Paper Technology Journal

News from the Divisions:
Republic Paperboard Company –the world’s first paper machine with
two gap formers.
Wet End Process™ – new technology
solutions around the paper machine
wet end.
Bauernfeind PM 1 – strengthening of
Frohnleiten mill.

10

Sirius – the online wind-up system.
Corporate news:
Voith São Paulo, Brazil.
Paper Culture:
Festas do Povo, Campo Maior.

Contents

EDITORIAL
Foreword

1

NEWS FROM THE DIVISIONS
Republic Paperboard Company –the world’s first paper machine with two gap formers

2

Stock Preparation: Wet End Process™ –New technology solutions around the paper machine wet end

7

Stock Preparation: Screening of recovered paper stock
for the production of graphic papers

12Paper Machines: DuoFormer TQv –a new twin wire former

17

Paper Machines: DuoCleaner –the optimal fabric and felt cleaning system

22

Paper Machines: Kehl PM 6 – a new production line for laminating papers

26

Paper Machines: Dongying Huatai successful start up

30

Paper Machines: Zhuhai BM 2 started up 2 weeks ahead of schedule

32

Paper Machines: Bauernfeind PM 1 – strengthening of Frohnleiten mill

36

Paper Machines: TissueFlex – first application in America

40

Paper Machines: Sirius – the online wind-up system

42

Finishing: “A look behind the scenes” –preparations for the start-up of the Janus MK 2 for Schongau PM 945

Service: Partnership with papermaker leads to innovative solution

49

Paper Machines: Process technology – meeting current and future demands
on system suppliers

52

CORPORATE NEWS
Voith São Paulo, Brazil

55

Stickies summit in Washington, D.C.

59

PAPER CULTURE“Festas do Povo”, Campo Maior
Frontispiece: Republic Paperboard Company – the first parent rolls produced on the new machinewith two gap formers.

60

1Dear Customer, dear Reader,
We have pleasure in introducing you to Issue No. 10 of our popular twogether Paper
Technology Journal for the pulp and paper industry. The positive feedback we continue
to receive from around the world encourages us to keep up the high standard ofarticles published in this truly international communications tool.

Hans Müller,
President and CEO
Voith Sulzer Paper Technology

We are fully aware that the consolidation trend among our customers has not ceased
and this continues to have a damping effect on worldwide order placement for complete new production lines, particularly in the graphic papers section. On the other
hand, demand for rebuilds aimed at product quality improvements, especially for finishing equipment, remains buoyant. Our Board and Packaging Paper operations also show
a healthy level of activity, pointing to a record booking level for the current businessyear. Similarly, we can see positive trends in demand for our stock preparation
product lines.
In the meantime, our leading position in shoe press technology has been further
substantiated with the order for the 200th NipcoFlex Shoe Press since market introduction of this innovative product.
The second calender generation of our Janus Concept line – Mark II –, has beensuccessfully introduced to the paper industry and the performance of our Janus technology in Port Hawkesbury, Canada, has been stabilized, providing a significant contribution to the record-breaking production levels for SC-A grades on PM 2 at this mill.
Successful integration of the Scapa Plc roll covering line into our Service Divisionconfirms the merits of this decision to add to the overall competence of our system
supplier approach. Our customers likewise benefit from the close link between
Voith Fabrics (now incorporating the complete range of Scapa’s fabrics activities) andVoith Sulzer’s development of new paper machine processes and components.
In short, we see an exciting time ahead of us and we have full confidence in the continueing fine performance of the industry we serve.

Yours sincerely,

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

Republic Paperboard Company –the world’s first paper machine with
two gap formers
On November 27, 1999, Republic

The Republic Group Incorporated –Paperboard Company, Lawton,

a company looking to the future

Oklahoma, USA, brought about a

The author:
Christoph Merckens,
Paper Machines
Board and Packaging

revolution in paper manufacturing:

Headquartered in Hutchinson, Kansas,

A new gypsum-grade paperboard

Republicmachine was brought on-line –RGC), the parent Company of Republic

the world’s first paper machine with

Paperboard Company, is comprised of

two gap formers. This milestone inthree business segments, namely paper-

board and packaging paper production

board manufacturing, gypsum wallboard

illustrates the technological leadership

manufacturing and paper recycling. The

and innovative spirit of Voith Sulzer

production of gypsum-grade paperboard

Paper Technology.

and gypsum wallboard has always been

Group

Incorporated(NYSE:

3

Fig. 1 and 2: Republic Paperboard Company inLawton, Oklahoma, USA.
2

perboard in the USA. To achieve thisucts can be manufactured on Lawton’sgoal, they were interested in new, innova-

PM 1. The requirements to be met by bothtive technologies, some of which were al-grades are complex; however, the mostready being used successfully in Europe.

decisive properties are high strength, ahydrophobic top layer (achieved by siz-1

Lawton, Oklahoma was chosen as the siteing) to shield the product against humid-of the paper mill due to its central loca-

ity from outside and a hydrophilic backtion in relation to both Republic’s internallayer to achieve optimum bonding be-

and external customers. A large part oftween gypsum and paperboard. Current-

the production is sold to other domestic

ly, basis weights range between 190 g/m 2

gypsum wallboard manufacturers through(39 lbs/MSF) and 200 g/m 2 (41 lbs/MSF),

long-term delivery contracts.

but are to be reduced to 180 g/m 2

core businesses of Republic. To offer(37 lbs/MSF) in the years to come. Apart

gypsum-grade paperboard also in thelower basis weight range, it was decided

from the two gypsum-grade paperboard
Gypsum-grade paperboard as a productto supplement the Company’s paperboard

products, the mill can produce a variety
of other products.

The machine is de-mills located in Hutchinson, Kansas;

Gypsum wallboard is made of a gypsum

signed to produce basis weights from

Commerce City – Denver, Colorado; andcore and two sheets of paper, accounting

127 to 244 g/m 2 (26 to 50 lbs/MSF).

Halltown, West Virginia, with a newfor both strength and appearance of thegreenfield paperboard mill. In a press re-wallboard. The two-component creamface

lease, Phil Simpson, Republic's Chairman(white top layer and gray filler) is used

and President, declared that the groupfor the face of the gypsum wallboard;

had set a goal to become a leading manu-

whereas, one-component gray board is

Republic Paperboard’s vision was clearlyfacturer of lightweight gypsum-grade pa-

used for the back (grayback). Both prod-

defined right from the start – to double

An ambitious project is taking its course

4Fig. 3: Pulper in the stock preparation.
Fig. 4: Scheme KM 1.
Fig. 5: Final section of KM.
Fig. 6: DuoFormer Top with ModuleJet.
3

for board and packaging papers at
Ravensburg, Germany.
At the same time, the Voith Sulzer project
team presented a configuration with thetwo gap formers especially developed for
board

and

packaging

papers,Duo-Former™ Base and DuoFormer™ Top,
which seemed to be ideally suited for the
production of gypsum-grade paperboard.
Both gap formers were installed on thetest paper machine at the time when thetests for the fourdrinier wire design were
performed. The customer became interested in running tests with the gap formers as well, which then prompted anotherseries of tests. These extensive field tests
the group’s paper production with a new,determined that fitting the new machinehigh quality, low cost production plant.

with gap formers was the correct choice.

In the summer of 1997, Voith Sulzer was

The dedicated teamwork of Republiccontacted as one of several renowned

Paperboard and the Voith Sulzer team

suppliers to work on a project for thehelped to create the trendsetting design

manufacture of three or four-layer gyp-for the world’s first paper machine with

sum-grade paperboard. One of the cus-

two gap formers.

tomer's basic requirements was to use

4

only components that had already been

On February 19, 1998, Voith Sulzer Paper

tried and tested. Therefore, a design withTechnology finally obtained the order tothree fourdrinier wires was developed fordeliver two complete stock preparation

the wire section, which was being testedlines, the paper machine and a slitter-on the Voith Sulzer test paper machinewinder.

5

Stock preparation
The stock preparation system was delivered and started up by Voith Sulzer Paper
Technology, Appleton, Wisconsin, USA. It
consists of two lines, one for the white
top layer of the creamface and anotherone for the gray filler and backlayers ofcreamface and all layers of the grayback.

5

6

To achieve excellent results in slushing

the stock is supplied to a coarse and fineand cleaning of the recycled paper, thescreening system. The cleaner system fordesign for both lines was developed inseparating heavy and lightweight contam-

close cooperation with the customer andinants is followed by fractionation and re-on the basis of tests performed atfining equipment for short and long fiber

Ravensburg, Germany, and Appleton,components. In addition, Voith Sulzer’s

Wisconsin.

scope of supply included Meri rejects
handling units, as well as Andritz refiners

The white line is fed with primarily un-

and disk filters.

printed white grades of paper and has acapacity of 240 tons/day. It consists of acontinuous pulper, as well as pressure

Paper machine: two gap formers andscreening, cleaning and refining systems.

other state-of-the-art components

The gray line is primarily fed with
ONP and OCC and has a daily capacity of

The paperboard machine’s former design

745 tons. After the continuous pulper,

sets new standards for the board and6Facts and figures
Working width: 4,000 mm (161 inches)
Maximum roll diameter: 3,000 mm
Annual production: 220,000 t
Operating speed: 762 m/min (2,500 fpm)
Products:
Gypsum-grade paperboard:
Creamface 180-200 g/m 2
Grayback 170-190 g/m 2
Packaging grades: 127-244 g/m 2

In March 1999, the installation of the paper machine and the stock preparation
plant was started under the supervisionof Voith Sulzer personnel. The electro-mechanical testing of the entire plant, first of
the stock preparation system and then of
the paper machine, was started in August.
packaging paper machines of the new

mum strength values while ensuring high

The common goal of completing such anmillennium. In the future, not only inporosity at the same time. Additionalinnovative project required rapid andgypsum-grade

production,

benefits of the press configuration are

constructive cooperation between the

but also for many other liner and board

high runnability and simple transfer. The

highly motivated teams of Voith Sulzer,

grades, two or more gap formers will beentire dryer section is two-tiered, theRepublic Paperboard and Fluor Daniel.

used in one machine.

fabrics of the first two dryer groups are

paperboard

fitted with Voith Sulzer DuoCleaners™
The machine is running

Two gap formers were used in the wirefor cleaning. – After the dryer section, asection on the Republic machine. The

hard-nip calender with heated bottom roll

first former, DuoFormer™ Base, produces

and EcoNip top roll is installed, and final-

Finally, in November 1999, the time had

a top layer. The second former, thely, a cooling unit is installed consisting ofcome: “stock on wire” was attained on

world’s first DuoFormer™ Top, forms afour cylinders which helps to keep theNovember 21. Six days later, the entire

bottom layer. The most important advan-

temperature on the reel operator-friendly.

paper machine was put into operation

tage of the gap formers is to achieve

The paper is wound on a horizontal reel(paper on the reel). Start-up can begood formation within a wide MD/CDwith reel spool magazine.

described best by a short comment of
Republic Paperboard’s most important

ratio range. Compared to the fourdrinier
wire, higher consistencies can be run

The paper machine was delivered andcustomer in Lawton: “Don't change any-

while obtaining a comparable formation

started up by Republic and Voith Sulzer

thing!” Already, the second roll of gypsum-and the bond strength is better, which

Papiermaschinen AG, St. Poelten, Austria.

grade paperboard was salable quality!

makes spraying starch unnecessary. To
Voithachieve optimum CD profiles, the headbox of the DuoFormer Top is fitted with a

Installation and start-up

Sulzer

Paper

Technology

andRepublic Paperboard are proud to have
set this milestone in paper production

ModuleJet™ dilution water control. And
last, but not least, little space is required

Fluor Daniel of Greenville, South Carolina,

together. The thanks and congratulations

for a gap former, compared to alternative

was selected as general contractor for in-of the Voith Sulzer team go to the staff ofdesigns.

stalling the complete plant. Excavation

Republic Paperboard who have put theirwork started in late June 1998, and astrust in us, which was absolutely needed

The Tandem NipcoFlex™ press (a double

early as January 1999, the first paper

for putting an entirely new concept ofshoe press) was chosen to obtain maxi-

machine foundation plates were installed.

such dimensions into practice.

N e w s F R O M Stoffaufbereitung
THE DIVISIONS

7

Wet End Process™ –new technology solutions aroundthe paper machine wet end
Both for graphic grades and packaging

Main functions in the Wet End Process™

papers, the trend towards higher operating speeds continues unabated. At

The Wet End Process™ mainly consists

the same time, the dilemma of higherof three subsystems: the approach flow,

quality at lower cost is being solved byfibre recovery, and broke handling. These

using a broader mixture of furnish

subsystems in turn can be broken down

components.

into clearly defined functions (Fig. 1). At
the beginning of the approach flow, theThe authors:
Dr. Michael Schwarz,
Anton Gmeiner,
Stock Preparation

In this context, a decisive role is played

various furnish components are mixed inby the process technology around thethe right proportions. Apart from a cor-

wet end of the paper machine. The Wet

rect solids ratio of the individual compo-

End Process™ (WEP) plays a criticalnents, the papermaker also needs torole in paper production due to theensure a constant stock consistency.

immediate vicinity of the sheet forma-

Return stock flow from broke treatment,tion zone and the complex interfaces

the extraction of sweetener stock andwith other process subsystems.

filter thick stock return flows all have tobe taken into account, – in conventionallyarranged systems by arranging the mixing and machine chests in series.

8

Fig. 1: Functions in the Wet End Process™.

nents and the press filtrate are directly
cleaned by microflotation. Broke treat-

Former/press
sectionHeadbox

Screening

Deaeration

Cleaning

Dilution withwhitewater

Mixing of furnish
components

1

ment has to accommodate the various
broke flows (coated or uncoated), and it
has to offer sufficient storage capacity.

Whitewater
handling

Voith Sulzer has critically investigated
the functionality of all WEP subsystems
and redesigned them where necessary.

Fiberrecovery

The result is a “toolbox” of optimum subBroke
treatment

system designs on a modular basis,
enabling customized, favourably priced
system solutions for all individual needs.

The subsequent dilution with whitewaterty in the pipework and headbox distribu-

Some of the less familiar components asplays a key role, since from this mixing

tor. All machines and design measures inwell as certain new developments in thestage onwards, the stock is in a pressur-

the approach flow should be judged on

approach flow are presented here.

ized closed-circuit loop right up to thetheir ability to stabilize stock consistency

headbox slice. In other words, any pres-and pressure.

