge some funda-

comparable sludge presses on themental criteria were obvious. The ma-market.

chine must be sufficiently robust and• Screw press centerline is close to the foundations for minimizing deflection• Main components are integrated into themachine frame for even distribution of forces and for a very robust and stable machine

stable to withstand the high torques

In the new design, the forces gener-

generated when squeezing out theated when squeezing to maximum

maximum amount of liquid fromdryness are distributed much moresludge. Operation must be easy andevenly over the machine length thanreliable. Bearing in mind the high wear

is the case with conventional screw

often seen in sludge applications,presses. This is achieved by integrat-

With 80 years of accumulated experi-

easy maintenance is also a crucial

ing the discharge housing, inlet sec-ence in designing screw presses thefactor. And to be competitive, thetion and screen supports into theThune design engineers have, ofcost per ton of sludge treated mustmachine frame. In addition, the cen-course, also designed a very service-

be acceptable for the customer.

treline of the complete screw press

friendly machine and built in sound,• Robust bearing arrangement enables
reverse operation at full loadLess segments.

some secondary criteria also needed

The result is a very robust and stable

to be defined. Total weight of themachine with minimum deflection,

sludge presses must be similar to oreven at the highest torques.

MuHeight = 895 mm

proven technology such as the Wear-chine height above the foundations.

Height = 270 mm

has been lowered to minimize maTo comply with these basic criteria,MuThune screw press for sludge.

The Thune screw press for sludge(on the left) compared with a standard
screw press.
With the new Thune design for sludge,
the height of the press above the foundations has been radically reduced.

22 I 2006 I Voith Paper I twogether

25

TECHNOLOGY

Voith product manager Lars
Smedsrud with his new baby at
Adolf Jass, Schwarza, Germany.

Customer CommentHåkan Ohlsson
Production Manager,Örebro Kartong,
SwedenDischarge consistency (%)

57
55
Without bio-sludge
53
51

With bio-sludge

49
47
45
30

35

40

45

50

55

60

Torque (%)“When we needed to replace our old wireFirst installation of an SPS70

tinuous operation and after only twopress we entrusted Voith Paper in Norway

screw press for sludge

months it was already operating bet-

to supply the new sludge dewatering sys-

26

65

Discharge consistency in the Thune
sludge press obtained at different
torque settings.

ter than the expected values. All finetem. From the very first project meetings

In February 2005 the first Thune

rejects and sludges in the mill are fed

we have had only positive experience withscrew press for sludge started up at

to the Thune sludge press for final

the service and the Voith people involved.

the Adolf Jass Schwarza mill nearmechanical dewatering. Fine screen

Even with sludge tonnages considerably

Rudolstadt in Germany. This green-

rejects, DAF rejects and bio-sludge,

above the guaranteed values we havefield mill, for which Voith delivered

are fed via a Meri BlueDrain gravity

stable operation and only minimum atten-

the entire process technology fromtable to the Thune sludge press.

tion is required. With the service agree-

stock preparation to winder, produc-

Cleaner rejects and pre-screened

ment recently signed with Voith Paper we

es fluting and testliner from 100%

sewer material are sent to the Thune

expect the system to continue its success-recovered paper. Since start-up, thesludge press after pre-dewatering in

ful operation for years to come.”

SPS70 sludge press has been in con-a Meri Sediphant.

22 I 2006 I Voith Paper I twogether

TECHNOLOGY

WearLess segments are mounted
on the last screw flight at the discharge end of the screw press.
Different wear-resistant materials
are used, based on the application
requirements. Replacing a worn
segment with a new one takes only
a few minutes and with the bolt-on
solution the segments are always
exactly positioned.

Material flow.

risk when agreeing to include a pro-included all necessary pumps, valves,

totype in a project, but without confi-

instrumentation, piping, foundations

dence in a new product winners are

etc. as well as local PLC for control

not made!

of the system, making it a complete
supply package. The system, which

Variations in feed to the sludge press

System supply capability

control system. In this way a constant

The dewatering group at Tranby

discharge consistency is obtained forsupplies screw presses for sludge

varying sludge flows and different

not only for large projects. The groupsludge compositions.

also has the capability to take on
smaller system supplies in the sludge

Voith Paper’s headquarters for dewa-

dewatering business. One such exam-

tering technology in Tranby, Norway

ple is the system delivery to Örebro

would like to express thanks to all

Kartong in Sweden (see Customer

the people involved at Adolf Jass

Comment on page 26) where a sys-

Schwarza for their support and assis-

tem consisting of a Meri Elephanttance in helping to make this a suc-filter and a Thune screw press werecess story. There is always a certain

the main components. The delivery

22 I 2006 I Voith Paper I twogether

replaced an old wire press, has now
been running smoothly for more thanare handled by an integrated torque

two years.

Contact
Lasse Norli
Fiber Systems
lasse.norli@voith.com

Lars Smedsrud
Fiber Systems
lars.smedsrud@voith.com

27

TECHNOLOGYExchanging the refiner fillings of a
TwinFlo TF1D double disc refiner.

Voith Paper Vaassen –Wear-proofing for rotors and more...
In view of the considerable cost pressures facing the paper industry, it is increasingly important to reduce life cycle costs. The Voith
Paper Fiber Systems Division responsible for stock preparation
not only offers highly efficient machines for optimal fiber yield withminimal fiber losses and energy costs. The Division also offers
extensive services to help papermakers reduce their stock preparation costs without sacrificing machine efficiency.

28

22 I 2006 I Voith Paper I twogether

TECHNOLOGYOver the last fifteen years Voith Paper

Multi-layer hard surfacing for

B.V., Vaassen, Holland has accumu-

high wear resistance

lated extensive know-how in refurbishing pulper and flat screen rotors.

Voith Paper Vaassen’s modern hardThis small, efficient and customer-

surfacing technique consists of ap-

oriented subsidiary of Voith Paper

plying a material which is wear-resis-

Fiber Systems GmbH now manufac-

tant, reweldable, and resistant totures and overhauls more thancorrosion and cracking. A buffer layer

400 rotors every year. In the mean-stops any cracks that may develop

time, Vaassen’s specialized know-

in the wear-resistant top layer during

how is available practically through-operation from extending into theout the Voith organization, so thatbase material. This prevents crack-

customers have this wide range of

induced fracture of the rotor blades

services available to them worldwide.

during operation, and ensures optimum wear protection at the same

Robot welding technology
for repairing rotors.

Rotor repair throughtime.

hard surfacing
Voith Paper Vaassen provides a lifePulper and flat screen rotors operate

time guarantee against rotor blade

under corrosive and abrasive con-fracture due to cracking, provided

ditions and are therefore subject tothe manufacture and all subsequent

wear. Voith Paper Vaassen repairs

repairs of the rotor have been under-these rotors by hard surfacing. Thistaken exclusively by Voith Paper

restores the original geometry of the

Vaassen.

rotor blades and provides them withwear-resistant edges, thus achieving

Innovations in material

an optimum between operating costs

and process technology

and technological performance.
Voith Paper Vaassen continuously reThe company has access to con-searches new methods and improved

struction drawings of all types ofmaterials for providing even better

Voith rotors and of most non-Voith

hard surfacing, including a proprie-

rotor types. Restoring the blade

tary welding wire manufactured ex-

geometry to the original condition

clusively to Voith Paper specification.

ensures the technological function

22 I 2006 I Voith Paper I twogetherof the rotor in stock processing is

A new technique has been developed

maintained without limitation. Thisfor hard surfacing rotors using a

specialized knowledge and extensive

welding robot. This provides repro-

experience distinguishes Voith Paper

ducible restoration of the original

Vaassen from its competitors.

rotor blade geometry.

29

TECHNOLOGYThe Voith Paper B.V.
Service Center in Vaassen,
Netherlands.

Another speciality is the repair ofan extremely high wear-proof surface

screws for reject, fiber and sludge

that ideally combines material hard-presses by hard surfacing using spe-ness and ductility. This prevents

cial wear-resistant welding material,material breakaway problems that

thus considerably extending operat-

can occur with some products.

ing life.
Maintenance of stock
The repair methods and material

preparation machines

specifications used by Voith Paper
Fibersorter rotor.

Vaassen have been taken over as a

Many papermakers still maintain andVoith Norm for Voith Fiber Systems

repair their own stock preparation

Service Centers worldwide. Thismachines. However, more and moreensures a uniform high quality for all

mills are coming to Voith Paper Fiberrotor and screw repairs.

Systems because of our day-in, dayout maintenance work and vast expe-

Manufacture of rotors

rience from thousands of installations
worldwide. Our knowledge of specific

Voith Paper Vaassen’s welding ex-

system behaviour in plants handling apertise also includes new rotor pro-wide variety of fibers is a further sig-

duction. A welding robot using twonificant advantage.

welding processes – MIG (Metal Inert

30Gas) and PPAW (Plasma Powder Arc

Customers benefit not only from get-

Welding) – provides new rotors withting their machines back on line again

22 I 2006 I Voith Paper I twogether

TECHNOLOGY

faster, but in many cases we can also

Examples of such service contracts:

offer small but effective innovations● Board and packaging paper mill into these machines. Longer operating

the UK.

life, greater reliability and better stock

Since 2000, all rotors have been

preparation results are only some ofrepaired in Vaassen. Transport

Voith Paper Fiber Systems’ contribu-

costs and technical support for thetions to life cycle cost reduction.

customer are included.
● Board and packaging paper mills in

Using a special checklist, our engi-

the Netherlands and Germany.

neers assess both Voith and non-

Maintenance of UniPulpers. In bothVoith machines to identify problems.

agreements, a spare rotor is madeThe customer then receives a precise

available to the customer for a

description of the state of his equip-

period of 5 years. At planned inter-ment before and after maintenancevals, other wear parts such as

work. Any measures that might havescreen plates, screen plate bars,

to be taken in future are also dis-packings, etc. are delivered andcussed, such as general overhaul

installed.

work, repairs or rebuilds.

● Tissue mill in the Netherlands.
Complete maintenance of 10 stock

Service contracts

preparation machines over 5 years,
including delivery of wear parts,

A growing number of customers haveavailability of spare parts, and alltheir machines maintained on a con-maintenance and repair work.

tract basis with Voith Paper. These
service contracts can be either allinclusive (including maintenancework, spare parts, repairs, replacements, overhauls, etc.), or may only
cover some of these aspects. IndiUniPulper rotor.

Contact
Remy Habets
Fiber Systems
remy.habets@voith.com

vidual parts, such as rotors and bearing assemblies, can be made available to the customer for the durationof the agreement. The repair andoverhaul of these components then

Gerard Wekking
Fiber Systems
gerard.wekking@voith.com

forms an integral part of the contract.
Typical for such agreements is a fixedmonthly payment for the duration of
the contract.

22 I 2006 I Voith Paper I twogether

Geert Tichler
Fiber Systems
geert.tichler@voith.com

31

TECHNOLOGY

From idea to installation – Market launch of an
innovative pulp bale dewiring machine
At the beginning of 2005 the engineers at Voith Paper Euskirchen,
Germany (formerly B+G Fördertechnik) started development workon a new dewiring machine for single pulp bales. While the existingmachine had a high capacity, it no longer satisfied the other parameters of modern handling technology. After a detailed evaluation ofcustomer needs and market demands, the development objectivesof optimal capacity and dewiring efficiency at reasonable cost were
established.

The new concept should also incor-

project enquiry for an automated pulp

porate well-proven components suchbale dewiring machine. We therefore

as the wire cutter and coiler head

had to decide which machine to offer,of the unit dewiring machine. These

particularly with such a short delivery

initial considerations were soon

deadline of only six months. We no

converted into sketches and draft

longer wanted to offer the old version

designs.

– and we could not yet offer the new
one which didn’t even have a name.

32

At the same time our JapaneseIn the end we called it the BE-Z “C”

colleagues at Voith IHI received amodel, following on from previous

22 I 2006 I Voith Paper I twogether

TECHNOLOGY

model designations and reflecting its

all of them accepted our invitation,der. The bale wire locations are auto-

average capacity of 100 bales per

and returned home with a very posi-

matically detected by sensors which

hour. After joint discussions we gave

tive impression. We would have liked

position the coiler heads exactly

all available information to our Japa-

to continue with these customer

against the wires when the bale hasnese colleagues and put together ademonstrations, but unfortunately

been lifted into position. When thePowerPoint presentation. This was

our delivery deadline in Japan for thewires have been cut on the other sidethen adjusted and extended in Japanfirst machine did not allow this.

of the bale, the rotors in the coiler

to suit local market requirements.

heads then coil the wires into small,Seven weeks later – in Japan.

compact and easily handled bundles.

