1

Dear Customer, dear Reader,
The past year 2001 has been a rewarding one for all divisions within the Voith Groupof Companies that supply to the pulp and paper industry.
Bookings and sales were at an all time high with a correspondingly good financial
performance.
We do not anticipate the same order intake performance for the current business year,
although our strong performance in China seems to compensate to some degree forthe slowing demand in most of the other geographic regions.
Consolidation continues unabated among our customers. Likewise we, Voith Paper,
have continued to complement our product platform with the acquisitions of Kvaerner
Recycling and Finckh, both becoming members of the Fiber Systems Division.
Jagenberg Papiertechnik in Neuss, Germany, Enfield, USA and Basagoitia, Spain will
enhance our position in both paper machine divisions, graphic and board and packaging, as well as in the finishing and service divisions.
Hans Müller,
Voith Paper

In addition to the acquisitions just mentioned, we have converted long lasting license
relationships with IHI, Japan and Larsen Toubro in India into joint ventures. Both ventures will solidify our footholds in these two most important markets.
With these new members, and in conjunction with Voith Fabrics, we are now in theposition to offer the most comprehensive process know-how and the technology andproducts for every demand in the paper and board industry.
As China continues to develop into a major producer of pulp and paper, we have committed to building a state-of-the-art service center in Shanghai for roll services androll covers, as well as for a mechanical service center in Huatai, Shangdong Province.
Last but not least, we have added roll cover capabilities in our service center in Düren,Germany.
This issue of twogether No. 13 clearly demonstrates our wide range of activities.
This is depicted by the article on the Ultrastar machine of Sappi Gratkorn, Austria,
representing the world’s largest unit for the production of coated free sheet or thehighly cost-effective newsprint machine of Inland Empire in the USA.
With our growing sensitivity towards providing elements and components forthe enhancement of productivity, we are successfully deploying products such as theforming fabric Horizon™ or press felts such as the Vector™. In this issue you will readabout many more products of low investment demands, but high and quick returns.
We recognize and appreciate that all these achievments could only be attained withyour continued confidence and support of Voith Paper and Voith Fabrics.
Thanks for all this and enjoy reading our twogether No. 13!

Hans Müller
On behalf of the Voith Team Supplying the Pulp and Paper Industry

2Startup highlights in 2000/2001

Fiber Systems
Stock preparation systems andsub-systems for graphic papers
Stora Enso, Langerbrugge,
Belgium.
Keräyskuitu, Sunila,
Finland.
Haindl Papier, Schongau,
Germany.
Sappi Nijmegen, Nijmegen,
Netherlands.
Arjo Wiggins Papiers Couchés,Bessé-sur-Braye, France.
Fabryka Papieru Malta-decor,
Poznan, Poland.
Minfeng Paper Mill, Zheijiang,
China.
Pan Asia Paper, Singburi,
Thailand.
Steyrermühl AG, Steyrermühl,
Austria.
Pan Asia Paper, Chonju, South
Korea.
Papierfabrik Utzenstorf AG,
Utzenstorf, Switzerland.
Stora Enso Fine Paper, Uetersen,
Germany.
Papeteries Matussière et Forest,
Voreppe, France.
Felix Schoeller jr., Weissenborn,
Germany.
Dresden Papier AG, Heidenau,
Germany.
Steinbeis Temming Papier,Glückstadt, Germany.
Holmen Paper, Hallsta, Sweden.
Grupo Pulsar, San Juan del Rio,
Mexico.

Bowater, Coosa Pines, USA.
Newstech, Coquitlam, Canada.
Bowater, Gatineau, Canada.
Mississippi River Corp., Nathcez,
USA.
Stock preparation systems andsub-systems for board and packaging
papersLEIPA Georg Leinfelder, Schwedt,
Germany.
Genting Sanyen, Selangor,
Malaysia.
Roman Bauernfeind Papierfabrik,
Raubling, Germany.
Propapier, Burg, Germany.
SCA Packaging New Hythe,
Aylesford, Great Britain.
Papierfabrik Niederauer Mühle,Kreuzau, Germany.
Packaging Corp. of America,
Tomahawk, USA.
Stock preparation systems andsub-systems for tissue papers
WEPA Papierfabrik, Müschede,
Germany.
Kimberly-Clark, Koblenz,
Germany.

Paper machines
Graphic papers
Inland Empire Paper Company,
Millwood, USA.
Minfeng Special Paper Co., Ltd.,
China.
Quena Newsprint Paper Co., Kairo,
Egypt.

Papierfabrik August Koehler AG,
Kehl, Germany.
Board and packaging papers
SAICA, Spain.
Rebox, USA.
Visy Paper Pty. Inc., Australia.
CMPC, Puente Alto, Chile.
Oji Paper Co., Ltd., Japan.
Newark America, Fitchburg, USA.
TissueMili, Brazil.
ICT Poland, Poland.
LPC, Great Britain.
Installations and rebuilds
Klabin-Celucat, Brazil.
JSC Solikamsk Bumprom,
Solikamsk, Russia.
UPM-Kymmene Corporation,
Kaukas, Finland.
Neusiedler AG, Kematen,
Austria.
Mitsubishi Hi-Tec Paper Flensburg,
Flensburg, Germany.
Schoellershammer IndustriepapierGmbH & Co KG, Germany.
Haindl Papier GmbH, Schwedt,
Germany.
Haindl Papier GmbH, Schongau,
Germany.
Sappi Fine Paper (PTY) LTD.,
Stanger, South Africa.
Temboard & Co. Ltd., Temiscaming,
Canada.
Felix Schoeller Jr. GmbH & Co. KG,
Weissenborn, Germany.
Sora Uetersen GmbH, Uetersen,
Germany.

Sappi Alfeld Papier, Alfeld,
Germany.
Balkrishna, India.
Westvaco Corporation, Evadale,
USA.
Papierfabrik Hermes GmbH & Cie
KG, Hermes, Germany.
Kruger Inc., Corner Brook, Canada.
Kübler u. Niethammer, Kreibstein,
Germany.
Metsä-Serla, Kangas, Finland.
Nagoya Pulp Co. Ltd., Nagoya,Japan.
Atlantic Packaging Products Inc.,
Union, Canada.
Nippon Paper Industries Co. Ltd.,
Geibo, Japan.
Consolidated Papers Inc., Rapids,
USA.
Sora Enso Reisholz GmbH, Reisholz,
Germany.
Irving Paper Mill, Irving, Canada.
Tohoku Paper Mfg. Co., Akita,Japan.
Hokuyo Paper Co. Ltd., Nayoro,
Japan.
DAIO Paper Corp., Mishima,
Japan.
Alberta Newsprint Co. Ltd.,Whitecourt, Alberta,
USA.
Jinjiang Paper Co. Ltd., Ishinomaki,
Japan.
Baceli S.A., Bacell, Brazil.
Aracruz Cellulose S.A., Aracruz,
Brazil.
Cartiera Nicoli SRL, Carbonera,
Italy.
Munksjö Paper Decor GmbH,
Janköpping, Sweden.

3

Nippon Paper Industries Co. Ltd.,
Yufutsu, Japan.
West Linn Paper Co. Oregon,
USA.
Champion Papel e Celulose Ltda,
Mogi Guacu, Brazil.
Inland Empire Paper Company,
Millwood, USA.
Inland Container Corp.,
New Johnsonville, USA.
Willamette Industries Inc.,
Hawesville, USA.
Khanna Paper Mills, Ltd., Khanna,
India.
Torraspapel Montananesa,
Montananesa, Spain.
Neusiedler AG, Austria.
Productora de Papeles S.A. Propal,
Propal, Venezuela.
Bear Island Paper, Ashland,
USA.
Klabin Papéis, Brazil.
Aralar, Spain.
Longview Fibre, USA.
Cartiera die Carbonera S.p.A.,
Italy.
Nippon Paperboard, Japan.
Frantschach Swiecie Spolka
Akcyina, Poland.
LEIPA Georg Leinfelder GmbH,Germany.
Mayr-Melnhof, Kolicevo, Slowenia.
Stora Enso, Imatra Mills,
Tainionkoski, Finland.
Mayr-Melnhof Karton GmbH&Co KG,
Austria.
Archangelsk Pulp and Paper Mill,
Russia.
Tecnokarton J.M. Weig, Mayen,
Germany.

SCA de Hoop, Eerbeek,
Nederlands.
Melhoramentos, Brazil.
Coating technology
Papelera del Aralar S.A., Spain.
Quena Newsprint Paper Co.,
Egypt.
Sappi Muskegon, USA.
UPM Kymmene, Kaukas Mill,
Lappeenranta, Finland.
Neusiedler AG, Kematen,
Austria.
Stora Enso Magazine Paper,
Veitsiluoto Mill, Kemi, Finland.
Minfeng Special Paper Co.Ltd.,
Minfeng, China.
Cartiere Burgo S.p.A., Verzuolo,
Italy.
Stora Enso Kabel GmbH, Hagen,Finland.
Torraspapel Sant Joan Les Fonts,
Spain.
M-real Hallein AG, Austria.
Sappi Fine Paper, Stanger,
South Africa.
Torraspapel Montananesa,
Spain.
Stora Enso Uetersen GmbH,
Uetersen, Germany.
Papierfabrik August Koehler AG,
Kehl, Germany.
Mitsubishi Hi-Tec Paper,
Hillegossen, Germany.
Felix Schoeller jr., Weissenborn,
Germany.
Sappi Alfeld AG, Alfeld,
Germany.
Steinbeis Temming Papier GmbH& Co., Glückstadt, Germany.

Sappi Fine Paper Europe,
Lanaken Mill, Belgium.
Winding technology– Sirius
Oji Paper Co., Ltd., Fuji,
Japan.
August Koehler AG, Oberkirch,
Kehl, Germany.
– Pope reel winders
Stora Uetersen GmbH, Uetersen,
Germany.
SP Newsprint, Newberg, USA.
Minfeng Special Paper Co., Ltd.,
Minfeng, China.
Roman Bauernfeind PapierfabrikGmbH, Germany.
Quena Newsprint Paper Co., Kairo,
Egypt.
Frantschach Swiecie Spolka
Akcyina, Poland.
Shandong Rizhao Wood Pulp Co.
Ltd., Rizhao, China.
Felix Schoeller Jr. GmbH & Co. KG,
Weissenborn, Germany.
Papierfabrik August Koehler AG,
Kehl, Germany.
Sappi Alfeld Papier, Alfeld,
Germany.
Papeles Cordillera S/A Puente Alto,
Chile.

FinishingJanus-Concept
UPM Kymmene, Tervasaari,
Finland.
Madison Alsip, USA.

Ecosoft-Kalander
Mitsubishi Hillegossen, Bielefeld,
Germany.
Quena Newsprint Paper Co.,
Kairo, Egypt.
Visy Paper Tumut, Australia.
Portals Overton,
Great Britain.
Maltadecor, Poland.
Linan, China.
Yang An Paper, China.
Century Paper, Pakistan.
Sun Paper, China.
Papierfabrik August Koehler AG,
Kehl, Germany.
CalendersBlue Ridge, USA.
UPM Kymmene, Kaukas,
Finland.
Felix Schöller Weissenborn,
Germany.
Solikamsk, Russia.
Frantschach Swiecie,
Poland.
Supercalender
Ahlstrom La Gère, France.
Twister/ Roll HandlingGreat Northern Paper, USA.
Bacell, Brazil.
Maul Belser, Nürnberg,
Germany.
Sappi Lanaken, Belgium.
Biegelaar & Jansen,
Nederlands.
Roto Smeets, Nederlands.
StoraEnso Hagen Kabel,
Germany.

4

Recent large orders

Fiber Systems

Stock preparation systems andsub-systems for graphic papers
Bear Island Paper, Ashland, USA.
Grupo Pulsar, San Juan del Rio,
Mexico.
Bowater, Coosa Pines, USA.
Newstech, Coquitlam, Canada.
Bowater, Gatineau, Canada.
Madison Papers, Alsip, USA.
Abitibi-Consolidated, Thorold,
Canada.
Mississippi River Corp., Nathcez,
USA.
Newstech PA, Northampton, USA.
Shandong Huatai Paper Group,
Dong Ying, China.
Stora Enso, Langerbrugge, Belgium.
Jinfeng Spike Paper Products,
Chengdu, China.
Zhejiang Jiaxing Minfeng Special
Paper, Zhejiang, China.
Mudanjiang Hengfeng Paper Group,
Yangming, China.
Felix Schoeller jr., Weissenborn,
Germany.
Fedrigoni Cartiere, Arco, Italy.
Myllykoski Paper, Hürth,Germany.
PAPRESA, Spain.

SCA Graphic Laakirchen AG,
Laakirchen, Austria.
Steinbeis Temming Papier,Glückstadt, Germany.
Stora Enso, Uetersen, Germany.
Nanping Paper, Fujian, China.
Shixian Paper, Jilin, China.
M-real, Biberist, Switzerland.
Papierfabrik Palm, Neukochen,
Germany.
Matussière et Forest, Voreppe,
France.
Haindl Parenco, Renkum,
Netherlands.
Nordland Papier, Dörpen,
Germany.
Stock preparation systems andsub-systems for board and packaging
papersPackaging Corp. of America,
Tomahawk, USA.
Inland Paperboard & Packaging,
Ontario, USA.
Gaylord Container, Antioch, USA.
Norampac Inc., Mississauga,
Canada.
The Newark Group, Fitchburg, USA.
Jefferson Smurfit, Carthage, USA.
Pactiv Corp., Macon, USA.
Wuxi Longchen Paper, Jiangsu,
China.
Europa Carton, Hoya, Germany.

Cartitalia, Mesola, Italy.
Papierfabrik Palm, Wörth,Germany.
Technokarton, Mayen,
Germany.
Papierfabrik Schoellershammer,
Düren, Germany.
P.T. Indah Kiat Pulp and Paper,
Serang, Indonesia.
Union Industrial Papelera,
La Pobla de Claramunt, Spain.
Hsin Wu Mill, Taiwan.
Propapier, Burg,
Germany.
Stock preparation systems andsub-systems for tissue papers
Copamex, San Nicolas de los Garza,
Mexico.
Procter & Gamble, Green Bay,USA.

Paper machines
Graphic papers
SCA Graphic Laakirchen A.G.,
Laakirchen, Austria.
Myllykoski OY, Hürth,Germany.
CNTIC Trading Co. Ltd., Huatai,
China.

Board and packaging papers
Shandong Rizhao Wood Pulp Co.
Ltd., China.
Lee & Man Paper MFG Co. Ltd.,
China.
Ibema CIA Brasiliera de Papéis,
Brazil.
TissueGuitang TM 1+2, China.
Hengan, China.
Copamex, Mexico.
Installations and rebuilds
Kappa Herzberger PapierfabrikGmbH, Herzberg, Germany.
Chuetsu Pulp Ind. C. Ltd., Sendai,
Japan.
Myllykoski OY, Alsip, USA.
Nanping Paper Mill, Nanping, China.
MD Papier GmbH, Dachau,
Germany.
Zanders Feinpapiere AG,
Germany.
Bowater, Catawba, USA.
Papelera Espanola S.A. Renteria,
Papresa, Spain.
Ripasa S.A., Celulose e Papel
Limeira, SP, Ripasa, Brazil.
Steinbeis Temming Papier GmbH &Co, Glückstadt, Germany.
Copamex S.A. de C.V., Phimsa,
Mexico.

5

Hokuetsu Paper Mills Ltd., Niigata,Japan.
VIPT, Saga, Japan.
Tamil Nadu Newsprint & Papers
Ltd., Tamil Nadu,
India.
Ripasa S.A., Celulose e Papel
Limeira, SP, Ripasa, Brazil.
Champion International Corp.,
Quinnesec, USA.
Aracruz Cellulose S.A., Aracruz,
Brazil.
Zibo Bohui (Paper) Enterprise Co.,
Shandong, Bohui,
China.
Riau Andalan Pulp & Paper,
Riau Andalan, Indonesia.
Shandong Rizhao Wood Pulp Co.
Ltd., China.
Lee & Man Paper MFG Co. Ltd.,
China.
Ibema CIA Brasiliera de Papéis,
Brazil.
Segezha Pulp and Paper Mill,
Russia.
M-real, Äänekoski,
Finland.
St. Regis Paper Co. Ltd.,New Taplow, United Kingdom.
Kappa Herzberger PapierfabrikGmbH, Germany.
Mayr-Melnhof Karton GmbH&Co KG,
Austria.

Schoellershammer IndustriepapierGmbH & Co KG, Germany.
Papelera de la Alquería,
Spain.
Madeireira, Miguel Forte, Brazil.
Mili, Brazil.
Coating technology
Shandong Chenming Paper,
Shouguang, China.
Steinbeis Temming PapierGmbH & Co., Glückstadt,
Germany.
Sappi Alfeld AG, Germany.
Sappi Fine Paper Europe,
Lanaken Mill, Belgium.
M-real, Äänekski,
Finland.
Papelera de la Alqueria,
Spain.
Torraspapel, Motril,
Spain.
Kübler u. Niethammer, Kriebstein,
Germany.
Neu Kaliss Spezialpapiere GmbH,Germany.
Madeireira Miguel Forte, Brazil.
CIA Suzano de Papel e Celulose,
Brazil.
Compania Brasileira de Papel,
Ibema, Brazil.
Stora Enso North America,
Interlake, USA.

Shandong Bohui Industrial Co. Ltd.,
China.
Cartiera di Toscolano, Italy.
Tamil Nadu Newsprint & Paper Ltd.,
India.
Winding technology– Sirius
Shandong Chenming Paper,
Shouguang, China.
Myllykoski OY, Alsip, USA.
SCA Graphic Laakirchen A.G.,
Laakirchen, Austria.
Consolidated Papers Inc., Duluth,
USA.
Myllykoski OY, Hürth, Germany.
Bowater, Catawba, USA.
CNTIC Trading Co. Ltd., Huatai,
China.
– Pope reel winders
Ripasa S.A., Celulose e Papel
Limeira, SP, Ripasa, Brazil.
Papelera Espanola S.A. Renteria,
Papresa, Spain.