Furnish mixing
Apart from high installation costs, con-sure fluctuation or change in stock consistency immediately affects headbox

On all high speed paper machines and forventional stock mixing in mixing and ma-

mass flow, and therefore the basis weightcertainmechanicalchine chests has a further serious draw-of the finished paper product.

deaeration is undertaken together withback. The large stock volumes result instock cleaning in the LC range, althoughcontrol system deadtimes which delay

The approach flow directly before thecleaning at this point is not mandatory.

stabilization (Fig. 2). With smaller vol-headbox is an extremely sensitive area

Screening is installed immediately before

umes and more efficient mixing, thewhere it is essential to keep all parame-

the headbox, usually mainly as a policing

ComMix™ system ensures more stableters stable. Pressure variations are prop-

measure.

mixing and consistency than convention-

speciality

grades,al mixing and machine chest systems.

agated in the pipework at sonic speed
through to the headbox, where mass flow

In the former and press sections, spaceat the slice outlet changes simultaneously

available for water removal is steadily de-

As shown in Fig. 3, the individual fresh

across the entire machine width. This

creasing with modern new paper ma-

stock flows, together with broke andonly influences the MD, and not the CDchines. Special attention must therefore

thick stock from disk filtering, are fed

basis weight profile. On the other hand,be paid to optimum whitewater collection.

into a horizontally arranged mixing tube.
By tangentially staggered feeding, thestock consistency deviations affect both
the CD and MD basis weight profiles be-

Whitewater I surplus is passed to fibre

kinetic flow energy of the individual stockcause they show up staggered across therecovery together with whitewater II,

components is efficiently converted intomachine width depending on flow veloci-while heavily contaminated flow compo-

mixing energy.

Stock Preparation

9

Fig. 2: Furnish mixing
Conventional:
I Large volumes
I Slow control response
I 2 pumps
ComMix™:
I Volume reduction by 70%
I Improved control strategy (filler, consistency)
I 1 pump.

Fig. 4: Stock mixing with whitewater
Conventional:
I Large volumes
I Good mixing
HydroMix™:I Volume reduction by 80%
I Space saving installation
I Fast control response
I Good mixing.

Fig. 3: Furnish mixing in the ComMix™.

Fig. 5: HydroMix™.

2

3
Conventional:

Mixing chest

ComMix™:

Machine chest

Sweetener stock4
Conventional:

5Whitewater

HydroMix™:

Backflow
To fan pump

Overflow fromdeaeration

Stock

Cleaner
pump

Stock

Cleanerpump

Thick stock

Retention agent dosage

Subsequent static mixing elements are

purely as a hydraulic flow mixing system.

recommended where the ratio of furnish

The individual flows enter and are imme-

components fluctuates widely.

diately passed on. Exhaustive trials have

Given today’s wide variety of furnishes

enabled us to accurately define the opti-

and fillers, a correct choice of retention

mum conditions for efficient stock mixing.

agent, and in particular correct mixing,

Stock mixing and whitewater

are decisively important. To reduce costs

Conventional system technology is tostore whitewater in a generously dimen-

Fig. 5 shows a HydroMix™ installationandsioned tower, with fresh stock entering at

operating for the last 2 years on an LWC

need to be mixed in quickly and distrib-

optimize

effectiveness,

additives

the bottom for mixing (Fig. 4).

machine. Since this rebuild and elimina-

uted evenly. We have therefore carefullytion of the whitewater tower, the mill has

investigated the hydrodynamics involved

HydroMix™ is a new development which

reported significantly reduced MD/CD

in the mixing process. The present state

has no storage capacity, but functions

profile variation coefficients.

of technology is to introduce the reten-

10Fig. 6: Mixing trials for retention aids.
Fig. 7: Whitewater handling with the VortexBreaker™.
Fig. 8: Whitewater handling with HydroPipes™.

tion agent against the direction of stock

6
Counterflow:

Parallel flow:

flow, although introduction in the flow
direction has also been recommended inrecent times (Fig. 6). Extensive tests

3xD

3xD

were carried out to establish the conditions for optimum mixing kinetics. The

Autocorrelation of mixing effect:

mixing results were evaluated by digital
photographic analysis (auto-correlation ofl = 0.47

l = 0.89

Øthe mixing image).

ØAs expected, a high velocity differentialØØ

between retention agent and stock flow isessential for the efficiency, and in partic-

7

ular, for the speed of mixing. The trials

VortexBreaker™:

Conventional:

also showed significantly better mixing
results with introduction of the retention
agent against the direction of stock flow.
Whitewater handling
Voith Sulzer has developed a family of
new components for efficient collection
Air entrainment in tray outlet,
vortex is generated

No air entrainment in tray
outlet, no vortex

and removal of the large volumes ofwhitewater in the restricted spaces available in modern paper machines. The
components can be used individually or

8Conventional:

HydroPipes™:PM

in combination, thus ensuring reliable
management of all process water flows.

PM

VortexBreaker™
Where a horizontal flow is diverted into aWWWWvertical flow, the invariable result is vortex formation and risk of air entrainment.
Installing flow equalizers to remove al-

Air entrainment
by waterfall effectNo air entrainment

ready formed vortices is costly, and inmany cases impossible due to local con-

Stock Preparation

11

Fig. 9: Whitewater handling with the CyclonAir™
I Water with entrained air from paper machine is
distributed into small jets
I Entrained air bubbles can easily escape fromthe jets
I Entrained air is removed by low vacuum.

For further details, please refer toVoith Sulzer Stock Preparation brochure
VPR-SD-14-0003-GB-01.

Fig. 10: New Wet End Process™.

ditions. By installing a suitable lamellar

Vacuumconnection

grid just below the surface, vortex forma-

9tion is prevented before it can occur inthe first place (Fig. 7).

Inlet

HydroPipes™
The collection of whitewater on the drive

Housingside of the paper machine often involves
considerable height differences (Fig. 8).

Flow
distribution
basketIf no costly measures are taken – such as
LIC controlled flow retention – the resul-

Fresh water (warm)

tant waterfall effect can generate uncon-

pipes so that any height difference can be

Wet broke
tower

accommodated.

Dry broke
tower

Sweetener stock

CyclonAir™
The whitewater from the forming sections

Dryer section

Press section

FormerWW I
ScreenMultiJet™

wall and installing staggered drainage

WW II

the whitewater tray with an inclined side-

Headboxbances. This can be avoided by designing

Screendistur-MultiJet™

systemCleaner

causing

HydroMix™

entrainment

10
ComMix™

trolled hydraulic flow conditions with air

Thick stock
Make up(Stock preparation)

Water buffer

Clear filtrate

Save allCloudyfiltrateof high-speed paper machines often contains so much entrained air that it be-

the paper machine, the CyclonAir™ re-comes very difficult to handle. Even high-moves the majority of entrained air.

New Wet End Process™ (Fig. 10)
The components described here compli-

ly efficient mechanical deaeration is notenough to ensure trouble-free operation,

In the CyclonAir™ the incoming white-ment Voith Sulzer’s comprehensive range

since the deaerator feed pump perfor-

water is directed tangentially into a sta-of machines and equipment in the Wetmance is often seriously affected by thetionary screen basket, which breaks it up

End Process™. The units are carefullyhigh air content. In such cases, or for

into a large number of small individual

fine-tuned to each other, enabling modu-

special applications as an alternative tojets. Free air bubbles can escape into thelar design of any configuration using

mechanical deaeration, this problem canperipheral chamber, which is maintained

well-proven components. The benefits

be solved by installing the CyclonAir™

at a slight vacuum. The deaerated water

are faster grade changes, improved sys-

(Fig. 9). Located directly at the whitewa-

flows into a standpipe immersed in thetem stability, greater quality consistency

ter collection point on the drive side ofwhitewater tray.

and lower overall process costs.

12

Screening of recovered paper stock for the
production of graphic papers

+
+

+

+
+

+
+

+
+

+
+

+
+

+
+

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+

+
+

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+

+
+

+

+
+

+

+
+

+
+

+
+

+
+

+
+

+

+

+
+

LC Screening++

HW Cleaning

+
+

+
+

+
+

+
+

+
+

+
+

+
+

+
+

+
+

Refining

+
+

+
+

Press

+
+

+
+

Bleaching II

+
+

+
+

Dispersion II

+
+

+
+

Press

+
+

+
+

Disk filter

+
+

+
+

Flotation II

LWC papers
standard
improved++

Bleaching I++

Dispersion I

+
+

+
+

Press

+
+

+
+

Disk filter

SC papers
standard
improved

Although screening stickies is no easytask due to their inherent characteristics,
removal can be facilitated under certain
conditions. These include the choice ofsuitable screens, screen baskets and rotor design (see twogether Journal No. 1
and 4.). However, no measures on theirown can guarantee optimum screening,since acceptable stickies removal is notpossible with single screening systems
or machines. Recovered paper processing therefore consists of several subsystems, of which screening is by far themost important. Fig. 1 shows a typicalrecovered paper processing line. Hole
screening removes problematic contaminants to protect the downstream systems
and to make the stock suitable for fineslot screening. Although every effort ismade to exploit all potential for optimum
stickies removal, stickies removal rates(by number) in hole screening are rather
low. An efficiency as high as 50 % for thecomplete hole screening system would be

LC Screening //++LW Cleaning++

HW Cleaning

MC Screening ø++paper: Using recovered paper means
having to solve the stickies problem!

1
Flotation I

Protector system

Newsprint
standard
improved

MC Screening //Pulping

The author:
Reimund Rienecker
Stock Preparation

Since graphic papers are bulk grades
produced on high-speed machines,
operating economics have a highpriority. For the higher quality grades,
however, additional aspects must be
considered. Although primary fibres arestill preferred here, a certain content ofrecovered paper is not a bad idea since
it brings advantages on the paper machine. This presents no problems withtoday’s advanced technology for processing recovered paper, but specificcriteria must still be met. Only white
paper grades should be used and theyshould have a sufficiently high quality
potential, and be available in suitably
large quantities. The only reliable
source meeting these needs is household collection. Recovered paper is,
however, very different from primary
fibres. It contains contaminants virtually unknown in primary stock and thesecan decisively influence production,and the end product itself. The main
problem is stickies, which occur wherever recovered paper is used. The following statement is therefore fundamental in the screening of recovered++

Stock Preparation

13

Fig. 1: Schematic arrangement of recovered fibre
stock preparation for various graphic paper
grades.
Fig. 2: Hole pre-screening in DIP systems.
Left: Normal stickies size distribution in the inlet
Right: Stickies removal as a function of particle
size.
Fig. 3: Comparison of stickies removal withvarious screening system concepts.
2

Stickies size distribution(Inlet to hole screening)
11

Efficiency h [%](Number)

0100

500 1000
3000
Stickies diameter [mm]

0
100

10000

500 1000
3000
Stickies diameter [mm]10000

Measured using TAPPI Test Method T 277 pm-99

3

ø1.4

ø1.4

2
0.25

LC slot screening

3

4
0.15

0.25

Cleaning

1

MC slot screening

Flotation

MC hole screening

5

0.15

0.2
0.15

ø1.4
0.15
100

MCø+MC//+LC//
MCø+LC//
MCø+MC//

Efficiency %50

Reducing slot size means more and morefine sand is retained. This is virtually impossible to remove in the MC range andleads to increased system wear. Stickies
removal is also more difficult in the MCrange (see twogether Journal No. 4). The
usual practice in modern plants is to

Stickies removal as afunction of particle size

1
Stickies no. concentration
[
]
kg•mm
Size class range

an extremely good result. Screening efficiency is critically dependent on various
factors, above all on the stickies size distribution (Fig. 2). On the left-hand side, atypical stickies distribution according tosize shows that the stickies count increases asymptotically with reducing particle size, a trend which extends beyond
the measurability limit. This indicatesthat many stickies pass through the relatively large screen holes, and also cannot
be detected by conventional laboratory
measuring methods. It is therefore difficult to make an objective assessment.
The right-hand side of the graph summarizes the average stickies removal efficiencies of several screening systems (allwith a hole diameter of 1.4 mm) as afunction of stickies size. Removal efficiency falls off to a minimum of 10 to
30 % as particle size reduces to about
750 µm, and it remains constant until themeasuring limit of 150 µm is reached.
Efficiencies of over 70 % therefore cannot
be expected, since most stickies are below 600 to 700 µm in size. It is therefore
advisable not to demand too high aremoval efficiency, since this just leads
to reducing the stickies size below themeasuring limit rather than removing
them. This apparent good efficiency provides enviable removal rates but only
makes things more difficult for the downstream systems. The next process stage
is usually slotted screening.

Residual stickies (area)
5.4
0%
6.2
+ 15 %
23.2+ 330 %

0
0
0
0

33.3
33.3
33.3

53.8
33.3
53.8

76.83
66.7
76.83

94.6
93.8
76.83

Overallefficiency %14Fig. 4: Scale size comparison of fibres and shives
from wood-containing DIP stock with the crosssection of a 0.1 mm C-bar ® slotted screen basket.
Fig. 5: Effect of slot width changes on system
operating reliability in a DIP fine screening
system.

install LC cleaning after deinking andthis is then followed by fine slot screening with today’s standard slot width of
0.15 mm, although the trend is towards
even finer slot widths.

4

1.0 mm0.1

Voith Sulzer had the rare chance of examining various screening systems in a
DIP line (schematic arrangement shownin Fig. 3) for graphic papers made from
100 % recovered paper. Their direct influence on paper machine runnability wasassessed. The system was originally operated exclusively with MC hole and slotted screening. An LC slotted screeningstage was added at a later date. Stickies
removal then improved from 76.8 % toan overall system screening efficiency of
94.6 %, and sheet breaks on the paper
machine were reduced from about three
per day to only about one in six weeks.
This drastic improvement underlines theneed for a well-designed and sensibly
operated LC slotted screening stage.

mm

5

1st stage

2nd stage
3rd stage

0.15 //

0.10 // =0.10 // =0.10 // = 0.10 //0.12 //

0.15 //

0.10 // =0.10 // =0.10 // = 0.10 //0.12 //

How far can slot widths be reduced?