Our colleagues in the Land of the

Our commissioning engineer was

Rising Sun very quickly convincedhighly impressed when he arrived

After each cycle, all components

their client of the advantages of theon site in Japan. Not only was theautomatically return to their start

new bale dewiring machine and wemachine completely assembled andposition. At the same time the coils

received the order just three weeks

wired, but also fully operationalof wire are ejected onto a conveyor

later. This put our development

except for some small final adjust-belt for disposal in a container, andpeople under considerable pressure,ments. We were thus able to start

the raised bale is rotated throughsince the delivery date had alreadystraight away on the throughput and90° ready for dewiring on the second

been fixed.

dewiring efficiency guarantee trials,

side.

all of which the customer followed
When all the mechanical components

very attentively. The guaranteed

The most outstanding advantage ofwere ready in our Euskirchen works,

throughput was easily reached, andour new machine is its extremely highthe machine was completely wired

the dewiring efficiency of 98% won

dewiring efficiency. But all otherand started up. Everything worked

a standing ovation.

important features are in place, too:fine straight away so that we werethe usual very high reliability andable to invite other interested cus-

The operating concept of the new

runnability, a robust design, minimum

tomers to witness bale dewiring trials

BE-Z “C” machine is quite different

floor space and the very attractiveon their own problem bales. Nearly

from that of its predecessors. For the

price-performance rating.

first time, the complete range of modern handling technologies have been
incorporated into a single machine:
hydraulics, pneumatics, electric motors and servo systems.The travellingwire cutter unit is located on one sideof the machine, and the positionable
coiler heads on the other side. The
centrally located chain conveyor in-Contact
Frank Kern
Fiber Systems
frank.kern@voith.com

corporates an elevation platform withcombined lifting and swivelling cylin-

22 I 2006 I Voith Paper I twogether

33

TECHNOLOGY

Holmen Paper Madrid “Peninsular” –New world record start-up speed for newsprint machines
Holmen Paper AB commissioned their new Voith PM 62 standard newsprint machine intheir mill in Madrid, Spain, so successfully that it went on line in only five weeks – thanks
to the One Platform Concept with well-proven technology. The first test with stock onwire took place on November 11, 2005, and after thoroughly testing the wet and dry ends
under operating conditions, paper on reel was attained on November 13 – only 36 hours
later. The start-up speed of 1,640 m/min set a new world record for newsprint machines.

34

22 I 2006 I Voith Paper I twogether

TECHNOLOGY

Voith production lines currently operating at Holmen Paper
PM No.

Wire width (m)Capacity (t.p.a.)Paper grades

Hallsta Paper Mill

PM 2
PM 3

5.75
7.10

110 000
140 000

Magazine, letterpress
SC paperBraviken Paper Mill

PM 51

9.15

180 000

PM 52
PM 53

9.15
9.65

270 000
300 000

Telephone directory,
light newsprint
Newsprint
Newsprint

PM 62

9.65

300 000

Newsprint

Holmen Paper Madrid

Stable quality was achieved immedi-

eleven paper machines in these mills

1938, and from 1958 to 1967 threeately after first paper on the reel.

totals 1.8 million t.p.a. of coated andmore Voith machines were installed

After fine-adjusting the auxiliary sys-

uncoated wood containing printing

in Hallsta. At the Braviken mill threetems and CD/MD profile control, first-

papers, mainly for newsprint, maga-

new Voith paper machines started upclass saleable newsprint was alreadyzines and inserts, advertising materi-

between 1977 and 1996. PM 62 at

produced a few days later. Thanks

als and telephone directories.

the Madrid mill is the latest addition

to the ideal machine layout and very

to Holmen’s “Voith collection”.

high profile stability, runnability andOut of the fourteen Voith paper ma-

printing results were excellent rightchines sold to Holmen Paper during

Over the years, many of thesefrom the beginning.

the last 95 years, six are still in opera-

machines broke several world speed

tion. The long-standing partnership

records for newsprint production.

Holmen Paper – more thanbetween Holmen Paper and Voith

95 years of partnership withdates back nearly a century. The

Voith

company’s first Voith paper machine

Holmen Paper Madrid

went on line in Norrköping as long

The Papelera Peninsular paper mill,Holmen Paper AB of Norrköping,ago as 1911, followed by two further

built in 1998 by Grupo Unipapel, was

Sweden is, with 2,500 employees,

machines in 1927 and 1931. Three

acquired by Holmen Paper in 2000

one of Europe’s leading producers ofVoith paper machines started up

and renamed “Holmen Paper Madrid”.

printing paper. Apart from the Madrid

between 1915 and 1917 at Hallsta

The entire output of this mill, withmill, the three Swedish mills are

Pappersbruk, which, at that time,

more than 350 employees, is based

located in Braviken, Hallstavik andwas Europe’s biggest newsprint mill.

on recovered paper furnish mainly

Vargön. Production output of the

The fourth machine was added incollected in Spain and Portugal.

EcoCell deinking system, heart of the recovered paper preparation line.

22 I 2006 I Voith Paper I twogether

35

TECHNOLOGY

MultiSorter coarse and MultiScreen finescreening, with C-bar baskets and MultiFoil rotors.

TopDuoRun Drying section and Sirius reel.

The two paper machines (PM 61 andcludes a DuoFormer TQv with Voith

EcoSoftDelta softnip calender fitted

PM 62) can produce 470,000 t.p.a.

BlackStone S rubber roll covers, inwith Vantis S roll covers, that isof newsprint, uncoated and lightly

combination with a MasterJet G

equipped with gloss and CD thick-coated magazine paper, mainly forheadbox with OnQ-ModuleJet andness profile control and a steam blow

marketing on the Iberian peninsular.

Profilmatic control to ensure first-

box. This is followed by the state-of-class formation. The Tandem Nipco-the-art Sirius reel.

The new Voith machine that came on

Flex press, fitted with G2000 polyure-line in November 2005 has a design

thane roll covers, OnQ-ModuleSteamAll the parameters affecting winding

capacity of 300,000 t.p.a. newsprint

steam box, and transfer belt to thequality can be displayed and opti-

from recovered paper, with a basis

second nip, guarantees the highest

mized on the RollMaster control pan-weight of 40-49 g/m2. PM 62 has adryness content at optimal paper

el. Well-proven Fibron vacuum tech-wire width of 9,650 mm and a design

quality. Immediately after the press

nology enables ropeless tail transfer

speed of 2,000 m/min. The invest-

section is the OnQ-EnviroScan mois-

throughout this high-tech production

ment cost totalled 306 million Euro.

ture measurement system enabling

line, which is rounded off with two

fast-response control of sheet mois-

VariFlex winders with VariTronic

A One Platform Concept

ture content. The drying section isprocess control and a high-capacity

production line using

equipped with advanced TopDuoRun

Classic roll wrapping machine. Voith

well-proven technology

drying technology and with OnQ-

supplied the entire paper machine

ModulePro moisturizers for moistureautomation system including OnCon-

Based on the One Platform Concept,

cross-profile and curl control.

trol process control, OnQuality quality

this complete production line in-

The web finally passes through an

management system with MD and

36

22 I 2006 I Voith Paper I twogether

TECHNOLOGY

Roll wrapping machine Classic.

CD profile control, and OnView infor-

An EcoCell pre- and post-flotation

PM 61 had already secured Voith’smation system with trend recognition

deinking system forms the heart ofgood reputation within the Group.

and reporting functions covering all

PM 62’s recovered paper preparation

the machine and technology monitor-line. For dispersion Voith supplied its

Erection, commissioning –ing systems.

biggest DX disperger with the highest

and a picturebook start-up

production throughput up to now.
Apart from the paper machine itself,

The DX type disperger is designed for

The Voith erection team started tack-Voith also delivered the key compo-

direct steam heating.

ling this project in April 2005. Whennents critical for efficient operation of

the foundations were ready, the first

PM 62’s recovered paper deinking

An iConRet retention controller is

pre-assemblies were brought by spe-line and approach flow. The line has

installed in the Wet End Process forcial transport from the port of Bilbao

a capacity of 1,000 t / 24 h finishedoptimum retention agent metering.

to Madrid. Thanks to extensive pre-stock.

assembly in the Voith works, optimal
Voith took over the guarantees for the

product quality was assured with

Here Voith supplied a PreClean

complete deinking plant and ensured

minimal time spent for final assembly

Protector system to ensure effectivethat the required stock quality andon site. This enabled the punctual

stock cleaning, MultiSorter coarse

production were achieved directly

completion of erection by the end ofscreening with an integrated IC slot-

after commissioning, thus fitting in

September 2005.

ted screening module for optimum

with PM 62’s fast start-up perfor-

screening efficiency as well as Multi-

mance.Previous supply of the com-

In parallel to the erection work, aScreen fine screening.

plete deinking line for Peninsular’scomprehensive theoretical and prac-

22 I 2006 I Voith Paper I twogether

37

TECHNOLOGY“Nobody here thoughtsuch figures werepossible, our paper roll
store is almost full.”Anders Öquist, Holmen Paper Madrid

tical training program was arranged

tomer was able to optimize the per-for the Holmen operators, mechanics,

formance of the PM 62 forming sec-

electricians and control system tech-tion. The customer’s satisfaction was

nicians to optimally prepare them forreflected in an additional order forthe start-up. The result of all thesemore of these forming wires.

training sessions, led by Voith experts, was a picturebook start-up in

The paper machine currently oper-

November 2005. It even set a newates at 1,750 m/min on the Sirius reelworld record of 1,640 m/min forwith good time efficiency and minimal

newsprint machine start-up speed.

broke. A further speed increase isplanned. In February 2006 production

A couple of months after start-up,

output had already reached 661 t/day

Voith Paper Fabrics installed Print-(as against the planned 584 t/day),Form HC wires (part of the PrintForm

and at the end of the first week in

H Series of forming wires) at the innerMarch production was 879 t/day.

and outer position of the DuoFormer.

Currently the line is operated forabout 640 t/day. “Nobody here

The wires showed good formation

thought such figures were possible”,

and drainage properties, high service

said mill manager Anders Öquist,

life and stability and helped the cus-“our paper roll store is almost full –tomer to increase machine speed.

because we’re already producing

With Voith Paper Fabrics‘ forming

more than Holmen originally planned

wires and technical service, the cus-

for”.

38

Contact
Helmut Grimm
Paper Machines Graphic
helmut.grimm@voith.com

Patric Romes
Paper Machines Graphic
patric.romes@voith.com

Axel Dreyer
Fiber Systems
axel.dreyer@voith.com

22 I 2006 I Voith Paper I twogether

TECHNOLOGY

Ettringen PM 4 – ProQuality rebuild “MyFuture44”
Lang Papier Ettringen, a subsidiary of the Finnish Myllykoski
Corporation, decided in December 2004 to improve its SC paper
quality by modernizing PM 4. On December 16, 2004 Voith Paper
was entrusted with the rebuild, which was completed in
September 2005.
The scope of supply covered a

Stock preparation

ModuleJet dilution technology retrofit
to the existing SymFlo headbox,

To comply with more stringent cleanli-conversion of the Symformer HHS toness requirements on the end product,state-of-the-art DuoFormer TQm

the DIP line was upgraded with newtechnology, and installation of HiVac

IC screening and EcoCell flotation.

highvacuum suction box and five

IC screening is used in recovered pa-

ProRelease+ stabilizers in the thirdper preparation when particularly ex-

dryer group. Significant extension

acting demands are placed on finishedwork was also undertaken in the DIP

product quality. Inlet stock consisten-line and approach flow.

cies are typically around 2 to 2.5%,
i.e. between MC and LC consistencies.

This ProQuality rebuild was mainly

In combination with the fine screening

directed at better printability andsystem, which was also upgraded,runability as a function of formation,

the new IC screening substantially

2-sidedness, profile stability and fast

improved stock quality, in particular

grade changing. This report summa-

as regards the reduction of stickies.

rizes the main measures taken in the

Situation prior to rebuild.

22 I 2006 I Voith Paper I twogether

stock preparation and approach flow,

The new EcoCell flotation technology

on the headbox and former.

replaced old flotation cells and has

DuoFormer TQm after rebuild.

39

TECHNOLOGYHighVac high-vacuum
suction box.

ProRelease+.

ModuleJet-DR LC dosing.

ModuleJet valves with Profilmatic
actuators on the LC distributor pipe.

made another important contribution

MultiScreen MSA screening

fitting the HC header, the new LC

to achieving the required stock clean-

Optimized throughflow for maximum

header with ModuleJet valves wasliness.

screening efficiency. Well-provenattached to the headbox. The newtechnology for minimized pulsations.

cover plate with wind deflector was

Approach flow

then fitted, together with the reutiThe rebuild measures substantiallylized shower pipes. Toward 3 a.m. on

The approach flow was rebuilt withimproved both the hydraulic and con-

September 24 the rebuilt headbox –Advanced Wet End Process compo-

sistency stability. This is reflected in

now weighing 55 tons – left Heiden-

nents, including the following:

the excellent MD profile now obtained.

heim, and at around 2 p.m. it was
already in place on site.