FinishingJanus Concept
Bowater Catawba, USA.
SCA Laakirchen, Austria.
Chenming Shouguang, China.

Ecosoft calender
Ibema, Brazil.
Ripasa, Brazil.
Jiteng Hebei, China.
Rheinpapier, Hürth,Germany.
Nanping, China.
Huatai, China.
Miliani, Italy.
Ningxia, China.
Nanping, China.
Calenders
Chenming Shouguang,
China.
Jingxing, China.
Procor, Chile.
Bowater Catawba, USA.
Ibema, Brazil.
Lee & Man, China.
Shanying Maanshan, China.
Twister/Roll Handling
Steinbeis Temming,
Germany.
Springer, Ahrensburg,
Germany.
SCA Laakirchen, Austria.
Huatai, China.
Roll cutting machines
Rizhao, China.
Ripasa, Brazil.

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THE D

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1

The new DIP Line 4
at Steyrermühl –from the first planning meeting to production
in only 13 months
In May 2000, Steyrermühl AG andVoith Paper Fiber Systems Ravensburg signed acontract for the delivery of a new stock preparation
system and the rebuild and extension of theexisting DIP line.

The author:
Leo Engelmann,
Fiber Systems

Thanks to close co-operation between
Steyrermühl AG and Voith Paper, all work for the
new DIP Line 4, from the first planning meetingthrough to production start-up, was accomplishedin only 13 months.

Steyrermühl AG
Steyrermühl, in the heart of Austria, situated between Linz and Salzburg at the
gateway to the “Salzkammergut” and only
a few kilometres away from the picturesque Lake Traunsee, can look backon over 130 years’ tradition in paper production. The people of the region have
papermaking at heart, the papermaking
school in Steyrermühl and the papermaking museum founded in 1993 bear witness to this.
Steyrermühl AG, member of the UPMKymmene Group, produces 450,000 t
newsprint and magazine papers annuallyon two paper machines. TMP groundwood, almost exclusively own-production, and DIP are used as raw material. In
the direct vicinity, the 100 % affiliatedFiber Systems

7

Fig. 1: EcoCell pre- and post-flotation together
with secondary cells in compact design.
Fig. 2: LC screening.

sawmill Steyrermühl Sägewerks GmbHproduces approx. 300,000 m 3 lumber for
the furniture and building industries.
Apart from the advantages of central purchasing of wood, the remaining wood offcuts from the sawmill mainly serve as
raw material for the TMP plant. A fully
biological effluent plant and thermal recycling plant underline the standards
Steyrermühl is setting in responsible
paper production. Sustainability and environmental protection play a central rolein the company strategy.

maintain paper production during implementation of the project, a separate line
(DIP Line 4) was first installed, independently of the existing DIP plant. On startup of this line, the existing DIP plant,
which until that time had been operating
without post-flotation, was then rebuilt toreflect the required technical and technological standards (DIP Line 3).

The Project

The resulting higher production capacityof approx. 60 %, and the excellent qualityof the stock from the new equipment
have meant the mill could increase theuse of recovered paper for both paper
machines.

The “DIP 2000” project, covering both a
new deinking line and rebuild of an existing one, closely follows Steyrermühl AG’s
ecological and economic philosophy. To

Reduced use of process chemicals, aswell as the best possible removal and recycling of the rejects, help protect the environment. In addition, the water circuits

have been adjusted to the new requirements by implementing a mill-wide water
management strategy.
The new DIP Line 4 has been designed
for 600 t/24 h, based on a furnish of sorted mixed household collection. When thecompletely rebuilt DIP Line 3 starts up,
the additional 130 t/24 h will increase thetotal mill capacity to approx. 300,000 t
deinked stock per year.
The System AP 2000 (Advanced Process)
implemented here ensures optimised
space and energy requirements. Minimum use of chests between the individual process stages and strategic use of
fan pumps provides for stock transport at
maximum possible consistencies, thus
minimising hydraulic throughput without
reducing production throughput.
2

8

3

Fig. 3: The two DeltaPurge micro-flotation
units supplied by Voith Paper’s joint venture
partner Meri; in the foreground for Loop II,
in the background for Loop I.

Scope of delivery
The design of the two plants was jointly
defined in detailed discussions with the
Steyrermühl project team. The agreed
concept was based not only on the latest
knowledge and technologies from Voith
Paper, but it has also included Steyrermühl’s many years’ of experience as an
operator of deinking systems.
The Voith Paper scope of delivery mainly
included the key machines in the process
stages that determine finished stock
quality, such as: Three-stage IC slotted screening
with 0.25 mm C-bar ® screen basket
technology
 Two-stage EcoCell™ pre-flotation
including flotation pumps and deaeration cyclones
 Four-stage LC slotted screening
with 0.20 mm C-bar screen basket
technology Dispersion I with EcoTherm™ heatingscrew Two-stage EcoCell post-flotation,
including flotation pumps and deaeration cyclones.

one source greatly reduce the number ofinterfaces, providing clear advantages inprocessing the project.

Voith’s joint venture partner Meri installed
two DeltaPurge™ micro-flotation units, aTrenner™ fractionating filter for water
purification and Sediphant™ reject handling equipment.

All details were discussed and agreed
with the relevant specialists in Steyrermühl, beginning with the flow diagrams.
As well as using the experience gained
from its own machines and systems,
Voith Paper smoothly integrated the datafrom the outside suppliers into its overall
concept philosophy. Design calculations
for pumps, pipework, valves, etc., including determining steam, water and air consumption, were the next steps.

Services
Apart from delivery of the key components for the stock preparation, Steyrermühl also ordered the complete process
and control engineering for both lines
from Voith Paper. This also included theplanning work for chemicals dosage, forthe sludge and reject handling sections,as well as for water treatment and theintegration of machines from other suppliers.
As in other mills, the Steyrermühl project
has again shown that machine delivery
and system engineering services fromAll work for the erection and piping of themachines was carried out down to thesmallest detail using a 3-D planning system. This ensured virtually error-freeerection of the new plant and optimal useof available space. The rebuild of the existing DIP Line 3 was also planned basedon this system. Despite restricted building dimensions, solutions were found for
ensuring optimal arrangement of pipework routing.

Fiber Systems

The control and instrumentation engineering played a major role in the success of the project. As with process engineering, the amount of work carried out
here was very extensive.
The Voith Paper team’s responsibility inRavensburg included drawing up bid documentation for field instruments, theprocess control system, installation ofcontrol and instrumentation equipment,
evaluation of tenders, right through toassistance in technical decision-making.
Data taken from Voith’s basic and detailed engineering work served as a basis
for going out for tenders.
The functional planning, which served as
the basis for programming the processcontrol system, was also an important
responsibility. Logic diagrams and thedepth of detail enabled the DCS supplierto carry out the work virtually free ofWalter Pillwein
Chairman of
the Board of
Steyrermühl AG.

interpretation errors. Start and stop ofprocess groups through to one-button
operation were implemented in the sameway, as well as overall production controlof the system, using only one setpointvalue.
The high degree of automation achieved
with these requirements has provided the
production personnel with reliable andreproducible
operation.
Productionchanges as well as start and stop sequences run smoothly, quality variationsin the product are reduced to a minimum.
A subsequent order for analysing water
management of the entire paper mill, together with a mill-wide water management plan, was also completed on schedule by the Voith engineering team. Mostof the resulting measures have now been
implemented and the rest will be undertaken when the DIP Line 3 starts up.

Ernst Spitzbart
Technical Manager of Steyrermühl
AG: “...a very good and successfulproject, fully meeting our technological requirements”.

Leo Engelmann
Project Manager,
Voith Paper
Fiber Systems.

Herbert Domokosch
Technical Planning,
Project Manager,
Steyrermühl AG.

9

Another facet of Voith’s comprehensive
service work was to support the customer with experienced erection specialists. Close co-operation with the logistics
department in Ravensburg enabled Voith’ssite erection supervisor to order “just intime” deliveries onto site. As a result,most of the machines could be unloaded
from the lorry and placed straight onto
the prepared foundations. Time-consuming intermediate transport was thus
avoided and the restricted space on siteused for prefabrication of pipework.
The Voith commissioning engineers
started with the first checks at the end of
May 2001. Specialist teams from bothcompanies checked all plant control circuits, from the field to the monitors in thecontrol room. Efficient co-operation between Voith’s and Steyrermühl’s project
teams, together with the customer’s own
experienced and highly skilled production

Dr. Marko Lesiak
Manager,Fiber Production,
Steyrermühl AG.

Heinz Walter
Manager, Purchasing,
Steyrermühl AG.

10Fig. 4: Chemical preparation.
Fig. 5: Central control room.
4

team, secured full operation of DIP Line 4
just five weeks after commencing control
and instrumentation checks. On 6 th July,
the complete plant ran with stock andfrom 7 th July onwards PM 4 was fed withstock from the new DIP Line 4.

To meet the requirements of the new production tonnage, most of the chemical
dosage operations had to be re-designed
and built. Here, planning and processing
also came from one source, allowing thevarious storage, dissolving and dosage
facilities to be put into operation in time
before production start-up. From Sunday,
8 th July, 2001, the PM 4 newsprint machine has been continuously suppliedwith deinked stock from the new DIP
5 Line 4. The PM 3 magazine paper machine started receiving stock from DIP
Line 4 on 12 th July, 2001. After rebuilding the old plant to become DIP Line 3,
two recovered paper preparation plants
will then be available for both paper machines.
Since start-up of DIP Line 4 the use ofchemicals for recovered paper pulping
and bleaching has been reduced, andproblems with deposits in certain sections of both paper machines have
dropped significantly. Right from the beginning, the technological results showeda clear improvement in quality of the finished DIP in terms of stock cleanliness,brightness, strength characteristics andstickies content.
The entire project, from signing the contract through to continuous production,
was completed in 60 weeks, an achievement with which all concerned in the project can certainly be more than satisfied.

Fiber Systems

11

Fiber Systems e-business –Spare parts shop and second-hand machines
e-business is the generic term for thegeneration and processing of business transactions
by electronic means, – business we have been
doing for a long time, but by using faxes, e-mails,
etc. The difference lies simply in the method ofcommunication used. Common to all modern
e-business applications is the use of modern internet technologies, ensuring fast and reliable connections around the world. This communication
medium opens up new possibilities for customer
services.
Spare parts availability –a fine line between immediate delivery
and costs of stocking
Spare parts availability represents a significant cost factor in the paper industry.
On the one hand, immediate availability
on site helps reduce downtime, but on
the other hand it involves ongoing financial outlay – a balancing act which demands close teamwork between paper
mill and machine supplier.

The author:
Josef Hund,
Fiber Systems

Voith Paper has taken up this challenge.
Bearing in mind the large number of machines involved, our Fiber Systems Division has optimised its spare parts logistics so that today more than 25,000 items
are stocked for immediate delivery from
Ravensburg, Germany and Appleton, USA.
In addition, Regional Stockage Centersserve local customers with stocks adjusted to their specific needs.
This concept covers not just the present
product range of Voith Paper Fiber
Systems but also the former stock preparation products of Voith, Voith Sulzer,
Sulzer Papertec, Sulzer-Escher Wyss,
Bird, Bird Escher Wyss and Morden.
Paper mills can thus optimise their spareparts stocks to suit their individual needs
and keep redundant machines to a minimum. From now on this will be even easier, thanks to Voith Paper’s internet stock
inquiry system.

1

http://www.voithpaper.com/index_e.htm

Group Division

Fiber & Paper

Current

e-Business
Solutions
Spare Parts Shop
Second-hand machinesHome

DeutschOne Platform Concept
New headbox system for Neusiedler
Nordland Papier Relies on EcoMizer™

Welcome To Voith Paper
Voith Paper is the process supplier for the worldwide paper industry.
We develop technological solutions that cover the entire paper
production process – from fiber to wrapped paper.

more

Fig. 1: Voith Paper homepage.

Worldwide

SearchContact

Sitemap

Sound on12

Fig. 2: Extract from the Fiber Systems
Spare Parts Shop on the internet.

The Spare Parts Shop is located on theVoith Paper homepage www.voithpaper.
com under “e-business”.

2

Fiber Systems – Spare Parts Shop
LogoutContact

Material number
4561443

Search
Add List

Help

DeutschIdentify Data

Spare part information
Set of Refiner Segments (6-Parts)
660 x 27
stainless-steel casting, alloyed

Stock location

Ravensburg

Lfd.
No

Material
numberSpare part information

1

4561443

Set of Refiner Segments (6-Parts)
660 x 27
stainless-steel casting, alloyed

DetailStock inquiry
Quantity ofmaterials

Send

Stock
availability

Offer
Order

8
piecesall

offer

Voith Paper Fiber Systems also offers
customised stockholding concepts tailored to individual needs. We support you
here with special IT tools, such as for
managing consigned stocks.

yes

Simplified inquiry procedure: Enter material number.
 Start search, the spare partdescription is then displayed.
 Add to list.
 Enter quantity required.
This procedure can be repeated as
many times as necessary.
When all required parts have beenfound and added to the list: Select the required stock location
where availability should be checked.
 Send inquiry.
 Whether parts and required
quantities are available at thedesired location is then indicated.

Material number

When you need a second-hand machine– then best of all one generally overhauled by Voith Paper

Search
Add List

Stock location:

Ravensburg
Stock inquiry
Quantity ofmaterials

Stockavailability

1
pieces

A quotation can now be requested forthe parts listed. In the Remarks Field
you can also give the responsible
person at Voith Paper Fiber Systems
further information, such as yourrequired delivery date.

Via the new online Spare Parts Shop withshopping basket facility, customers can
now check parts availability at Voith
Paper Fiber Systems in real time roundthe clock.

yes

After sending your inquiry you receive
an immediate e-mail confirmation ofreceipt, indicating which parts you haveinquired about. A quotation will then be
sent to you in the normal way.

Voith Paper machines are well-known for
their long service life and high performance. However, stock preparation system modifications often free-up individual machines for re-use. Such machines
can be bought back by the Fiber Systems
Division and in most cases are generally
overhauled and upgraded to the latest
state of technology.
A newly-created marketplace for secondhand machines is now available, also at
www.voithpaper.com under “e-business”.
Here you can call up the second-handmachine database of the Fiber Systems
Division.

Fiber Systems

13

Fig. 3: Extract from the display for second-handmachines in the process stage of screening.

Procedure here in simplified form forscreening:

Fiber Systems – Second hand machines
home
Request information

Screening
Processes
Deflaker
Dewatering
Disperger/Disintegrator
Flotation
Grinder
Pulping
Pumps
Refiner
Screening
Screening - C-bar ™
Washing

Process stage
selection.
All screening
machines orcomponents are
displayed.

Contact

DeutschHelp

Confirm request

Nothing found?

Your offer to us

Screeningprocesses
Machines
Info
No

Newsletter

Last update: 2001-11-08
US-Standard

selectParts
Type

Machine/Part

Year

Class

142

TS12W

Turbosorter

1986

3

143

TS10

Turbosorter

1981

4

145

TS11

Turbosorter

1983

4

150

VSI1

Vertical Screen

1967

99

151

VSI1

Vertical Screen

1972

4

Confirm inquiry (1)DetailCasted versioni

If you are interested in a machineor component, simply click on “ i”.
The item is then placed in an
inquiry basket. Any number of
items can be placed in it.

For further details, in somecases with illustrations, click on
the camera icon.

152

VSI1

Vertical Screen

1965

4

153

VSI1

Vertical Screen

1979

4

Vertical Screen

1989

99

Casted version

524

VSI40/19

Without screen basket and rotor

850

VSI35

Vertical Screen

Condition of machines and components

Additional services

Voith Paper Fiber Systems classifies thecondition of the second-hand machinesand components according to the following categories:

If you cannot find what you need in our
online shop, or you want to sell an itemof our stock preparation, just e-mail the
person indicated at Voith Paper Fiber
Systems. Please include full details of thecomponent and/or machine.

Confirm inquiry (1)Click “Confirm inquiry” to transfer yourchosen items to the person responsible
at Voith Paper Fiber Systems who will
send you the requested information by
return e-mail. Before confirming, you
can add any remarks or requests in the
Remarks Field.

1996

Class 1: As new, unused
Class 2: Generally overhauled, as new
Class 3: Overhauled and fully functional
Class 4: In need of repair, but fully
functional afterwards
Class 5: Old, – substantial repair workrequired.
In what condition you buy the secondhand machines and/or components is
open to negotiation. Machines in need ofrepair (Class 4 or 5) can be reconditioned
to Class 2 or Class 3 in the Fiber Systems
Repair Center.

Future prospects
e-business is a subject much talked
about. However, we will soon be using it
as readily as we now use phone, fax ande-mail communications.
Visit our internet website
www.voithpaper.com to get the benefits!

3

14Jürgen Heindl, President of theProwell Group (left):
The plant in Burg was our entry
into the production of corrugating medium and testliner. By
choosing a competent system
partner we wanted to move into
the complicated and closely interconnected technology of recovered paper preparation with absolute confidence. Our decision
to place our order on Voith Paper,with their leading process technology, comprehensive knowhow and references,
was the right one.

1

Innovative stock preparation plantat Propapier in Burg, Germany –new dimensions in drum pulping
Propapier GmbH is a subsidiarycompany of the Prowell Group, with headquarters
in Offenbach, Germany. Prowell is one of theleading producers of corrugated board in Europe,with converting operations in Germany, France,
and in the near future also in the Czech Republic.

The author:
Hermann Probst,
Fiber Systems

Prowell’s business concept is based on
the strategic use of new technologies in
informatics, production and management,with the objective of securing fast andsuccessful development in the rather traditional industry of corrugated board production.
This strategy is obviously successful
thanks to Prowell’s optimal Supply Chain
Management, i.e. the computer linkage ofall business operations, starting with thesystem supplier, via the paper and corrugated board production, right through to
Prowell’s customers.

15

Fig. 1: Jürgen Heindl, President of the ProwellGroup, with Karl Turobin-Ort (right), Manager ofSales and Marketing, Voith Paper Fiber Systems.
In the background, the TwinDrum pulping drum,on the far right the drum screen.