0.15 //

0.12 //

0.10 // =0.10 //

0.12 //

0.12 //

0.15 // =0.15 //

0.12 //

0.15 // = 0.15 //0.12 //

0.15 // =0.15 // =0.15 // =0.15 // = 0.15 //0.12 //

reliable
operation

reliable
continuous continuous reliable
operation operation
operation operation
impossible impossible
2nd stage
1st stage
not operable plugs up
after
6 hours

Today, slot widths of 0.15 mm are standard practice, but particularly for improved qualities, requirements are much
more demanding and the trend is therefore towards even finer slots. Here there
are limits. Fig. 4 shows a cross-section
through a C-bar ® basket with a slot widthof 0.1 mm, and on the same scale, fibres
and shives from a deinking line for processing wood-containing recovered paper
grades. Clearly, even normal TMP fibres
or fibre bundles can only pass throughsuch fine slots when they are forced
through. This means accepting either
large rejects quantities and/or a reduction

reliable
operation

Stock Preparation

15

Fig. 6: Scale size comparison of scanningelectron microscope photographs of calenderedpaper made from various furnishes with thecross-section of a 0.1 mm C-bar ® slotted screenbasket.
Fig. 7: Comparison of standard and A/B screening
concept (single stage).
Fig. 8: Comparison of 3-stage forward-flow
concepts with different stickies size distributions.
System A: Standard arrangement with simple
screening in all three stages.
System B: First stage with simple screening,
second and third stages with A/B arrangement.

in stickies size. The tolerance between required efficiency and operating reliability
is very narrow with fine slots, particularly
on wood-containing grades, as shown in
the following mill example.
A fine screening system (Fig. 5) consisting of five machines in three stages, originally with 0.15 mm slot widths (systemon the left), was systematically converted
to finer slots. One can easily see howeven the slightest modifications canheavily influence operating reliability ofthe overall screening system. In themeantime, this plant has now been completely fitted with 0.12 mm slotted baskets and some changes have also been
made in the loop layout as well. This
arrangement also operates completely
trouble-free like the arrangement before
it. Although these measures increased
slot velocity, the measurable number ofstickies has been reduced by 32 %, andthe stickies area by 51 %. With wood-freefurnishes, the use of ultra-fine slots isless critical. This is illustrated in a DIPline for wood-free copy paper production,
where a complete fine screening system
has been installed. All screen baskets
have 0.10 mm slots. This four-stage
system with the first two stages arranged
for forward flow is extremely effective
and has been in trouble-free operation forseveral years.

6

1 mm

Groundwood(stoneground)

TMP fornewsprint

DIP from householdcollection

0.1

mm

7

Mean
stickies removal
85.7%

R30 yield
56%

0.12 mm A/B arrangement

96.07%

48.3%

0.15 mm A/B arrangement

91.78%

56.7%

0.20 mm A/B arrangement

81.45%

64.34%

0.12 mm standard arrangement

8
Stickies
distribution
Inlet to 1st stage

ζ G =26%
System A
Standard
arrangement

ζ G =25%
ζ G =30%

Overallstickies
removalOverallrejects
removal

large

small

80%
20%

20%
80%

78%
70%

1.95%
1.95%

80%
20%

20%
80%

81%
80%

2.59%
2.59%

1.95%

SC and LWC papers
ζ G =20%

SC papers require the highest possible
surface quality, in particular smoothness.
Prerequisite for high surface quality is afine-grade stock, free of shives and fibre
bundles. If recovered fibres are used,ζ G =20%

ζ G =20%
System B
A/B arrangement in
2nd and 3rd stage

ζ G=20%2.59%

ζ G = reject rate by mass
ζ G =20%

16

problems may arise due to the contaminant content. For this reason, today’s recycled fibre content hardly ever exceeds
30 % for top quality grades. With LWC
grades, these requirements are not quite
so extreme. On the one hand, the R14
fraction should not exceed certain limits
due to the risk of fibre rising when the
sheet is re-wetted during coating. On theother hand, R30 fibres are desirable forstrength reasons. This situation is best
illustrated by the comparison in Fig. 6
which shows a cross-section through a
0.1 mm C-bar ® screen basket and same
scale microphotographs of calendered lab
sheets made from various stocks. Clearly, the TMP fibre size in particular cangreatly exceed the slot width. Such fibres
have little chance of passing throughsuch fine slots without considerable help.
Although such fine slots have afavourable influence on stickies removal– and manufacturing C-bar ® baskets withslots under 0.1 mm is no problem today– slot widths do have their natural limit.
This limit is determined by a practicalcompromise between throughput and acceptable conditions. Narrow slots alone
are no general cure for stickies problems.
Another possibility is the A/B arrangement.

A/B arrangement for improving
efficiency
An A/B arrangement consists of two or
more screens in series, where accepts
from the first machine A are screened
again in machine B. Stickies removal efficiencies and R30 yields with standard
and A/B arrangements are compared in

the following for various slot widths(Fig. 7). Individual efficiency values foreach size class are used instead of overall average efficiency values. An overall
rejects rate of 25 % is assumed, i.e. 15 %in the A stage and 12 % in the B stage ofan A/B arrangement.
For the single screen with 0.12 mm slot
width, mill data reveals an average stickies removal efficiency of 85.7 % with an
R30 yield of 56 %. In the second case,
the A/B arrangement with 0.12 mm slot
widths increases the stickies removal efficiency to 96 % and reduces R30 yield to
48 %. The third example shows a stickies
removal efficiency of almost 92 % with
the A/B arrangement and 0.15 mm slot
widths. The R30 yield here is around
56 %. In other words, we have a significantly higher stickies removal efficiency
than with the single machine, yet roughly
the same R30 yield. If the A/B slot width
is increased to 0.20 mm, the average
stickies removal efficiency is 81.5 % withan R30 yield of 64 %. These examples
show that even with a larger slot widthof, for instance, 0,15 mm, the stickies
removal efficiency can be significantly increased for the same long-fibre yield.
In another example the effect of theabove arrangement variants when using
several stages was investigated. Removal
efficiency is based here on two stickies
size classes. To calculate the overall
stickies removal efficiency in each case, ahigher efficiency is taken for the large
particles and a lower efficiency for thesmaller ones. This method was used forcomparing two 3-stage screening systems (Fig. 8). System “A” consists of“simple screening” with only an “A” ma-chine in each stage, while system “B” hasan A/B layout in the second and third
stages. Both systems were computed
twice, using different stickies size compositions each time: in the first case
80 % large and 20 % small stickies, andin the second case vice-versa. In systemA, 26 % rejects were assumed in the firststage, 25 % in the second stage and 30 %in the third stage. This gives an overall
substance loss of 1.95 %. In system B,
20 % rejects were assumed for all stages,
the resultant substance loss being
2.59 %. With a stickies size distributionof 80 % large and 20 % small, system A
has a stickies removal efficiency of 78 %compared with 81 % for system B. These
examples show that with an above-average proportion of large stickies, the influence of system arrangement on stickies
removal efficiency is only slight. But witha predominant proportion of small stickies, the picture is completely different. In
this case removal efficiency in system A
falls steeply from 78 to 70 %, while insystem B it falls only by one percent from81 to 80 %.
In other words, an A/B arrangement provides a high removal efficiency even if alarge number of smaller particles are present, and, above all the arrangement
ensures a high quality consistency. Thisis therefore a good way to attain optimum removal efficiencies.

For further details, please refer toVoith Sulzer Stock Preparation brochurest.SD.05.0004.GB.01

Paper Machines

17

1

DuoFormer TQv –a new twin wire former
Many paper properties are determineding gap created by the top and bottom

at the former section. For this reason

wire. The initial drainage starts on theforming sections are critically important

forming roll. The forming roll promotes

in papermaking. But today’s highly de-retention and enables a far less criticalmanding markets want more than excel-

headbox jet positioning in comparison tolent paper properties. Simultaneously,a pure blade former. The roll is followed

productivity and expenses for a formingby the well known D-Section – a blade

section must be handled with great

section – which delivers excellent forma-care. Productivity is strongly affected bytion. A wet suction box further increases

machine speed and web width.

the dry content before the web arrives atthe couch roll. The wet box, placed in the

If productivity and paper quality is fore-

top wire loop, ensures that almost no

most then the DuoFormer TQv is first

free water is left on the top wire. Water

choice. The DuoFormer TQv represents

splashing at the couch roll is reduced to

the latest generation of Voith Sulzer gap

a minimum and thus means a big save-allformers. The former can be applied forpan at the drive roll (top wire) is not

all mass papers.

needed. The large couch roll wrap and ahigh vacuum flat suction box deliver agood dry content of the paper web before
the web enters the press section.

The authors:
Hans Moser,
Volker Schmidt-Rohr,Dr. Joachim Grabscheid,
Werner Eckl,
Paper Machines Graphic

DuoFormer TQv (Fig. 1)
Due to the vertical arrangement of the
The former comprises the well-known rollforming elements, the white water han-and blade forming concept. A ModuleJet

dling is most simple. Suction deflectors

headbox delivers the stock into the form-

and weirs can be avoided.

18

Fig. 1: DuoFormer TQv.
Fig. 2: DuoFormer TQv and different furnish.
Fig. 3: D-Section and drainage down the table.

DuoFormer TQv, major benefits

2
DuoFormer TQv
wood-free

DuoFormer TQv
wood-containing

Paper properties
A curved suction box and forming blades(counter blades), also known as D-Section, are a prerequisite for excellent formation (Fig. 3, left hand side). The box
has two chambers and vacuum is applied
for controlling sheet structure in Z-direction. The forming blades are loaded
against the suction box by a pneumatic
system and they are well protected from3

white water thrown off at high speed at
Composite
blade
sectionFlow distribution
Total
48 %

the forming roll .
Total
49 %

Hydrodynamic forces increase with highmachine6%

speed.

For

efficientwater

removal and good sheet properties, the4%1%blade geometry should be perfect. In or-8%

der to install or remove ceramic blades,

4%

38 %

conventional T-bar holders require a cer36 %tain clearance. The clearance leads tofaulty geometry; i.e. the blades do not

100 %skim the water off properly. To correct
this at high-speed machines, a composite
DuoFormer TQ v for different paper

strength properties, forming blades areblade section replaces single blades. All

grades (Fig. 2)

recommended.

wood-free

single ceramic blades are embedded in a

Stock

for

grades drains quickly and shows highreinforcement structure which forms a

The stock for wood-containing grades

shear resistance. The wrap angle is small

single cover of blades with high preci-

has normally high drainage resistance andin order to allow enough water into thesion. This cover is connected to the suc-

low shear resistance. For those grades,

blade forming section. For excellent for-tion box by a clamping mechanism.

the TQv is designed with a large forming

mation up to three blades are installed.

roll wrap angle and no forming blades.

Additional blades will result in a minor

Fig. 3, right hand side illustrates the

improvement of formation however, si-flows down the table. All flows are based

However, for wood-containing grades,

multaneously wire wear will be increasedon the headbox flow, which is set tobased on a slow stock with a significant

markedly. Indeed too many blades are a100%.

amount of long fibre required for good

disadvantage.

through the top and bottom wires which

De-wateringisalmostequal

Paper Machines

19

Fig. 4: Dry content and wire life.
Fig. 5: Wire change.
Fig. 6: Maintainance.

results in a symmetric sheet. About 48%

Dry content as a function of dwell time

Wire cycles as a function of edges

4of water is drained through the top wire
Couch roll
20

curs at the forming roll. This means 36%

16

suction box and the forming blades remove about 12% of the water. The wet
suction box further increases the dry

8
4

60 KPavolume of the forming roll. The curved

12
65 KPapasses through the top wire into the void

35 KPapasses through the bottom wire and 38%

Dry content [%]Approximately 74% of the drainage oc-

Highvacuumbox

008

16 24 32 40
Dwell time [ms]Roll-Blade-Gapformer
Newsprint
DIP furnish

15
Wire cycles (number •106)

and 49% through the bottom wire.

10

5

0
4

62
110
26
32
54
Ceramic edges (number)content. Approximately 6% of the water

5

is removed at this drainage element. With
the large couch roll wrap, 4% of the water is removed. Finally, entering the press
section, the high vacuum flat suction box
removes a further 1% of the water.
Dry content before pick up
A large couch roll wrap plus a Hi-Vac-Box
are very efficient tools to improve the drycontent before the web enters the press
section (Fig. 4, left hand side). A box,
running at 60 kPa, boosts the dry content
from 14% to 18%. This excellent improvement in dry content was measured
on SC-paper. A second couch roll would
be much less effective.
Wire life
The life depends heavily on the numberof edges in the loop (Fig. 4, right handside). In this example fast newsprint
machines, running with DIP, have been
investigated. Every ceramic blade has twoedges, one upstream and one down-

Forming roll change

Couch roll change

620

Fig. 7: Inspection of forming zone.
Fig. 8: Graphic paper, distribution of formation
and DuoFormer TQv performance.
7

Fig. 9: SC Paper dry contents.
DuoFomer TQv, 52 g/m 2, 30-34 % filler.

8

wood-free9

wood-containing

100

300

90

60
50
40
30
20
10
0
0,3 0,4
good

0,5

0,6

0,7

0,8
poor

Ambertec formation [√g/m 2]

18%

200
150
100
50

8%
5%
DuoFormer TQv

Number of tested samples

70

DuoFormer TQv

Number of tested samples

15%

250

80

0
0,3 0,4
good

2.8%
1.3%
0,5

0,6

0,7

0,8
poor

Ambertec formation [√g/m 2]

stream tip. Both edges create wire wear.

of the top and bottom wire loop when the

Maintenance, forming zone inspection

The number of blades has an significant

former is fully prepared. Bends are re-

The curved suction box and wet suction

impact on wire life or, in other words,

duced to a minimum.

box can be taken off the forming fabrics

wire cycles. In order to optimise wire life

during crawl and shut down for inspec-

for the DuoFormer TQv, the number oftion. During this procedure the forming

blades in the top wire and bottom wire

Maintenance, roll change

fabrics do not become slack. Therefore

loops has been reduced to a minimum.

The forming roll and couch roll are key

the risk of damaging the forming fabrics

components in a state of the art gap(wrinkles) is reduced to a minimum

former. To prepare the machine for the(Fig. 7).

Wire change

forming roll change the top wire drive

The top and bottom wire loop structuresroll-bearing house is disconnected fromare fully cantilevered. In order to prepare

the rotating mechanism while the roll isthe former for wire change the breast roll

resting on the couch roll-bearing house.

is moved away from the forming roll(Fig. 6, left hand side). The mechanism

Formation is always a matter of interest

Graphic Paper Formation(Fig. 5). A mechanism rotates the top

rotates away from the drive roll with the(Fig. 8). The graphs depict the formation

wire drive roll and the wet suction box,

wet suction box and forming blades. The

distribution of graphic paper. Paper

along with the forming blades, away fromcurved suction box and the breast roll aresamples from fourdrinier, hybrid and gap

the wire run. The curved suction box isplaced at the wire change position.

former concepts were tested. High-normalised Ambertec values represent poor

moved back towards the press section.
These measures provide free access to

Direct access for the crane is provided information and low-normalised Ambertec

the top and bottom wire. Both stretcherorder to carry the forming roll. With thevalues represent good formation.

systems are adjusted to minimum wire

top wire drive roll in the wire change po-length. Replacing old wires with new is asition the crane can immediately accessAmbertec values were most frequently

most simple procedure due to the shape

the couch roll. (Fig. 6, right hand side).

measured between 0.45 and 0.50 g/m 2

Paper Machines

21

Fig. 10: Voith Sulzer forming systems.
DuoFormer TQ

DuoFormer TQv

DuoFormer D

10

D-Section

on wood-free paper. This represents av-

consistency of 1.3% a consistency ofFor special paper and all mass papers, toerage wood free paper quality. Owing to

2.8% was achieved ahead of the D-Sec-be made with a machine speed below

the powerful D-Section, the DuoFormer

tion. The wet suction box increases the

1,200 m/min, a hybrid former is prefered.