ComMix

ModuleJet-DR

Premixing in the mixing pipe with

The headbox rebuild has brought

offset inlets. Static fine mixer. HighThe ModuleJet-DR dilution retrofit

remarkable paper quality improve-

flexibility for accommodating varying

feeds dilution water through a dosing

ments. PM 4 now delivers basis

stock compositions.

plate between the cross-flow header

weight profiles comparable withand the manifold tube bank. Module-

those attainable on new state-of-the-VoithVac

Jet valves on the LC header control

art machines. Immediately after

Improved hydraulic stability for a

the dilution water dosage rate. Basis

restart the 1sigma-Tapio value forstable paper machine operation.

weight control is taken over by thebasis weight cross-profile improved

Voith Profilmatic system.

to < 0.4%.

The headbox rebuild was completed

On page 41 is shown the Tapio basis

in 3.5 days. On September 20 PM 4

weight profiles as measured in the lab-

was shut down for dismantling. The

oratory before and after the rebuild.

EcoCell flotation.

subassemblies could be transported
to Heidenheim for machining andEven without subsequent headbox

reassembly.

gap optimization, fiber orientation is
first class. The cross-profile has im-

Dismantling of the 50-tons headbox

proved to +/-2° as against +/-4° priorand transport to Heidenheim went

to rebuild. This proves that a rebuild

very smoothly. On September 21

with ModuleJet-DR installation is awork already started on fitting, align-

highly efficient way of greatly improv-

ing and fastening the new headbox

ing the basis weight and fiber orienta-

dosing plate before installing andtion profiles.

grinding the injection inserts. After

40

22 I 2006 I Voith Paper I twogether

TECHNOLOGY

DS

4

8 FS
TSO[°]

TSO[°]

8 FS

after rebuild

0

4
0

-4

-4

-8

-8
0

2,000

4,000

0.60
DS

6,000

0

Sample width [mm]

2,000

4,000

0.50
0.40
0.30
0.20
0

Sample width [mm]Fiber orientation cross-profiles before and after rebuild.

DuoFormer TQm

6,000

Formation Ambertec [ √ g/m]

before rebuild

2

4
6
8
10
Technical age [years]

12

14

Formation improvement

The two drainage blades on the top

By using intelligent and effective so-wire were replaced with the top wire

lutions, a large improvement potential

Our goals in rebuilding the former

suction boxes of the well-provenhas been exploited to significantly

were in particular to optimize 2-sid-

D-section, and adjustable drainage

improve printability and runability.

edness as well as formation. We had

blades were installed on the bottom

As a result, the SC proportion ofof course discussed at an early phasewire. The subsequent suction boxes

PM 4 production output has been

the merits and consequences of in-on the bottom wire round off theincreased in the meantime.

stalling a new DuoFormer TQv, but a

new DuoFormer TQm drainage

thorough check on the existing for-concept.

mer showed that these goals could

Particularly notable throughout thisproject was the outstandingly good

be reached with a DuoFormer TQm

Apart from the excellent profile values

cooperation of the Ettringen team,(where “m” means modified).

mentioned above, this rebuild also

who provided us with all available

brought outstandingly good forma-data and were ready at all times for

The breast roll and forming roll weretion, as shown in particular by com-

discussions and optimization mea-

swapped over. To this purpose theparison with third-party machines.

sures.

forming roll was modified for use inFormation has improved by 25% andthe bottom wire, and the headbox

is now in the upper reference range

The resounding success of thishad to be repositioned as well. Reuti-

for new machines on the SC market.

“Myllykoski Future for PM 4” project

lization of the cantilever system was

Ash distribution 2-sidedness is excel-

is further proof of the effective team-an extremely important requirement.

lent at 6%.

work between Lang Papier and Voith.

Tapio basis weight profiles.

Dosing plate installation on the headbox.

Contact
before rebuild

Ole Hansen
Paper Machines Graphic
ole.hansen@voith.com

after rebuild
Klaus-Peter Oltrogge
Paper Machines Graphic
klaus-peter.oltrogge@voith.com
averageCD-profile

Color map of
measured samples

22 I 2006 I Voith Paper I twogether

41

TECHNOLOGY

Single Tier Dryer.

Areas where contaminants adhere to the dryer fabric.

New fabric technology for single tier drying
The fabric development team at Voith Paper continually tests
different ways dryer fabrics can be designed to maintain theperformance of the dryer section throughout fabric life. The latest
development is a new fabric design concept that has exceeded thecustomer requirements of the paper machine trial.

The fabric is an essential part of achanges to yarn material or profile,dryer section. It transmits under pres-most paper machines are still running

sure to the sheet to improve runnabil-the same dryer fabric weave patterns

ity; provides uniform sheet contact toand spiral structures. Voith Paper

improve heat transfer for evaporation,

Fabrics recognized this and began

and it drives most of the cylinders,the process of developing dryer

vacuum and felt rolls.

fabric technologies, adapted to thenewest machine concepts.

During the past 10 years there has
been continuous evolution of sheet

Understanding the processcontrol, machine layout and cleaning

42

equipment to improve machine

Papermakers need low permeability

efficiency and increase operating

fabrics (between 95 to 125 cfm) in the

speeds. However, apart from minor

first dryer groups for good interaction

22 I 2006 I Voith Paper I twogether

TECHNOLOGY

Sites for contamination

Critical Success Factors

TargetNumber of yarn crossovers

Every converging junction between MD and CMD yarns is an opportunity for acontaminant to become trapped between the two surfaces.

Reduce the number and distance ofcontacts between yarns.

Number of MD and CMD layers

Contaminants can become trapped between layers of yarn inside the fabric.

Minimize the number of fabric layers.

Structural void volume

Cleaning systems can clean fabric surfaces, but the water jet is less effectivein cleaning inside structural voids of the fabric as the force of the water jet isdissipated.

Reduce the structural void volume.

Aperture size

Fine apertures are easier to plug with contaminants.

Increase the size of apertures.

Aperture movement“V” shaped apertures of fabrics need to be flexible as this can help to loosen
contaminants for easier cleaning.

Maximize the MD flex points at theapertures.

Number of MD and CD yarns thecleaning nozzle jet sprays at in a
90° angle

The cleaning force from the high pressure water jet is dissipated on contact
with the fabric surface. The fabric yarns can fibrillate if the pressure is toohigh or the nozzle is to close to the fabric.

Ensure that at least 50% of every
yarn has direct contact with thewater jet.

Distance between two MD yarns
where the contamination accumulates
until it reached the surface

Contaminants of baked pitch and fibre grows behind a yarn contact point toclose the apertures. The following apertures become closed with the growth of
the burr.

An aperture always follows eachcontact point, however position
the next aperture as far away as
possible.

with sheet control equipment for tailalso have to satisfy the requirements

The properties of the new fabricthreading and runnability. Aero-for easy installation, wear resistance,

design achieved the targets for cus-

dynamic, low thickness fabrics have

CMD stiffness and length stability,

tomer success criteria on demanding

layers of machine or cross machinewith optimal paper quality.

first dryer groups of high-speed pa-

yarns that are woven closely together. This creates locations for contami-

per machines using recycled furnish.
Finding a solution

nation on the fabric surface or in the

According to industry opinion, sur-structure. Contaminants such as stick-

The second stage of the development

face contact points and contact area

ies from the paper or dust from fillers

process was to design a fabric struc-are two factors that influence drying-and fines are pressed or filtered into

ture to match the values of the theo-efficiency. However, there is no stand-the fabric reducing its effectiveness.

retical model as shown in the Criticalard measuring system for contact

Success Factor table. Because thisarea as values quoted are often test-

Voith Paper studied samples fromwas not possible using conventional

ed at several thousand times greater

fabrics that had run on different

interlacing of warp and weft in dryerpressure than the paper is subjected

paper machines and identified the lo-

fabrics, a loom had to be modified toto between the fabric and thecations where contaminants adheredcreate the desired effect for paper-

cylinder.

to the fabric. The critical successmaking. The resultant fabric structure

factors were determined in order towas completely different from normal

Therefore, the accurately measured

create a theoretical model for fabricdryer fabrics and combined thenumber of contact points on the fab-performance (see above figure). In

elements of both woven and spiralric surface were increased for better

addition, the theoretical fabric would

fabrics.

heating up of the sheet.

22 I 2006 I Voith Paper I twogether

43

TECHNOLOGY

Yarn crossover level/1000 mm2Structural void volume mm3/100 mm2

40 0004000
29376

30 000

Number of surface contact points/100 mm2
50

31464

3132
3000

40

39

37
29

30
20 000
10 000

16168
8096

2000
1000

10

186
0
PrintTech PR

0

0
A
B
C
Normal Fabric Designs

18

20

PrintTech PR

A
Normal Fabric Design

PrintTech PRA
BCNormal Fabric Designs

Yarn crossover level
Every converging junction between MD
and CMD yarns is an opportunity fortrapping a contaminant between the two
surfaces.

Structural void volume
On-machine cleaning systems can clean
voids at the fabric surface, but are less effective at removing contaminants from theinternal structural voids to maintain sheet
control. The structural void volume ofPrintTech PR has been nearly eliminated.

Number of surface contact points
The new concept of dryer fabric has a
Negative Pressure Matrix (patent appliedfor) and large apertures at its paper-contacting surface. These are directly acted
upon by the water jet of the cleaning nozzle and the high number of fabric contact
points with the paper is retained.

An under pressure matrix was cre-The 9 m wide fabric was easily joinedThis new concept in dryer fabricated on both surfaces of the fabric inat the seam and started up well withtechnology has progressed from theorder to transmit the under pressure

good tail threading and sheet runnabil-theory to practice and has proven tofrom sheet control systems to theity. The press section has a closed

run successfully on highest machine

sheet around any surface contami-

web run and requires a high vacuum

speeds under commercial paper-

nants during the life of the fabric.

from the transfer belt to the dryers,

making conditions.

This was done with the objective of

which can increase the risk of web

maintaining optimum tail threading

mark defects due to dryer fabricThis new concept of fabric technol-and sheet runnability throughout

marking. Image analysis of paperogy, PrintTech PR, will be madefabric life.

samples showed that the trial fabric’s

available for different paper grades

unique surface, structure and aper-on single tier dryer sections. It willtures maintained the normal markrun on demanding sections of paper

intensity through the dryer section.

machines with the target of maintain-

Successful trial
The match between theoretical anding the performance of the dryer

resultant structure was excellent andFabric permeability retention andsection during the lifetime of fabrics

the project progressed to the third

profile level were better than target

for improved efficiency and operation

stage of producing and running a trial

and the fabric was removed for evalu-

of the paper machine.

fabric on the 1st dryer group of aation after exceeding the running life

high-speed graphics paper machine.

requirements of the customer.
PrintTech PR.

Contact
Mark Hodson
Fabrics
mark.hodson@voith.com

44

22 I 2006 I Voith Paper I twogether

TECHNOLOGY

Klabin Brazil invests
in a liquids packaging board production line
The Brazilian Kraft liner and pulp producer Klabin ordered from
Voith a complete production line mainly for liquids packaging board(LPB) but also for carrier board and folding boxboard (FBB). It will
be installed at the company’s main mill in Brazil, Monte Alegre inTelêmaco Borba, Paraná state.

Klabin is Brazil’s biggest producer

This contract, for one of the biggest

Process Line Package, Voith Paperand exporter of paper and board, andorders ever received by Voith Brazil,

Fabrics will be supplying three fulla leading supplier of packaging paper

will be executed according to thesets of paper machine clothing fromand carton, folding boxboard andProcess Line Package (PLP).

the MultiPlatform (MultiForm, MultiFlex and MultiTech) for this machine,

bagging paper for industrial use.
The new machine, with a wire widthand Voith Paper Rolls will deliver spe-

Klabin was the first pulp and paperof 7,300 mm and a design speed

cial roll covers and coatings for the

producer on the American continentof 1,000 m/min, will produce up to

individual paper machine sections.

to have its forests certified by the

1,100 tonnes per day of high quality

FSC (Forest Stewardship Council).

board in a basis weight range ofThis very important project for Brazil

This ensures a high level of contribu-

170 to 390 g/m2 to meet both nation-is an excellent example of Voith’stion to environmental protection andal and international market require-commitment to supporting the papersocial-economic sustainability.

ments.

industry in South America. The startup of the production line is planned

In very close cooperation also with

Included in the Voith scope of supply

industrial users, the new production

are the following One Platform

line has been conceived to take fullConcept installations: the entire stock

account of customized liquids pack-preparation line, the approach flow

aging requirements such as for milk

section, slitter-winder, paper rolland juices.

transport and wrapping system,
paper machine auxiliaries and electrical installations, erection and com-for September 2007.