Propapier GmbH signifies the beginningof the process chain for corrugated board
production. With Propapier, Prowell have
now made themselves independent of
their previous suppliers by building a
new high tech paper mill in Burg near
Magdeburg, Germany for the productionof corrugating medium and testliner.
Construction of the new paper mill began
on November 22, 1999. For a greenfieldproject of this magnitude, the time takenfrom construction go-ahead to the production of stock, namely approximately
15 months, could well break records.

Propapier is scheduled to produce around
300,000 t p.a. of corrugating medium andtestliner on the new machine, using
100 % recovered paper. This production
covers most of the demand coming fromthe four Prowell converting operations inLille (France), in Landau and Burg (Germany) and from the facility under construction in Pilsen (Czech Republic).
Testliner from 90 to 230 g/m 2 (brandname Proliner) and corrugating medium
from 80 to 140 g/m 2 (brand name Promedium) are produced.

The finished stock for the paper machine
is supplied by a Voith Paper stock preparation plant incorporating the latest technology.
The stock preparation system was successfully put into operation on 19 th February 2001 on schedule, following thecheck phase begun in January 2001 andsubsequent test runs with water. Production capacity is 980 t/24 h, using 100 %recovered paper of the grades B12 (sorted mixed recovered paper) and B19 (recovered packaging material from super-

16

2
Fig. 2: The EcoMizer
heavyweight cleaner system.

markets). In a possible future extension
phase, up to a maximum of 20 % postconsumer liquid packaging board may be
used.

competitors far behind. (For more detailed information, see twogether 9).

the heating screw, normally arranged in
front of the disperger for heating thestock, is now no longer required.

EcoMizer™ heavyweight cleaner system
Voith Paper delivered the majority of thestock preparation process blocks, including the following new products:

All cleaner stages in the multi-stage
cleaning system have been equipped with
the new EcoMizer cleaner, both in thelong fiber and short fiber lines (Fig. 2).

TwinDrum™ drum pulping system
The recovered paper is pulped in the new
Voith Paper TwinDrum pulping system(Fig. 1), – the first time TwinDrum has
been used for this type of raw material.
The complete pulper charging system
was supplied by Voith Paper’s groupcompany B+G Fördertechnik, Euskirchen,
Germany.
At Propapier this new development indrum pulping has a charge capacity of up
to 1,100 t/24 h recovered paper. This represents a world record for this kind of
pulping technology, and leaves all otherdrum pulping systems so far built by ourInformation on the EcoMizer has been
given in twogether 12. Advantages compared with the previous cleaner type are:
 Reduced number of stages and cleanerunits Higher removal efficiency
 Reduced fiber losses
 Low pulsation as well as plug-free
operation.

Requirements for an innovative stock
preparation plant
Trends towards reducing the basis weightof corrugating medium and testliner, together with the increasing speed of paper
machines and converting operations, callfor a defined level of paper strength andstiffness characteristics. This becomes
more and more difficult considering theconstantly decreasing quality of the recovered paper grades used.

EcoDirect™ Dispersion

Two aspects of the mixed recovered paper composition – the amount of inorganic and sticky substances – place particularly high demands on stock preparation systems for high quality corrugating
medium and testliner.

With the new disperger type installed forthe first time in Burg, stock is directly
heated in the disperger. This means thatIn the new corrugating medium and testliner mill in Burg an innovative stock
preparation system philosophy has been

17

Fig. 3: On the left, the first stage in hole screening(MultiSorter), in the middle, the Protector Systemand far right the second stage in hole screening(Combisorter).
Fig. 4: From left to right: EcoMizer heavyweightcleaner system, MultiScreen slotted screening
and MultiSorter hole screening.

put into operation to meet these requirements. A distinguishing feature of theconcept supplied by Voith is a clearlyhigher efficiency in raw material yield andrequired specific energy consumption,compared with existing plant systems.
The pulping technology used by Voith
Paper at the beginning of the process in
Burg is an essential factor in achieving
this efficiency level.
A distinctive characteristic of the TwinDrum drum pulping system with integral

displacement body in the pulper drum itself is its very high pulping efficiency.
The flake contents which can be obtained
are in the range of only 3 to 4 %. Up tonow, specific energy consumption for
pulping, subsequent drum screening andhigh density cleaning is below 20 kWh
per air dry ton of recovered paper.
Voith Paper has already used TwinDrum
technology elsewhere for pulping postconsumer liquid packaging board. TwinDrum ensures particularly gentle pulpingof recovered paper. Contaminants, such34

as larger pieces of foil, generally maintain their original size and can be removed in the subsequent drum screen, –with virtually no loss of fibers.
Experience from other stock preparation
plants with comparable raw materials
show time after time that inadequate
measures for removing abrasive contaminants and other heavy rejects at the beginning of the stock preparation processlead to wear of, for instance, pumps,
pressure screens and cleaners after only
a relatively short period of operation.

18

Part of this article has been published in
Prowell’s inhouse magazine “Profil 1/01”,
author Dr.-Ing. Alf-Mathias Strunz,
Fiber Technology Department, Papiertechnische
Stiftung, Heidenau, Germany.

Fig. 5: Partial view of the EcoDirect dispersion
system.
5

In such cases, higher costs due to an unstable process, additional maintenancemeasures as well as quality losses cannot
be avoided. In the new Voith Paper stock
preparation plant, such negative effects
are avoided by the combined use of highand low density cleaners (Protector™
System, Fig. 3).
Fiber recovery from the rejects of thecontinuously operating cleaner stages isundertaken by separate sedimentation
systems. Here, specifically heavier contaminants are reliably removed from themain stock flow.
As already mentioned, the new generation of EcoMizer cleaners has been installed in Burg for the removal of specifically heavier contaminants.
Another important contribution towards
higher fiber yields is provided by the simple screening systems operating with avery low specific energy consumption.
These have been installed directly after
the TwinDrum and Protector Systems dueto the low flake content and good cleanliness levels achieved here. The hole
screening system (Fig. 4) consists of only
two stages, – the MultiSorter™ with a
1.6 mm screen basket hole diameter for

the first stage, and in the second stage a
Combisorter™ with a 2.0 mm hole diameter in the screen plate and 2.2 mm in
the screen basket. The rejects here arealmost free of fibers. One can assume
that using another pulping technology
would require considerably more systemequipment to achieve a comparable stockcleanliness.
The next process stage consists of onestage fractionation with MultiFractors™
using 0.2 mm screen basket slots.
Cleanliness of the short fiber fraction isso high that only a four-stage EcoMizer
heavyweight cleaner system is needed
ahead of stock thickening and storage.
After long fiber fractionation, the heavy
rejects are moved in a three-stage EcoMizer cleaner plant. After this, a threestage MultiScreen™ slotted screening
system (0.2 mm slots) operates in the
low consistency range for removing
stickies and other contaminants.
Since the stock preparation system fully
meets the requirements for feeding ahigh grade finished stock quality to thepaper machine, the disperger system withdirect heating installed in the long fiberline (Fig. 5) has so far not been required

for ensuring the necessary quality. However, the system is available for increasing optical homogeneity, dispersing stickies and for reactivating the mechanicalstrength of the stock, without substantially decreasing CSF, should a deterioration in the quality of the recovered paper
used make dispersion essential.
Propapier has selected first class hardand software components from Voith
Paper Fiber Systems, and this has been
confirmed by the very good operating experience achieved over the past few
months.
Based on excellent cooperation on the
Burg project, Voith Paper are pleased toreport having since received a further order from Propapier. The new order includes supply of a fiber recovery system,
including basis and detailed engineeringfor both the process and control and instrumentation, as well as basis and detailed engineering (also covering process
and control and instrumentation) for extending the existing paper machine cooling system.
For the original overall project in Burg
Propapier had placed the complete basis
and detailed engineering for the processelsewhere.

19International Customer Conference
Voith Paper – Graphic Papers
September 4 to 6, 2002

S c i e n c e

D i a l o g

What will the future bring? Where will
the market grow, and how will competition develop?
Which demands will be made by print and media
technology development trends? And what are themost promising solutions to meet these demands?
These questions affect us all, and wewould like to discuss them with you fortwo days of science-based dialogue.

for “Quality tons on the reel” – that is
how we are shaping our future supplierand producer in the world of paper.

We, therefore, invite you tojoin us from September 4 to 6
this year at our International
Voith Paper – Graphic Papers
Customer Symposium in thebeautiful city of Salzburg,
Austria.

Some of the topics to be covered at this
symposium:

Apart from an outstanding program ofinteresting papers by our specialists andreputed guest speakers, you will also beable to participate in some unforgettable
events and sight-seeing in the Mozart
metropolis. This global conference willclose with a guided tour of the world’s
most modern production plant for SCAplus papers in Laakirchen.
“Process & Progress” – integrated but
custom-tailored processing, based on an
efficiency-oriented one-platform concept

Quality tons on the reel:
The One Platform Concept
 for SC paper and better printability…
 for LWC paper and higher
runnability…
 for newsprint and greater costeffectiveness…
 for fine grade papers and faster
operating speeds…
 for special grades and flexible machine
concepts…

If you would like to attend this symposium, please fax your name and address
to the twogether editorial office at++49 73 61 94 98 94. We shall then send
you further details.

Left: Our conference
venue: the Mozart
metropolis of Salzburg.
Top: The congress centre.
Below: Trip by historicalsteam train to Laakirchen.

www.processandprogress.com

20

ULTR@STAR –the world’s biggest production line
for wood-free coated papers“Those who think they are perfect

Conception

will never reach perfection”. In other words,

The author:
Johannes Rimpf,
Paper Machines
Graphic

records are there to be broken – which is why

In mid-2000, sappi Gratkorn decided tosappi Gratkorn GmbH had their ***Triple Star***increase the capacity of their number

line rebuilt by Voith Paper. Then on February 3,

4 production line – so far known as2002 they broke their own production record of***Triple Star*** – after establishing

May 1 on PL 4. In 24 hours, the coating machinethat this would be possible with a rela-turned out 2,735 ton of Magno Matt paper attively low investment. The main results of

150 and 170 g/m 2. Then, on September 25, 2001,

the feasibility study were as follows:

the paper machine broke the world production

 Capacity increase by 100,000 t.p.a. torecord at 1,732 ton of the same grades.

570,000 t.p.a.

Paper Machines

21

Fig. 1: PM 11 at sappi Gratkorn GmbH.
Fig. 2: The paper machine output is 1,732 t/24 h.

2

Preparations

 Improved screening: new screens in
the ModuleJet™ line and rebuild of

After thorough groundwork by the sappi
team – market analysis, technical andtechnological concepts, detailed scheduling and cost/benefit analysis – the project was approved by sappi in Brussels
and in Johannesburg. It took several
preparatory meetings and marathon ne1

gotiations lasting 21 hours before this rebuild contract was finally closed. Toward
5 am on October 12, 2000, the order was Paper machine speed increase to
1,420 m/min
 Coating machine speed increase to1,650 m/min
 Project completion within eightmonthsawarded by handshake to Voith Paper
Heidenheim. These were the longest ongoing negotiations ever held by KlausDieter Merzeder (Manager Technology andEngineering sappi Gratkorn) in his nearly
30 years of worldwide project experience.

 No reduction in high environmental

three existing screens Shortening the web draw after thethird and fourth press Deckle adjustment on the double
suction press roll Steam pressure increase to 6 bar in
the predryer section
 Larger air squeezer roll on the coatingmachine Modification of the coating machinereel Coating machine unwind system cycle
time shortened
 Basic engineering for the extension of
all IR systems
 Complete installation and commissioning of all of the above.

standards despite productivity
increase

Realization

 Installation of a steambox in the press Investment cost not to exceed€ 34.8 million.

sappi also took the following measures:

Voith Paper implemented the sappi concept goals as follows:

section Higher IR drying capacity after the22online coaters and in the coatingmachine.
In conjunction with the productivity increase, the printability of the end productwas optimized. The DuoFormer™ CFD
was converted into a DuoFormer™ TQm inorder to attain the quality of first-classhybrid formers.
Rebuild
Only sixteen days of shut down time wereavailable for the rebuild from March 12 to28, 2001. With detailed network planningand pro-active time management, all possible preparations were made before the
shutdown. Nevertheless, additional maintenance and modification work still had
to be fitted into the available shutdown
time. Thanks to meticulous planning, theentire rebuild was carried out with optimal efficiency. Due to outstanding team-record has already been broken twice,

The editorial staff of Voith’s twogether

work among all parties involved (with up

thus confirming the outstanding rebuild

magazine extends hearty congratulations

to 520 people on-site in peak phases), theperformance.

on this great honor!

rebuild was completed one half day earlier than planned. “Paper on reel!” was cel-

Tribute is due to Manfred Tiefengruber,

ebrated on March 27 at 22.20.

production manager line 4 and his entire

Work safety

team. Manfred Tiefengruber maintains
Picturebook startup

the production and maintenance team at

Accident prevention and significant worka very high training level. Together withsafety improvement were already set

Hermann Waltl, Karl Weber and Hans

as overall project planning goals, andSaleable paper was produced, right from

Zettl, Manfred Tiefengruber won thewere reached as follows:

the first reel, with 97.6% production time“sappi technical innovation award 2000”

 A new access control system applying

efficiency over the first full operating day.

in Europe for the Eco-change W develop-

Printability was further improved after

ment work carried out together with Voith

only a few days. The world production

Paper Heidenheim.

to every single person on site
 Comprehensive safety training for all
project personnel

23Fig. 3: The coating machine produces 2,735 t/24 hof Magno Matt grades at 150 and 170 g/m 2.
Fig. 4: K. Merzeder (left), Dr. D. Radner and
M. Tiefengruber in front of the rebuilt PM.

3
4<0.25 % rel. CD, <0.5 % rel. MD and<0.9 % rel. random variation, the parameters meet expectations.

Project goals
 Personal safety equipment to be wornat all times
 Work discipline and safety awareness.

pared to 3.07 at Gratkorn for the year
2000 as a whole. For a project such as

All project goals were achieved: rebuild

ULTR@STAR, a much higher DIFR factor

measures, deadline compliance, work

would have been expected.

safety and investment costs. In the opin-

The results of these high work safety

ion of our customer sappi Gratkorn

standards are shown by a DIFR factor(differential incident frequency rate) com-

GmbH, the main reasons for the successQualityputed from the number of incidents re-of this ULTR@STAR project were as follows: Highly motivated and committed

sulting in at least one missing day x

Dimensioning capacity was fully attained.

200,000 hours, divided by the number of

The paper machine is still 7% below andhours actually worked in the period con-the coating machine 3 % below design

 Outstanding teamwork

cerned. During 168,000 working hours

speed. Raster mottling has now stabilized Highly competent partner companies

from October 2000 to March 2001, threeat the targeted printability quality level.

 Joint target-setting.

slight accidents occurred. This corre-

Retention lies between 45 and 55%. With

Voith Paper was clearly the right choice

sponds to a DIFR factor of 3.57, com-

a 2 sigma basis weight cross-profile offor sappi.

people24

Klabin Piracicaba –EcoTech: a new concept proves its worth
With South America’s steeply rising

The new EcoTech papermaking concept

paper consumption, particularly in Brazil, the(optimally combining economy with tech-amount of recovered paper available for recycling

nology) was developed by Voith Paper

purposes has greatly increased. Since the paperSão Paulo for small paper mills. Using

industry there cannot afford the heavy investments

well-proven Voith Paper technologies, it

required, Voith Paper has developed a machine

minimizes investment costs for high-out-

concept specially tailored to this market situation.

put production of first class paper fromsecondary fibres, thus ensuring optimal

The author:
Jair Padovani,
Voith Paper São Paulocost-effectiveness. The resultant production costs are extremely competitive, withvery low investment costs per tonne ofpaper.

Fig. 1: The new PM 2.
Fig. 2: PM 2 layout.

25

Klabin Fabricadora de Papel e Celulose
S.A., founded more than a century ago,
has always been one of the most innovative pioneers in the South American
pulp and paper industry. Apart from pulp
and paper production, Klabin also1

manufactures corrugated board, paperbags, envelopes, sanitary articles, liquid
packagings and deep-frozen foodcartons. This company pays particularattention to reforestation projects.
Klabin has twenty production sites with
offices and mills. In some market segments Klabin has set up joint ventureswith reputed international companies, forexample in the sanitary paper sector with
Kimberly-Clark in the USA, and in the

In teamwork with Klabin Brazil, the first

250 t per day of liner and corrugating

newsprint segment with Norske Skog ofVoith EcoTech concept has been realized

medium is produced here at 600 m/min

Norway.

at Piracicaba. Klabin is South America’s

within a basis weight range of 100 -biggest paper producer, but so far it only

210 g/m 2, for a cut sheet width of

had a machine with a daily output of

2,500 mm. The very first roll of paper

65 tonnes in this mill.

was fully up to production standards,
thus meeting the high expectations ofThis joint effort by Klabin Piracicaba andthis EcoTech line. The use of recycled

Voith Paper – to establish the cost-effec-

paper as furnish has also been justified

tive production of high quality paper atcompletely.
Hélio Biagio

lowest possible investment and operating
costs – was crowned with success inWith an optimal start-up curve, guaran-

Mill Manager,

January 1999, when the first EcoTechteed output was attained only three

Klabin KPO

line (PM 2) was commissioned.

months after commissioning. By January“We are very satisfied with the performance of our PM 2. Thanks to Voith
Paper’s consolidated technology andBrazilian team, product quality and2

output fully comply with our expectations.”