TQv delivers Ambertec Formation below

dry content from 5 to 8%. Due to the

At present, almost 190 DuoFormer D’s

0.5 g/m 2 Ambertec.

large wrap of the couch roll a dry content

are in full scale operation. The key com-On

wood-containing

grades,quality is between 0.4 and 0.45

of 15% is achieved ahead of the high vac-ponents are an inverted suction box in-averageuum flat suction box. With 60 kPa in theside the top wire loop and flexible loaded

g/m 2.

box, the dry content is about 18% before

counter blades inside the bottom wire

entering the press section.

loop (D-Section).

The TQv former delivers formation values
between 0.35 and 0.45 g/m 2.

The well known D-Section, which is a key
All results were obtained from pilot trials

Voith Sulzer Forming Systems (Fig.10)

element in the Duo Former D, can also be
installed into existing wire sections. Quite

on Voith Sulzer’s new pilot machine number 4. The type of furnish has a strong

The DuoFormer TQv is Voith Sulzer Paper

often, the section is installed ahead of an

impact on sheet properties. Therefore,

Machinery’s forming section for highexisting forming roll.

pilot trials are strongly recommended in

speed paper machines. The new former isorder to determine formation quality

tailor made for wood-free and wood-con-

when applying a new former.

taining grades.
Summary
For machine speeds above 1,200 m/min

DuoFormer TQv, flows and solids

and for rebuilds, the DuoFormer TQ is theVoith Sulzer Paper Technology delivers

down the tableprefered forming system. The TQ utilises

tailormany components of a fourdrinier or hy-

selecting and implementing the right

Many pilot trials have been made for SC

brid former which means cost savings forequipment, paper mills can achieve thepaper. Mass balances and gamma gauge

the rebuild. This results in a gap former

optimum balance of technological per-measurements

design with a horizontal or inclined twin

formance, productivity and expenses forwire section.

their machinery.

deliveredconsistencies

down the table (Fig. 9). At a headbox

madeformingequipment.

By

22

DuoCleaner – the optimal fabricand felt cleaning system
DuoCleaner
1stretch roll

The author:
Hans Ruff,
Paper Machines
Graphic

dryer

Modern high-speed paper machines,

switches with signal and control cables

together with the growing use of recov-

are encapsulated in the rear wall of theered paper, demand intensive condi-

beam to protect them from water, chemi-

tioning of the fabric and felts. The

cals and temperature effects.

DuoCleaner meets this demand with anunexcelled cleaning efficiency. Felt

All components of the DuoCleaner tra-and screen properties are maintainedverse system are made of stainless steel,at uniformly high level during ongoingheat-resistant, generously dimensioned

production, without affecting paper

and practically maintenance-free. Great

quality. The DuoCleaner is also highly

attention was paid during development toreliable, and the investment pays backa compact design insensitive to dirt andin only a few months.

optimally maintenance-friendly.
A typical example of such an installation

Concept

in a dryer section is shown in Fig. 1.

The DuoCleaner comprises a traversing

The lower part of the cleaning headsystem with cleaning head, a high-pres-swivels, and is rotated by reaction forces

sure pump aggregate, and the electricalfrom the tangential drive nozzles.

controls.
At the bottom are one or more water
Traversing system

spray nozzles for removing dirt. The

The electrically driven traverse trolleycleaning head can be replaced in a matter

carries the cleaning head. The limitof seconds, and without the need for any

Paper Machines

23

Fig. 1: DuoCleaner – Dryer section.
Fig. 2: Traversing cleaning head
1 Cleaning head
2 Rotating water jet
3 Separated dirt particle
4 Reflected water drops
5 Suction air flow.
2

DuoCleaner system for the entire paper machineMax.
operatingpressure

Wire section

Water
consumption

Traversing direction

Nozzlespercleaning
head

Cleaning headrotation speed

1

Vacuumsuction2
3

250 bar

6-10 litres/min-10

1000-2500 rpm

No

Press section 200 bar

3-10 litres/min

2-10

2000-3500 rpm

No

Dryer section 350 bar

2- 4 litres/min

1- 2

500-2500 rpm

Yes

4
5

tools. To this purpose the head is moved

Control system

particles and reflected water spray areto the parking position outside the ma-

All functions are controlled and moni-

sucked into the chamber, thus preventing

chine frame. This facilitates maintenancetored by a programmable control system.

sheet striping or collection of dirt parti-

and nozzle replacement.

Apart from automatic mode, all functions

cles (Fig. 2).

can be operated individually for mainteRotation is monitored by sensor whichnance and overhaul purposes. Operation

Part of the water jet flows right throughshuts down the DuoCleaner if the clean-is clear and simple. Faults are automati-

the fabric, thus thoroughly cleaning evening head comes to a standstill. This reli-cally detected and displayed in clear text.

the bottom side. In case of heavy conta-

ably prevents fabric and felt damage.

mination, a dirt trap is installed under-

Typical operating data for papermachine

neath the fabric.

clothing are shown in the table.

Operating principle

High-pressure pump aggregate

The pulsing water jets from the rotating

Water is supplied to the DuoCleaner bycleaning head impinge on the dirt parti-

a self-regulating high-pressure pumpcles in the fabric from various directions.

By continuous cleaning during operation,

aggregate with intelligent control system

The jet operating pressure of up to 350

outstanding results are attained. Fig. 3

which automatically adapts the waterbar removes even the smallest particles.

shows the visual effects of cleaning.

Benefitspressure and flow to operating condimodeIf DuoCleaners are used on forming fab-

Even fillers and fines are efficiently

ensures optimal pump service life. The

ric, high-pressure showers can be re-washed out of thick press felts.

entire pump aggregate is designed on a

duced. For use in the dryer sections, themaintenance-friendly basis. Appropriate

DuoCleaner cleaning head is surrounded

Former section benefits

filters and treatment aggregates are pro-by a vacuum chamber sealed against the

I Less tearing than with high-pressure

vided, according to water quality.

fabric by a membrane. The loosened dirt

tions.

Thissmoothoperatingshowers

24

Fig. 3: Cleaning results on a forming fabric,press felt and dryer fabric (from top to bottom).
Left: before, right: after.
3

Paper Machines

25

Fig. 4: DuoCleaner – Perlen PM 5.
Second dryer group top double tier, operatingtime 11 months.
Fig. 5: Fabric lifetimes at Dachau PM 8.
Fig. 6: DuoCleaner sales figures.

I Less mist generation and fines
deposits

I Outstanding effectiveness of web

4100%

stabilizers

I Less formation interference and paper
I Uniform drainage thanks to perma-

85%

I No shutdowns required for cleaning,
no chemicals.

Permeability [CFM]

sheet damage by stickies removal
nently clean fabric.

Furthermore, fabric life is often extended
Press section benefits

by a factor of 4 to 5. Fig. 5 shows a typi-

I Less tearing thanks to constant clean

cal example of this.

280 CFMnewfabric16%
44 CFM
contaminatedfabricfelt surfaces
With conventional cleaning systems, this
I Good CD profile thanks to intensive
and uniform cleaning

238 CFMfabric cleaned
with
DuoCleaner

fabric had to be changed every 5 months
on average. The DuoCleaner extended the5service life to more than 20 months.

20

I Long felt service life thanks to lessdeposits of abrasive fillers and less felt

15

Prospects

Dryer section benefits

Today more than 250 DuoCleaners world-

Fig. 4 shows definitive cleaning results

wide are improving the production effi-

on dry section felts and fabrics. The air

ciency of paper machines including tis-permeability of a new fabric is comparedsue, pulp and board. DuoCleaner sales

here with that of a conventionally cleaned

figures since market launch in 1995 are

fabric and one continuously cleaned byshown in Fig. 6.

Monthhair losses.

105

without DuoCleaner with DuoCleaner

the DuoCleaner. The uniformly high air
It goes without saying that all new Voith

fabrics, and the removal of stickies, re-Sulzer Paper Technology machines are

sult in the following benefits:

equipped with DuoCleaners, but the suc-

6200

cess of the DuoCleaner so far is mainly
I Less tearing

due to rebuilds and retrofits. With ongoing development and extension of the ap-

I Less sheet perforation

plication range, the DuoCleaner will continue to improve papermaking efficiency

I Lower energy costs thanks to im-

and cost-effectiveness.

8

Number of units cumulated

permeability of the dryer section felts and

150
14

191
100

3

50

proved sheet evaporation
I Uniform CD profile

to 1995

1996 1997

1998 1999

26

Kehl PM 6 –a new production line for laminating papers

The author:
Dieter Blaschka,
Paper Machines
Graphic

In April 1999 August Koehler AG, Ober-

izationkirch/Germany ordered from Voith Sulzer

August Koehler AG regards itself today as

Paper Technology an additional produc-“a world company with a family charac-tion line for laminating papers. Foundedter”. This description aptly fits the com-in 1807, August Koehler AG has expand-pany structure and culture: largely fami-

ed in the meantime into a papermaking

ly-owned and run, with close customer

group still headquartered at the originalcontact, high reliability and quality, ongo-

location of Oberkirch in the Black Forest,

ing success through specialization, andbut with four other mills in Germany atopen to innovative developments.

andexpansive

development,

Kehl, Ettlingen, Bensheim and Greiz.
Products range from carbon copy papers,

Innovative paper applications these days

thermo and fine papers, to recycling

include the increased use of special-pur-board and special papers as well as wall-pose laminating papers for laminating

paper base. With this successful special-chipboard surfaces in the furniture and27

1Fig. 1: The Kehl plant of August Koehler AG,
showing the new PM 6 building in the left
foreground.

construction industries. The paper is ro-

printing and impregnation processes, as

The production concept and integration

togravure colour printed with a wide vari-

well as high opacity for adequate cover-

into the existing Kehl plant buildings andety of imitation wood graining, masonrying of the base material. Although lami-infrastructure is the result of close team-

textures or other patterns, then impreg-

nating paper production needs only a rel-work between the project engineeringnated with resin and pressed onto theatively modest machine width for thegroups of August Koehler AG and Voith

chipboard surface.

subsequent processing requirements, theSulzer Paper Technology. Scope of sup-stringent quality criteria involved require

ply for Voith Sulzer Paper Technology is

The paper properties required for this ap-

modern high-speed paper machine tech-as follows:

plication are exacting: excellent printabili-

nology. The new production line for thety and dimensional stability, yet at the

Kehl mill, which already has a Voith ma-same time good ink absorption and uni-chine for carbon copy and thermo pa-

Stock preparation

form resin penetration. On top of this,pers, is the first complete new production

I Pulper charging, including virgin pulp

high strength and good wet tensile

unit to be built in Germany for laminating

strength are required to stand up to thepapers.

bale conveying system
I Pulper for virgin pulp

28

34

K2

10

K1

2

I High density cleaningwater circulation system for use duringsimplified since they only have to carry

I Deflaking

production stoppages.

the weight of the shake unit.

I Low density cleaning
I MultiScreen fine screening

Together with the Profilmatic cross ma-

DuoShake shake units have been operat-chine profile control system, these en-ing successfully for a number of years insure ideal conditions for optimum crossKoehler’s Oberkirch and Ettlingen mills.

Dry broke preparation

machine basis weight and fibre orienta-

I Pulper charging systemtion profiles.

I Slat conveyor with roll slitting and

I Press section
3-roll Nipco press with separate pick-up,

Any pulsations coming from the approach

followed by a Nipco straight-throughI High consistency pulping

flow system are dampened directly aheadpress.

I High density cleaningof the headbox using our well-proven

I Deflaking

pulsation damper.

weighing

I EconoMix mixing propellers

Broke pulpers

This concept has the following advantages:

The distributor and turbulence inserts are– Uniform drainage on both sides

easily accessible for cleaning purposes– Uniform sheet consolidation on bothby swinging off the headbox back wall.

I Couch brokesides– High dry content

I Press broke

I Sheet formation

I Dry broke

Fourdrinier with dandy roll and drainage

A press of this type has been operating atelements (designed and supplied by

the Koehler mill in Ettlingen since 1998.

August Koehler).
Paper machine– Suction couch roll

I Dryer section

I MasterJet F– DuoShake high-intensity shake unit for

Particular attention has been paid to aheadbox with ModuleJet for thermal sta-

optimum formation. DuoShake has no

reliable web guidance for low-strength

bility during operation and Constatherm

reaction forces so that foundations arewebs and high operating speeds. The

29

Fig. 2: Technical data of the new PM 6:
Wire width: 2,750 mm
Sheet width at reel-up: max. 2,300 mm
Reel diameter: max. 2,000 mm
Design speed: 1,000 m/min
Drive speed: 1,000 m/min
Product: laminating papers from 50 to 110 g/m 2
Production capacity: 42,000 tonnes per year.
Fig. 3: The August Koehler AG management:
Klaus Furler, member of the board andcommercial director (left),
Wolfgang Furler, member of the board andtechnical director (right).
3

first two TopDuoRun dryer groups are

required for various reel widths. A wrap-

therefore equipped with vacuum rolls andping machine of this type is already in

DuoStabilizers. Web stabilizers ensure

operation at the Oberkirch mill.

smooth running of the sheet in the remaining dryer groups. A cooling cylinder

I Engineeringgroup incorporating high performance– Machine and system engineeringcooling cylinders is located at the end of– Basic and detailed engineering forthe dryer section.

process, paper machine and auxiliaries– Basic and detailed engineering for the

A rope-free feed-up system ensures fast

control and instrumentation systems.

feeding up of the sheet, thus helping tomaximize overall machine efficiency. The

The topping out ceremony for the newsteam, condensate and cooling systems

PM 6 building was held on September 3,

precisely control web drying behaviour

1999. Paper machine erection started in

and web temperature.
I Janus calender

I Reel-up

January 2000, and commissioning iswith reel-spool magazine for automatedplanned for August 2000.

spool transport and changing.
Klaus and Wolfgang Furler, board direc-

This consists of a vertical five-rollarrangement. Trials with laminating pa-

A combination of perforated reel drum

tors of August Koehler AG, commented

pers at the Voith Sulzer test facility inand winding tension control ensures per-on their decision to place the order with

Krefeld/Germany confirmed that this cal-fectly wound reels from the core out.