Contact
Nestor de Castro
President
Voith São Paulo, Brazil
nestor.castro@voith.com

missioning. As part of Voith Paper’s

22 I 2006 I Voith Paper I twogether

45

TECHNOLOGYUPM Kaipola – a Perfect Fit rebuild“It is not often that you can say a project has gone so well!
I wish to express my heartfelt thanks for a very successful performance. The project was carried out in an exemplary mannerin every respect.”46

22 I 2006 I Voith Paper I twogether

TECHNOLOGY

Juhani Kauppila, PM 7 production

central Finland has an annual produc-manager at the UPM Kaipola TDtion capacity of over 700,000 tonnes

paper mill, sent this message to theof paper. Directory paper and news-

UPM’s goal was to improve the run-

Voith Paper staff in Finland. He wasprint produced on paper machines 4nability of PM7 by rebuilding the 4th,

praising the rebuild project carriedand 7 account for more than half of

5th and 6th dryer groups. The projectout by Voith in Kaipola last year.

this volume.

also included ropeless tail threading,

Major technological changes pro-

Rebuild for a perfect fit again

which was also delivered by Voith.

posed by Voith were made in the

PM 7 produces 230,000 tons ofdryer section of the paper machine

TD and newsprint annually. The

In its early stages the project wasin order to improve the paper ma-

machine’s wire width is 9,150 mm

complex – the paper machine hadchine’s runnability. The outcome ofand its maximum speed is above

started to produce lighter paper

this challenging work was excellent.

1,600 m/min. The raw material mix

grades and, as a consequence, dry-On the UPM side the project was led

is mechanical pulp and about 60%

ing capacity exceeded production

by Kauppila, while Voith Paper Oy’s

recycled fiber. The paper machine

requirements. For this reason, someproject leader was Jani Kivelä.

started up in 1989. The end productof the cylinders in the paper machine

has changed several times through-had already been closed down when

Kaipola paper mill is part of the UPM-

out the years towards lighter paper

producing lighter grades. Because of

Kymmene Group. UPM is one of thegrades. Today, the main product isthe available drying capacity UPM

world’s leading forest industry com-

directory paper with a basis weightassumed they could change to thepanies and the clear market leader inrange of 34-45 g/m2; the annual aver-single tier system and at the samemagazine paper. The Kaipola mill inage basis weight is 38 g/m2.

time improve the support of the web.
Based on this Voith offered the required DuoStabilizers for three dryer
groups and drilling of the bottom
dryer cylinders. Stabilizing the web
improves runnability, which thereby
reduces web breaks. At the sametime the web stays fixed to the dryer
fabric, which reduces paper flutteringand facilitates tail threading. Goodsupport also enables an increased
web width.
UPM was taken by the offer andVoith secured the contract to deliver
thirteen DuoStabilizers for dryer

UPM Kaipola, Finland.
Above left: Juhani Kauppila (center) withproject manager Jani Kivelä (left) andJuha Behm of Voith Paper Oy in front of
the new dryer section.

groups 4, 5 and 6 and to carry out theon-site drilling of 13 drying cylinders.
The drilling and mechanical installation were performed by Voith’sFinnish subsidiary Pikoteknik Oy. The
delivery also included 13 new doctors. Rebuild work was completed in
October 2005.

22 I 2006 I Voith Paper I twogether

47

TECHNOLOGY

Tribute by Juhani Kauppila

expressed,” said Kauppila after thepaper when drying it very aggres-rebuild.

sively and how this thin paper might“At the quotation stage Voith took achange its behaviour. This issue hasrealistic and serious look at the re-“However, Voith’s proposal was con-been settled after the rebuild to ourbuild, and all submitted information

sidered a good solution. Furthermore,

full satisfaction. Furthermore theon the advantages of the rebuild andits simple method of implementation

paper web coming out of the ma-

the sufficiency of the drying capacity

was very interesting, as was the factchine is wider, which was one of

was up-to-date,” says Kauppila.

that all the work could be carried out

our goals. Following the rebuild it isduring a short nine-day shutdown

now approximately 13 centimeters

period.

wider than before,” explains“We regarded this project as feasible
because the beginning of the dryer

Kauppila.

section had already been realised as“Since the rebuild, we now know thata single tier system. However, thethe drying capacity is definitely suf-

On Kaipola’s PM 7 a lot of efficientsufficiency of the drying capacity was

ficient. Of course, based on the cal-work was carried out by professional

an obstacle that needed to be over-culations, Voith was convinced fromteams on all sides. “Different skills

come. Whether or not it would be

the start – as was I – that the drying

and a combination of these cansufficient was a central consideration,

capacity would suffice. We also

only bring a good end result,” says

especially as opposing views werediscussed what might happen to the

Kauppila.

48

22 I 2006 I Voith Paper I twogether

TECHNOLOGY

Extension of the RCF lineordered back in 2004
“I wish to express my heartfelt thanks

In mid-2004 UPM-Kymmene Kaipola

At the same time, the existing pre-for a very successful performance.

enlisted Voith Paper Fiber Systems

and post-flotations were upgraded by

The project was carried out in an

to extend the existing RCF (recycled

adding further flotation cells in the

exemplary manner in every respect.

fiber) plant. Aim of the rebuild was toprimary stage as well as a flotation

For this I would like to thank theincrease production from 440 to 540

cell with pump in the secondary

staff at Voith who participated in thist / 24 h and to improve the DIP quality.

stage. All flotation cells are equipped

project.” – Juhani Kauppila.

with EcoCell technology.
The RCF line, which already included
Voith components, was modernized

Voith completed the rebuild, including

by adding a 3-stage IC screening

installation and start-up, in less thansystem with integrated cleaner plant.

six months. Delivery took place within

As well as MultiScreens using proventhe agreed time at the end of Novem-

C-bar technology, Voith supplied

ber and in mid-December 2004. The

EcoMizer cleaners for efficient heavy

installation work, supervised by Voith,contaminants removal and for extend-

was carried out on schedule anding the service life of working ele-

partly without stopping production.

ments in the downstream machines.

Commissioning and test runs werealso completed on time. At the beginning of 2005 the RCF plant came backon stream with increased capacity
and with improved stock quality. The
customer expressed his full satisfaction, as indicated by his praise of thegood project cooperation.

Part of the recycled fiber line.

Contact
Jani Kivelä
Voith Paper Oy, Finlandjani.kivelae@voith.com

22 I 2006 I Voith Paper I twogether

49

TECHNOLOGY

Zaragoza50

22 I 2006 I Voith Paper I twogether

TECHNOLOGYSAICA boosting production by another 400,000 tons –Two-million tons within reach
On March 17, 2006, the new PM 10 at SAICA, in El Burgo de Ebro,
was put into successful operation two months ahead of schedule.
The first paper of 90 g/m2 basis weight was wound on the reel at a
speed of 1,030 m/min. The PM 10, with a wire width of 8,550 mm
and a design speed of 1,800 m/min, produces 400,000 t/y of corrugating medium and testliner in a basis weight range of 75-145 g/m2
from 100% recovered paper.
With the start-up of PM 10, SAICA

In the years to follow, continuous in-has become the largest producer ofvestments were made in new paper

testliner and corrugating medium inmachines, as well as rebuilds andSpain and operates a total of eight

upgrades. As early as 1954, the PM 2

paper machines with an annual out-

with a production capacity of

put of approximately 1.9 million tons

3,150 t/y was put into operation. Overat two locations in Spain and at two

the years, the Zaragoza mill distinctly

locations in France. SAICA is also theboosted its production, partly by up-

largest recycler of recovered paper,

grading the existing paper machines

processing about two million tons inand partly by building new paper

2005.

machines.

SAICA looking back on success-In 1992, the PM 8 with an annual out-

ful development

put of 120,000 tons went online at the
new mill in El Burgo de Ebro, about

Old PM 1 producing 1,937 t/y
at 1.1 m working width.

SAICA (Sociedad Anónima Industrias

25 km out of Zaragoza. In the mean-

Celulosa Aragonesa) was establishedtime, it has been rebuilt and upgrad-in 1943. The invested capital was

ed several times, now producing

around 3.5 million pesetas at thatmainly up to 350,000 t/y of white top

time. The successful history of theliner.

100% family-owned group in Zaragoza, Spain, began with the paper
machine PM 1, producing 1,937 t/y at

Efficiency PM 9

1.1 m working width. Straw pulp was
mainly processed on the first paper
machine. After producing various
paper grades and pulps at the beginning, SAICA very soon specialized in
producing testliner and corrugating
medium.

22 I 2006 I Voith Paper I twogether

Year

2000

Production (net) (t/y)

312,000 387,000

2005

Average PM speed(m/min)

1,058

1,255

Efficiency

83.9%

89.2%

Average basis weight

103 g/m2 92 g/m2

51

TECHNOLOGYContract signing for project
SAICA 4 PM 10.

Shortly after the successful start-up

With Voith Paper, SAICA has chosenof the new PM 9 at El Burgo de Ebro,

the right and reliable partner, as is

SAICA and Voith decided to intensify

demonstrated by several figures giv-

their cooperation beyond the normal

en below. Although, since the start-

scope of supply and contract toup of PM 9, the average basis weightincrease the PM 9 capacity andhas decreased from about 103 g/m2

efficiency, as well as to enhance theto 92 g/m2, the PM 9 production,

corrugating medium quality.

speed and efficiency were considerably increased.

From the beginning of this cooperaIn 1998, SAICA acquired the papertion, it was clear to both partners that

Excellent partnership as key

mill Papeteries de Gaves in Orthez,successful cooperation would de-to placing of order for SAICA 4France, with one paper machine and,pend on an intensive exchange of ex-

PM 10

in 2002, La Rochette Venizel with twoperience between them. Therefore, allpaper machines.

optimization measures for the PM 9

The excellent cooperation between

were jointly planned down to the last

SAICA and Voith is reflected in theVoith and SAICA – Many years ofdetail before they were implemented.

fact that on May 20, 2004, SAICA

customer-oriented partnership

New developments and improve-placed an order with its preferredments were jointly worked out andpartner Voith Paper for another new

In January 1999, SAICA placed anthen tested and optimized on thepaper machine PM 10, includingorder with Voith Paper for a new pro-

PM 9. SAICA and Voith fostered anstock preparation equipment, at its

duction line for corrugating medium

open and intensive exchange of infor-

El Burgo de Ebro mill.

at its El Burgo de Ebro mill. The stock

mation even during realization of the

preparation system, the paper ma-

PM 9 project and have further intensi-

Stock preparation,chine and the reel were delivered

fied the open customer/supplier rela-approach flow and broke

according to an “all from one source”

tionship in recent years.

systems

into operation in October 2000, still is

SAICA’s well trained and highly moti-

Voith supplied the key components

the world’s fastest and definitely thevated team has also contributed sig-

for the stock preparation system, as

most efficient paper machine for cor-nificantly to achieving SAICA’s suc-well as the complete approach flow

rugating medium.

cess and excellent market position.

and complete broke systems. The

EcoMizer cleaner plant.

Thune disc filters for thickening (background)and the final stage LC slot screening for thelong fibers (foreground).

concept. The PM 9, which was put

TwinFlo double disc refiners
for refining the long fibers.

52

22 I 2006 I Voith Paper I twogether

TECHNOLOGYNew PM 10.

approach flow is designed according

stage slot screening system before

The press section is a DuoCentri-

to Voith’s Advanced Wet End Pro-

being returned to the production

NipcoFlex press configuration andcess. It is equipped with the mixing

process.

ensures maximum runnability. High-elements ComMix and HydroMix andquality roll covers, such as Aqualis,with VoithVac deaeration units for the

In the fiber recovery system, the

PolyDyne and CeraLease SDe, are

top and backliner lines. In the subse-

white water to be reused for theused. A zone-controlled Module-

quent screening system, low-pulsa-

paper machine showers is clarified

Steam steam blow box ensures opti-

tion MSA MultiScreens – speciallyusing a DeltaPurge and a Conus-

mum dry contents and CD moisturedeveloped for the approach – flow

Trenner, both from Meri.

profiles after the press.

Paper machine PM 10

The pre- and after-dryer sections,

are installed in the top and backliner
lines and in the dilution water line.

with a total of 47 dryers, use the TopThe machine broke is pulped down

Sheet forming takes place on a

DuoRun concept. ProRelease boxes

and then passed to a separate two-

DuoFormer Base specially designed

are installed in the first two dryer

for producing packaging papers atgroups to ensure excellent runnability

maximum speeds. The DuoFormer

at low basis weights and maximum

Base has been dimensioned to allow

speeds.