26

3
Fig. 3: Klabin Fabricadora de Papel e Celulose S.A.

2001, after two years of operation, theogy, were previously put off by the highpaper density and strength are also in-

production guarantee was exceeded bycosts and relatively low value-added.

creased. For the type of product manu-

more than 20 % with an output of 305 t

Judging by the large number of inquiries

factured by Klabin, this can be used toper day at 140 g/m 2.

received, this market segment has enor-

attain low basis weights and resultant

mous growth potential.

furnish savings.

concept has now been adopted as a stan-

The EcoTech concept:

for an operating pressure of 10 bar.

dard. In the future, less and less design

Economy through technology

Thanks to excellent operating experience
The dryer section cylinders are designedwith this first Voith EcoTech line, theeffort will be required, manufacturing will

The reel is equipped with automatic reelbe simplified still further, and erection

The former section of Voith’s EcoTech

procedures improved. It goes without

paper machines for Klabin includes a pri-saying that the EcoTech concept has,mary and secondary fourdrinier, each of

The winder attains operating speeds up

therefore, raised great interest in thewhich has a hydraulic headbox with pul-to 2,000 m/min.

market.

sation damper.

spool loading.

This modular system also enables modThe Klabin success story and the expect-

The press section incorporates two dou-

ed 4% p.a. increase in corrugated board

ble-felted

consumption have led to further orders

through presses with nip loads of 110

Further savings are attained by optimalfor such machines (including a goodand 350 kN/m, respectively. Not only

use of the recycled paper furnish frommany new ones) from customers who,

does the high final dry content attained

the stock preparation line to produce

although willing to invest in new technol-

save energy in the dryer section, but the

testliner and white top grades.

highperformanceernization by stages.

straight

27

1

Inland Empire’s recovery project –Millwood PM 5
Inland Empire Paper Company is

The author:
Gareth Jones,
Voith Paper Appleton

500 tons per day. The competition for

unusual. Founded early in the last century, it has

their new machine was fierce, but despite

produced newsprint in Millwood (Spokane),

admitting to being impressed by Voith

Washington state continuously since 1911. The

Paper’s wet end technology, in a closecompany is owned by the Cowles family, who alsodecision they awarded the machine andown and publish the local newspaper, thewinder to Beloit in December 1997. This

Spokesman Review. They are, therefore, one of

was not to be a fast-track project, with

their own customers.

startup planned for January 2001.

For many years the mill has run just one

In early 2000, Beloit went bankrupt.

machine, PM 2, using a mixture of virgin

Inland Empire had by then received some

pulp and recovered paper as furnish. The

stock preparation equipment and themachine was rebuilt at various times. The

complete dry end of the paper machine,

last rebuild included a soft calender,

including the winder. Nothing of the wet

making Inland Empire a pioneer of thisend had yet been received, although thetechnology for newsprint in North Ameri-

wet end foundations and other civil work

ca. They were also one of the first mills

were almost complete, designed and pre-to try the Hydranip in the drying section.

pared for the Beloit wet end. Discussions
were quickly held, and Voith Paper was

In 1997, Inland Empire decided that achallenged with the fast delivery of a new

new, state-of-the-art newsprint machine

wet end that would fit, as close as possi-

was necessary for them to be able to pro-ble, the already existing civil work. Tech-duce the sheet quality required by an evernical and commercial details were agreed

more demanding market. They also de-upon in March, and Voith Paper received

cided to increase production from 250 toan order in April.

28

2

The Voith Paper supply was as follows:
MasterJet G Headbox with ModuleJet
DuoFormer TQv, Gap Former
DuoCentri NipcoFlex Shoe Press
Wet End Lube System
DuoFoils, Stabilizers and Transfer Foils
for the Dryer Section

Voith Paper’s design and manufacturing

Stock was fed to the wet end on April 9th

whelmingly positive. The delay in com-peopleHeidenheim

and Inland Empire’s startup team, Voith

pleting the project ended up being rela-worked very quickly to produce the ma-

Paper’s startup engineers and, of course,

tively minor and the silver lining… wechinery. Careful choice and engineering

the wet end equipment worked so wellconsider the Voith equipment to be theof equipment options ensured that thethat a sheet went into the press pulper

first major upgrade to our new machine.”

civil alterations necessary on site were

the same day. The first paper reached theminimal. Drive points and tie-down points

reel on April 14th and the project teamThis project is an example of what can bewere nearly all maintained, enabling econ-

was able to celebrate a remarkableachieved when each team member con-omy of cost and time.

achievement. Paper was on the reelcentrates on their own tasks and leaves

12 months after order, and only three

the other members to concentrate on

The lean Inland Empire project team, ad-months later than the original plan, de-theirs, without undue interference or bu-

mirably led by Bob Sallee, worked withspite the bankruptcy of the original main

reaucracy. The Inland Empire team con-the Voith Paper team led by Project Man-

supplier!

tributed greatly to this. Meetings wereinAppletonandager Richard Toth. Together they acceler-

kept to a minimum and were focused andated the project progress so well, that

Kevin Rasler, Production Manager, said

effective, with decisions made quickly.

even with Voith Paper’s normal, detailed“After three years of planning and

The fact that the overall team was small

pre-erection in Appleton, WI, major deliv-

preparing, and then working through thehelped enormously.

eries started in November and were com-challenges created by the default of theplete by February 2001. Plant Engineer

original supplier, to have this machine

Paper quality has been impressive since

Ed Orr and his team, assisted by Voith

come up and run this well was a tremen-

startup. Profiles in all three directions are

Paper’s erection supervision group, in-dous reward for all our employees. Initial

excellent. The pressrooms are alreadystalled the equipment quickly and pre-paper quality was superior to the old ma-

unanimous in their approval of the sheet,cisely, enabling commissioning to begin

chine even before we began optimizing,

which runs very well on their presses.

in early March.

and customer response has been over-Optimization will, nevertheless, continue

Paper Machines

29

Fig. 1: Inland Empire in Millwood (Spokane)in the state Washington/USA.
Fig. 2: Rebuild PM 5.
Fig. 3: The team at the first reel after the
successful rebuild.
Fig. 4: Bob Sallee, Director (left) and Ed Orr,
Plant Engineering and Maintenance Manager.

as Inland Empire drives towards its ob-

4jective of the best newsprint sheet inNorth America.
Runnability has also been excellent on
the paper machine. Startup speed was
3,500 fpm, and good runnability was
obtained the first week. Runnability hasremained good as the speed is gradually
increased, and the operating people happily expect a better than average machine
efficiency even when the eventual production speed of 5,000 fpm is reached.
Paper

Main Data:
Design Grade Standard Newsprint
Furnish 40-50% TMP, 10-25% RMP,
25-40% Deinked ONP
Products:
Standard Newsprint
Improved Newsprint
Directory (SC Grades in Future)
Basis Weight Range 22.1-38 lb/3,000 sq. ft.
(46-62 g/m 2)
Maximum Operating Speed 5,000 fpm(1,524 m/min)Wire Width 250.8 in. (6,370 mm)
Sheet Width on Reel 227 in. (5,766 mm)

Kevin

Wayne Andresen, President and General

Davis commented, “We ended up withmachinesuperintendent

Manager of Inland Empire, who oversaw

the machine components we wanted

the whole process, deserves the last

originally. The machine is a clean run-word. “For a company of Inland Empire

ning machine and has shown great po-

Paper Company’s size, a project of thistential to operate very efficiently. I am

magnitude was a huge undertaking, espe-very excited about what we can achieve

cially when you consider that it was donewith paper machine 5”.

primarily with in-house personnel. I amvery proud of our people and the job they3

Bob Sallee, for many years Director ofdid. However, we could not have beenSpecial Projects at Inland Empire, andsuccessful without the tremendous effort

Ed Orr, longtime Plant Engineering andby our outside contractors, especially

Maintenance Manager, had reached theVoith Paper who helped us through a

end of their careers when the PM 5 pro-very critical stage of this project’s life.

ject started. Both agreed to stay to com-

With the state-of-the-art paper machine

plete the project. There can be no betterthat we now have, along with our out-

testimonial to the quality of their profes-

standing customer service, Inland Empire

sional capacities than the extraordinary

Paper Company is well prepared to meet

success of this project. Both retired soon

the future”.

after startup, but what a way to go! For

As the proud owners of the most techno-

the Voith Paper team, it was a pleasurelogically advanced newsprint machine in

and a privilege to work with them, and we

North America, Inland Empire Paper Com-wish each of them a happy, fulfilling andpany is indeed “well prepared to meet thelengthy retirement.

future”.

30

The author:
Klaus Schmidt,
Paper Machines
Graphic1

31

Coating machine 3
for Mitsubishi HiTec Paper,
Bielefeld –Exemplary for teamwork in partnership,
fast project completionand successful high-tech coating
How to meet – despite an extremely
tight project deadline – all engineering requirements and exceptionally high quality demands,
with perfect high-tech functionality at the sametime? The answer is deceptively simple: throughclose teamwork between customer and machine
supplier, with efficient project handling on bothsides, and with a common understanding ofpotential problems and how to solve them.

32

2

3

33
4

Figs. 1 and 2: Coating machine 3
Mitsubishi HiTec Paper, Bielefeld.
Fig. 3: Schematic layout of coating machine 3.
Fig. 4: Dynamic Coater.
Fig. 5: End section with EcoSoft calenderand Sirius reel.

This applied precisely to the project
handling – and above all the results,
start-up and product quality – of the new
coating machine 3 for our customer
Mitsubishi HiTec Paper, Bielefeld-Hillegossen. From the beginning, both teams
completely agreed that the goals were demanding, but not unattainable, if special
approaches were adopted. These included
starting with the engineering work very
shortly after project commencement. At
the same time, the technical concept of
the entire machine was finalized. Its mainfeatures are as follows: The offline coating machine is designed
for the final expansion phase, i.e. production of all technical communication
papers with multiple and reverse surface coating. This requires a broad
basis weight and coating density spectrum, a working width of 2,900 mm
and a design speed of 1,500 m/min.
 For the start-up with thermo paper,
presizing is done by Dynamic Coaterwith blade, and the surface layer by
DF coater (curtain coater).
According to this concept, the air drying
stretch after the modified curtain coatertakes into account of the maximum admissible web temperatures for thermosensitive coatings. A polygonal arrangement was chosen, with additional airturnto ensure a stable web run.
A softnip calender precedes the Sirius
reel with Senso Roll for high-sensitivity

5

34

6

Fig. 6: Sirius reeler with SensoRoll.
Fig. 7: The project team.

nip adjustment and optimal wind-up. To

No problems or delays occurred either inenable precise quality optimization andthe planning and design phase or duringcontinuous control, corresponding sys-

erection. The extremely tight commission-tems are installed for the humidity anding deadline was met, but only thanks tocoating density control.

exceptional efforts on the civil engineer-

DieterBaumgarten,
Profit center
manager“large rolls”

ing side. Our customer’s equally outstand-

Dieter Baumgarten, profit center manag-

The scope of supply also included pe-

ing project organization ensured the per-er “large rolls” at Mitsubishi HiTec Paper,

ripheral systems, such as central lubrica-

fect coordination of all activities as well.

expressed his appreciation of this successful teamwork as follows: “I tendertion and machine air supplies, as well as
machine building ventilation systems andOn October 15, 2001, the first thermo

my sincere thanks to Voith Paper for

extensive services. The latter covered thepaper of saleable quality was produced

their outstanding performance. The newentire machine engineering, process con-immediately after start-up of the ma-

coating machine started up right on time,

trol systems, complete installation andchine. Just 2 weeks later, a production

and produced saleable paper on the firstcommissioning, and comprehensive train-

speed of 1,300 m/min was reached, while

day of operation, October 15, 2001. The

ing of the customer’s operating team.

achieving 90 % runnability in production.

planned operating speed of 1,250 m/min
was easily attained, already reaching amaximum speed of 1,300 m/min. Product quality is at a very high level, significantly improving over that of our competitors. No problems at all have been
experienced with the DynamicCoater andthe modified Curtain Coater units. Voith
Paper sent an excellent team to Bielefeld,
and we were very happy with them.”

35

ProRelease –gentle web run

Der Autor:
Roland Mayer,
Uwe Joos,
Papiermaschinen
Grafisch

The authors:
Roland Mayer,
Uwe Joos,
Paper Machines
Graphic

Since its introduction, the single-tierdryer section – equipped with DuoStabilizers andropeless tale threading technology – has provenextremely successful. The complete single-tier
TopDuoRun is now the preferred dryer section
configuration, especially for high-speed paper machines and lightweight paper grades. Furthermore,in combination with double-tier dryer groups – theCombiDuoRun – for heavy grades and at somewhat
lower speeds, it permits high runnability throughstable web run and reliable, fast tail transfer.
The newly developed and alreadysuccessfully installed ProRelease Stabilizer now
offers further optimization potential in the particularly sensitive area of the first dryer groups by
reducing the required tension of the still wet andweak paper web during detachment from the dryer.

Web release at the dryer
The detachment, or release, of a paper
web from a plain dryer surface is affectedby a number of forces. Fig. 1 shows
schematically the main forces that occur
at that release point. Because there is alack of ventilation to the opening nip,which has to act against the running of
the cylinder and the web, a negative nip
force is created, which holds the paperon the dryer surface. In addition there are
centrifugal forces, which have no loading
effect while the web is in contact with thedryer, but act after detachment due to the
sharp deflection of the web.
Adhesion forces also apply, which are dependent on temperature. These forcesmust be overcome by increasing tension
in the paper web, preventing the web

36Fig. 1: Forces during web detachment from aplain dryer.
Fig. 2: Schematic arrangement of the ProRelease
Stabilizer.
Fig. 3: Tension reduction and speed increase by
the installation of a ProRelease Stabilizer on
Eltmann PM 3.
Newsprint, 45 g/m 2, 100 % DIP
Before rebuild
After rebuildfrom following the dryer away from theseparation point. Insufficient tension will
result in web wrinkles or sheet breaks.
This tension is built up by differential
speeds, or draws, between the drivegroups. The maximum possible web tension is limited by the initial wet strengthof the paper.

1

Dryer

Run-off nip vacuum
Adhesion

Stabilizer
vacuumCentrifugalWebtension2

DuoStabilizer

DynaSeal

Release zone

ReleaseSeal

Stabilizing
zone
Stabilizing
zoneWith increased production speeds, theforces on the web increase. At the sametime, the web must continue to be picked
up reliably and trouble-free regardless of
small fluctuations during production orafter felt changes in the press section.
The operating window available between
the minimum necessary web tension forgood web running and the initial wet
strength, therefore, diminishes and, inmany cases, limits the production speed.
Vacua introduced by web stabilizers canrelieve the effect of the forces on the paper web, allowing for reduced tension.

Drilled roll with
tailing zone

Mode of operation of the new stabilizer
To improve the situation, the web should
be fixed on the fabric as close to therelease point as possible and the forces
holding the web to the dryer should becountered by increased stabilizer vacuum. To avoid negative effects due toincreased air leakage or intense fabricdeflection, the increased vacuum must be
limited to the pick-up area.

3
3.4
Draw press – 1st dryer (%)

Limit of initial wet strength
3.0

2.6
More than
50 m/minspeed increase

2.2

1.8
1400

1500

1600

1700

Speed at reel (m/min)

1800

The new ProRelease Stabilizer (Fig. 2) optimally meets these demands, while stilldrawing on the proven advantages of the
DuoStabilizer. The release zone offers ahigh vacuum targeted in the pick-up areawith a reliable and non-contacting seal

against the stabilizing zone. The stabilizing zone continues to work at a low vacuum level, which is sufficient to hold the
web fixed on the fabric even at a highproduction speed. The drilled roll continues to be subjected to suction by the stabilizer. The vacuum in the release zone
and that in the stabilizer can be adjusted
and optimized independently from eachother.

Successful in operation
Following extensive trials on our pilot
paper machine, the first ProRelease Stabilizer was put into operation at the endof August 2001, on Palm Papier Eltmann
PM 3 (newsprint, 100% DIP). Despite
starting with four new press felts, aspeed increase of over 50 m/min wasreached immediately (Fig. 3). At the sametime, the web run in the first dryer
groups became less sensitive to fluctuations in the moisture profile or to minor
disturbances in the edge areas, which
led to smoother running and fewer sheet
breaks.
Also, the installation of four ProRelease
Stabilizers in October 2001 in the first twodryer groups of PM 2 at Soporcel, Portugal (copy paper, 80% eucalyptus) wasvery successful. The reduction in draw of
0.4% achieved after the press, combinedwith the more gentle web pick-up and theimproved web run in the press due to theinstallation of a transfer belt, increased
the speed over 100 m/min, bringing themachine up to world record level.
Fig. 3 shows how the increase of the
ProRelease vacuum on PM 3 in Eltmann

Paper Machines

37

Fig. 4: Draw reduction on Eltmann PM 3
in relation to vacuum increase.
Tandem NipcoFlex Press
Newsprint, 45 g/m 2, 100 % DIP, 1,560 m/min
Fig. 5: Draw reduction for various stocks on thepilot paper machine at 1,550 m/min.
SC (100 % DIP, 28 % AiP)
Newsprint (100 % DIP, 18 % AiP)
Copy Paper (80 % eucalyptus, 12 % AiP)
Newsprint (100 % TMP, 11 % AiP)
Newsprint (100 % TMP, 4 % AiP)
Fig. 6: Schematic cross-section with patented
transfer zone.

The greatest effect occurs on paper
machines with a tandem NipcoFlex™ shoepress or other presses without a centerroll. Here the paper web does not need tobe pulled off a smooth press roll. The
improvement of the web run at the firstdryers can, therefore, be fully utilized. To
achieve the maximum potential, three to
six ProRelease Stabilizers are necessary,
making a 0.4% to 0.7% reduction in draw
possible.
On machines with a center roll and possibly a fourth press, the ProRelease Stabilizers can also provide some runnability
enhancement. However, in this case theimprovement potential is somewhat less,as the tension required to detach the webfrom the press roll is not directly influenced, but only the percentage of tensionthat is required for a good web run in thefirst dryer groups is reduced.

Proven functionality and reliability

4

The heart of the stabilizer is the crossmachine sealing. Both the well-known
DynaSeal at the top of the stabilizer andthe new ReleaseSeal, work with an air
gap and without contact during operation
and, therefore, do not cause any wear on
the dryer fabric. Nevertheless, they sealvery effectively and permit, through theadjustability of the pre-tensioning and the
distance, optimal sealing even at maximum speeds and high negative pressures. Both seals are flexible and cangive way when paper wads or broke comewith the fabric.
These innovative seals provide a much
more energy efficient alternative to machine wide air knives, since the consumption of supply air is minimized.
Through the flexibility of the seals, thedistance between the wire and the fixed
elements of the stabilizer can be large
enough that fabrics can be pulled on
without any problem and there is no riskof fabric damage in the event of a dryer
wrap or paper jam. Both the supporting
and the sealing blades can be changed
without removing the box, even if they
are located behind framing supports.