Voith Sulzer Paper Technology:

printing results. A disengageable rope

I Roll wrapping machine“This was certainly the right decision.

system was selected for reliable sheet

Type: Twister Combi 1

The project is running very smoothly,transfer through the Janus calender to

The advantage of this concept is that only

and above all the technological optimiza-

the reel drum.

one width of wrapping paper roll istion teamwork is outstanding.”

endering concept is ideal for optimum

30

1

Dongying Huatai successful start up
Clear blue sky in northern Shandong

the-art ModuleJet headbox – computer

Province – close to the scenic view ofcontrolled with the Profilmatic M fromthe Yellow River mouth where it flows

Voith Sulzer Automation, this headbox

into the Beihai sea a huge new expan-

controls a perfect basis weight profile bysion project is underway. Approachingmeans of 42-Control zones.

the vicinity of the mill the new impres-

The author:
Frank Opletal, Voith Sulzer
Paper Technology, Beijing
Central Representative Office

sive power generation plant and right

Voith Sulzer Automation delivered theafter this the new papermachine

whole QCS system including

building are beaming into once eye.
I the complete headbox control function,
As reported already in our twogether No. 7

I the CD caliper control actuator

under the topic “Speedcoater for Chinese

ThermaJet with 34-zones,

market leadership” the Shandong HuataiGroup in Dongying, did not stop to invest

I two AdvantagePlus frames, eachin Top technology in buying a speed-

comprising sensors for basis weight,

coater and a softnip calender only. To staymoisture and caliper, andahead with technology and paper quality
and be a leader to let the Chinese paper

I the brandnew technology: the InfoPac

industry prosper, Director Li Jianhua (seePapermachine Information System,

separate comment from him), decided towhich allows papermakers as well as

go even further and purchase a state-of-mill management rapid access to, andPaper Machines

31

3Fig. 1: Paper machine Dongying Huatai.
Fig. 2: ModuleJet stock preparation.
Fig. 3: Speedcoater.
Fig. 4: Ecosoft calender.
2

4

powerful analysis of paper quality andmachine performance. Moreover, thefunction of the archives also allows forstorage of quality datafor the mill’s
internal quality control system. This is
the first such system to be in operation in China.
Li Jian Hua,
All in all the installation and commission-

President Dongying Huatai

ing went very well, even the very cold

To face up the challenge of world market

winter brought some obstacles to cir-competition after China enters into thecumsail. Using 70% pulp made from riceworld trade organisation, Chinese paper

straw and 30% bleached market pulp, themills have to strengthen themselves withnew paper created is first class LWC,

input of modern advanced paper technol-

coated simultaneously with a speedcoater

ogy equipment, to produce the high gradeof the newest generation. In the future

value added products. With this vision in

Reed pulp will be used instead of themind, we decided to purchase from Voith

bleached market pulp. The final finishing

Sulzer the most advanced equipment. We

touches are performed with a new twoare very much satisfied with the machin-nip Ecosoft modular calender.

ery supplied by Voith Sulzer and we arelooking forward to co-operate with eachother on other projects in the future.

32

Zhuhai BM 2
started up 2 weeks ahead of schedule
The board mill of Hongta Renheng Co.
is located rather close to the downtown
area of Zhuhai City, which is, as locals
say, a “bright pearl among Chinese
cities” regarding quality of life andenvironmental surroundings. Its outstanding geographical location directlyat the South China Sea and its proximity
to Macao and Hongkong make it not
only the ideal place for a vacation, butalso a strategically perfect businesslocation.
Zhuhai S.E.Z. Hongta Renheng Co. Ltd.
is the leading supplier of cigarette-box
cardboard in the Chinese market, and ispart of Hongta Renheng, the joint venture
between Yunnan Hongta Industrial Co. Ltd.
and Hongkong Renheng Investment Co.
The Yunnan Hongta Group comprises
50 enterprises, with tobacco being thelargest and core business, and thus it is
the third largest manufacturer of cigarettes worldwide. Other businesses include power generation, paper & board
manufacturing, printing, construction materials, banking and insurances as well as
light trucks.

The authors:
Robert Adolf Dokter,
Paper Machines
Board and Packaging;Frank Opletal, Voith Sulzer
Paper Technology Beijing
Central Representative Office

On February 25th, 1998, Zhuhai S.E.Z.
Hongta Renheng Co. Ltd. and Voith
Sulzer Papiermaschinen AG St. Poelten
signed the contract for the delivery ofboard machine No. 2 during a customer’svisit to St. Poelten in the presence ofhigh-ranking political officials from thePeople’s Republic of China. The project
was entirely financed by Zhuhai S.E.Z.
Hongta Renheng Co. Ltd.
The follow-up order for the supply of another new board production line from

Zhuhai S.E.Z. Hongta Renheng Co. Ltd.
can be regarded as the direct success ofboard machine No. 1, which was also
supplied by Voith Sulzer St. Poelten. At
that time, the main structural parts camefrom Liaoyang Paper Machinery Works.
BM 1 was taken on stream in 1993. These
facts, combined with the leading positionof the Voith Sulzer Board and Packaging
Paper Division worldwide and in China,
resulted in the delivery of the fourth fully
imported board machine to China. While
BM 1 has been run over its design capacity by almost 50% for quite a long time,

33

Fig. 1: Board machine 2.
Fig. 2: Press section with Flexonip press.
2

the new BM 2 is currently steaming
ahead from one record quality production
to the other. This being the case, thequality parameters have been reachedalready in early March 2000 – merely twomonths after going into continuous production. The taking-over certificate wassoon signed thereafter.
By making every possible effort to see
the project through within the shortest
possible time, the civil construction
works started on August 1st, 1998 withthe first pile being driven into the earth.

1

34

3

Zhao Wanli, General Manager Zhuhai

contributed to the success of this project.

Hongta Renheng Paper Co., Ltd.

The BM 2 project, including design, manufacturing, tests, installation and start-

We have been enjoying a relationship ofup, was completed, achieving high quali-

good cooperation with Voith Sulzer Paperty and efficiency. The high design speedof BM 2 caused a great sensation among

Technology for several years, based on
mutual trust and assistance. After com-

product quality and help to strengthen

the board producers in China. We believe

paring many suppliers, we chose Voith

our market position.

that choosing Voith Sulzer as the supplier for BM 2 will again prove to be a

Sulzer for board machine No. 1 (BM 1).

wise decision.

Our choice proved to be wise and correct

Voith Sulzer was again chosen as thein practice. This machine has been run-supplier for the key equipment (board

ning to our full satisfaction since it wasmachine) and began to execute the BM 2

We are making plans for a BM 3 project,

put into operation, and its machine

project in 1998. BM 2 has an untrimmed

which will increase the production ca-

speed reached 270 m/min 1 1/2 years

working width of 4200 mm, a design

pacity by 300,000 tons, and hope to con-ago, far exceeding its design speed of

speed of 600 m/min and produces

tinue our good cooperation with Voith

250 m/min. The key point is that the

150,000 tons/year. Construction of BM 2

Sulzer.

quality of the coated board produced bystarted in August 1998, and start-up took

BM 1 has reached international first-rate

place in December 1999. As early as

Zhuhai Hongta Renheng would like tolevel: our products are welcomed to the

March 2000, board was produced, whichtake this opportunity to express theirChinese market for top-quality board andfully met the quality requirements. Our

heartfelt thanks to Voith Sulzer’s man-

demand for it exceeds supply. The suc-qualified engineering personnel and theagement and all engineering, technicalcess of BM 1 has set new technologicalother technical personnel, together withand service personnel involved in BM 1

standards,

Voith Sulzer Paper Technology’s experts,

and/or BM 2 projects.

which

positively

influencePaper Machines

35

Fig. 3: On-line coating equipment.
Fig. 4: Speedsizer.
Fig. 5: Horizontal reel.
Fig. 6: Winder.
6

4

By February 1999, the installation of theboard machine foundation plates could
be finished so that the first componentsof the dryer section were installed earlyin March 1999. A highly qualified team ofengineers assigned by the customer,
locally hired construction firms with excellent previous experiences in installing
paper machines and a team of Voith
Sulzer experts were teaming up to meet
the tight time schedules and high quality
requirements during the installation
period. Thus, no-load tests could bestarted by September 1999. On December
5 15th, 1999, the first board was produced
at the horizontal reel after a very well organised commissioning period. – Twoweeks ahead of the contractual schedule,
Voith Sulzer delivered the complete multi-fourdrinier board machine, including
shoe press, on-line coaters and finishingequipment like the slitter winder, as wellas key equipment for all board machinerelated auxiliary equipment.
The plant engineering was performedin close co-operation with the Changsha
Design Institute, which had been nomi-

nated by the customer to provide theoverall engineering scope. This co-operation had been proven successful on several other projects in China before.
The layout design of the board machineallows the customer to produce cigarettebox cardboard and liquid packaging
board accounting for a yearly gross production of 150,000 tons. As raw material
sources, Zhuhai S.E.Z. Hongta Renheng
Co. Ltd. prefers to buy NBKP and BCTMP
from North American suppliers, while
LBKP is mostly purchased from Brasilian,Indonesian and Thai pulp producers.
Currently, the production still covers the
local South Chinese market, like theprovinces of Guangdong, Yunnan, Hunan,
Hubei and Sichuan. But Zhuhai S.E.Z.
Hongta Renheng Co. Ltd.’s future sales
strategy is to ship high-class board also
to other countries in South East Asia.
Voith Sulzer Paper Technology offers its
heartfelt congratulations to the management of Zhuhai S.E.Z. Hongta Renheng
Co. Ltd.

36

Bauernfeind PM 1 –Strengthening of Frohnleiten millAfter a major rebuild, PM 1 at Frohnleiten mill of Roman Bauernfeind AG
was successfully put into operationin November 1999. The aim of therebuild was to boost PM 1 production,
tripling the output of corrugated board
base papers from 100% recycled
furnish.
The author:
Petra Resch,Paper Machines
Board and Packaging

The rebuild was accomplished in twophases. The first upgrade in the summer of 1998 included the installationof a state-of-the-art shoe press.
With the second phase being completed, including a renewal of the approachflow system and paper machine as
far as the winder, the entire PM is now
designed for a speed of 1000 m/min.

Roman Bauernfeind Verpackungswerk AG
was founded in 1945. In a former comb
factory, they started converting solid
board, and in 1963, corrugated board. In
1972, they started producing corrugatedboard, and in 1984, when Frohnleiten Paper Mill was acquired, paper production
was started. Today, Roman Bauernfeind
Papierfabriken AG produces corrugatedboard base papers at 5 different locations: Frohnleiten (Austria), Raubling(Germany),
Niedergösgen,Moudon(Switzerland) and Monza (Italy).
More than 500,000 tons/year of highgrade packaging paper from 100% recycled furnish are produced on these machines. Currently, 400,000 tons/year are
converted at the group’s locations in Germany, Belgium, Austria, Italy, Poland andChina. The majority of exports from Aus-Paper Machines37

1Fig. 1: Roman Bauernfeind AG, Frohnleiten mill.
Fig. 2: Stock preparation MasterJet F/B.

tria goes to Germany, Czech Republic and 2
Belgium.
The export share is about 60%. Roman
Bauernfeind AG is the market leader inAustria and the second largest supplier inEurope for pre-print products. In addition, Bauernfeind is one of the largest
privately owned paper and packaging
groups in Europe.
After the successful rebuild of the press
section in the summer of 1998, the follow-up order for the rebuild of the othercomponents of PM 1 was placed by
Roman Bauernfeind AG with Voith Sulzer
in February 1999. Through these two upgrades, the paper machine was almost
completely renewed, presently operating
at 800 m/min working speed. The entire
rebuild was completed in a record time of38

Technical data of PM 1 after the rebuild:
Wire width: 2,950 mm
Maximum production speed: 800 m/min
Paper grades: Corrugating medium: 90-180 g/m 2
Wrapping paper: 90-180 g/m 2
Maximum capacity: 330 tons/day.

3

approximately 11 weeks with production
stops of less than three weeks.
The main goal of the rebuild was to set
new standards in paper production. At
Frohnleiten mill, most of the corrugating
medium is produced by PM 1. Especiallyin this product range, a new trend has
become apparent in recent years. The
general tendency towards thinner flute
profiles requires lower basis weights. A
product with thinner flutes will better
meet the market requirements such as
improved printability. Although a lower
basis weight results in a lower specific3

output with constant speed, this is morethan compensated by increasing PM 1’s
output. After the rebuild, its output increased to 300 tons/day of corrugating
medium and 330 tons/day of wrapping
paper.
The following basic components wererenewed: The wet end was equipped witha MasterJet headbox (refer to twogether
Journal No. 8, page 24). A special featureof this latest member of the headbox family is that no heating is required to ensure
a parallel slice. Due to the quality demands
made on the CD profile, precise adjusting

units with oblong spindles are used tocontrol the CD basis weight profile.
To optimally utilize the structural conditions and at the same time find an optimum solution to meet the high quality
standards, a decision was made in favorof the topwire former DuoFormer™ D.
The advantages of this two-sided
drainage are an improvement of formation and a shorter drainage section compared to a conventional fourdrinier.
The press section rebuild was completed
in the summer of 1998. The installation

Paper Machines

39

Fig. 3: DuoFormer D.
Fig. 4: Final section.
Fig. 5: Mill owner Roman Bauernfeind
and Otto Heissenberger, executive vice presidentof Voith Sulzer Papiermaschinen AG, St. Pölten.

of a NipcoFlex™ press was the first step 4
towards an increase in PM 1 output,
improving the dryness with constantquality.
The first group of the pre-dryer section
has been designed as a serpentine groupwith DuoStabilizers™ – the remaining
groups and the after-dryer section are ofconventional two-tier design. DuoStabilizers™ and web stabilizers ensure asmooth web run. A ropeless transfer
system is installed in the pre- and afterdryer sections.
A transfer doctor takes the tail off the lastpress, and the transfer foil directs it into
the dryer section. The blowpipes installedat the blowing doctors ensure ropelesstail transfer. With speed and production
increases expected, the size press andthe reel also had to be redimensioned. In
the reel area, the building had to be ex- 5
tended, but remained unchanged in thewire section area. This extension wasnecessary to allow for the required drying
capacity and the installation of the newwinder.
As installation work was completed ontime, paper was on the reel again twodays ahead of the scheduled start-up
date. Just hours after start-up, salable
paper was produced. The hybrid former
improved formation by about 50%.
After a short optimizing phase, the desired strength increase and the reductionof the 2-sigma values of the basis weightprofile have already met the expectations.
Within the first three months, wrapping
paper was produced at the design speedof 800 m/min.

40

1

TissueFlex –first application in America
Late in January 2000, the first commer-of today’s technology, the same speed

cial application of the TissueFlex in thecan be achieved using only one shoe

Americas and the second in the worldpress against the Yankee.

started up successfully. The TissueFlex
technology consists of a shoe press

The entire machine rebuild was complet-against the Yankee dryer surface.

ed over a 6 1/2 day shutdown period inwhich several other services were execut-

The author:
Ronaldo Parucker,
Voith S.A. São Paulo

This equipment was installed in Mogi

ed, including the Yankee dryer grinding.

das Cruzes, São Paulo, Brazil, at

The installation of the TissueFlex™ itself

Companhia Melhoramentos de São

took approximately four days.