Improved framing of the dryer group.

for future speed increases and quality
improvements of the machine.

At the end of the after-dryer section,a ModulePro P is installed to control

The double-layer MasterJet M2 head-

the CD moisture profile. A ModuleProbox is equipped with ModuleJet

C is used to control the web flatness.

dilution water control. For CD basis

22 I 2006 I Voith Paper I twogether

weight profile control the Profilmatic-

For uniform starch application,

software is used in the back layer.

a SpeedSizer unit with StratoSize

53

TECHNOLOGY

Optimum winding quality by RollMaster on the Sirius.

rubber roll covers is used. The carbon

Beside the automation products

fiber rod beams allow to apply thewhich were already mentioned, Voith

starch solution at highest tempera-

Paper also supplied the complete ba-tures. A Voith Krieger Airturn allows

sic engineering, and was responsible

optimum web transfer without con-

for installation and start-up.

tact from the SpeedSizer into the after-dryer section. The complete dryer

Installation and start-up

section is equipped with a ropelesstransfer system. In the area of Speed-

Project teams that are well adjusted

Sizer and Sirius, Fibron threading

to work together and the experience

units are used. Together with thefrom five years of cooperation on PM

high-pressure water jet cutter in the

9 helped to continue the success

wet end shortest possible transfer

shared by SAICA and Voith during

times are realized.

start-up of the PM 10. As for PM 9,
SAICA has again trusted in Voith’sTechnical data of PM 10
Wire width

8,550 mm

Design speed

1,800 m/min

Product

Corrugating medium
and liner

Basis weight

75 - 145 g/m2

The web is wound on a Sirius reel,extensive process know-how. Suc-

permitting roll diameters up to

cessful installation and start-up of the

4,000 mm. The RollMaster on thecomplete machine two months ahead

Production (net)400,000 t/y

Sirius guarantees optimum windingof schedule were accomplishedRaw material

100% recovered fiber

quality. The parent roll change isthrough excellent cooperation in a

Contacteffected fully automatically by means

spirit of partnership throughout theof EcoChange W.

realization phase of this large-scale
project. All persons responsible forthis success really do deserve a big

Helmut Riesenberger
Paper Machines
Board and Packaging
helmut.riesenberger@voith.com“Thank you”.

54

22 I 2006 I Voith Paper I twogether

INTERVIEWWorking together and common goals
On the occasion of the start-up of the PM 10,
we ask Mr Francisco Carilla, Project Director, for an interview:

twogether: When did you first think

the problems and opportunities andPM 9, all of us felt very familiar with

about building a new machine here inputs the ideas into practice. Openthe new PM, allowing us to be fasterEl Burgo de Ebro? What were thecommunication, honesty, working

and safer.

reasons?

together and common goals are thekey to developing a climate of trust

This early start-up date means to us

Carilla: We started to think about it in

and to achieve good results for boththat amortization of the investment

late 2002 and made a decision in

the customer and the supplier.

has started sooner, at a time when

2003. The main reason was to keep

the rising energy and raw material

our paper business growing accord-

twogether: What is your opinion ofprices make life more difficult for pro-ing to our company strategy. We

Voith’s project handling competence

ducers of board. For our customers,

wanted to maintain our position as aand cooperation?

this has been another example ofmajor player on the Spanish market

SAICA’s reliability. Rolls of paper

as well as to strengthen our position

Carilla: Project handling was profes-

ready on the truck for delivery fromin the European market. The mill was

sional. Due to our long partnershipthe very beginning!

planned at El Burgo de Ebro, as weand based on the experience of Voith

already had adequate land with theand Saica from similar projects, thetwogether: SAICA is Spain’s largest

required infrastructures as well as

whole project has run smoothly. Voith

privately owned producer of corru-

motivated and well-trained human

St. Poelten efficiently coordinated thegating medium and liner and nearly

resources.

different Voith locations and sub-sup-hits the two-million tons bordert.

pliers without any major problems.

What does the future hold for SAICA?

twogether: SAICA and Voith are unit-

What are your goals?

ed by long-term partnership. What, in

twogether: The machine started up

your opinion, is the heart of this rela-

two months earlier than originally

Carilla: With the new PM 10, our in-tionship? What is important to you inplanned. How did you experience thestalled production capacity is 1.9 mil-a customer/supplier relationship?

last months? What does this earlylion tons. We want to put another PM

start-up date mean to business?

for 400,000 t/y into operation by 2010

Carilla: The partnership was estab-and to keep our business growing.

lished for our previous Saica 3 PM 9

Carilla: The last months are always

For us, as a partly integrated group,

project. After the PM start-up, wevery activity-intensive. In any case,this means increasing our waste

signed several agreements enabling

we managed to finish the installation

paper collection centers as well as

the two partners to share profits fromand check-out activities without any

corrugated board facilities.

their investments to make the new

injuries and two months ahead ofline more profitable.

schedule. Commissioning was also

twogether: Many thanks indeed forvery fast, and we did not face any

this interesting interview – and con-

We appreciate that the supplier lis-

major problems. As the PM 10 design

gratulations on your new production

tens to our experience, recognizes

is based on that of our previousline!

22 I 2006 I Voith Paper I twogether

55

TECHNOLOGY

Productos Familia
Sancela in Cajicá,
Columbia.

Productos Familia, Columbia – Expansion in Tissue
Productos Familia Sancela, a partner company of the globallyrenowned tissue producer Svenska Cellulosa (SCA), is a leading
supplier of tissue products in Columbia and neighbouring countries.
As part of its expansion strategy Productos Familia has built a
new tissue mill in Cajicá, conveniently located near the capital city
Bogotá where consumer demand is the highest.
This comprehensive greenfield pro-istics and to optimize machine con-duction facility is comprised of the

figuration taking into account thetissue machine itself, the stock prep-

customer’s specific production re-aration line, some processing ma-quirements. To this end tests werechinery, and a full complement ofconducted with a wide variety ofauxiliaries. Voith partnered with themachine configurations.

customer right from the beginning of

56

this project by carrying out tests at

The convincing test results from thisthe Voith Brazil Process Technology

fruitful teamwork led Productos Fami-

Center for Tissue with Productos

lia Sancela to entrust Voith in March

Familia furnish. The goal was to opti-

2004 with supplying the entire tissue

mize the process in order to reachproduction line. With a wire width ofthe desired tissue product character-

3,585 mm and a design speed of

22 I 2006 I Voith Paper I twogether

TECHNOLOGYThe new
Tissue machine.

Customer Comment
Juan G. Gallon
Productos Familia
Sancela“It is very important to uphold goodsynergy and teamwork between thecustomer and supplier right through the
project. Due to the similarity of theBrazilian and Columbian cultures weenjoyed excellent relations with Voith in
2,000 m/min, the tissue machine will

Voith’s scope of supply also includes

all phases of this project – engineering,produce up to 120 tons per day in a

the stock preparation line for virgin

manufacturing, erection and commis-

basis weight range of 15-25 g/m2.

pulp having a capacity of 120 t / 24 h.

sioning – both in technical and collegial

This line is comprised of a make-respects. Also with regard to cooperation

Among the main components of thedown pulper for maintaining a coarsewith engineering and commissioning

tissue machine are a crescent former

pumpable suspension, HC cleaners,

supervision in other areas where Voith

with 2-layer headbox enabling differ-

refiners and agitators. The approach

was not the main supplier, there was aent stock qualities per layer for opti-

flow section includes screens, mixing

high level of responsibility and trust

mizing product cost and quality. The

pumps, agitators and broke pulper.

between the partners. We are extremelypress section is equipped with a suc-satisfied with Voith’s delivery and per-tion press roll, but already designed

Thanks to the outstandingly goodto accommodate a TissueFlex press

teamwork between Productos Familia

later on if required. The Yankee cylin-

and Voith, their meticulous commis-

der diameter is 16 feet (4.8 m). A highsioning planning, and efficient coordi-

efficiency dryer hood ensures opti-

nation of all the project participants

mally fast drying. The dust extraction

both during execution and in thesystem is fitted with active stabilizers.

commissioning phase, the punctual

An ONP scanner installed by Voith

start-up in September 2005 was very

Automation between the Yankee

successful. This project has further

cylinder and reel measures and con-extended the partnership alreadytrols the basis weight profile andbuilt up with other tissue producers

sheet dryness. The maximum parent

with similar SCA Group affiliation androll diameter is 2,700 mm.

participation.

22 I 2006 I Voith Paper I twogether

formance.”

Contact
Carlos Galo
Voith São Paulo, Brazil
carlos.galo@voith.com

Ronaldo Parucker
Voith São Paulo, Brazil
ronaldo.parucker@voith.com

57

TECHNOLOGY

Premium tissue produced with the new Atmos technology.

Tissue pilot machine at the Voith Process
Technology Center in São Paulo.

Atmos –
Innovative technology for premium tissue production
This article gives readers a preview of our completely new technology development for premium tissue production. Within the next
few months Voith will be launching this innovative technology underthe brand name “Atmos”.
Atmos technology was developed at

For more than thirty years premium

the Voith Tissue Process Technology

tissue has been the domain of large

Center in São Paulo, Brazil in close

tissue producers using through air

teamwork with Voith Paper Fabrics.

drying (TAD) technology. With thisThis joint achievement shows once

technology the formed sheet is main-

again how much our customers

ly dried by hot air, without any me-

benefit from synergies between the

chanical pressing, in order to ensure

various divisions of Voith Paper –premium tissue quality by avoiding

truly a “Powerhouse”!

negative effects on sheet characteristics.

Premium tissue is distinguished by58

its outstanding physical properties

According to tissue producers, thecompared with products made on

drawbacks of TAD technology areconventional tissue machines. It

the high investment expenses andmeets the highest demands for bulk,

the high production costs due to very

softness and water absorption.

high energy consumption. That is

22 I 2006 I Voith Paper I twogether

TECHNOLOGY

Bulk [cm3/g]

1210Premium

8

50% HW/50% SW
Re-Crepe
TissueFlex
Dry-Crepe

Toilet paper bulk characteristics.

6

Water absorption characteristics ofkitchen towel.

40.002 0.004 0.006 0.008 0.010 0.012
Geometrical Mean Dry Tensile/BW

why only the largest companies werewilling to use this technology.

70% SW/30% CTMP
Atmos
14
100% SW
100% Rec
12 80% SW/20% Rec
Re-Crepe
10
TissueFlex
16

Absorption capacity[gH2O/gfiber]

70% HW/30% SW
Atmos
35% HW/65% SW

14Premium

8

Dry-Crepe

600.02 0.04 0.06 0.08 0.10 0.12 0.14
Geometrical Mean Wet Tensile/BW● Premium: the best tissue quality,● Up to 30 % lower energy costs,

produced so far with TAD tech-and 35 % lower overall costs fornology.

operating materials (stock, chemi-

Voith, therefore, made the strategiccals), labour, fabrics, maintenance,

decision to develop an innovative

As shown in figures above, Atmos

technology that would enable premi-

product quality is very clearly in theum tissue quality while eliminating thepremium sector, even if secondary

TAD drawbacks.

fibers are used.

By far the greater volume of tissue

Our Atmos line with a 5,500 mm di-mously installed in a customer’s millproduction today comprises so-called

ameter yankee cylinder and a 500 °C

strategically selected according to aclassical grades such as toilet papers

dryer hood attains operating speeds

Voith market survey. Commissioning

and kitchen towels. The most impor-of 1,000 to 1,500 m/min, dependingis planned for the third quarter 2006.

tant physical quality requirements

on basis weight, furnish and product.

and auxiliaries.
● User-friendlier operation, andhigher productivity.
The first Atmos line is being anony-

are bulk, hand-feel and structural

Further details of Atmos technology

softness for toilet paper, and water

Compared with TAD technology,

will be reported in a forthcoming

absorption for kitchen tissue.

Atmos technology has the following

edition of twogether magazine.

advantages for premium tissue
Tissue paper characteristics are gen-production:erally expressed in terms of dry andwet strength as a function of basis● It enables the use of 100 % sec-

weight. Figures above show the

ondary fiber, still maintaining thevolume characteristics of toilet paper

premium tissue quality and speed

and the water absorption capacityof commercial TAD machines.

of kitchen tissue for the three main

● Up to 40 % less capital investment

product grades currently available

costs because of less requiredon the market:

machinery, reduced erection,● Dry-Crepe: standard tissue

manufacturing and building costs.

machine product quality.

● Dry-Crepe tissue machines can be● TissueFlex and Re-Crepe: im-retrofitted with Atmos technology

proved tissue quality produced on

for operation either in yankee

the Voith TissueFlex shoe press

cylinder mode, or in Atmos modemachine and an additional quality(Swingmachine), if required byproduced on tissue machines withpremium tissue market develop-

two yankee cylinders.

ments.