Draw press – 1st dryer (%)

3.2
3.0
2.8

0.5 %
draw
reduction

2.6
2.4
2.2
2.0
0

200 400 600 800 1000 1200 1400
Vacuum in Release zone (Pa)5
Minimum draw 1st press – 1st dryer (%)

positively affects the required tension after the press. At a negative pressure of
800-1000 Pa (standard ProRelease operating range), the tension can be reduced
by 0.5% (Fig. 4). The maximum negative
pressure reached was even higher, at
1300 Pa. On the pilot paper machine, theeffect was successfully tested for numerous stocks and paper grades (Fig. 5). To
the extent that the initial wet strength allowed, trials were run up to 2,000 m/min.
This impressively demonstrated the stabilizer’s abilities, particularly that of theseal, even for maximum production
speeds.

3,8
3,4
3,0
2,6
2,2
1,8
1,4
0

200

400

600

1000

6
Release zone

Lateral sealing on the front and drivesides is done with bolted-on air knives
extending over the entire height of thestabilizer. Therefore, the release zone –operating at high negative pressure – isalso sealed laterally against air leakage.

800

Vacuum in Release zone (Pa)Stabilizer
Tailing
flap
Drilled rollTailing zone

38

Freshwater

Stock components
Fillers

Make up waterin stock preparation

Broke

1

Automation in the
Wet End Process™
The Wet End Process (WEP) is com-

Chemical additives are used both forprised of all machines and equipment around theprocess stabilization and for paper quali-

wet end of the paper machine. The three main

ty optimization. The efficiency of thesepartial systems are: approach flow, broke treat-

additives is due to their strong and direct

ment and fibre recovery. A simplified view clearly

effects on the fibres and fillers.

shows that not only the interplay between these

The author:
Dr. Michael Schwarz,
Paper Machines
Graphic

three sections has to be taken into account, but

On the other hand, the active mecha-also, in particular, their complex interfaces withnisms of these additives charged mostly

the paper machine itself.

at the surface are in turn influenced by
the properties of the fibrous stock. This
interplay is extremely sensitive to fluctu-

Immediately ahead of the headbox, allations, which can only be mastered byfluctuations – whether periodic or sto-efficient monitoring and optimal process

chastic – must be avoided in order not tocontrol immediately before the headbox

affect the finished paper product.

(see Fig. 2).

Paper Machines

39

Fig. 1: Wet end process: approach flow,
broke treatment, fibre recovery.
Wet End
Automation

Fig. 2: Automation and chemical additives in the
wet end process – perfect match.
Fig.3: Online sensors and overall automation
concepts.

Wet End
Chemistry2

Fig. 4: Retention control.
3

New online
sensors allow
precise processmonitoring

FIC

Overall
automation
concepts improve
quality control

 Better stability upstream from theheadbox Improved quality constancy of thefinished paper

4

Retention controller
Cons

FI

FI

Cons

Retention agent

Broke
Furnish 1
Furnish 2

 Better overall process runnability

Automation in the Wet End Process

new in theory, but so far they have beenretention itself, but the whitewater con-unsuccessful in practice due to a lack ofsistency that is kept constant.

Every efficient control concept depends

reliable online sensors (repetitive, see

upon reliable online sensors. However,last paragraph).

Since retention is defined as the quotient

the suspension parameters are far moreof the difference between headbox anddifficult to measure than the finishedBy further developing and optimisingwhitewater stock consistencies, the re-paper characteristics. Even determining

control concepts in conjunction with sen-tention figure would assume the same

stock consistency places high demands

sor systems, not only can paper quality

value for an indefinitely large number ofon measuring technology, not to mention

constancy be improved, but significant

ratios between headbox consistency andmeasuring chemical properties such as

costs can be saved by enhancing plant

whitewater consistency. Thus, a retention

charge level or air content.

availability and reducing additive require-

control would be impossible.

ments (Fig. 3).
New findings in online measuring tech-

Measured for this reason is the white-

nology, and recent advances in existing

The goal is to develop clearly definedwater stock consistency, which is main-techniques, have brought a decisive

control

implementation

tained constant by adjusting the quantity

breakthrough in this direction. Significant

separately or in combination with others.

of retention agent accordingly. The sec-

strategies

for

improvements have been achieved bothin absolute precision and in repetition

ond measurement taken in the headbox
Retention control

accuracy, and particularly in the speed ofmeasurement.

intake enables retention to be computed
precisely (Fig. 4). This concept gives pa-

The central module of all controls in thepermakers a tool for controlling retention

Wet End Process is the control of reten-

as a function of formation, stock grade,

This opens up new possibilities for im-tion via the various stock consistencies.

lip flow, etc. while independently allowing

plementing control strategies. Impressive

Retention control is a rather confusing

the elimination of undesirable stock con-process control concepts are nothing

term, in so far as it is primarily not thesistency fluctuations.

40

Fig. 5: Newly developed stock consistency sensor
TCT 2.
Fig. 6: Retention control with SC paper.
Fig. 7: Basis weight stabilisation by retention
control.
Fig. 8: Charge control in fresh stock.

5

Together with our alliance partner, BTG,

tently good retention, charge fluctuations 6

Säffle (Sweden), we developed the firstin the stock must be avoided or eliminat-

new sensor enabling genuine inline mea-

ed. A fluctuating charge level before thesurement of total stock consistency andheadbox would reduce the effectivenessfiller content separately. This finally elim-of the charged retention agent, and theinates the drawbacks of “continuous off-

inorganic particle systems, leading toline” operation with its intensive mainte-

variable retention.

Consistency in %2.5

Retention50%

2.0
Headbox(main flow)
1.5
Dilution water
(WW)

1.0

nance requirements (Fig. 5).
Online charge measurement now enables
With these high-precision suspension

fluctuations to be detected at the earliest

sensors, full real-time balancing aroundpossible point right after the mixing

the headbox and the former section ischest. By regulating the input of charged

now possible. Retention control is thus

additives (fixing agent), such fluctuations

fully integrated into the paper machine

can be corrected accordingly. Therefore,

quality control system.

stock charge measurements are taken

0.5
Retention control OFF

0.0

Retention
control ON

Time frame: 6 weeks
7

g/m2
1.2

directly after the machine chest, without
Comparison of the stability of various pa-

Basis weightb.d. CD(2sigma)

sample dilution (Fig. 8).
If, in contrast to this, charge is measured

pressive results (Fig. 6). This also showsin the whitewater or in the headbox recir-

why “retention control” is always based

culation, there are two serious draw-

on the constancy of whitewater stockbacks. First the high whitewater flow

consistency rather than on the retention

has a dampening effect on the readings,

itself.

and secondly only the sum effects of

0.3
Consistency
hitewater

1.0
0.5
Retention control OFF

0.0
Consistency in %detected.

constant stock consistency in the forma-

8
Charge controllertion section, but more constant paper

Extensive tests with parallel installed in-quality. Figure 7 illustrates this in terms

struments provided by our alliance part-of basis weight.

ner Mütek, Herrsching (Germany) have
proved above impressively (Fig. 9).

FIC
Fixing agent
Broke

Charge monitoring
Online gas content measurement
Even with optimal stock preparation, furnish-related fluctuations cannot be en-

Deaeration by applied vacuum reliably

tirely avoided. In order to ensure consis-

eliminates free and dissolved gas from

Furnish 1
Furnish 2

Retention
control ON

Time frame: 6 weeks

fixing agent and retention agent can be
However, the main purpose is not merely

0.9
0.6

rameters before and after commissioninga retention control system gives very im-

70%

Retention

ChargePCT

0.0

Paper Machines

41

Fig. 9: Comparison of charge control in theheadbox and after the mixing chest.
Fig. 10: Gas content control in whitewater.
Fig. 11: How gas content in whitewater affects
pump speeds.
Fig. 12: Potential benefits of Advanced Controls
in the Wet End Process.
9Particle charge µeq/l

12

the suspension before entering the headQuality
improvementbox. The residual gas content measured

500

Cost
savings

after the deaeration is less than 0.1 %.
Mixing chest

400

In the closed, pressurised piping system

Thick Stock+++

Retention++++ahead of the headbox, small pressure

300

thrusts can then no longer intensify and200

Gas content+++

build up into pulsations, and the feared
Headbox100

gas pressure spring effect cannot occur.
Sheet formation in the former area or on

Particle charge++

Filler content+++

the fourdrinier is not disturbed by free0Time frame: 1 week

air. Nevertheless, chemical additives are10

Gas controllerGasstill required here in the whitewater for
deaeration purposes to avoid pumping

This demands continuous monitoring of

problems due to air in the whitewater,

the gas content in the system.

and also to prevent foam formation in the

FIC
Defoamerducts (Fig. 10).

As shown in Fig. 11, the pump operating
speeds vary as a direct function of gas

Broke
Furnish 1
Furnish 2

These deaeration/defoaming additives arecontent. Clearly, regulating the defoaming

comprised of surface-active substances

agent input so that the maximum tolerable(such as fatty alcohol) which may reactgas content is not exceeded can result inwith other chemical additives. Further-

substantial cost savings.

more, their cost is significant.
For each installation, there is maximum
Pump speed in %90

Gas content in %1.2

Gas content

1.0

80

0.8

70

0.6
60

Deculator
0.4 pump

50

0.2

11 tolerance

limit for gas content in the40
Dilution water pumpTime frame: 2 weeks

in the wet end process

whitewater. If this limit is exceeded,pumping efficiency falls off sharply andThein extreme cases the paper machine has

above and the control concepts based on

to be slowed down. However, since thethem can be applied either individually or

gas content can fluctuate considerably,in combination. They not only improveenough defoaming agents have to be

the paper quality in various ways, but

added to eliminate problems with exces-

also reduce production costs. These re-sive gas content even in the most un-sults are summarised in Fig. 12.

favourable cases. Deaeration additives
0

Potential benefits of advanced control

should, therefore, be minimized at all
times to the smallest amount necessary.

onlinemeasurements

discussed

42

1

Oji Fuji N-2 –the five-star board machine

The author:
Jörg Fischer,
Paper Machines
Board and Packaging

Fuji City, south of Tokyo, is located at
the foot of the famous white top volcano, MountFuji, and is reachable within one hour by Shinkansen super express train. The area has been Japan’scenter of papermaking from the very beginning due
to its abundance of forests and clear water. Today,
approximately 100 paper mills (most of themsmall and obsolete) in a city of 200,000 residents,
still provide evidence of long tradition. Just
realizing this may have been one of the essential
spurs to tackle the project for building a new board
machine N-2 at the Fuji mill. It was indeed an
ambitious, but promising project launched by
Oji Paper Corporation at the end of 1999.
Four small and obsolete board machines,
owned by the company, were to be replaced by one new, larger machine. Whata challenge when considering Japanesetradition and market habits! In Japan, thecustomer is still the principal focus, but
now many small clients will have to beconvinced to accept a standardized prod-

uct instead of a grade that had always
been tailor-made for them. Producing anddistributing minimum order lots of only
two tons would be a logistic challengewith such a huge machine. There would
also be the problem of releasing many
long-time employees where previous
tasks would now be eliminated throughnewer technology. This in a country where
employment with one company for one’s
entire working career is a standard wayof life. On top of all this, there is the disadvantage of being in the center of a big
city, operating under perhaps the strictest
environmental regulations worldwide!
The only solution possible was a highly
automated and flexible production line
making use of the latest experiences intechnology and engineering from the beginning of the stock preparation systemand ending in the shipping department.
The decision on the supplier of the board

43

Fig. 1: Oji Paper at Fuji City at the foot ofMount Fuji.
2

machine was made in favor of Voith
Paper. Excellent references and the confidence in Voith Paper’s know-how andworkmanship were the main criteria forthe selection. The N-2 machine at the Fuji
mill is now the largest board machine inJapan, and with a designed production
speed of 800 m/min, it will also be thefastest multi-fourdrinier machine forwhite lined chipboard worldwide. The
board grades produced on this machine
include top-side double-coated white
lined chipboard and two-side doublecoated special board with a basis weight
range between 160 and 450 g/m 2. 100%
recycled fibers are used as furnish. The
machine has been specially designed tomeet the quality targets of the product:good stiffness with the highest possible
bulk; but even more important is an excellent surface in terms of smoothness,gloss and printability. Surface properties
have the highest priority in Japan because boxes are mainly printed by gravure
printing, but are also offset printed.
The investment cost by Oji Paper for the
N-2 project was 27 billion Yen (250 million EUR), substantially strengthening thecompany’s leading market position forfolding boxboard in Japan. This grade isone of Oji Paper’s strong points in theJapanese market besides their newsprint
and coated paper grades.

The Mill
In 1908, the first board machine wasstarted up at the Fuji mill. In the mid-sixties, the deinking process was introduced
into the mill to substitute groundwood.
The deinking process has been steadily
developed and improved over the years,

Fig. 2: Press section with NipcoFlex™ press.

recently with special emphasis on highbrightness pulp. Today, the recycled pulp
capacity is more than 1,000 tons/day
consequently making the mill one of thelargest worldwide. Virgin pulp is nolonger needed, since the mill operates arecycling line for used liquid packaging
boxes. The recycled pulp is used not only
for board production, but also as furnish
for the N-1 machine. The LWC machinewith on-line coating started up in 1990
and is running with 90% recycled pulp at
a speed of 1,200 m/min.
For energy supply, the mill owns a 10 MWhydropower station and three steam
boilers with a total capacity of 100 MW.
Before the new board machine N-2 wasinstalled, the Fuji mill had been runningtwo smaller board machines. Owing to its
existing resources in assets, as well as
the experienced and educated personnel,
the Fuji mill was the preferred place tosuccessfully carry out such a project.
Engineering, Construction
and Installation
Oji Paper is one of the two major paper
producers in Japan and number seven in
the world ranking. Typical for most big
companies, it is well staffed with experts
in technology and engineering. No wonder that Oji was able to make great use of
its resources for the new project. Millowned engineering companies did the engineering for the stock preparation system and finishing department, the civilengineering and the detail engineering for
piping and electricity. The engineering
services for ancillary equipment aroundthe board machine and the board machine building were also performed by Oji
Engineering, however this work was

based on Voith Paper’s basic engineeringand recommendations. Limited space inthe center of an operating mill was achallenge for the planning engineers andconstruction companies.
In European countries, the use of prefabricated concrete elements is often considered as the most efficient and fastest
way to construct a paper machine building. The Japanese have demonstrated thecontrary. Five months after starting thecivil engineering work, the first foundation rails were installed. From the basement to the operating level, the wholebuilding was made from on-site cast concrete in a solid construction. From thispoint upward, steel construction wasused. The Fuji area in Japan is known to
be a high-risk earthquake region. For
this reason, the board machine and thefoundations had to be designed for anearthquake factor of 1.3 g, making thebuilding and the machine heavier thanusual.
Voith Paper supervised the installationand start-up of the machine, while the job
itself was done by Oji Paper’s installationcompany together with the mill’s staff.
The performance of installation, the management of transportation and the reliability in keeping to the time schedule
were excellent. The majority of pre-piping
was done outside the mill. The entire
installation of the board machine wasfinished four months after the foundation
rails had been put in place. After six
weeks of operational tests, the first board
was wound on the reel, 18.5 months after
contract signing. On October 1, 2001, theboard machine started its commercial
production.

44

Wet End
The wire section comprises five fourdrinier wires. The backliner is formed on
the bottom fourdrinier with a length of
105 meters. The underliner back isformed on the first top wire, the second
top wire with a DuoFormer™ D produces
the middle layer, and the underliner top
and the topliner are formed on the thirdand fourth wires. All five headboxes fromthe latest family of MasterJet™ F/B headboxes have shown an excellent performance. The middle layer headbox isequipped with ModuleJet™ dilution valvesand controlled by a Profilmatic™ M CD
profile control system. The expected CD
basis weight profile was achieved withina short time.
The press section has been designed for
two nips and four felts. The first press isa double-felted suction press with suc-tion roll web pick-up off the fourdrinier.
The second press is a double-felted
NipcoFlex™ shoe press with the shoe in
top position and a solid backing roll.
Similar to the first press, the web is taken off the first felt, maintaining a completely closed web run through the whole
wet end. The shoe press can be loadedwith 800 kN/m, but usually a lower load
is used. Before the web enters the dryer
section, an offset press without feltssmoothes both surfaces of the board.
Upstream of the NipcoFlex™ press, aModuleSteam steam box is installed
above the bottom felt of the first press.
Cylinder Drying and Machine Ventilation
The cylinder drying and machine ventilation equipment was not included inthe Voith scope of supply. Oji Paper
purchased it directly from domestic suppliers.

Calenders, Coaters
Ahead of the coater section, the web iscalendered in a Voith Paper hardnip calender. A ThermaJet hot air blower with
Profilmatic™ TJ control unit controls the
CD thickness profile, both from Voith
Paper Automation. Four LDTA coating
stations of the SmartCoater type with applicator rolls, two for each side, are available for coating application. Metering of
the precoats is done by smooth rods, andthe top coats are applied in bent blade
mode. A combination of gas-fired infrared dryers by Krieger, and hot air dryers
by Langbein & Engelbracht, provide forsmooth and efficient evaporation. One
row of the gas IR dryers is suited for CD
moisture control.
Web Run and Wind-up
Before winding up at the reel, the propersmoothness and gloss can be achieved

45
Design criteria of the board machine
Design speed

800 m/min

Drive speed

800 m/min

Speed range

200-800 m/min

Wire width

4,700 mm

Paper width on the reel

4,250 mm

Maximum roll diameter

4,000 mm

Gross production on the reel

800 t/24 h

Daily average sold production 650 t/day
Basis weight range

3

Fig. 3: Oji Fuji N-2 board machine.
Fig. 4: Sirius reel with 4 m parent roll.