Paulo, a long-established Brazilian
tissue manufacturer.

The objectives of the rebuild, and thebasis for return on investment were an
operating cost reduction, saving 5% ofPrior to the installation, the machine

fiber, and product quality improvement.

operated with two presses against theNow, after a short period of approximate-

Yankee, at speeds limited to approxi-

ly two months, this new technology has

mately 1,600 m/min. With the application

reached all the objectives that were set.

Paper Machines

41

2
TissueFlex pressing
directly against theyankeeFig. 1: General view of TissueFlex installation at
Companhia Melhoramentos de São Paulo, Brazil.
Fig. 2: TissueFlex technology for tissue.
Fig. 3: Tissue machine Melhoramentos
Papéis S.A.

NipcoFlex rollFig. 4: TissueFlex control panel.

Suction rollAfter the TissueFlex™ start-up, a bulk in-

As to production itself, Melhoramentos

crease of approximately 20% was real-points out that after the felt compaction

ized, and paper softness was greatly im-

the machine already reaches the same

proved. After some analysis, it was also

production as before the rebuild. How-

noted that fiber reduction would possibly

ever, they feel that the next target will be

be even greater than 5%. The conversion

to determine the best felt for this newof toilet paper, now being manufactured

technology, since the felt compaction

with the new TissueFlex™ technology,

time significantly increased.

4

presented no problems. The other mainfore the rebuild. The consumption of

product of this tissue machine is napkin.

There was a small increase in steam con-water, vacuum and fuel for the hood re-

The company now achieves the same

sumption with the production of papers

mained unchanged. Total drive power

package size with 50 units, compared towith a higher basis weight. However, it isconsumption remained the same, thea package of 60 units before the rebuild.

believed that this consumption will be

suction roll and the Yankee consume

significantly reduced through the use of

more power, but, on the other hand,

Even with a basis toilet paper weight re-

the right felt. Consideration has to be giv-

there is no longer any blind drilled press.

duction of approximately 5%, the diame-en to the fact that the machine now oper-

ter of the converted paper roll increased

ates with only one press, compared toAnother important issue at Melhoramen-

approximately 2.5%.

the two presses against the Yankee be-tos is that some items requiring frequent
maintenance were eliminated, such as the3suction press and the rolls for the secondpress. Previously, the press rolls had to
be exchanged or serviced every fourmonths, due to problems with the rubber
covers (plugged shell drillings, total cover loss etc.), causing long down time,
which resulted in lost production. With
the installation of the new TissueFlex™
technology, the mill feels that these problems have now been solved.
Even considering the relatively small
amount of time that the mill has been using the new TissueFlex™ technology,
Melhoramentos is pleased, since thetransition phase, as well as the learning
curve was very short and the objectives
set for this rebuild were fully achieved.

42

Sirius –the online wind-up system
When the first Janus calender was
retrofitted to PM 4 at the Ettringen
paper mill, Gebrüder Lang started considering the online concept for natural
papers well before installing PM 5.

The author:
Oliver Rudolph,
Paper Machines
Graphic

Paper Machines

43

Since the design of this new machine was

The basic idea of separate linear load

to set new milestones, including out-

generation and parent roll movement dur-standing winding characteristics, the idea

ing winding – systematically implement-of using a Sirius wind-up system was im-

ed by the SensoNip control system – thus

mediately accepted. There were some

had to be retained.

very good reasons for this decision: notonly had excellent winding results been

As a result of this development work, theobtained with the first four Sirius instal-latest Sirius generation covers all re-lations on the ***Triple Star*** line atquirements. Operation of the moving

Sappi/Gratkorn, but for online Janus cal-SensoRoll – the well-proven heart of theendering to SC-A quality standards, only

SensoNip control system – remains un-

the latest winding technology suits thechanged. Overall space requirements are

dimensions of modern production lines.

much less, and the complex web guidesystem of the first generation has been

In the meantime, the second Sirius gen-considerably simplified. The new machine

eration had been developed at the wind-

now fits almost like a conventional wind-ing technology COC (centre of compe-

up system into the paper machine layout.

tence) in Heidenheim. The mechanical de-This is very important, since it makes thesign concept of the enormously large

Sirius more suitable for upgrading exist-

first installations in Austria had to be re-ing production lines.

placed with a much more compact solu-

Winding system design datation – but of course without sacrificing

The commissioning of PM 5 in Ettringen

the outstanding paper roll handling bene-

was planned for September 1999, byfits of this well-tried winding principle.

which time the sister aggregate – a Sirius
Transfer arm
Center drive

Center drive
Parent roll movement

Design speed 2200 m/min
Max. operating speed 1800 m/min
Min. roughness 1.2 PPS
Min. porosity <20 ml/min Bendtsen
Max. parent roll diameter:– newsprint 3700 mm– SC grades 3100 mm
Reel spool diameter 1050 mm
SensoRoll for linear load generation

EcoChange Secondary nip system

44

Gebrüder Lang Ettringen paper mill.

with identical layout geometry – was also

respective operating conditions of theexhaustive testing on our R&D facility

to be commissioned on the new PM 3 at

two paper machines.

with all kinds of paper.

duces newsprint from 100% recovered

Both installations enable comparatively

Both installations meet all requirements

paper, and winding requirements withlow free web tension. And as is well

for residual slab and winding quality,

finished rolls 3700 mm in diameter are

known, low web tension at the end of thethus increasing the efficiency of their re-just as demanding (and perhaps record-line generally reduces the risk of web

spective production lines.

breaking) as on PM 5 in Ettringen.

breaks – thus boosting the overall pro-

Papierfabrik Palm in Eltmann. This pro-Operating experience so far with theduction efficiency.

Sirius wind-up system is very encourag-It was quite a challenge for Voith Sulzer
Paper Technology to commission these

Tail transfer in the area of the new Sirius

ing with regard to further development.

two almost identical aggregates – both ofwind-up system was quickly optimized.

Future applications will cover nearly all

them the first of their kind – but the risk

Even prior to actual commissioning, themain paper grades such as LWC, copying

was more than rewarded. Both the Ettrin-

Fibron vacuum tapes and related transfer

papers, liner and coated board.

gen and Eltmann units showed perfectequipment were pre-adjusted. Using awinding results, even with the imperfectspecially

tailPapermakers will thus benefit increas-

sheet quality to be expected during initialtransfer procedure was thoroughly test-

ingly from the advantages of our Sirius

operation.

ed. As a result, only slight adjustments

SensoReeling concept:

developed

unwind,thewere required for production startup
The two highly motivated commissioning

when the paper machine was finallyteams, supported from time to time byready.

I Surface protection thanks to gentle
contact with the SensoRoll
I Conservation of volume and elasticity

our development and technology people,
exchanged findings to ensure a really ef-

These are two examples of the efficientby the SensoNip control systemficient optimization phase thanks to theprocedures – including new experiences

I Optimal paper roll structure thanks toresultant synergy effect.

– which led to the high reliability of thesensitive control of winding para-

Sirius wind-up system in such a shortmeters: minimal residual slab even

Only shortly after startup, the winding

time. Commissioning of both the newwith the largest roll diametersparameters of web tension, centre drive

Sirius installations was completed with-I Highest possible production speed

torque and – most important of all – lin-out a hitch – thanks to careful prepara-

thanks to the contour-adaptive

ear load control were finalized for thetions and the know-how gained from

SensoCover.

Finishing45“A look behind the scenes” –preparations for the start-up of theJanus MK 2 for Schongau PM 9
When the old PM 9 rolls in Schongau
come to a standstill as scheduled at
midnight on May 3, 2000, then the plant
will have produced its last ton of newsprint. Within just 54 days, the existing
PM 9 will be dismantled and the reconstruction of the new PM 9 carried out.

Customer/supplier teams –the key to a smooth start-up

This article describes the preparations
made at Voith Sulzer Finishing location in
Krefeld during the planning phase to ensure this extremely demanding start-up.
These include

The teams included staff from Haindl production, planning and maintenance aswell as specialists from the Voith Sulzer
Finishing Division’s order team. The
teams were kept small to facilitate goaloriented solutions.

I Setting up customer and supplierteams
I Installation of the calender in the
production hall in Krefeld and
I Further internal start-up preparations.

The Janus MK 2 for Schongau PM 9

The authors:Peter Herbrik,
Christian Münch,FinishingThis new paper machine represents thesecond Janus MK 2 calender to go into
operation. SCB+ paper can be produced
from 100 % recovered paper with 2 x 5rolls, four steam moisteners, a line loadof up to 500 N/mm and a surface temperature of 160°C at 1,500 m/min. The paper
width is 6,150 mm. The photograph on
page 46 shows the MK 2 under pre-erection. The rigid frame arrangement canclearly be seen. One can also imagine,
how short the free web draws and the
web drying lengths upstream and downstream of the Janus will be after the calender’s integration into PM 9.

All the participants were aware at the beginning of the project that they had letthemselves in for a demanding project.
Thus, at the customer’s suggestion,teams were set up to tackle the high objectives and devise optimum technicalconcepts.

The requirements and possibilities were
to be made to coincide within the concept
without any loss of communication. Critical groups uncover weaknesses, develop
new ideas and optimize concepts. Not
least, they promote the integration of
those who will later have to work with themachines, cause acceptance for the new
equipment and accelerate familiarization
among all participants.
CD Profile Control Strategy TeamThe CD profile control strategy team had
the task of optimizing the individual CD
profile regulating units and integratingthem into a closed control concept. The
most important point for Finishing Division was to guarantee the 2-sigma values
for caliper deviations. Coarse CD profiling is effected by the 14-zone Nipcorect‚
rolls, fine CD profiling using the 30-zone
steam moistener.
Threading TeamThe threading strips are slit on drying

46

Finishing47

Fig. 1: Web transfer demonstration on the VPKR
testbed.
Fig. 2: Nipcorect ® roll installation.
12cylinder 38 by a twin tip slitter and guided through the Janus MK 2 to the pullstack via 2 Fibron belts and ropes. From
there, the strips are automatically transferred to rewinding using 5 further vacuum belts.
Rope arrangement and belt positioning
were optimized and interruptive edges in
the calender were reduced in numerous
discussions. Successful transfer at
1,500 m/min was demonstrated in the
Finishing Technology Center in Krefeld.
(Fig. 1).
Roll Change TeamThe restricted space available (low craneheight, roll change with only one crane,
no storage possibility at PM level) required an adjustment of the roll change
concept.
A working group including experiencedroll changers from Haindl Papier maintenance devised a roll change concept
which ensures an ergonomic and rapidroll change using special swivel crossarms and clamps (Fig. 2 and 3).

Fault Finding Team
Shortening standstill times for maintenance represents a vast potential for
improving efficiency. The concept of an
extended fault detecting system is toopen up this potential. Visualizing thestatus of the calender interlockings simplifies fault identification and accelerates
fault elimination.
Roll Cleaning TeamThe furnish from 100 % recovered papercauses increased dirt accumulation inmachines and installations. Stickies on
the surface of calender rolls or filler deposits covering the rolls result in gloss
spots on the web and may even lead toroll damages. Successful developments
by Haindl Papier were adapted for theJanus MK 2 to prevent this problem.
At the end of the day, the production experience of a notable papermaker and theknowledge gained from over 20 Janus applications were combined to form optimum
calender planning, thanks to the Teams.

48

Fig. 3: Roll erection in the works.
Fig. 4: Just-in-time delivery on the site.
3

4

Installation and preparations
for start-up
After technical planning, the focus wason installation and preparations for startup. Initially, the calender was subjected
to internal audit. The PM 9 Order Team
had to reply to questions by Voith Sulzer
Finishing experts and “defend” the design. At the end, the Order Team had
carried out about 100 interesting optimizations.
A second group was subsequently
formed. It consisted of technologists, installation and commissioning engineers
for Schongau PM 9. Experience with comparable installations was exchanged inorder to prevent repetition of mistakes
and to facilitate successive system improvement.
The Janus MK 2 was completely assembled at Voith Sulzer Finishing GmbH. In
doing so, conditions at the site of final
erection were reproduced as far as possible. Thus installation and alignment of
the frame was carried out using only acrane hook. Since the frame had been divided due to the restricted lifting capacityof the crane in Schongau, this was noteasy. Functional checks on the doctors
and roll change processes as well as
commissioning of the four traversers
were carried out. At the beginning of
installation, 25 requirement-oriented
loaded trucks for just-in-time delivery
were to be provided at the site of construction (Fig. 4 and page 46).
Stand-by Team consisting of the specialists from all departments involved wasestablished and is permanently on call via
mobile phone. The installation and startup groups working around the clock at
the site of erection have to be assured ofcontinuous back-up from “home”.
In order to guarantee a continuous flowof information, conference calls are to be
set up twice a day between the erection
site and Krefeld. A permanent check on
construction activities via a time registration system and a erection site secretarypermit timely response to deadline deviations.

The previous good experience with teams
led to the formation of the Start-up Team.
It examined installation and start-up
planning and discussed machine operation thus ensuring that all the companies
involved are well-informed about thestart-up phase. Check lists for operational tests and I/O checks support system start-up.
While the old PM 9 was still running,large auxiliary units, such as Nipco‚ combined hydraulic and thermo oil systems
etc. were installed and piped subsequently flushed and started up with the control
system. Start-up of the threading system
is to begin 5 days before the first day of
production.
When this article is published, start-up
will probably already have taken place.
We hope that sufficient preparation has
been made so that paper of superior
quality can be seen at the rewind according to schedule on 26th June 2000 despite any imponderables and surprises.
To be continued...

Service

49

1

Partnership with papermaker leads toinnovative solution
Desperate to resolve runnability prob-of its kind – to replace existing rubber

lems associated with the lumpbreakercovers solved the problem.

position on its two fourdriniers, theSmurfit-Stone Container Corporation’s
mill in Ontonagon, Michigan, USA,The two containerboard machines at theturned to the innovators at Scapa Rolls,

Ontonagon

now part of the Voith Sulzer Paper

medium with a recycled content of 33%.

Technology Service Division, for help.

Both paperboard machines have conven-mill

producecorrugatedtional fourdrinier wet ends with a steam

The authors:
Joe Asiala, Smurfit-Stone Container,
Ontonagon, Michigan, USA;
Mike Woller, Voith Sulzer
Paper Technology North America

Build-up on the roll was causing breaks

box located approximately three feetand downtime. Steps taken previously

ahead of the lumpbreaker roll position.

to solve the problems had been ineffec-

Stock temperature is 170° F to 190° F out

tive. The innovative use of a polyure-of the steam box. The mill loads its lump-thane roll cover – the first application

breaker rolls to between 40 and 90 pli.