22 I 2006 I Voith Paper I twogether

Contact

Rogério Berardi
rogerio.berardi@voith.com
Luiz Carlos da Silva
luiz-carlos.silva@voith.com

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

59

TECHNOLOGY

Faster quality tons on the reel –Turbo-upgrade of Perlen Papier’s LWC PM 4 “Pioneer”
PM 4 “Pioneer”, the first online-calendering paper machinedelivered by Voith Paper to Perlen Papier AG in Switzerland for
LWC offset printing grades, started up in October 2000. It not only
met all expectations immediately, but also lived up to the Voith
slogan “Engineered reliability” so well that already in 2004,
Perlen Papier decided to increase the production capacity of PM 4
from 160,000 to 200,000 t.p.y.

60

22 I 2006 I Voith Paper I twogether

TECHNOLOGY

To this end the operating speed had

During 2003 Voith succeeded in iden-

to be raised from 1,300 m/min totifying an additional gloss control

1,600 m/min, which was no problem

parameter: extensive trials on thethanks to the drive power reserves

Janus MK 2 calender test facility inbuilt into PM 4 right from the outset

Krefeld proved that with a revolution-

by Voith. Perlen Paper was not only

ary new remoistening system, gloss

interested in higher output, however,

could be improved by up to 4 points.

but also in upholding quality at theThis opened up a way of compensat-

same time. In other words: fastering for gloss reduction due to speed

quality tons on the reel. That wasincreases, but first the problem

quite a challenge, because speed

had to be solved of maintaining theincreases on such machines arenecessary FlexiTherm roll surface

normally at the cost of gloss andtemperature despite additional heatsmoothness. Which is why Perlen

losses due to remoistening and high-Papier asked whether Voith could

er speed.

actually break this vicious circle. To
put our readers at ease: it goes with-

The simplest solution would haveout saying that once again, Voith

been to increase the thermo-roll feedsolved the problem! As explained

temperature of the online Janus MK 2

below, this was done by adopting

calender in Perlen, but the existing oil

two approaches: process technology

heating system capacity was too low.

on the one hand, and machine design

It was designed for a feed tempera-on the other.

ture of 235° C, and in any case, therolls would have been overloaded

The process technology

under such conditions. Installing theapproachVoith FlexithermCoil inductive exterior
heating system solved this problem.

22 I 2006 I Voith Paper I twogether

Although gloss is so important for

Originally designed as high-perfor-

calendering LWC grades, until 2003

mance external heating for NipcoFlex

there were only three ways of control-

calender rolls subject to extremeling it: by varying thethermal loading, this system also

● temperature,

served in Perlen for increasing the● pressure, andinstalled capacity of heated rolls● number of nips.

while at the same time ensuring

61

TECHNOLOGY

JanuLock in the open andclosed positions.

Customer Comment
Franz Graf
Perlen Papier AG

Faster quality tons on the reel was cer-

future, we agreed with Voith to install adependability. The FlexithermCoil

tainly an ambitious goal. It is of course up

JanuLock system. This framework onheating system comprises a speciallyto the customer to say whether this goal

which everything above the rolls is mount-designed inductor bar that applies

was reached. So Franz Graf of Perlen

ed can be quickly lifted by hydraulic cylin-

additional heating to the roll precisely

Papier AG has the last word:ders for easy crane access, so that nowhere it is needed: on the roll surface

time-consuming dismantling work is

and immediately below to a depth of“Only five years after PM 4 started up we

require prior to roll changing. In fact the

only a few millimeters. The big advan-

decided to increase our LWC machine ca-

JanuLock makes roll changing consider-tage is that this additional heat in-pacity by increasing the speed. This wasably faster despite the additional post-creases and decreases immediately,

done in two phases, involving substantial

rebuild installations. The user-friendly

and that the temperature distribution

rebuilds above all of the press section, theswivel mechanism opens and closes inin the thermorolls is almost homoge-

coater and the Janus calender.

only ten minutes, and the rope tensioning

neous. The result is far more depend-

station has been modified so thatable roll operation despite greater

We had found so far that Janus calenderthreading rope loosening or release isheating and higher surface tempera-roll changing accounted for a good deal of

unnecessary.

ture.

stalled above the calender first had to be

Right from the outset, our JanuLock has

The following figures show how welldismantled. By adding further components

proved a good investment. Over the lastthis goal was reached:such as a steam blow box and two induc-three months it has saved our mainte-● 20% more heat transfer from hottion heaters, the capacity increase rebuildnance crew a lot of roll changing work andwould have exacerbated this problem. In

above all time.”

shut-down time, because everything in-order to avoid longer roll change times in62rolls to paper● 30% better roll dependability at thesame time.

22 I 2006 I Voith Paper I twogether

TECHNOLOGY

6
5

4
3

2
3

1 Flexitherm roll2 Nipco roll3 Steam moisturizer
4 FlexiTherm coil
5 JanuLock closed
6 JanuLock opened

1
2
2
1
2

JanuLock layout.

The process technology approach,

adapt this concept to the Janus MK 2

despite reverse loading when thetherefore, brought a promising solu-

calender. The result they came uplevers pass through the point of equi-tion in 2004. It involved retrofittingwith was the JanuLock, a lever sys-librium. Opening and closing takes

the following components to thetem integrated in the calender frame.

less than ten minutes. The results of

PM 4 online Janus MK 2 calender:

On the operator side and on the drive

JanuLock installation on the PM 4

● Two steam blow boxes,side of the calender a 7-meter long

Janus MK 2 online calender are● Two FlexithermCoil heaters, andswivel arm is installed above the roll

impressive: it now takes only three● New components for a redesigned

stack. A crossbeam joins the twohours to change a FlexiTherm roll,arms at top and bottom. This swivel-

instead of six hours prior to rebuild.

ingoing web run.

ling platform carries all exterior comIt turned out, however, that installing

ponents such as rolls, spreader rolls,

these additional components in the

inductor bars, steam blow boxes,

existing calender would not be easy

drives, supply piping including oil

at all: clearly the machine design

lubrication components, etc. For rollwould have to be revised as well.

changes the entire assembly isretracted to give immediate crane

The machine design approachaccess to all the calender rolls. The
JanuLock is opened and closed by

In their search for the optimal ma-

hydraulic cylinders on tender andchine design, the Voith engineers

drive sides respectively. The twowere able to draw on positive recent

JanuLock arms are synchronized byexperiences with their innovative

a sophisticated hydraulic control

DeltaLock system for the EcoSoft

system. This also ensures a constantcalender. It was “only” necessary to

opening or closing speed at all times

22 I 2006 I Voith Paper I twogether

Contact
Christian Löffler
Finishingchristian.loeffler@voith.com

Klaus Winkels
Finishingklaus.winkels@voith.com

63

TECHNOLOGY

Dresden Papier – optimized threading process
cuts threading time in half
The web threading process at the Fährbrücke mill of Dresden
Papier GmbH was radically improved after consultation with theexperts of the Voith Tail Threading Group (VTTG) and an extensive
threading process audit by TEAMS (Threading Evaluation andManaged Solutions). Threading is now consistent and takes lessthan half of the previous threading time.
Dresden Papier’s Fährbrücke mill was

equipment and existing threading

experiencing problems with theirprocesses. Current machine proce-threading process. They needed ex-

dures and specific problems in thepertise to help identify the exact

process were also discussed withproblems in the process and create

the mill personnel.

solutions for solving these problems.

Threading controls at Dresden Papier,Fährbrücke mill.

64

Voith TTG was chosen for this task

Up to the calender section the origi-

based on experience, good referenc-

nal threading was done mostly withes, quick delivery times and efficientrope systems. The main problems

manpower allocation. First, the millfound in these rope systems were

decided to commission a full machine

long, unsupported rope runs, improp-

threading audit, TEAMS, from Voitherly installed rope sheaves and in-

TTG. During the TEAMS audit, twoefficient rope stretcher operation. The

Threading Process Specialists exam-

dryer through calender to reel section

ined the paper machine, threading

was originally threaded with an air

VTT Turbo conveyors installed in the end
section at Fährbrücke mill.

22 I 2006 I Voith Paper I twogether

TECHNOLOGY

tray system. This threading method

The section from dryer 42 to the reel

resulted in inconsistent threading

through three open nip calenders was

performance and excessive threading

determined to be the section thattimes.

most needed full optimization. The

Customer Comment
Dr.-Ing. Ulrich Paris
Central Technology
Managertail transfer at this location was opti-

Dresden Papier GmbH

In addition, the original system at thismized using three VTT conveyors.

section tended to allow the paper

The VTT Turbo conveyors were in-to ball up and damage the closed nipstalled with a Flip Tray to stabilize thecalender roll covers, as the paper

tail and transfer it from the dryer onto

“Dresden Papier is extremely happy withwould jam going through the calen-

the first conveyor and a Tail Ripper tothe results of this optimization. Of all theder. Occasionally the damage was so

eliminate the double tail. In addition

projects we were implementing at theextensive that the whole calender rollto the VTT Turbo conveyors, calendersame time, the threading optimization wasneeded to be replaced. The time lost

shoes and a reel threader were in-the ‘smoothest’.

with threading combined with non-stalled to provide optimum threading

recyclable product and calender roll

performance. All of the equipment

Positive results at the Fährbrücke milldamage ensured a fast payback for

was installed on linear tracks to allow

encouraged Dresden Papier to implement

any potential threading optimization.

threading with different sheet widths.

another TEAMS audit at the Heidenau mill,Germany, to optimize the threading

After the audit, a specific report de-process at this location as well.”tailing all the findings and improve-

The Fährbrücke mill is still working

ment suggestions was created andon implementing some improvement

sent to the customer. Using thesuggestions that were made in the

TEAMS report as a road map, Dres-TEAMS report. However, threading

den Papier started optimizing thetime has already been reduced

threading process at Fährbrücke. The

by half, based on only the upgrades

mill started with the recommenda-

done so far (one automated VTTtions for improving the existing ropetransfer section and rope systemthreading systems. Small improve-

modifications).

ments were made throughout therope systems to improve efficiency.
Even though sometimes small, when
all rope system changes were implemented at the same time, they had
a significant positive impact on thethreading efficiency.

22 I 2006 I Voith Paper I twogether

Contact
Gerrit van EngelandFinishing, Tail Threading Groupgerrit.van.engeland@voith.com

65

TECHNOLOGY

Higher output at Dresden Papierand enhanced product quality at the same time
On PM 4 at its Heidenau mill Dresden Papier GmbH, Germany,
produces coated duplex and non-woven wallpapers, as well ascoated and uncoated laminating papers with basis weights ranging
from 70 - 160 g/m2. Last year the maximum operating speed ofthis 3,400 mm wide machine was 320 m/min, depending on grade,and Dresden Papier wanted to increase it. While the drive systems
would have handled a speed increase without problem, it wasvery doubtful whether the installed drying capacity would still havebeen adequate.
The approach

The solution

To clarify this situation, Dresden

The Krieger experts tackled their task

Taking account of the planned speed

Papier contacted Krieger GmbH &in three stages:

increase, use of higher grammage

Co. KG, Mönchengladbach, a leader● First, a meticulous examination

coatings and extension of the non-in non-contact drying technology

was made of the existing drying

woven wallpaper product range, theand since 2002 a majority holding ofconditions.

optimal solution was to replace thethe Voith Group.

● Secondly, the resultant data wasconverted into a computer model

Dresden Papier had already consulted Krieger in a similar case previous-

existing IR dryer with a more powerful
Krieger InfraAir drying system.

enabling simulation of all the feaFurthermore, to increase overall

sible drying solutions.

ly, with excellent results thanks to● And finally, the optimal solution fordrying efficiency, the exhaust air

Krieger’s several transportable test

PM 4 was worked out with Dresdenfrom this new system will be fed tofacilities for precisely checking out

Papier based on the simulation

the existing downstream air dryer.

drying capacity increases on site.

model.

PM 4 layout.

Air dryer system.
Recirculation air blower
Exhaust air heat utilization(to the existing air dryer hood)

66

Fresh air

22 I 2006 I Voith Paper I twogether

TECHNOLOGY

Dresden Papier
Heidenau mill.