160-450 g/m 2

Length from headbox to reel

230 meters

White-lined chipboard

top side
double-coatedand special board

both sides
double-coated

Furnish100% recycled
fibers
DIP and magazines

Hideki
Yamamoto,
Executive
Officer ofOji Paper andMill Manager
of Fuji Millby two soft nips. Two Voith Fibron va- 4
cuum belts assist in tail threading in thetwo positions where the rope run is interrupted. They show an excellent performance with all basis weights.

The main machine parts for the Fuji
Board Machine N-2 were directly imported from Voith Paper, Austria, owing
to the excellent technological concept
and with a view towards saving cost.

The board is finally wound on a Sirius™
reel, permitting roll diameters of 4,000
mm. RollMaster control ensures a uniform build-up of the roll during the wholewind-up process. The roll change is supported by an IBS turn-up system, cutting
the web with a tape. The Sirius™ reelallows easy roll changes with minimum
board loss.

This state-of-the-art and most advanced
machine has enhanced our productivity
and board quality.

Oji Paper purchased the automation systems for the machine directly. However,it should be mentioned that the DCS control system and the machine drive were
supplied by Toshiba, and the QCS control
system by Yokogawa.

Our aim is to gain a leading position interms of board quality. With this newmachine, we are in no way behind otherlarge machines in Southeast Asia.
Only recycled fibers are used at the Fujimill, and I believe it is one of the largest
mills of this type worldwide.
The Fuji mill, with its prime geographic
location and this big investment made,has set itself the goal to become theworld’s best recycled mill.

46

5Fig. 5: Oji Fuji N-2 coater.
Fig. 6: A look into the control center.

Finishing
The Voith Paper scope of supply ended at
the reel. Nevertheless, it is of interest to
mention some highlights of the sophisticated finishing department. The latter has
been designed for supplying even smallorder lots to many customers withinshort-time intervals, without having to
make too many grade changes.

termediate storage area. The pallets fromthe sheeters can either be conveyed to asorting area or directly to the automatic
reaming or wrapping station where paper
is used as packaging material.

Summary
On November 2, 2001, the new production line was inaugurated with an impressive and festive opening ceremony,
After the reel, the parent rolls are slit into
marking the final point of the project.
smaller rolls in the winder. The rolls are
The Executive Officer and Mill Manager,
then conveyed to a vertical roll storage
Mr Hideki Yamamoto, welcomed 400 inunit with a capacity of 13,000 tons. An
vited guests and was proud to demonautomatic crane with vacuum lift handles
strate a flawless production line rightthe rolls. From here, most of the rolls are
up to the last detail. The speeches wereconveyed to the sheeting department andbrief and the main participants were thecut on four Simplex sheeters. Others are
members of the project team and the opsold as complete rolls. Rolls, which are
erating personnel. The President and CEO
not totally sheeted, are returned to an inof Oji Paper Corporation, Mr Shoichiro
6 Suzuki, emphasized in his address theimportance of the new machine. He pointed out that the high quality and flexibility
would make it easier to serve a difficult
market, resulting in benefits for all customers.
With the Oji Fuji N-2 project, Voith Paper
has once again shown its strength ingroup-wide sourcing and its competencein project handling in the Asian market.
Due to new communication technologies,
even a distance of 11,000 kilometers was
no real barrier, as almost all documents
and drawings were forwarded electronically. Nevertheless, local support wasvery important. The local office, Voith
Tokyo, today Voith-IHI, as well as the
trading company, Mitsui Bussan Plant &Project Corporation, rendered important
services, such as local transportation,translation and communication with thecustomer, which were absolutely necessary for establishing and maintaining thelogistics and a good working environment. It was easy and a pleasure to work
together with the experienced and professional Oji project team members.
Within one month of continuous operation, the machine was running with nominal capacity and the essential quality
properties were reached. We would liketo congratulate and to express our appreciation to our Japanese friends on theirgreat success, and acknowledge those in
the Voith Paper organization who contributed to the success of this project.

47

Forming Fabrics
for graphic papers
The forming fabric is a precision made,direction (MD) yarns which interlaced

highly engineered, component of every former.

with one system of cross-machine direc-

To determine the most appropriate fabric for antion

application requires an understanding of thechanges in yarn diameter or weave pat-customer’s key papermaking needs and the paper

tern to improve the fabric’s on-machine

end use issues. Thus, a partnership between fabricperformance affected both surfaces ofsupplier and user is essential.

the fabric. “Multi-layer” designs were(CD)

yarns.

Consequently,anyrequired to overcome the limitations of
single-layer fabrics and to deliver major
benefits in the forming section.
Multi-layer FabricMulti-layer fabrics have either one MD
yarn system interlacing with multiple layFabric Structuresers of CD yarn systems or, several fabrics, each with its own MD and CD sys-

The author:
Stewart Hay,
Voith Fabrics

The perfect fabric that allows best prac-tems, bound together in some way. Everytice manufacture for all grades on each

multi-layer fabric allows independent en-

position of every machine has not yet

hancement, to some extent, of both fabricbeen invented. A range of fabric types ispaperside and wearside surfaces.

made so that added value can be provided for all product and process variations.

Fabric Surfaces
Indicators of a suitable paperside include

In this article the fabric types used for

acceptable formation, retention, rough-Graphic paper production are identified

ness and wiremark. Fabric papersideand compared. Each type offers a unique“support points” (yarn floats) significant-combination of properties. Applied ap-

ly influence these parameters. Support

propriately all types will deliver measur-

point distribution, orientation, planarity,

able benefits on the former.

effective length, support area, and number, are all important.

History
Fabric properties are largely determined

The paperside should form the initial fi-

by the weave structure together with yarn

bre mat on the fabric surface, as opposedparameters such as the number ofto allowing fibre penetration below the

MD/CD yarns per unit area, their diame-surface. In this way, sheet sealing of theters, and polymer type. The early single-

fabric drainage channels is avoided andlayer fabrics had one system of machine-

the fabric influences drainage.

48

Fig. 1: Double-layer.
Fig. 2: Triple-weft.
Fig. 3: Triple-layer.

On the fabric wearside, relatively long CD

Triple-weft Fabricfloats and thick CD yarns are used to ob-

In triple-weft fabrics a single system oftain the desired service life. However, theMD yarns interlaces with three CD yarn

overall suitability of the fabric applica-

systems.

1

tion, and not just the wearable yarn volume, will determine fabric life.

Double-layer –Paperside Surface<– CD –>

Fig. 2 illustrates a plan view of a typical“eight shaft” triple-weft fabric paperside

Double-layer Fabricand cross-sections through both CD &The most basic multi-layer type has one

MD yarns, respectively.

Section throughCD yarns<– MD –>

MD yarn system and two CD yarn systems. Fig. 1 illustrates a plan view of a

The three CD yarn layers provide thetypical “eight shaft” fabric paperside (i.e.

highest CD bending resistance of any

eight MD yarns per weave repeat) togeth-

fabric category. High CD stiffness has

er with cross-sections through both CD &improved sheet profiles associated with

MD yarns respectively.

fabric distortion on unsupported outer

Section throughMD yarns<– CD –>

2

positions.
Double-layer designs carry minimal waterand are associated with high solids at

The “extra-wefted” paperside surface pro-pick up. Optimisation of both fabric sur-vides good papermaking properties andfaces, as with all fabrics using a single

the dense triple-weft structure also bene-

MD system, is restricted.

fits retention by dampening pressure

Triple-weft –Paperside Surface<– CD –>

pulses from the dewatering elements.

Section throughCD yarns<– MD –>The so-called “two-and-a-half-layer” fab-

Triple-layer FabricSection throughMD yarns<– CD –>

rics have a paperside to wearside CD

Triple-layer fabrics actually comprise two(weft) yarn ratio of 2 : 1. The extra “half-

separate fabrics, each with its own MD 3

layer” of paperside CD yarns give in-and CD yarn systems. The fabrics arecreased fibre support when compared tobound together by additional MD or CD

equivalent double-layer fabrics.

binder yarns.

Larger wearside CD yarns are typicallyFig. 3 illustrates a plan view of the paper-

used to compensate for the reduced

side fabric and cross-sections throughnumber of these yarns. The larger CDboth CD & MD yarns, respectively. Plain

yarns create thicker fabrics with higher

weave paperside and five-shaft wearsidelevels of void volume than the double-

fabrics are shown with additional CD

layer structures illustrated in Fig. 1.

binder yarn. Both fabrics can be opti-(Double-layer) Extra Weft Added Fabricmised independently.

Triple-layer –Paperside Surface<– CD –>
Section throughCD yarns<– MD –>
Section throughMD yarns<– CD –>

49

Fig. 4: Self-stitched (Triple-layer).
Fig. 5: Permeability.
 Double-layer (Double-layer) Extra-wefted Triple-weft Triple-layer (Triple-layer) Self-stitched
Fig. 6: Paperside Openness.
4

The paperside has a very regular distribu-

Fabric Properties

tion of support points and high fibre sup-Self-stitched –Paperside Surface<– CD –>
Section throughCD yarns<– MD –>
Section throughMD yarns<– CD –>

300
400
Permeability (cfm)

Some of the properties typically used topoints in the paperside can cause wire-

compare fabric designs are discussed

mark.

below.

Historically, relative movement of thePermeability

fabric layers caused “internal” binder

Fig. 5 shows the permeability range forwear and fabric layer separation. This de-multi-layer fabrics. Most fabric is madelamination was largely resolved by using

between 300 to 425 cfm.

new binder materials.
Permeability is the volume of air (cubic
5200

port level. However, the single binding

500(Triple-layer) Self-stitched Fabricfeet per minute) that passes throughSelf-stitched fabrics also have two sepa-

the fabric at a given pressure difference

rate fabrics, each with its own MD and(127 Pa). It indicates fabric openness andCD yarns. However, certain paperside CD

is often considered to indicate fabricyarns also bind the fabrics together.

dewatering potential.

Fig. 4 illustrates a plan view of the paper-

However, the wearside and paperside ofside fabric and cross-sections throughmulti-layer fabrics give identical perme-both CD & MD yarns respectively. Again

ability values but forming on the different

plain weave and five-shaft wearside fab-fabric surfaces would not achieve therics are shown. Paperside to wearside CDsame drainage.

yarn ratios are effectively two to one.
6

Pairs of paperside yarns contribute to theRepresentations of fine and coarse fab-high number of fibre support points but

rics are shown in Figs. 6.1 and 6.2 re-also act as binders.

spectively. These “fabrics” have identicalopenness and permeability. However,

Fine
Paperside

CoarsePaperside

Both fabrics can be optimised indepen-

fabric 6.2 has fewer and larger holes,

dently. Self-stitched fabrics are usually

thicker yarns and less support points. It

thicker than equivalent triple-layer fabrics

gives a more rapid initial dewatering, re-and have higher void volume. The binder

sulting in reduced retention. The large

cross over regions sit lower on the pa-

holes fill with fibre to the detriment of

perside and can generate wiremark.

sheet properties and total drainage.
The fabric paperside influences where theinitial sheet is formed and how it drains

50

and thereafter, the initial sheet controls

ness allows calculation of the fabric’s 7

drainage.

nottheoretical worn out thickness. Thickness

enough to indicate fabric drainage capa-

is also a rough guide to water carry andbility – fabric and fibre interaction must

sheet solids at pick-up. Thinner double-

be considered.

layer designs are associated with high

Permeability

alone

is

sheet solids.
Fibre Support Index (FSI)
FSI was defined by Beran (Tappi, 62 (4),Thicker fabrics may give increased fabric1979). It estimates the fibre support pro-stability. Triple-weft designs have thevided by a fabric’s paperside. Fig. 7

highest CD bending resistance and canshows the range of (unitless) FSI values

minimise sheet profiles associated withfor multi-layer designs. The self-stitchedfabric instability.

designs with their plain weave paperside,

75

100
125
150
175
Fibre Support Index (FSI)200

8

and two effective paperside CD yarns for

Void Volume

every one wearside yarn, provide the

All multi-layer fabrics contain a signifi-

highest FSI values.

cant amount of empty space, or voids,
between yarns through which water is

FSI assumes that the fabric paperside is aremoved. Void volume values for multi-

two-dimensional grid (Fig. 8.1). Fig. 8.2

layer designs are shown in Fig. 10. The

shows an actual impression of a plain

relative ranking of the fabrics closely cor-

weave paperside as used in triple-layer

responds to that observed in Fig. 9 (fab-and self-stitched fabrics. The surface is

ric thickness).

FSI Grid ofPaperside Surface

very much three-dimensional. Consequently, FSI greatly over-estimates the

It is also useful to know the distribution

support from current self-stitched fab-and orientation of the void volume

rics. Double-layer, extra-wefted and triple-

throughout the fabric’s thickness as this 9

weft fabrics typically have longer support

will influence the fabric’s water handlingpoints such that FSI more accurately re-ability.

Impression ofPaperside Surface

flects reality.
Abrasion Resistance Index
There is an optimum FSI for each appli-

Theoretical abrasion resistance values

cation – it is often not the highest avail-are shown in Fig. 11. The triple-layer andable value.

double-layer

designs,

which

have

a

greater proportion of their CD yarns on
Thickness

the wearside, give the best abrasion

Fig. 9 shows fabric thickness for multi-

resistance values. In reality fabric life

layer designs. Knowledge of initial thick-potential will be influenced by the overall

0,5

0,6

0,7
0,8
Thickness [mm]

0,9

1,0

51

10 suitabilityof the fabric for the appli-

cation.

In determining the potential performanceof a new fabric design Voith Fabrics does
not rely exclusively on measured lab
properties or simulations which tell only

Summary

part of the story. As part of the development process, Voith’s unique pilot ma-

300

350

400
450
500
Void Volume [cm 3/m -2]

550

600

Several fabric properties known to be re-chine facilities are used to evaluate fab-

lated to fabric on-machine performanceric performance and to better understandwere investigated for various multi-layer

the interaction between fabric, furnish,fabric categories. No one category gaveand machine.

the highest or lowest value for all properties, i.e. there was no all round “winner”.
11

Voith Fabrics and Voith Paper work
closely together so that both expert fab-

All types of multi-layer fabrics enjoy

ric and papermaking knowledge is usedcommercial success in the Graphic paper

to determine the very best solution to thesector. Voith Fabrics supplies a wide

customer’s requirements.

range of designs in each category. Indications from the market are that demandPart two of this article will focus on casefor the full range of multi-layer designs

studies regarding the applications of mul-

will continue throughout the foreseeable

ti-layer fabrics.

future. Voith Fabrics will continue development work for all types of fabrics.
25

50

75
100
125
Abrasion Index

150

175

However, the key to a fabric’s success isin choosing the correct application.

Fig. 7: Fibre Support Index (FSI).

To identify the most suitable fabric forFig. 8: Paperside Sheet Support.

any machine requires a knowledge of thefabric, the machine variables, and theFig. 9: Thickness.
Fig. 10: Void Volume.
Fig. 11: Wearside Abrasion Index.

customer’s key objectives. Voith Fabrics
uses techniques such as the “Assist Program” to quantify the current situation on
the machine. The acquired data is used in Double-layer (Double-layer) Extra-wefted Triple-weft Triple-layer (Triple-layer) Self-stitcheddiscussions with the customer to determine the most suitable fabric for theapplication.

52

Seam Press Fabrics from
Voith Fabrics –building on two decades of continuing
technological evolution
In North America, seam press fabrics are

Seam press fabrics have evolved
dramatically since their European beginnings two

dominant in board and packaging grades.

decades ago. Their use has spread rapidly out of

Even for graphic applications, the number

the board and packaging sectors, where theof machines using seam press fabrics istechnology was initially applied, into a broad

approaching 50%. In Europe, many board

customer base ranging from graphics to tissue.

and packaging machines now regularly
use seam fabrics, although acceptancehas been slower on graphic grades. Nevertheless, the trend is beginning to accel-

Many mills, primarily in North America,

erate in Europe as the newest seam tech-

have realized that, in addition to easy,

nologies from Voith Fabrics can eliminate

quick and safe installation, improved

seam marking, even on the most criticalpress

grades.

performance

could

also

be

achieved. Seam fabric base constructions

The authors:
Dan Aldrich,
Mike Mason.
Voith Fabrics

are made from 100% monofilament yarns

Voith Fabrics’ advances in seaming tech-

and are stiffer and more “open” than theirniques, batt flap design, needling proce-endless counterparts. They can provide

dures and base construction have extend-

higher void volume, enhanced water flow

ed the benefits of seam press fabrics

and more resistance to compaction in theto the most prestigious graphics papernip.

They also result in easier cleaning,machines in North America. Notably,

better water handling, higher dryness out

Voith Fabrics supplied the world’s firstof the press, reduced shadow mark andsuccessful installation on a high speed

increased speed.

LWC machine shoe press.

1

Old technology Seam
Uncoated Fine Paper
2nd Press, 850 m/min,
31 days

New technology Seam
Same machine
2nd Press, 850 m/min,
32 daysFig. 1: New seamtechnology comparedwith traditional
technology shows
greater flap coverageof the seam even after
running a longer
lifetime.

Fabrics

53

Fig. 2: New technology seam fabric after running
44 days on a 1050 kN/m (6000 pli) shoe press.
Fig. 3: Seam press fabric use in North America
has increased dramatically in recent years,
saturating the packaging and board grades fabricmarket and now being used in nearly half of thegraphics paper machines.