50

Fig. 1: Smurfit-Stone Container’s mill in upper
Michigan produces recycled content corrugating
medium.

Start-up

Most mills that make this grade tradition-on the No. 2 paper machine were switchedally use a two-inch thick, 200 ± 50 P&J

to polyurethane covers. These rolls arerubber cover on the lumpbreaker roll.

located just downstream from the lump-

When the first PolyMax lumpbreaker cov-

The mill had tried to alleviate the build-up

breaker roll on the fourdrinier and are iner was installed on the No. 2 paper ma-

problems by trying a number of different

direct contact with the sheet. Previously,chine, the roll was two inches smaller incover compounds supplied by a variety of

the rubber covered press rolls would pick

diameter than it was when covered withcover manufacturers, but with little suc-and cause runnability problems. Switch-rubber and required a spacer to be in-cess. All of these rubber covers would

ing to polyurethane covers in the firststalled under the bearing housing. Dy-

pick at one time or another.

and second press positions eliminatednamic nip impressions were taken andbuild-up and picking problems.

scanned with a Voith Sulzer NipScan unit
to confirm uniform loading at the lower

Like many others, the Smurfit-Stone Container Ontonagon mill used showers and

The technical team wanted to be certain

pli. Because of problems with the sparechemicals to limit or prevent stickeys

the polyurethane cover was soft enoughrubber covered roll, the PolyMax re-from building up on the cover. This build-

to work in this application but hardmained in the machine for three months

up caused the rolls to vibrate andenough to resist water permeation. A

before it was removed for regrind and in-bounce, leading to breaks and subse-

50 P & J PolyMax cover was chosen as

spection.

quent machine downtime to clean them.

the best choice for a roll cover running in

The chemical addition to the cleaning

this position. Installing a 50 P & J cover

Together, the mill and the Voith Sulzer

shower was adding cost and the cleaning

where a 200 P & J cover had been run-technical team found a way around theshowers were causing wet end breaks

ning required adjustments by both thewater absorption problem inherent withand housekeeping problems.

mill and the Voith Sulzer technical team's

polyurethane roll covers. The mill agreed

roll cover design element.

to leave the roll out of the machine forfour weeks before re-installing it to give

Voith Sulzer Paper Technology agreed tosupply a polyurethane lumpbreaker roll

Voith Sulzer Paper Technology changed

it sufficient time to dry out and prevent

cover for a trial. A technical team was

the surface finish of the PolyMax rollmoisture from penetrating the bond layer

dispatched to assess this new application

cover to a very smooth finish compared

and loosening the cover.

for the possible use of a polyurethane rollwith the rather rough finish typical of acover.

rubber lumpbreaker cover. To save costs,

The idea of using polyurethane in this po-

the cover thickness was designed atsition has had little support in the indus-

1-inch instead of the traditional 2-inch

try because it was far different from what

thick soft rubber cover. The mill agreed

was considered to be typical. It should be

to a one-month grinding interval until thenoted that the nip width was reduced

effects of water permeation were deter-with the use of a polyurethane cover. Af-

The decision to try a polyurethane covermined. Keeping the polyurethane coverter successfully running with no build-up,

in this position was based on results theroll out of the machine for this time

the loading and crown were brought backmill had seen when rubber covers in thewould allow the cover to dry out before it

to where they were when the mill ran rub-first and second press top roll positions

was re-installed in the machine.

ber covers. The nip width was still only aApplication

Service

51

Fig. 2: New polyurethane lump breaker roll coverhas eliminated stickeys buildup problems andimproved machine runnability.
Fig. 3: Ron Howard, general manager of the
Smurfit-Stone Ontonagon mill.

With the overwhelming success of the2polyurethane roll on its No. 2 paper machine documented, Voith Sulzer was given the opportunity to cover the No. 1 paper machine lumpbreaker rolls in PolyMax. To date, all lumpbreaker rolls at the
Ontonagon mill are covered in PolyMax
and are achieving similar results.

fraction of what it was before, but thishad no ill effect.

3

I No downtime to clean build-up off ofthe PolyMax lumpbreaker roll coverhas been needed.

Increasing nip pressure actually helped toincrease machine speed without negative

I The reduced dwell time in the nip has

effect on sheet properties. Fears of sheet

not affected sheet quality andcrushing and the possibility of sealing

improved off-couch sheet dryness has

the sheet too early, preventing proper
drying, were not realized.

been achieved.
I Machine breaks were reduced
considerably and the No. 2 machine is

Ron Howard, general manager of the

now producing record tons at record

Smurfit-Stone

speeds.

“Both Mike Woller at Voith Sulzer Paper

Results

Ontonagon

mill,

said

Technology and Joe Asiala and Eugene
I The grind interval of the polyurethane

Lewis, assistant superintendents at the

Detailed, specific cost savings data can-roll cover has remained at threemill, are to be commended for their inno-

not be released, however, some of themonths with no water permeation

vations and development of new lump-

positive outcomes realized include:issues.

breaker operation technology. Few people
in the industry supported this concept

I The machine started up with no

I The machine continues to run with no

initially, but many mills will take advan-

cleaning shower and no chemicalchemical addition and no shower ontage of it in the future based on the

addition to the lumpbreaker roll.

the lumpbreaker roll.

Ontonagon mill’s success.”

52

Process technology –Meeting current and future demands
on system suppliers

Today’s machinery concepts are reaching their limits

More intensive
global competition in
the paper industry– Increased production
output– Cost reduction

Greater competitionby electronic media– Quality increase– Cost reduction

Process
technology

1

Currently there are two main trends deci-

To compete successfully with the elec-

sively affecting conditions in the paper

tronic media, paper must ensure an im-industry (Fig. 1):

proved printing quality. The trend towardhigher printing quality is already evident

I More intensive global competition in
the paper industry

as can be seen in the growing number of
4-colour printed newspapers and the increased complexity of the presses used

The author:
Bernd Güldenberg,
Paper Machines
Graphic

I Greater competition to the paper indus-

today. Since high grade wood-free graph-

try by electronic news and PR media.

ical papers are printed on sheet-fed offset
machines with up to 12 colour modules,

Growing competition in the paper indus-

they must fully comply with much higher

try is being countered by ongoing pro-demands on surface strength and dimen-

ductivity increase and cost reduction.

sional stability. This cannot be ensured

Rising operating speeds and the trend to-without a comprehensive knowledge ofwards online finishing processes (coating

printing technology.

and calendering), at the same time withdecreasing paper strength due to lower

As system supplier and partner to the pa-

basis weights, often approach the limits

per industry, Voith Sulzer Paper Technol-of today’s machinery concepts. To ensure

ogy takes pride in meeting these chal-adequate process stability at these limits

lenges in teamwork with our customers.

and extend them further, a deeper knowl-

To this purpose we have founded newedge of all production processes is indis-

Process Technology divisions for graphi-

pensable.

cal papers, board and packaging papers
and tissue papers. The Graphical Paper

Paper Machines

53

Fig. 1: Trends affecting the paper industry.
Fig. 2: Focal points of the Process Technology
departement.

Process Technology division is briefly described in the following:
Tasks of theProcess Technology division

Purpose of the Process Technology
departement
Plant optimization

Project engineering andguarantee performance

Printability

By systematic analysis of the entire
process – from furnish to printed product– to deepen process know-how with thefollowing goals:
I optimize new designs and rebuilds
I identify optimization potential in2existing production lines
I ensure optimal printability.

Project engineering and guarantee

examples of Process Technology departe-

performancement tasks:

Furthermore the analyses of new printing

Know-how supplied by the Process Tech-I System partnership with Ettringentechnologies in good time ensures that

nology departement provides a basis for

future requirements on paper products

conceptual machine design and guaran-

can already be incorporated in current

tee performance.

paper mill, Lang Papier AG
I Improvement of registration precision
for 4-colour rotary offset newsprinting
I Investigation of raw paper effects on

paper machine developments.
Printability and runnability in the press

printability of double-coated woodfree

To attain these goals, the main tasks of

Optimal printability and runnability in thepapers.

the Process Technology departement arepress is a common goal of the entire pa-

as follows (Fig. 2):

per production process. The wide variety

Organization: the Process Technologyof parameters involved ranges from fur-departement is divided into two groups

Plant optimizationnish characteristics and stock prepara-dealing with woodfree and woodcontain-

In partnership with our customers, Voithtion to paper machine and finishinging grades. The woodfree paper group fo-

Sulzer Paper Technology carries out plant

processes. Since in many cases notcuses on web and sheet-fed offset print-

optimization comprehensively – from fur-enough is yet known about their effects

ing and office printing process require-nish to printed product. The customer’s

on printability, these parameters have toments. Main focus in the woodcontaining

product know-how and VSPT systembe optimized to suit the respective paper

paper group is on rotogravure and web

know-how are fully exploited thereby tograde and printing process. In future

offset printing needs. Special-purpose

attain joint targets. As customer contact

the Process Technology departement will

papers are dealt with by the Process

partner, our Process Technology departe-greatly expand know-how in this connec-

Technology department in Ravensburg.

ment has access to the entire expertisetion.

This organization should ensure optimalof all Voith Sulzer Paper Technology divisions.

support and product utilization for all our
The following current projects are typicalcustomers, whatever their needs.

54

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

55

Voith São Paulo, Brazil“We are wherever our customers are!”Our story starts in 1964, when Voith S.A.

Long before the phrase Global Players

São Paulo was founded. After Germany,

was in fashion, the Voith Group wasAustria, Great Britain, Spain and India,

present in the main economic centers

this was the first Voith Group productionof the world with more than dozen

plant to be established in the Americas.

production plants, and supported by

It was not by chance that the location se-

many sales and service companies.

lected in South America was São Paulo,
since the city was an expanding industrial

The author:
Kurt Brandauer,
Voith São Paulo, Brazil

This previous global experience is now

metropolis where Voith products had

producing dividends in no uncertain

been manufactured under license sinceterms since the more international

1960. During the sixties, Brazil rapidly

markets merge, corporate cooperation

attained economic leadership among thearound the world must be more inten-

Latin-American nations and Hugo Rupf,

sive and focused in order to meet thethen Managing Director of J. M. Voith

demands of the Market. Voith is using

GmbH, convinced the owners of the com-the advantages of having a local pres-pany of the value of establishing opera-

ence to meet the competitive demands

tions on the other side of the Southof the customer, while simultaneously

Atlantic.

using the strength of the Voith Group1

2

to supply equipment from the various

During the past thirty-six years, Brazil

Factories of the world.

has progressed to become the tenth

56

3

4

largest gross domestic product (GDP) in

second largest population center after

exporter, with approximately 70% of thethe world, but this growth has not been

Mexico City. São Paulo also accounts forexports from the industrial products sec-

linear. For example, when Voith S. A. wasnearly 40% of Brazil’s tax income, andtor, and recently, responding to increas-founded, São Paulo had a population of 4

half of the country's industrial complex,

ing global market pressure, Brazil reval-million, while today this has grown tothus the headquarters of large private

ued its currency and implemented themore than 17 million in the metropolitan

companies and banks are located in thenecessary measures to comply with inter-area. This makes São Paulo the world’s

region. Brazil is South America’s largest

national standards.
These figures reflect the enormous
development of Brazil from an agrarian
exporter of coffee and cotton to a modern, industrialized nation. Voith S.A. São
Paulo has played a key role in this development with Voith providing equipmentin the Hydro Power, Propulsion andPapermaking Technology areas. One of
the most spectacular projects during thecourse of this industrialization process
was the construction of the Itaipu powerCorporate News

57

Fig. 1: The city of São Paulo.
Fig. 2: Inauguration of Voith S.A. São Paulo in
1964 by Governor Laudo Natel and Hugo Rupf.
Fig. 3: The Voith São Paulo site covers about
300,000 square metres.
Fig. 4. Paper machine production.
Fig. 5. Voith São Paulo locations in SouthAmerica
H Headquarters
H Service centres
H Representative offices.

requirements, but also is famous forrolls which are 1.8 m in diameter, 10.3 m

exporting high grade products, such as

long, and weigh 21 tons each. This is an

wood-free writing and printing papers

outstanding example of how well the cor-made of 100% Eucalyptus pulp to North

porate Production Capacity is integrated,

America and Europe. Voith S.A. Sãowith all components being manufactured

Paulo has played a key role in providing

to the same high quality Voith standards,

the necessary paper machinery as well as

whether being produced in Europe, thethe associated process technology, for

USA or Brazil.

these international market segments.
In addition to conversions and modernThe Voith site in Jaraguá, a São Paulo

ization projects, current orders on handsuburb, utilizes nearly 300,000 squareat Voith Sulzer São Paulo include newmeters with approximately 1,500 highly

machines for plants in Brazil and Argenti-

trained employees. After 36 years as ana. Also being produced in Brazil is a

jointly managed company, Voith S.A. Sãocomplete Kraftliner machine for Visy Pa-

Paulo, as of April 2, 2000, has become

per Australia, with a web width of 5.5 m

three independent business units, com-and an operating speed of 1,000 m/min.

prising Voith S.A. Paper Technology,
station on the Rio Parana, the largest

Voith Siemens Hydro Power Generation

Hydro Power facility in the world. The

Ltda. and Voith Turbo Ltda. (propulsion

Voith water turbines generate 13.4 GW –technology), all maintaining headquarters

enough to cover a large part of Brazil’sin São Paulo.

Caracaspower needs, including the industrial requirements of São Paulo.

Cali

More than 100 engineering specialists
are employed at Voith S.A. Paper Tech-

In 1969 and 1970 the first two paper

nology, a modern plant not only from themachines to be built by Voith São Paulotechnical point of view but also the quali-

were commissioned: “Cocelpa 1” in 1969

ty of the workplace. Facilities include afor Kraftliner production, and in 1970

foundry currently producing 850 tons of“Gretisa 2” for MG papers. These were

castings each month, thus Voith São

followed in 1973 by “Suzano B6”, a fold-Paulo is ideally equipped for manufactur-

ing boxboard line with an output of

ing large rolls and drying cylinders, in-

400 tons per day. Voith São Paulo was

cludingalso delivering new Paper machines

Equipment for the largest order in theworldwide and successfully completed

history of Voith Sulzer Paper Technology,

many conversions. The Brazilian paper

Dagang PM 1 and 2, was supplied fromindustry not only satisfies the national

Voith São Paulo including the 75 drying

Tissueand

YankeeDryers.

5
Lima
BrazilMucuriSão Paulo
Santiago

Buenos Aires

Ponta Grossa

58

The Voith São Paulo foundry.