Customer Comment
Dr.-Ing. Ulrich Paris
Central Technology
ManagerDresden Papier GmbHAt the end of September 2005,

Safety systems for fire prevention

Dr. Ulrich Paris, Central Technology

Dresden Papier assigned Krieger withand extinguishing round off the scopeManager at Dresden Papier GmbH, took

the PM 4 rebuild accordingly.

of supply.

this punctual restart and subsequent per-The scope of rebuild comprised the

Project management

for issuing a press release from which

delivery, installation and commission-and execution

we would like to cite the following extract:

formance verification as an opportunity

ing of a Krieger InfraAir drying system“This modern drying installation is notwith gas-heated K10 000 ceramic

The contractual deadlines were criti-

only able to dry coatings with a higher

infrared emitters in one triple and one

cal because the upgraded machine

grammage, but also helps to increase

double row, each between blower

already had to be on line again in the

PM 4 output and optimise product quality.

and vacuum ducting. The circulation

first week of 2006. Punctual compli-

The agreed performance targets were

air serves for adequate web ventila-

ance with this ambitious schedule

met in next to no time.”tion as well as for combustion gas

was due not least to the outstanding

and water vapour extraction. All thecooperation between the partners.

Many thanks Dr. Paris for your “well done

process-relevant parameters canOver the Christmas break they dis-Krieger!” praise, which gratifies us all thebe adjusted on a local control panel

mantled the old IR dryer, installed themore because this is the second time

providing an excellent overview.

new one and connected it to the ex-Dresden Papier has paid tribute to Voith –The gentle drying required for coatedisting air dryer, and recommissioned

see article on page 64 of this issue.

non-woven wallpaper is also assured

the entire system so that PM 4 wasby the integrated power control andable to start up again in the first week

And for readers asking the ROI question –circulation air temperature control.

of 2006 without problem.

“What is the payback time on this investment?” – Dr. Paris also has the answer:“We reckon the Krieger IR dryer rebuild

InfraAir dryer prior to installation.

InfraAir dryer after installation.

will pay for itself in about one year,
particularly in view of the speed increase
it enables in non-woven wallpaper production”.

Contact
Ralf Kohmanns
Krieger GmbHr.kohmanns@krieger-MG.de

22 I 2006 I Voith Paper I twogether

67

TECHNOLOGY

TerraSpeed –the new generation of ceramic coatings for press rolls
Recent developments in the paper industry result in increased
demands on paper machines. Larger machine components
and higher machine speeds set new requirements regarding thefunctionality of roll surfaces.
In the press section, Voith Paper

The function of the center

Rolls’ CeraLease set the standard

press rollWorld Wide for ceramic coated press

68

rolls. The culmination of all our

Since the inception of paper ma-

experience, improvements, andchines more than 100 years ago, thedevelopments was the basis for thecentral press roll position is consid-

development of the new standard

ered as heart of the machine. There,

in ceramic coating: TerraSpeed.

the before formed sheet touches a

22 I 2006 I Voith Paper I twogether

TECHNOLOGY

roll surface for the first time. In the

The situation is similar for single-nip

pography enables best sheet release

nip of the central press roll, thepresses, which are also, according towhile taking paper grade, machine

majority of the residual moisture ispaper grade, being used in modern

speed, and other specific character-pressed out of the sheet. After the

One Platform Concept machines.

istics into account. Compared topress nip the paper will be drawn

granite rolls, sheet tension can bewith the respective elongation fromFor several decades, paper makers

reduced by up to 50%. While granite

the roll surface and then transported

considered the naturally structured

rolls sometimes had to be groundwith a resulting speed difference

granite roll as the optimal solution

several times a year, a ceramic roll’sfurther on through the machine. Thisfor the central roll position. The highhardness and strength allow runningtension difference can have a remark-hardness was a guarantor for best

times of several years, even under theable effect on the speed and efficien-abrasion resistance. Granite’s struc-toughest chemical and mechanicalcy of a paper machine. If the sheet

ture with different phases was theconditions. Although better perform-

can not easily be released from thebasis for best sheet release. The dif-

ing than granite the first ceramicroll surface, it will overstretch andferences in hydroscopy between the

covers suffered from silicate contami-

break.

phases generate micro-turbulences

nation, caustic attack, and corrosion.

which fostered sheet release.
A next major step in technology came
The affinity of granite to silicate de-with the introduction of CeraLease

posits is one of the material’s short-the most successful ceramic coating

falls. The rolls became contaminatedin the industry. More than 800 instal-

sheet tension increased, and the rollslations in the paper industry speak forhad to be ground. The usage of steam

themselves. The undisputed advan-

showers, greater loading, and higher

tages of the high-purity single phasemachine speeds finally showed theoxide ceramic are the fundament forsevere limitations of granite. The sen-numerous advancements in the Base-sitivity of granite in demanding envi-

Layer that improved durability andronments resulted in its decline in the

corrosion resistance.

paper industry since the end of theCentral press roll –the heart of a paper machine.

22 I 2006 I Voith Paper I twogether

1980s. Cast iron rolls and steel rolls

Voith reviewed the performance ofwere covered with various functional

ceramic center press rolls withsurfaces made of different materials.

hundreds of years of accumulatedFirst approaches with rubber or filledrunning time and the latest develop-

resin are still used but not suitablements in coating technology. Thisfor the fastest machines. The crucial

helped to direct the research andbreakthrough was managed with

development of a new generation ofplasma-sprayed oxide ceramics thatcoatings. The culmination of thisremarkably outperformed granite’s

development is TerraSpeed, the next

properties. A tailor made surface to-generation ceramic cover.

69

TECHNOLOGY

TerraSpeed –a combination of 3 layers.

High quality top functional
layer structure.

TerraSpeedsible that the surface is kept clean

confidentially adjusted porosity offor a long time, even in chemicallythe functional layer determine Terra-

demanding production surroundings.

Speed’s outstanding properties.

The TerraSpeed coating is applicable

The barrier and bond layers were

An optimized cover thickness ofin the production process of all paper

optimized by customizing e-moduli

0.8 mm offers the paper makers agrades and is characterized by aand material combinations. While thegood compromise between excellent

combination of mechanical, chemicalbond layer provides a basis for opti-

functional properties, adequate op-

and technological characteristics

mal bond between ceramic and met-erational reliability, and more poten-

which surpasses all current applica-al, the very dense but neverthelesstial for regrinds than any competitors’tion limits.

ductile barrier layer offers adequate

current offerings.

TerraSpeed is the latest ceramic coating for press rolls with paper contact.

corrosion protection (even if pH < 4)
TerraSpeed is a combination of three

and improved bond to the roll core.

layers. The top functional layer con-

TerraSpeed offers best sheet release,best abrasion resistance, and highest

sists of the well proven high-purity

Recently developed methods forcontinuity over long running times.

oxide ceramic with a specific surface

post processing the thermally

These advantages are designed into

treatment. New approaches of pow-

sprayed TerraSpeed coating improvethe cover for all paper and board

der production and optimized plasma

the coating’s shape accuracy.

grades, press configurations, rollcoating techniques allow an evenpositions, chemical/mechanical expo-

more efficient and higher quality top

The adjusted micro-hardness ofsure or stock quality. Thus, the paper

layer composition. Recently devel-

about 1,300 HV with various

maker’s essential needs are not only

oped surface systems make it pos-strengths in the different layers andfulfilled but even surpassed.

70

22 I 2006 I Voith Paper I twogether

TECHNOLOGY

100
60

600

500

500

400

% to granite

140% to granite% to granite

180

400
300
200
100
0

20
0
GraniteOther
Ceramics

CeraLease

TerraSpeed

300
200
100
0

Other
Ceramics

CeraLease

TerraSpeed

GraniteOther
Ceramics

CeraLease

TerraSpeed

Relative sheet release.

Relative Abrasion Resistance.

Relative Running Time.

Performance TerraSpeedto unique performance improvements.

Only the numerous findings that have

In the production of all board, liner,

been gathered over years in close

A step-by-step product development

and packaging qualities, the low qual-

cooperation with the paper makers

and numerous field trials have uncov-

ity of recycled paper results in severe

made the launch of the TerraSpeed

ered TerraSpeed’s potentials. In highabrasions, especially in the press

coating possible. TerraSpeed will

speed applications like newsprint

nips. In this context, TerraSpeedsignificantly determine future press

production, the “open draw” is no

configured for these applications isroll performance. The many nonlinear

longer a bottleneck if TerraSpeed isclearly superior to past rubber prod-factors that have to be considered

used. Even if the machine speed

ucts. If special paper grades like lightwhen working on solutions for theexceeds 1,600 m/min, the tension

weight cigarette paper and banknotepress roll position were analyzed anddifference in the central roll position

paper are produced, paper makers

taken into account in the develop-

can be kept (depending on thebenefit from the outstanding combi-

ment of TerraSpeed, a coating fulfill-

operating conditions) to a minimum

nation of sheet release and wear

ing customer expectations.

for years. Highly filled decor andresistance only TerraSpeed offers.

SC papers can be dewatered with

Moreover, TerraSpeed even proved

Thus, TerraSpeed allows cost saving

TerraSpeed for long periods without

its worth in specific raw material

performance improvements, in slowly

deterioration of the press roll surface.

(e.g. cane trash) processing.

running specialty paper machines

The use of tungsten carbide-coatedsteel blades is allowed and offers theand in highly abrasive board and
The future of the press rollpossibility of extended blade life andwell as in high speed graphic andextremely efficient doctoring of the

In the development of TerraSpeed,surface. Organic and inorganic

Voith Paper combines advances indeposits are strongly reduced by de-modern production technology andsigning the cover surface as a system

material processing with their years

that is matched to the demands ofof experience in the thermal coating

the furnish in harmony with the doc-of paper machine rolls. The total

toring, showering and other physicalcombination of Voith Paper’s various

properties of the nip. Another exam-competences made it possible tople is the coating base paper produc-

set a new standard in the thermaltion process. There, the press rollcoated press roll cover design. The

surfaces are sensitive to deposits due

development of TerraSpeed wasto the coating surplus in the broke

possible because of Voith Paper’s

cycle. The opportunity to intensively

complete engineering and paper

doctor the TerraSpeed coating leads

production process competence.

22 I 2006 I Voith Paper I twogether

packaging production processes asnewsprint paper machines.

Contact
Dr. Hasso Jungklaus
Rolls
hasso.jungklaus@voith.com

71

SEMINAR

Service Seminar in Finland – Record attendanceJudging by the number of people attending Voith Paper Oy’s service
seminar, Finnish papermakers are very keen to know about Voith’slatest developments in paper technology. More than fifty paper millmaintenance and service specialists met at the end of January
2006 with Voith experts in Helsinki. The 1-day interactive seminar
included diverse presentations not only on Voith service but also on
Voith’s roll cover innovations.
Guests were welcomed by Jouko“Since company operations started

Jokinen, Managing Director Voith

in 1997, we have delivered eleven

Paper Oy, who was gratified at the

shoe presses and several coatingpresence of so many paper industry

lines amongst others. Our latest pro-partners: “We never thought thisject, worth more than 50 million Euros,

seminar would be so popular. Many

is a complete rebuild of PM 3 atthanks to all of you for taking the time

Stora Enso’s Veitsiluoto Paper Mill”,

to come. We are certainly going to

he reported.

have an interesting day, and I am all
the more gratified to see here so

The seminar focused in the morning

many experts interested in Voith.”on PikoTeknik activities and the newroll coatings. Ingmar Vesterlund of

Mr Jokinen started the seminar by

PikoTeknik Oy informed everyone

giving a brief historical overview ofabout the new generation of cylinder

Voith’s activities in Finland. Whenand roll coatings, while Jouko Niini-

Voith Paper Finland was founded inmäki, Dr. eng., of Oulu University

1997 the company only had fiveexplained the dirt deposit mecha-

employees. Today Voith has three

nisms on drying cylinders. Dr. Michelcompanies in Finland: Voith Paper

Beltzung of Voith Paper Rolls thenOy, Voith Paper Fabrics Oy andpresented Voith’s new Elastomer

PikoTeknik Oy. And the number ofcoatings.

employees has risen from five to 75:
14 at Voith Paper, 10 at Voith Paper

PikoTeknik Oy specializes in hard

Fabrics and 51 at PikoTeknik.

surfacings. The most important ofthese is PikoClean, now used as standard coating in all new Voith paper
machines (see twogether 19 and 21).

76

22 I 2006 I Voith Paper I twogether

READER OPINION SURVEY

Excellent response
Just what we had hoped for – and our hopes were far exceeded!
The twogether editorial team, authors and producers tender theirsincere tanks to all those readers who took time to participate in
our Internet survey as requested in twogether 19.

“We recently started looking hard

It is now more than ten years andWhy are our contributions so highly

for new coating materials, while at

21 editions since this Voith Paper

regarded? Primarily because they are

the same time developing newcustomer magazine was first pub-authored by everyday practitioners.

properties for the materials welished – as well as a number of spe-

And twogether magazine pays tributealready use. We are making goodcial editions devoted to various prod-

for this to the Voith Paper engineers

progress with this work”, said Ing-

ucts and countries. During this time

and technicians who take time tomar Vesterlund, “and we are very

total circulation figures in several

report on their work in research andlucky to be located in Finland as far

languages have more than tripled –development, project realization andas thermal coating is concerned.

reflecting the high interest in our ar-customer support.