Driving forces

With early seam fabrics, cutting of the

The driving forces for seam fabrics inneedled batt to expose the base fabricEurope today are focused primarily on

loops resulted in a tendency for the battreduced downtime and above all, on theflap to peel back and wear away from thesafety issue. Modern paper machines

seam area as it passed over Uhle boxes

have low manning levels, which meansand other abrasive machine elements.

the mills do not have a lot of people

This sometimes led to seam marking

available to change clothing. Thus, seamproblems and early fabric failure. The

fabric installation is well suited to today’s

way in which the seam flap was cut has

paper machine manning practices and tosince

the overriding need for safety.

beenchangedandimprovedneedling techniques, chemical treatments
and use of low melt materials have enhanced the fiber bonding in the seamMarket Applications – by Gradearea, resulting in a much stronger, wear
Press fabric usage in general has de-resistant flap as shown in Fig. 1.

clined in recent years due to consolida-

2

3

100

80
Machines using Seam Fabrics
in North America (%)

Evolution of Seam Fabric Technology

60

40

20

0

By the late 1990s, the base fabric used intion of papermaking capacity in conjunc-

seam press fabrics evolved into a muchtion with the fact that modern fabrics

more durable structure. Better materials

have a longer operating life than even

were used to make seam loops stronger,

those of five years ago. Yet the propor-

are running them. Inroads are being

stiffer and shorter, all but eliminatingtion of seam fabrics is continuing to in-made into tissue and toweling, after sig-

seam marking and loop failure.

crease. In North America, about 40 % ofnificant results have shown improved

Voith Fabrics’ press fabric output is in

runnability and water-handling. Some

As more and more machines started toseam designs, and it has an estimated

10 %-15 % of North American tissue ma-

use

were

28 % share of the world seam fabric mar-chine press clothing is seamed.

achieved on tougher and more demand-ket. Voith Fabrics’ average annual growth

ing positions, including shoe presses.

rate for seam fabrics has been more thanFig. 4 shows Voith Fabric shipments ofFig. 2 is a photograph of a new technolo-

10 % since the mid-1990s.

seam fabrics for graphics grades (includ-seamfabrics,

successes

gy seam fabric after 44 days on a

Board & Newsprint
Packaging

Fine
PapersTissue &Toweling

ing newsprint) in the U.S. from October

1,050 kN/m shoe press. Few positions

As shown in Fig. 3, some 80 % of board

2000 through June of 2001. During thatare considered unsuitable for seams withand packaging grades in North America

period, the trend toward increased seam

this advanced technology.

(concentrated in the U.S.) are using seamfabric use in graphics grades continued,

fabrics today. Approximately half ofparticularly

North American newsprint machines andwith some 1,051 units (180 ton) being

roughly 40 % of its fine paper machines

shipped to uncoated fine paper machines,

inuncoatedfinepapers54

MD

Fig. 4: Voith Fabrics’ shipments from October2000 through June 2001 reflect the continued
increase in seam press fabric usage on graphic
paper machines in the U.S.

CD

Fig. 5: Percentage of Graphics machines in
Europe using seam press fabrics in one or morepositions.

7Fig. 6: Vector Cross Section.
Fig. 7: Vector Tri-Axial technology.

conventional woven technology

4

Endless 59%

Seam CoatedPubl. 4%current axial technology

Vector Tri-Axial technology

385 units (107 ton) to newsprint ma-

fabrics over a blind drilled roll coverchines, and 154 units (25 ton) to coatedclearly show the marking from the holes.

publication paper machines.

Using a seam fabric, the roll cover marks
barely show, if at all. The seam fabric’s

As Fig. 5 shows, the switch to seam fab-

stiffer base provides a more uniform

rics in the graphics paper sector haspressure profile to the sheet.

been slower in Europe, with only someSeam News 10%

Seam
Uncoated
27%

29 % of machines (including newsprint)

A modern seam fabric, with its high void

currently running them in at least one

volume, handles water much better thanpress position.

traditional endless constructions. A seamfabric’s compaction resistance, higher
5 % -10 % ofvoid volume and lower flow resistance allother graphics grade producers in Europe

add up to increased water removal,

use them at the moment, and again, most

longer lifetimes and improved sheet qual-of these applications are on the medium

ity, as well as ease of cleaning. The result

to smaller, non-cantilevered machines.

is significant production gains throughExcluding newsprint, only
5

Endless 69%

higher sheet dryness out of the press.
European growth on the larger machines
is currently concentrated in the newsprint
sector, chiefly because this is a less

Safety Benefits

mark-sensitive grade, but also because
Seam 29%
Trials 2%

newsprint tends to be a slightly tougher

Recent UK legislation places heavy em-

sheet than, for instance SC or LWC

phasis on the risks related to press (andgrades.

forming) clothing operation and installation. Even where a mill has a fully cantilevered machine, changing press and6sheet side batt

Performance, Production Gains

Vector layer
any woven baseroll side battforming fabrics can be a strenuous, timeconsuming and dangerous process.

The single monofilament yarns used inseam press fabrics provide the best com-

The UK HSE measures are now being

paction resistance of any of today’s

considered for implementation as an EEC

woven designs. Besides this significant

standard. They are likely to be released

benefit, a seam press fabric also provides

within two years (EN 1034). Seam fabrics

exceptional masking characteristics. Nip

will answer some of the safety issues

impressions made with standard endlessraised by these standards.

Fabrics

55

VectorParenco saves time and
The new Vector design, unique to Voith

improves safety

Fabrics, is available in endless and seamversions and has the potential to become
the market leader due to its excellent sur-

The Parenco mill near Arnhem, Nether-“The endless pickup fabric was very

face characteristics, pressure uniformity

lands, has been using seam press fab-large, stiff, and difficult to handle. We

and water handling capability.

rics on its No. 2 newsprint machine forusually had to impregnate it with a soft-

approximately three years. Seam fabrics

ening agent to get it through the open-

As seen in Fig. 6 and 7, Vector is a com-were used first in the pickup position,

ings in the non-cantilevered frame,” hebination of a standard base fabric (or fab-followed shortly afterwards in the bot-notes.

rics) and a non-woven “tri-axial” layer

tom position of the first press. The mill

onto which batt is needled. Vector de-operates

producing

Seam fabrics in the bottom position ofsigns are ideal for seam fabrics because

newsprint and SC paper grades. PM 2 isthe first press have significantly simpli-

the tri-axial layer covers the seam area so

9.1 m wide operating at 1300 m/min

fied the installation process and cre-well, giving the most effective prevention

and has a production capacity of

ated a much safer environment forof seam mark of any

260,000 metric tpy.

employees. Mr. Keizer explains, “Withfabriccurrently

twomachines

seam fabrics, workers don’t have to go

available.
According to René Keizer, assistant mill

inside the machine anymore. We don’t

The Vector product line was launched inmanager, the mill switched to seam fab-have to open up rolls, nips, etc. Partic-

North America in the summer of 2001,

rics on the non-cantilevered PM 2 toularly with the endless bottom fabric,

and is rapidly being accepted by brown

improve safety and shorten installation

we had to shift some guide rolls, whichand graphic grade machines at the high-time, which had taken about five hours

we don’t have to do now.” The mill is

est speeds. Within the period of six

with an endless design in the pickup po-

also getting longer operating life. “Wemonths, 46 machines are already runningsition. This has now been cut to lesswill never go back to endless pickup

Vector seam fabrics with another 127 tri-

than two hours with seam fabrics.

and bottom fabrics” he insists.

als in hand. To date, the product has had
a 100% success rate and will be launchedin Europe in early 2002.

56“The Big One!” – shop assembly of a
Janus™ MK 2 calender for SCA Laakirchen
in Krefeld

1

In autumn 2000, SCA Laakirchen /Austria

Scope of supply for the finishing lineordered a production line from Voith Paper for
240,000 t.p.a. of SC-A paper, including an offline

Apart from the Janus MK 2 offline calen-

Janus™ MK 2 – the world’s largest calender of thisder with 10 rolls, the Voith Paper Krefeld

type.

GmbH scope of supply also covers an unwind and a rewind for paper rolls having
Due to the unprecedented size and

The author:
Martin Deitel
Finishinga width of 8,920 mm and 3,400 mm dia.,

component weights of this Janus™ MK 2 calender,

both equipped with a flying splice system

the shop assembly phase described here was an(Fig. 1).

extremely challenging task for the Krefeld erection
team.
Shop assembly procedure
Complete shop assembly is the best wayof ensuring trouble-free site erection andWith such large dimensions – each ma-

commissioning afterwards. This article explainschine stands 15 m long and weighs 65

the reasons why, and also takes a look at future

ton – the required welding and machining

development trends.

work clearly placed high demands on the
Krefeld erection crew (Fig. 2).

57

Finishing

2

3

Fig. 1: Janus™ MK 2 with un- and rewind section
including flying splice.
Fig. 2: Shop erection of the machine frames.
Fig. 3: Assembly of the roll bearings andhydraulically operated carrier arms.
Fig. 4: Frames erection with in-house and mobile
cranes.
Fig. 5: Erection of the pipe racks and stairways.
4

5

For detecting any interference points, theframes and upper cross beams were precisely aligned in exactly the same way as
they would be on-site. Subsequently, theinner traverse platforms, the pipe racks
on both the drive and tender sides andthe fixed or movable stairways on bothsides were assembled (Fig. 5).

Shop assembly started by installing theabout 100 ton each. A 250-ton mobile

In conjunction to this, assembly work

various modules and units, both for the

crane was therefore required to turn thecontinued around the clock on the cross-calender and for the upstream and down-

pre-assembled stands from the horizontal

machine components such as doctor

stream winding components. All theinto the lateral upright position (Fig. 4).

blades, steam moisteners, paper-rolls,

guideways, levers, top, bottom and inter-

Each upper stand pedestal is mounted on

top and bottom Nipco rolls, CeraCal-cov-

mediate bearings, cylinders and rolla standard foundation module made up ofered hard thermo-rolls and the intermedi-

retractors were pre-assembled, ready forseveral concrete blocks that can be ad-ate calender rolls with Saphir-S covers

installation on the frames (Fig. 3). Thisjusted to the calender size according to(Fig. 6).

increased the weight of each stand toorder.

58

Fig. 6: Installation of the rolls.
Fig. 7: Final calender assembly.
Fig. 8: Roll change testing.
Fig. 9: Completion!
Fig. 10: Machine frames with assemblies readyfor transport.
678much more rapidly and efficiently in thework-shops, thus reducing the risk ofhidden deficiencies and ensuring greater
product stability.
Another big advantage, certainly for thecustomer, is that site erection and commissioning times are significantly reduced by eliminating the need for structural changes and on-site optimization.

Although installation of the roll steam

Risk minimization thanks to shopmoisteners and paper-rolls largely com-

assembly

Apart from these objective aspects, there
is also a psychological advantage: “fin-pleted the mechanical assembly work,
there still remained a good many details

Shop assembly not only covers the com-ishing the job” brings a sense of attain-such as installing the rotary joints,

plete installation of machinery and units

ment and enhances product identification

lubrication systems, safety covers, etc.

(components), the precise alignment of

among the design and production team(Fig. 7). At the same time, the electrical,

all frames and pedestals and verified(Fig. 9).

hydraulic and pneumatic installations forcompliance with the site interfaces, but

all units were completed as far as possi-

also incorporates mechanical testing in-

Shop assembly is time well invested, as

ble.

cluding interference checking and adjust-shown in this case by the customer’s ap-

ment of all components.

preciation during regular inspections,

Shop assembly was followed by carrying

particularly close to completion. On-site

out operating tests on the various units,

problems are kept to a minimum and cansuch as roll changing (Fig. 8), doctor

Reasons for the Krefeld shop assembly

be corrected fast and easily together withblade adjustment and replacement, paper-

policythe customer’s team.

roll changing with a special traverse, roll
retraction hydraulics, cross machine plat-

There are various reasons for pre-assem-

form commissioning, etc. All these tests

bling such complex installations in thecommenced exactly on schedule, and all

Krefeld shops:
With ongoing technical progress and thewere successfully completed according toplan.

Prospects

To optimize design and quality, all errors

greater complexity of plant and machin-must be identified and systematicallyery, installation and control system effort

Adopting the same procedure, the un-eliminated whether in design, materials

will continue to rise. For this reason shopand rewind system was also completely

or manufacturing. Furthermore, particu-

erection in the future will involve muchpre-assembled, installed, and compre-

larly in the case of technical innovations,more than mechanical assembly: compre-

hensively tested using a reelspool provid-

all components must be optimized byhensive system installation and pre-com-

ed by the customer.

thorough testing. All this can be done

missioning will also be required.

59

9Short-term target for tomorrow

The substantial efforts in pre-erection al-

Technical data of the Janus™ MK 2 calender

low shorter site-erection, installation and

Production speed

1,300 m/min

start-up times to the benefit of our cus-

Maximum speed

1,500 m/min

complete piping system assembly includ-

tomers. Prerequisite for a successful re-

Maximum line force

500 N/mm

ing flushing, the wiring systems, I/O andalization of this ambitious goal is the

Thermo-roll temperature

150 °Csoftware checking, full operating tests

availability of a committed and dedicatedMachine frame spacing

10,360 mm

and pre-commissioning of the hydraulics

team, delivering high quality machines to

Height11,680 mm

and pneumatics units, doctor blades, etc.

our customers.

Length

10,460 mm

Our short-term goal is to develop this po-

As apparent from the above description,

Production datatential for more comprehensive shop as-

Voith Paper Finishing in Krefeld, meets

Paper grade

SC-A +

this goal.

Basis weight

54 g/m 2

Annual output

240,000 t

Web width

8,920 mm

paper machines, pre-erection is not as

Max. paper roll weight

100 ttime-critical as with rebuilds. For a calen-

Max. paper roll diameter

3,700 mm

Not yet included in shop erection are thesembly.
For new installations such as complete

der replacement, for example, every dayof a shut down saved reduces financial
losses.

10

60

Polyurethane Roll Covers –a technological overview

1

There are two basic product groups of

Aqualis – PolyDyne – G2000 design

Voith Paper polyurethane roll covers: Aqualis, (PolyDyneSR), PolyDyne and G2000, forWith few exceptions, all roll covers used

use in paper machine press sectionsin the wet end are designed for the press PolyMate, for dry applications, mainly reel andsection. They all have a very similar mul-

support roll covers.

ti-layer construction comprised of a composite fibre-plastic base layer, the uniqueA special-purpose product for marking
The author:
Dr. Michael Wokurek,
Servicepresses in cigarette paper production is the ultra-

AST bonding layer and the polyurethane
surface layer (Fig. 3).

hard HTP-1100 roll cover (Fig. 2).
The reinforced base layer provides outstanding bonding to the metal core, highstrength, and excellent resistance to water and chemicals even at high temperatures. This exceptionally sturdy design
ensures optimally reliable operation andminimizes accidental damage in case of
mishaps.
One of the worst examples of such damage experienced so far was a suction
press roll core fracture, which was onlyService

61

Fig. 1: Suction press roll.
Fig. 2: Product overview.
Fig. 3: Cover structure.
Fig. 4: Peeling resistance test.
Fig. 5: Fracture section through polyurethane/base layer.
Fig. 6: Cover damage caused by steam box.
Fig. 7: AST bonding in damage zone.
2
Product

Operatingenvironment

Loading

Hardness(P+J)

SurfacedesignApplications

Aqualiswet

high5, 10, 15

S, BD, G, P

Suction press rolls

PolyDyne

wet

high

5, 10, 15

BD, G, P

Press rolls

G2000

wet

very high4

BD, G, P

Press rolls

HT 1100

dry

medium0 (82 ShD)P

Filigree press rolls

PolyMate

dry

low

5…50

P

Reels, support rolls,

3
Polyurethane
operating surface
AST
Base layer
InterfaceCorerewinders, …

4

5

6

7

apparent from extreme eccentricity andconfirmed by inspecting the roll interior:the cover surface remained unaffected.
The unique AST bonding layer is muchstronger and hydrolysis-resistant thanany other adhesion system (Fig. 12). This
is attributable to powerful chemical binding, phase mixing between the base andsurface layers and waterproofing withspecial fillers.
The strength and water resistance of the
AST bonding system is even higher thanthose of the individual layers, as shownby the complete absence of adhesion
ruptures in destructive testing (Figs. 4
and 5).
Impressive proof of the AST bonding layer strength was provided by a case ofcover damage due to badly adjusted suction press roll steam boxes. Although
the polyurethane surface was completely

62

Fig. 8: Drainage paths.
Fig. 9: Surface with blind holes.
Fig. 10: Fluted surface.

8

9

10

destroyed by hydrolysis, the bonding to

web drainage is far more homogeneous.

with the same drying capacity. Further

the base layer remained virtually intact

Furthermore, this innovative surface de-benefits of polyurethane roll covers in-(Figs. 6 and 7).

sign optimally utilizes the effective water

clude significantly longer felt life andstorage capacity of the blind holes with-conditioning advantages, when compared

The surface layer normally comprisesout building up additional hydraulic pres-with an uncovered operation. In generalpolyurethane materials on a poly-THF

sure. This reduction also delays cover

the softer nip always has a positive effect(PTMEG)

compaction and thus improves mean flowon drainage and paper quality. The result

resistance.

is extremely gentle drainage, with lessbasis.

These

PU

materials

uniquely combine high strength with out-tendency to marking and crushing.

standing elasticity, exceptionally goodwear resistance and excellent resistance

The advantages of the new Aqualis

to hydrolysis. They are the best poly-drainage concept are proven in practice,urethane materials available for this pur-as reflected by the more cost-effective

pose at the present time.

operation of Aqualis roll covers.

G2000 – the tough press roll cover
The G2000 press roll cover is even

Compared with rubber coatings, the hightougher than the standard covers Aqualismaterial strength enables practically un-(PolyDyne SR, for suction press rolls)

The Aqualis – PolyDyne – G2000

limited combinations of holes and groov-and PolyDyne (for press rolls). The main

drainage concept

ing with up to 45% free surface area

advantage of the G2000 polyurethane ma-(Figs. 9 to 11), as well as outstanding

terial is its far lower heat development

Nowadays, optimal computer-aided sur-durability. In many cases the optimized

under fluctuating loads (less flexing fric-facing design saves up to 50 % of thesurface design has solved perforationtion). This enables its use in presses withdrainagerequired

imprint problems and also increased dry

extremely high dynamic loading, where(Fig. 8). This significantly reduces surface

content. The advantage of the latter is ei-

so far only grooved steel rolls were pos-

flow resistance in all directions, so thatther lower drying costs, or higher output

sible. These usually comprise high-speed

ductingpreviouslyService

63

Fig. 11: Surface fluted and with blind holes
Fig. 12: Hydrolysis resistance of binding systems.
HT 990 (BKU binding)
PolyDyne 5 (AST binding)Peeling resistance [N/Inch]

12

11

800

600

400

200

0

0

2

4

6
8
10
Hydrolysis duration at 70 °C [weeks]

12

14third or fourth stage presses with small

felting or roll cover changes must there-

Further potential lies in the development

roll diameters and high line forces. The

fore be carried out jointly by both prod-of polyurethane covers for sizing rolls,

primary advantages here are much longer

uct specialists.

mainly requiring high surface quality, homogeneity, and resistance to damage andfelt life, less vibration and less crushing.

melting.