In May 2000 VP was awarded anotheractually carried out at VP São Paulo de-Tissue production standards for both

Project as follow-up to the Procart board

pends on strategic circumstances andquality and output.

machine (see twogether No. 8) jointly

customer location, and logistically, Sãodelivered with Voith Sulzer Paper Tech-Paulo is favorably situated for deliveries

The commitment that Voith São Paulonology, and conversion of the two Inforsa

to many points around the world.

provides to Service, and recognizing themaintenance needs of its customers has

newsprint machines. Sao Paulo will be
supplying the Chilean pulp and paper

Together with Andritz as licensee, Voithbeen, and continues to be a high priority

producer CMPC, with a complete produc-São Paulo also specializes in Tissue ma-

item. With existing facilities in Sao Paulo,tion line for testliner on a turnkey basis,chines. In fact, Voith São Paulo is the

Ponta Grossa in the south of Brazil, andwith an initial output of 140,000 t.p.a.

Center of Competence (COC) for tissue

Mucuri in the north, Voith S. A. is provid-

technology within the Voith Sulzer or-

ing fast, efficient service to Brazil, andVoith São Paulo is basically able to sup-ganization. Research and Development

indeed, to all of South America. This ser-ply the entire spectrum of paper technol-

projects are managed in Sao Paulo byvice network is currently being expanded

ogy, with comprehensive services cover-

25 specialists, working in laboratories

in Brazil, Argentina, and Chile in order toing plant design, stock preparation, water

as well as operating a 2,000 m/min test

insure that Voith continues its leadershiploop management and finishing. The

facility. This facility was the cradle ofposition and its commitment to Customer

amount of design and production work

TissueFlex technology, which has set newService in South America.

Corporate News

59

Plaque awarded to Voith Sulzer
Stock Preparation for the best paper
for innovation at the TAPPI
Recycling Symposium, Washington/
USA, March 5-8, 2000.

Stickies summit in Washington, D.C.
The North American paper industry
perception is that stickies are still theNo. 1 degrading
culprit affecting recycled pulp. Stickies cost the U.S. paperindustry $ 700 million a year, according
to the American Forest & Paper Association (AF&PA). The personal computer
revolution in the office and at home iscreating not less paper consumption but
more and unfortunately an increased percentage of adhesive products are included in this paper boom. Of all types of adhesives entering the paper recycling
stream, pressure sensitive adhesives(PSA) give the recycling process technology the biggest challenge.
One of the biggest consumers of PSA’s in
the USA is the U.S. Postal Service. It isestimated that the U.S. Postal Service
has a 12-15% PSA market share. This
market share increases to 40% if thecomplete U.S. Federal Government istaken into account. Realizing its contribution to the problem, the U.S. Postal Service initiated an environmentally benignpressure-sensitive adhesive program in

The author:
Oliver Heise,
Stock Preparation

1995 to develop pressuresensitive postage stamps
which do not adversely affect the recycling process.
The ongoing efforts focus
on both pre-consumer andpost-consumer areas. The U.S. Postal
Service was successful in implementing
an industry-wide approach, promoting
the concept of vertical teams to determine the requirements and the testing ofa new generation of benign adhesives
which can be easily screened out in therecycling process. The vertical teams
consist of industry representatives fromadhesive suppliers, converters, stamp
printers, face and liner suppliers, finepaper recycling mills and equipment
manufacturers. Voith Sulzer’s project involvement also included pilot trials intheir Stock Preparation Research Centerin Appleton, Wisconsin/USA.
From March 5-8th, 2000, TAPPI, the U.S.
Postal Services, the U.S. Adhesive Council, the U.S. Forest Service and AF&PA
presented a “success story” during the2000 TAPPI Recycling Symposium in
Washington, D.C. Since 1997 all stickies
from U.S. self-adhesive postal stamps arescreenable in the recycle process with a
99%+ efficiency. Pilot and mill trials provided unequivocal testimonies to thissuccess story. The U.S. Postal Service istaking an additional path forward, now
tackling labels and silicon release liners.
It is expected that the new adhesive standards will carry over to other “sticky”
markets such as Post-It notes, tapes, etc.
This proactive program of the U.S. Postal
Service is receiving applause from
Europe. During the international session

at the TAPPI conference in Washington,
Dr. E. Krauthauf from Haindl Papier,Schongau/Germany titled his paper appropriately: “Europe looks to the U.S.
Postal Service PSA Project with Great
Expectations”.
At the TAPPI conference 70 highly technical papers were presented. Six papers
were selected to receive the “best paper
award” for various categories such as
University, Innovation, Paper Mill, etc.
The paper by Heise, Cao and Schabel entitled “A novel application of TAPPI T277
to determine macrostickies disintegration
and agglomeration in the recycle
process” received the award for innovation. The authors, located at Voith Sulzer
Paper Technology in Appleton/USA andRavensburg/Germany revealed in theirpaper the two different mind-sets which
exist in the adhesive and paper industry
when it comes to the screenability of
PSA’s. For the first time the detrimental
impact of shear forces at higher consistencies in pressure screening equipment
was presented. In addition, the authors
discussed a statistical methodology todescribe the disintegration and agglomeration probability of stickies in recycling
equipment.

60

P a p e r C U LT U R E“Festas do Povo”, Campo Maior
26th August through 3rd September 2000
Poured into place as if by a sensitive
hand between the infinite brown of thecountryside and the ocher fields in the
North of the Alentejo region, it shimmers delicately in the blazing summer:
the Campo Maior. And when the heat
abates, when the month of August approaches its final days, life awakes toa new spring in this town close to the
Spanish border, with its 12,000 inhabitants. It may last for only for one week,
but it brings forth an unbelievable
wealth of colors and shapes. A spring
season called “Festas do Povo” thatimmerses the entire town in a sea of
festoons, flowers and fruits. A rebirthof spring that disregards the fixed orderof the seasons, since it is hand-madethrough and through, by people, out of
paper and in millions of hours of work.

Paper Culture

61

Porto

Portugal

LisbonCampo Maior
Alentejo

Faro

Chickpeas are Fátima’s secret. They
make the base of the blossoms stand out
in three dimensions, they form a firm
center for ten layers of paper, which,when appropriately shaped, make up thetrue masterpiece: A flower which is anabsolute replica of the original, and thisnot only at first glance.
Fátima, assisted by Eduarda and Maria,
will have completed around 30,000 ofthese flowers by the end of August,when the “Festas do Povo” are celebrated
in Campo Maior: Roses, larkspur,bougainvillea, geraniums, orchids andmany other plants are made by skilled
slitting and cutting to shape, overlappingand slight curling of the delicate paper
between forefinger and thumb – orthrough little tricks like wrapping a chickpea.

Since December the women have beenworking with untiring eagerness, night
after night, seldom stopping before two
o’clock in the morning. And this has not
only been going on in Fátima’s house. Up
to 6,000 inhabitants of this town in the
Alentejo region have been occupied withpreparations for a festival that is unparalleled anywhere in the world.
During the “Festas do Povo” the blue
sky above the streets will disappear – because the sky will then be made of paper,
consisting of up to 50 million flowers andfestoons in all the colors of the rainbow.
Flower pots, arbors, lanterns, fences orpools of cardboard are arranged in thestreets like trees and bushes, in the
branches of which you hear the rustlingof millions of green leaves, cut to matchthe last detail of the originals.

It is mainly the elderly women in town
who have mastered this art of hand-madeillusion, passing on their knowledge andskills to the younger generation. Nevertheless, the Festas and the preparations
for this event are everyone’s project:“This makes us grow into a single large
community, where all the doors are
open.” What Eduarda describes in such
simple words has been described by thepress an “example of collective illusion”,
of “living equality” and as “a place where
the people make the rules.”
It is not only an abundance of coloredpaper that creates the fascination of the“Festas do Povo” but also this almost
unique solidarity demonstrated by the
12,000 citizens when organizing their“Festival of the People”. The festival is
not scheduled to be held at regular inter-62vals, but only after a joint resolution thatthe time has come. From the moment thedecision has been made, direct cooperation awakens to life and the planning, butalso the secrets, begin.
Directed by a “leader” and taking into
account all the ideas that the residents
have submitted, every street designs its
individual decoration, its share of theoverall masterpiece, and keeps it underlock and key up to the very last moment.
The men of Campo Maior are mainly incharge of the manual tasks such as attaching fastenings and illuminations tothe buildings; it is the women who, in a
total of three million hours of work,
process about three million sheets of tissue and 60,000 sheets of crepe paper.
The complete material was imported fromthe Werola company of Rastatt, Germany,weighing, including 5,000 kg of cardboard, a total of 28 tons. Enough material
to decorate a area of 110,000 square
meters.
Visitors arriving in Campo Maior as lateas the eve of the festival will be disappointed when exploring the town’s deserted streets. There isn’t the slightest
clue that a few hours later one of thecountry’s most fascinating shows willtake place. But as night falls, the doors
open and gigantic rolls of festoons andbaskets full of flowers are carried out of
the houses. Quietly but without losing asecond, the teams put up the festoons
from house to house and drape them withflowers, fruits and ornaments. It is four,
five or perhaps even six o’clock in themorning before all the decorations are inplace. A joint meal is followed by an im-

portant ceremony: “em arruda”. Walking
arm in arm and singing, the paper artists
wander through the 112 transformed
streets of the town, survey the lavish creations, take in this collective work of art.
Before they go to bed and dream of nothing but flowers, they will pray: that
Campo Maior will be spared from the rain
for one week. But in the event of theseprayers remaining unanswered, they
won’t admit defeat: in a final display ofcollective determination they take off theflowers and festoons, dry them, hangthem up again and continue to celebrate.
Amazing solidarity and the will to start
all over again if necessary has characterized the inhabitants of this Spanish-Portuguese border town for many centuries.
Conquered by the Moors, seized by the
Spaniards around 1230, occupied by thePaper Culture

Portuguese in 1296, Campo Maior and its
fortress was originally a symbol for “facing the Spanish enemy defiantly”. It reverted finally to the Portuguese crown in
1297. In the following centuries fierce
fighting along the border flared up again
and again. But just as often the courageous citizens were able to escape capture and even succeeded in defying
Napoleon’s soldiers. This heritage earned
them the official title “loyal and brave” inthe year 1811. At that time, with theirusual toughness, the people of Campo
Maior had also survived prolonged epidemics and the consequences of a gigantic explosion.
As a result of the detonation of the municipal gunpowder magazine during athunderstorm in 1732, two thirds of theroughly 1,100 houses making up thetown at that time were destroyed andhundreds of people killed.
Peace has long since returned to Campo
Maior. Today its inhabitants make theirliving from agriculture and a thriving coffee roasting industry. The latter also supplies us with the most popular of thenumerous theories about the Festas do
Povo’s origin: They are an extension ofsmaller, spontaneous celebrations commemorating the successful outcome ofcoffee-smuggling tours to Spain! Anothertheory sees the stimulus for the Festas in
the worship of John the Baptist. It is certainly true that so far a procession has
been organized in his honor as part ofevery “festival of the people”.
However, nobody cares much any longer
about the precise origin of the feasts,
which were organized for the first time on

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a grand scale in 1893. The pleasure ofcreativity, of producing wonderful things,
is what predominates: “Preparing the festival is great fun, and the results are truly
fantastic!” says Eduarda with great enthusiasm, and Maria, shaping pink flowers with her usual tireless enthusiasm
and placing them in a large box beside
her, adds: “The Festas are there to makelife more beautiful. Thousands of people
work hand in hand for a great idea!” Sherecalls the tears in the eyes of the womenof this town, when at the end of the“Festas” a huge fire is kindled and theentire splendor, the result of many
months of tired, sleepless nights, iswiped out in a matter of minutes.
For Fátima, who has experienced as manyas twenty “Festas do Povo”, it is thepower of the group that counts: “Ownership is in abeyance. Everybody is free togo wherever he or she likes. Anyone whoenters the house, owns it! The bigger thefamily, the greater the festival!”
Such words may evoke spontaneous ifs
and buts in those who do not understandthe philosophy of the “Festas do Povo” –or are incapable of understanding it. Thisis because they have never participated insuch living solidarity, which after all thedesigning, creating and decorating workis over is still far from having reached its
peak. When the blazing midday heat
abates, large tables are placed in front of
the houses, the proud artists sit down at
the tables in their streets, enjoy the admiration of the visitors, explain and tellstories. On the table there is bread, waterand all kinds of food ready for anyone
who needs a rest, who wishes to experience the town’s awakening. People eat,Paper Culture65
Our thanks are due to Gustavo de Almeida
Rebeiro, Lisbon, for kindly granting permission
to reproduce some pictures from the book
“Campo Maior – a magia do povo”, of which heis the author and publisher.
Also, we would like to thank to the organizers of
the “Festas do Povo” and the photographer
Mr. Otto Hahn for additional pictures and supplemental informations.

regardless of the fact that the costs ofthe material alone amount to about
150,000 dollars for every festival. They
are borne by the municipality and, inpart, by private sponsors.
Accepting money from the tourists
would contradict the basic principle anchored in all this commitment. But the
exception proves the rule: Voices havealready been raised calling for better
marketing of the whole event, and theresidents of various streets have threatened not to participate in the Festas.
talk and dance on several squares, andyou can hear the sounds of the “Saias”,
songs about Campo Maior, its past andits future. Traditional songs, written inverse and composed during the longnights of the preparation period.
“When someone approaches you andinvites you, don’t be surprised – simply
accept the invitation!” declares Maria, because hospitality and openness towards
other people is part of Campo Maior’s
principle of life. However, for some years
practicing the “tradition of the poor
houses” has been almost impossible.
This is because every festival attracts anincreasing number of visitors to the little
town north of Elvas. Those visitors not
only stretch the residents’ most generous
hospitality to the limit, they need – since
they arrive in up to 50,000 cars and
2,000 coaches – to be well organized
down to the smallest detail. A 150hectare parking lot has been provided,and hard-working catering booths dotheir very best to feed the tourists. Apartfrom a small parking fee, the splendid
spectacle itself is still free of charge,

The tissue paper rustles softly as Fátima
shows the other two women how to create tiny red buds. Eduarda and Maria areamong those, who have the skill anddetermination needed to pass on the tradition. It has of course come to Fátima’s

ears that some of the younger citizens
foresee a profitable business in the Festas. But she does not believe that theFestas are threatened, not in the near
future: It is the beautiful things thatcount, the masterpiece as a whole. Thereis a power for body and soul, anchored inthis unique achievement. One gives to it,
and one is rewarded in return.
Even though she only knows the latest
flower and festoon motifs from her immediate neighborhood, Fátima is surethat the “Festas do Povo 2000” will
eclipse all previous festivals. Not only toachieve the impossible, but to outperform
it again and again, is a wish that the citizens of Campo Maior reveal in anothermotto: “Show people heaven – and thatyou can share your heart!”
Heidi Hahn

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