Six people here chose thermal

ticles. Besides that, other specialized

spray coating as their doctorate

journals at home and abroad publish

We also pay tribute here to our cus-thesis, and there are two faculties

reprints taken from each edition.

tomers, whose articles and commen-

at Finnish universities conducting

taries play a key role in upholding

research in this area. That makes

The popularity of twogether magazine

the quality of twogether magazine.

our development work much easieris primarily due to our ongoing re-

Despite heavy workloads and respon-– there is no shortage of help andporting on innovative technical devel-sibilities, they too find the time tosupport!”.

opments and their successful imple-

make their contributions. We would,

mentation. “I know of no other journal

therefore, like to pass on all the

The afternoon was mainly dedicat-

to which I can attribute so much use-

thanks we have received from oured to Voith maintenance and repair

ful information for my work”, writes

readers to every single one of ourservices. Discussions centered on

one of our regular readers. Althoughauthors. It is they as experts who

ceramic coatings for central rolls,

we receive many such letters, we

provide the solid foundations of ourpaper roll rebuilds, and the operat-

shall not rest on our laurels by any

customer magazine.

ing characteristics of Voith machin-means – criticism and suggestions forery in the pre-drying zone.

improvements are always welcome.

And last but not least, we heartily

In this edition, for example, we havecongratulate the three principle prize-

This busy day concluded with a visit

tried to improve the layout and ar-winners who took part in our reader

to a tough ice-hockey match be-rangement of twogether magazine.

survey. We wish Klaus Gödrich of

tween two Finnish league teams

LEIPA GmbH, Schwedt, Germany, afrom Helsinki. Exciting as it was towonderful weekend in the Black For-see the best team win, participants

est, and we hope Ismo Rossi of Sappi

seemed to enjoy at least as much

Tugela, South Africa and Beatrice

the time they spent together at thisAlm of Holmen Paper AB, Hallstavik,

interesting seminar.

Sweden will also have a lot of funwith their prizes.

22 I 2006 I Voith Paper I twogether

77NEWS FROM THE VOITH GROUP

Voith Maxima® 40 CC –Crossing new frontiers in traction power
Voith Turbo’s new locomotive – A breakthrough in diesel-hydraulic traction
Rather than just traction components, Voith Turbo now offers a complete
locomotive for the first time. The Maxima 40 CC 6-axle diesel-hydraulicmainline locomotive is designed both for hauling heavy freight trains at
speeds up to 120 km/h, and for high-speed passenger transit up to
160 km/h. By developing and manufacturing the Maxima locomotive at
the newly founded Voith Turbo Lokomotivtechnik in Kiel, Germany,
Voith Turbo demonstrates that diesel-hydraulic traction has a very competitive future in the high-performance sector as well.
It is an ongoing challenge these days

transmission with up to 4,200 kW

transport and operations possibilities

for transport companies to safeguard

gearbox input. Based on the existing

not only by eliminating the need fortheir market shares in face of growing

family of cost-effective hydrodynamic

locomotive changes between electri-competition for freight transit world-transmissions, this new system puts

fied segments and different power

wide. In particular the rail freight sec-

Voith Turbo in a completely new hy-

supply systems, but also thanks to its

tor needs more cost-effective anddrodynamic drive performance class.

high traction rating and adhesion.

innovative concepts, both with regard

This innovative development, based

to operations logistics and traction

Imminent completion of the Voithon highly effective application of thetechnology.

Maxima 40 CC will provide operators

Voith hydrodynamic drive concept,

with Europe’s first catenary-indepen-

illustrates the enormous potential of

The Maxima 40 CC is powered by thedent locomotive in this performance

this ideal rail traction technology.

Voith Turbo LS 640 re turbo-split

class. It opens up more cost-effective
The Voith Maxima 40 CC will debut in
September this year at the Innotransinternational rail engineering trade fairin Berlin.
Voith Turbo is a Voith Group division
specializing in hydrodynamic drives,
couplings and braking systems forroad and rail, marine and industrial
applications.

78

22 I 2006 I Voith Paper I twogether

NEWS FROM THE VOITH GROUP

Voith Industrial
Services

Voith Siemens
Hydro

The industrial sector faces ever in-

In order to provide the optimal ser-

Voith Siemens Hydro Power Genera-

creasing pressure to develop innova-

vice for your requirements, Voithtion has been awarded a contract bytions while keeping costs as low as

Industrial Services relies on the com-

E.ON Wasserkraft for supplying equip-

possible. As a result, companies are

bined power of strong brands. Voith

ment for the modernization of theforced to work more efficiently, eco-and Hörmann are the specialists for

Waldeck I pumped storage station.

nomically and flexibly. In times likeprocess services, an area in which

E.ON Wasserkraft is going to invest

this, it is good to have a strong part-industry-specific know-how is essen-€ 50 million in the hydro power projectner who can provide comprehensive

tial. DIW and Premier have madelocated in Germany’s federal state ofservices, allowing your company tonames for themselves as experts for

Hesse. The contract value for Voith

focus on the essentials.

location-related facility services.

Siemens Hydro runs up to € 24 million.

Voith Industrial Services offers you a

The comprehensive coverage of

The overall technical concept – fromunique combination of process andFacility and the clear industry orien-

structural to electro-mechanical design

facility services from one source –tation of Process enables Voith– was elaborated by Voith Siemens

with the two complementary compe-

Industrial Services to offer all services

Hydro in close cooperation with Bilfin-

tence areas, Process and Facility.

you need for your production facilities

ger Berger. While Bilfinger Berger will

and plant infrastructure – whereverexecute the civil works for the new

you are in the world.

complex Voith Siemens Hydro will be

The Process competence area offers
all services directly or closely linked

responsible for the supply of a new

to the production process: from

Voith Industrial Services, a groupreversible pump turbine with 74 MW

planning, engineering, assembly anddivision of Voith AG, counts as one ofturbine output, motor-generator,

maintenance to the renovation andthe leading providers of technical ser-shut-off valves, start-up converter,

modernization of machines andvices for the key industries. With moretransformer and process control.

systems.

than 150 business locations worldwide and over 15,000 employees,

Voith Siemens Hydro Power Genera-

The Facility competence area covers

it posts sales of about € 700 million

tion is a Group Division of Voith and –all location-related services: fromin 2006.

with a workforce of around 2,600

overall facility management and theemployees and sales of € 600 million

cleaning of technical systems toin the past business year – it belongs

maintenance – across all industry

to the worldwide leading companies

sectors.

for hydro power equipment.

22 I 2006 I Voith Paper I twogether

79

CULTURE

80

22 I 2006 I Voith Paper I twogether

CULTURE

Green turf, beautiful gameand lots of paper
The object of desire is as green as a soccer field,
only a few grams in weight, the size of a postcard
and entitles you to share the passionate atmosphere at the biggest sports event in 2006:
a ticket for the 2006 Soccer World Cup. A totalof approximately 3.3 million tickets are being
produced according to state-of-the-art security
standards in order to exclude any forgeries or
black-marketing. But there are also countlessother paper products all relating to the World Cup,which are making the German paper industry toflourish. At the start of the production chain are
the paper machine manufacturers such as Voith
Paper, one of the largest in the world.
Anyone who has got hold of one oforganisers will receive 688,000 tick-the coveted World Cup tickets on theets and the final quota of 347,000

open market can count themselves

tickets goes to corporate customers.

lucky, as there were roughly 40 million people applying for the internet

Stylised La-Ola wave decorates

quota of 1.112 million admission

the ticket

tickets that were on sale to the fans.

22 I 2006 I Voith Paper I twogether

According to current information

The lucky ticketholders will them-from the German Soccer Association

selves only receive the admission

DFB and figures provided by thetickets for the sports event of theBavarian broadcasting station Baye-year a few weeks before the firstrischer Rundfunk, the entire quota

kick-off. Only then will the tickets beof 3.37 million World Cup tickets issent to the recipients. Only a handful

divided up as follows: 1.112 millionof VIPs were allowed to get hold oftickets are sold directly to fans on thea specimen of the coveted ticket

internet, soccer associations receive

months before the World Cup. At the783,000 tickets, and 440,000 tickets

official launch of the ticket by theare available for media representa-

World Cup mascot lion “Goleo”,

tives and VIP guests. Sponsors andexactly 100 days before the start of81

CULTURE

The object of desire –in paper.

the World Cup, the thing that people

with a valid chip. Secondly, the paper

will be used for everything relating to

liked most about the grass-green

is embossed using a state-of-the-art

the World Cup. The paper industry

ticket was the stylised wave, which is

production technique and is unmis-

will profit from the fact that many

supposed to be reminiscent of thetakeably marked with a printed-on

more paper products will be required

typical La-Ola wave of enthusiasm inbar code. The thermal printing pro-– the tickets themselves play an al-

the stadia. To ensure that tickets arecess used ensures optimal display ofmost secondary role in this respect.

as forgery-proof as possible, an inge-

the bar code. Additional copy protec-

From official World Cup posters tonious mix of security standards hastion is ensured by a printed-on shiny

stadium magazine, a vast range ofbeen implemented.

hologram. “I can vouch for the factprinted products will accompany thethat the tickets can’t be forged”, said

fans.

Forgery-proof tickets – what does

the OC Vice-President Wolfgang

this mean? Firstly, the tickets have an

Niersbach.

invisible electronic chip embedded

In World Cup merchandising, paper
products constitute a major aspect of

into the paper, which stores the per-Whether fan guides or matchthe items available. With calendars,

sonal data of the ticketholder. And it

programs, a lot of paper is being

newspapers, books, games, audio-

is precisely this chip that is used forprinted for the World Cup

books, quiz-books, posters, puzzles,

access into the stadium. You will only

stickers and much more besides,

be allowed to go through the turnstile

Yet the tickets represent just a frac-soccer fans can get in the mood forinto the stadium if you have a ticket

tion of the total amount of paper that

this massive event.

Cards, games, calendars, posters, puzzles, art – all paper products to do with the World Cup.

82

22 I 2006 I Voith Paper I twogether

CULTURE

If you imagine a normal stadium visit,

At half time, the fans satisfy their hun-it will soon become clear how many

ger and thirst with sausages in paper

products made of paper will benapkins and beer in paper cups.

accompanying the fans into thestadium.

And after the World Cup? The paperindustry does not stop there by any

To help you find your way aroundmeans – the most emotional mo-town, special fan guides have beenments, the most spectacular scenes

provided, including a map of the city,in the game and the most memorable

a ticket for local public transport andgoals are recorded for posterity intips on where to go. The route to thebooks, calendars and programs or on

stadium is accompanied by posters

posters. This is some sort of consola-drawing attention to matches, soccertion for those who were unable toPM 4, Switzerland – a Voith paperstars and sponsors. Once you arrive

attend live and a treat for those whomachine that specialises in the pro-in the stadium, the admission ticket

wish to indulge in memories. Having

duction of top-quality online coatedwill allow access to the fans’ para-

the Soccer World Cup in your own

program paper. Vast quantities ofdise. First of all, all fans are given acountry is undoubtedly a major cata-

paper are also being used in mer-match program, so that they can findlyst. The wealth of different qualities

chandising for the sports event ofout all about the two teams that faceof printed products also reinforces

2006. For example, puzzles are being

each other that day.

Germany’s position as a producer of

produced, which are stored in special

diverse types of top-quality paper.

boxes, again stemming from Voith

Specially designed paper bags
are particularly chic

paper machinery.
“Countdown” paper is made byVoith paper machinery

So that the program doesn’t get in

And who would have thought that art
and soccer could enter into a fruitful

your way, it comes with its own paper

A large volume of the paper for thesymbiosis? Famous artists from thebag. And then away you go. After theWorld Cup has been produced by

six FIFA confederations have em-

whistle, the teams are spurred on byVoith paper machinery. Fans can now

braced the beautiful game. The result

the cheering crowds, while young

get in the mood for the big event

is fourteen top-quality posters thatand old alike encourage their heroes

through the launch of “Countdown”,

were published in the context of theby passionately waving paper flags.

a program produced on the Perlen

official art and culture program for the2006 World Cup, artistically embracing the “soccer” theme with photographs, paintings or collages.
The impressive art posters are printed on PhoeniXmotion deluxe paper –a unique premium paper that is produced on the PM 2 at the Scheufelen
Paper Company in Lenningen, Germany. “A deluxe print substrate for
emotive messages at the highest
level,” is how Scheufelen Paper Company’s Head of Marketing, SusanneTodorovic, describes the premium
paper from the Voith machine.

22 I 2006 I Voith Paper I twogether

83

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 22, July 2006

Copyright 7/2006: 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