This material is also much more heat resistant than the standard covers, i.e. its

Future potential and prospects
Development work is also underway on

melting point is higher. This is very important in the case of felt failures, be-Several other promising applications forpolyurethane covers for paper-rolls in thecause melting of the cover material is de-polyurethane covers are currently under

wet end. The special challenge here is tolayed long enough to prevent serious

development or in the field trial phase.

produce a high quality yet cost-effective

damage. The G2000 is also ideal for use

This particularly includes the applicationroll cover, meeting the respective require-in felted shoe presses.

of Aqualis and PolyDyne roll covers forments for corrosion protection, water andtissue machines, requiring the develop-

heat resistance and doctoring.

ment of softer covers with very highresistance to hydrolysis and heat.

Press optimization
Due to the high complexity and interdependence

of

the

variousdrainageprocesses in the press nip, neither perfect roll cover design nor optimal felting
alone

guarantees

the

best

possibledrainage. Only optimal balancing of thetwoelements

ensuresthehighestdrainage efficiency in the press nip. Any

64Strong Partnershipfor a market with a future
Voith is not an unfamiliar name inphasized by the Beijing Representative

China’s paper industry, or in Chinese industry as a

Office opened some time ago, the newwhole for that matter. This traditional partnership

Voith Siemens Hydro works in Shanghai,

goes back a long way. For three-quarters of a cen-and the Voith Turbo drive systems plant.

tury in the Middle Kingdom, Voith machines have

As one of the most important members of

been a hallmark of quality “made in Germany”.

Voith Paper Technology, Voith Fabrics

Not long ago yet another Voith installation – built

has a large manufacturing facility in Kun-in 1929 – was modernized for further decades ofshan near Shanghai for former wires,

dependability.

press felts and dryer fabrics. It is therefore logical to expand Voith’s presence at

China’s successful economic policy andthe growing industrial centre of Shanghai

intensive industrial expansion has revital-

with a Voith Paper location.

ized this long-term partnership.
Shanghai Service CenterNot only is Voith involved in China’s mostThe author:
Martin Scherrer,
Serviceambitious power project, with water tur-

The first step in this direction is to set upbines for Sanxia hydro station, but also

an efficient service center. Detailed plan-with drive and traction systems for indus-

ning is almost complete, and construc-trial installations, rail and road vehicles.

tion work will start in April 2002. At the
beginning of 2003, the machine tools andVoith’s partnership with the Chinese pa-

testing equipment will be installed, so

per industry is particularly fruitful. The

that by April 2003, the service center

delivery of powerful new machinery is ac-

should be open for business after only

companied these days by a higher degree

twelve months of construction.

of know-how transfer, and Chinese subcontractors are increasingly included.

With 5,500 square meters of floor areaand 700 m 2 of office space, the new ser-

Voith’s commitment to China is long-term

vice center is designed to meet all futureoriented. Voith is on the spot! This is em-

needs. At first, the service offered will

Service

65

Voith Paper Liaoyang

BeijingVoith Paper Representative Office
Voith Paper Service Shandong

Voith Fabrics Kunshan

Chinamainly include comprehensive roll servic-

Shanghai

Stronger Engagement in General

Voith Paper Service Shanghai

Voith Fabrics will be significantly expanding production capacities in Kunshan, ex-ing, with machining capacities up to 100
tonnes roll weight, 15 m length and 2 m

Since 1999, Voith Paper machinery start-

tending the line of products, offered so todiameter. Covers and coatings will be

ups and orders in China represent a pro-also improve exports from China soon,

available in rubber, polyurethane, com-duction capacity of well over two million

not only to other Asian markets, but also

posite high-tech and ceramic. Complete

t.p.a. in a wide range of grades. Including

to North America and Europe.

service facilities will also be provided forthe capacity of previously installed ma-

deflection compensating rolls.

chinery, the importance of the Chinese

In the past, the market for stock prepa-

paper industry as a Voith Paper customer

ration lines in China and several otherbecomes very apparent.

countries has been served by Andritz. In

The purpose of this investment is toview of the growing customer preference

deepen our partnership with the Chinese
paper industry and to cut roll servicing

For this reason, Voith Paper is founding afor complete single-source installations,times drastically for the benefit of Voith

new company in Shanghai specialized inincluding overall responsibility for opti-

Paper customers. Clearly, a good manysourcing and assembly. Speed, flexibility

mal process technology from pulper tocompanies have been waiting for someand cost-effective procurement are only

reel, Voith Paper will be terminating thistime to have their roll servicing and cov-

some of the reasons for this. Anothercooperation with Andritz as of June 30,

ering, overhaul and grinding work done

reason is our corporate policy of trans-

2002. In the future, all stock preparationin China.

ferring an appropriate portion of value-

needs will be covered by Voith Paper in

added to the country where Voith Paper

China, including service and spare parts

earns a good deal of its income.

for the systems previously provided byAndritz.

Another Service Center inShandong Province

In this connection, cylinders and dryer
section components are already being“We want to move ahead with our lead-A thousand kilometers north of Shanghai,

manufactured in Liaoyang – proving thating technology in the Chinese market, of-the paper industry in the Shandong

with intensive know-how transfer, close

fering an outstanding performance wor-

province has substantially increased its

teamwork, systematic quality manage-

thy of our reputation. We want to be evencapacities. This increase has also createdment and certification, Voith’s globallymore so a long-term partner to the Chi-a need for local professional roll servic-

accepted production standards can benese paper industry, rather than merelying.

met in China for selected components.

exporting from Europe to China. By cre-

Additional companies will be included inating jobs in China, we want to uphold

this cooperation policy.

and increase the prosperity of this coun-

True to the Voith philosophy of being

try and its people”.

conveniently located, Voith Paper will,
therefore, be opening an additional ser-

To ensure perfect coordination of tech-

vice center in this region. The main em-

nology, service, sales, customers andThese were the words of Hans Müller,

phasis here will first be on roll machining

suppliers, the Voith Paper Representative

Managing Director of Voith Paper, at theand repairs, but additional services will

Office in Peking will also be transferred

new service center project presentation in

be added later on according to demand.

to Shanghai.

Shanghai.

66

China Paper 2001 –Process & Progress
The tenth China Paper and Forest
Exhibition in Beijing impressively showed theprogress made by China’s paper and board industry
in only one decade. There is still no sign of any
slowdown in China's headlong but systematicadvance toward an international market standing,appropriate to its size and global significance.
Accordingly, great interest was shown at thisThe author:
Frank Opletal,
Beijing Central
Representative Office

exceptionally well attended trade fair in the latest
paper technology developments and current trends
in integral process solutions.

67

Voith Paper’s status as a dependable

This situation was similar at the press

ment, particularly in the paper industry.

partner to the Chinese paper industry isconference, with every available seat tak-With the growing sophistication of tech-reflected in our production plants anden. Here the Voith Paper management,

nology, increasingly professional service

local service centers in the People’s

represented

Sollinger,

is required. And further production ex-

Republic. This high commitment was un-

Otto Heissenberger and Lothar Pfalzer,

pansion will soon bring new challenges,

derlined at the country’s most importantanswered a barrage of questions assisted

demanding specific solutions – for exam-

trade fair by a new exhibition stand, new

by Martin Scherrer and Ming Ming Liuple, in raw materials procurement.

information media and publications – allfrom the Voith Paper China Representa-

in the local language. No wonder thetive Office. Main interest was in the new

The enormous investments of recent

Voith Paper staff could hardly cope withservice center and production expansion

years already raise the questions of how

all the questions and the rush for infor-

in China (see report overleaf).

to ensure enough raw materials supplies,

byHans-Peter

which technologies to use for recycledmation and brochures. Indeed, the Voith
Paper stand had to be barricaded off at

Voith Paper is taking account thereby of

paper processing or for greater use oftimes for the sake of public safety!

China’s

fast-growing annual plant furnish.

expansiveindustrial

develop-68

During the Voith seminar, ten of our

The conference centre remained almost

industry in singing Chinese-English Kara-

staff informed the numerous customers

completely full right into the evening

oke together.

present about the latest technologies

hours.
This one-week trade fair in Beijing up-

and solutions. Papers were translated forthe attentive audience by the Mill AccountAt the traditional VIP dinner held on theheld our contacts and intensified themand Mill Service managers of the Voith

last night, Chinese government officials

through new inspiration. China has an

Paper

and

heartily

exciting future, and Voith Paper intends

applauded the harmony found between

to play a full role in this process with on-

Voith staff and guests from the paper

going progress.

Beijing

CentralRepresentative

Office and Voith Fabrics Kunshan office.

Germanembassy

staff

C

O

RP

S

69

O R AT E N EWFounding of Voith IHI Paper Technology, JapanOn the left:
Mr. Takeo Nakazawa,
President Voith IHI,
with the Voith IHI
Paper Technology
management team:
Mr. Yuji Kose, Bernhard Müller andMr. Hideo Joshida.
On the right:
Hans Müller, President
Voith Paper, andMr. Shozo Ojimi talking
with a customer.

On June 6, 2001 the founding ceremonyof Voith IHI Paper Technology Co. Ltd was held in
the Golden Room at the Palace Hotel, Tokyo. Morethan one hundred invited guests from the Japanese

Below: Welcome
address by Masao
Kobayashi, Chairmanof the Japan Paper
Association.

paper industry brought good wishes for the newcompany – an encouraging start into a promising
future on a new basis.

After more than twenty successful years

The participation of IHI and Voith Paper

as a Voith Paper Technology licensee, IHI

in this joint venture are initially 70% and(Ishikawajima-Harima Heavy Industries

30%, respectively. Voith will manage theCo., Ltd.) has now formed a joint venturebusiness and plans to increase its partici-

with Voith Paper for machine-building,pation accordingly in the future. The joint

erection and after-sales services in stock

venture incorporates all the independent

preparation, paper machinery, coatingstock technology know-how of both part-and finishing. The Japanese paper indus-

ners, Voith Paper Japan and Ishikawajima

try – one of the world’s largest and mostIndustrial Machinery. Sales activities intechnologically demanding – will thus re-

the Japanese market are the exclusive

ceive even better support with papermak-

responsibility of Voith IHI Paper Technol-

ing equipment and service.

ogy, while export sales of the new jointventure company will be handled by theVoith Paper global marketing organization. Voith IHI Paper Technology currently employs 100 people. Company headquarters are located near the Tokyo central rail station.

70

Finckh becomes Voith Finckh Fiber Systems

As already published in the paperindustry magazines, Voith acquired the shares ofHermann Finckh Maschinenfabrik GmbH & Co.,
Pfullingen, Germany in October 2001.
The products of the traditional company
Finckh ideally supplement the productrange of Voith Paper’s Fiber Systems
Division. Finckh is well-known as a leading manufacturer of screen baskets andscreen plates for the paper industry.
Together with Finckh, Voith Paper is now
able to offer the complete product rangeof screen baskets and screen plates fromone source, whether perforated, slottedor milled, as well as wedge wire typescreen baskets (C-bar™).
A company that has been active inscreening technology as long as Finckh
can, of course, also contribute a numberof additional synergies in the joint development of screening technology for the
future. Combination machines, such as
the CYCLO™ unit or horizontal screens,now complement Voith Paper’s existing
range of products.
In addition, there are other Finckh products also of strategic importance for us.
With its system of soaking – mixing –screening, Finckh possesses extensive
process knowledge in the field of drum
pulping. Voith Paper will apply this know-

The management teamof Voith Finckh Fiber
Systems: (from left toright) Jochen Pfeffer,Manager, Sales;
Bernhard Wandinger,
Managing Director;
Erich Czerwoniak,
Manager, Technology.

how in the application of the TwinDrum™
for raw materials that are easy to pulp
down.
Using Finckh’s expertise in honeycombtype designs, Voith Paper’s range of paper machine components is now supplemented by dandy roll equipment, forming
and couch rolls, as well as cylinder moulds.
With the acquisition of Finckh, approximately 120 additional employees havejoined the Voith Group, the majority aresituated in Pfullingen and some in theUSA.
The first joint project discussions have
not only shown that the Voith Paper andFinckh products complement each otherperfectly, but also – and this is actually
the more important point – that theteams harmonize together very well. This
comes as no surprise since Pfullingen is
only about two hours’ drive away fromboth Ravensburg and Heidenheim.

Picture sequence at
top: (from left to right)
fold-design drum
thickener, screenbaskets and screen
plates, dandy roll inhoneycomb design.

Corporate News

71

Voith Paper acquires dewatering product linefrom KvaernerFrom left to right:
Dag Ivar Caspersen,Manager, Sales andProject Management;Pål Bendiksen, Manager,
Product Development;
Lars Smedsrud, ProductManager, Dispergers;
Morten Haga, ProductManager, Screw Presses;
Even Gulowsen,Manager, Finance andAdministration; Terje
Fjellkleiv, ProductManager, Disk Filters.

Yet another important acquisition ofenormous strategic significance has been completed within the Voith Paper Fiber Systems
Division almost simultaneously with the take-overof Finckh, – the purchase of the Recycling and
Dewatering Division of Kvaerner Pulp and Paper,
Norway.

With effect from November 30th, 2001,
all previous activities as well as the complete know-how and in particular all employees have been taken over by Voith
Paper. The Centre of Product for dewatering is now Voith Paper AS in Lier,
Norway, where approximately half of the
60 employees are located. The others are
employed at the locations in Charlotte(USA) and Laval (Canada) and have been
integrated into the organizational structure of Voith Paper Fiber Systems in
North America.
This acquisition complements the Voith
product range, especially in dewatering,where Kvaerner is the world’s leader forscrew presses and disk filters for thepulp and paper industry. Voith Paper has
thus extended its product range withequipment of high strategic importance,
and at exactly the right time, now thatthe co-operation with Andritz will cometo an end. The desired co-operation with
Kvaerner FiberLine will, if not immedi-

Picture top left:
Two disk filters in a
newsprint mill.

ately, certainly be of importance in themedium term. As a process supplier, weneed to extend our knowledge of thecharacteristics of virgin fibres. In addition, both partners see interesting synergies for their products. Timing was thedecisive factor for the acquisition ofKvaerner Recycling and Dewatering. From
now on, Voith Paper offers a competitive
product line for thickening, dewateringand fiber recovery. We can now concentrate our know-how and fully dedicate ourefforts to the ongoing development of aproven product line.
After all the uncertainties the employeesof Kvaerner have had to endure over the
past few years, and even more so in thepast months, we could feel how relieved
the Kvaerner team was when the future
co-operation with Voith was signed andsealed. In the meantime, we have got toknow our new colleagues and find it apleasure to work with such friendly anduncomplicated people.

Picture below:
Christen GrønvoldHansen, Managing
Director, Voith Paper AS,
in front of two screwpresses in a kraftliner
mill in Sweden.

72

Off to a good start: Voith Paper Technology Ltd., India

Fig. left: Offices ofVoith Paper
Technology Ltd., India.
Fig. right: The Victoria
Memorial, Calcutta.

In April 2000, the long-standing licenceagreement between Voith Paper and Larsen &Toubro Ltd., India’s largest engineering andconstruction group, was transformed into the jointventure company Voith Paper Technology Ltd.,
India. A particularly good reference for the fruitful
teamwork leading up to this new company was
the “Tamil Nadu” newsprint line, commissioned in
1994 for bagasse furnish, a sugar cane residue
product.

Paper and board consumption in India,
one of the world’s largest and most heavily populated nations, is steadily growing
with ongoing economic development. Because of the shortage of primary raw materials and the technological resources
required for processing recovered furnish
part of this demand is still covered byimports. The market prospects for Voith
Paper are therefore very good, especiallywith the company’s know-how in processing fast-growing annual plant residues
and recovered paper. This joint venture
takes full account of future needs by further strengthening the partnership between Voith Paper and India’s paperindustry.

The new company offices in Calcutta are
directly opposite the Victoria Memorial.
All fifteen members of the team here haveyears of paper industry experience andmost of them have worked in our Heidenheim or Ravensburg facilities. They are
off to an excellent start, and have alreadybooked a number of attractive orders.
Apart from some smaller projects, thesenotably include two press rebuilds for“Tamil Nadu” where the machines will be
upgraded with the latest NipcoFlex technology.

A bright future
together: the Voith
Paper team in India.

73

P

A

PE

R CU

R
LT U

E

Quite something –the Emperor’s favorite wifeor the fascinating playof light and shadow
Paper, scissors, a quantity of Indian ink
and a source of light: that’s all one needs to put ona Chinese-Style shadow play in its simplest form.
Of course, such simple silhouettes and professional shadow play theaters are worlds apart. But
even the lavishly designed stages of the traditional
Chinese shadow theater and the productions ofmodern ensembles depend far more on the simple
effects of light and shade than on the use of costly
materials.

174

Unlike all other conventional theater
characters, the shadow-theater figure
could be said to be in hiding, revealing
only its outline to the audience. This ‘disembodied’ appearance gives it something
unreal, dreamlike, fantastic. Small wonder, then, that Chinese and other shadow-plays are only made for the presentation of fairy-tales, sagas and myths.
The shadow figure can grow into a giantor shrink to the size of a dwarf. Within
the twinkling of an eye it can be transformed from a human being into an animal; objects can appear and disappear,
clarity can dissolve into empty space.

Day and night, darkness and fire, brightand dark objects, light and shadow are all
elementary phenomena of the Earth. One
can easily imagine that from time immemorial humans have sat in front of awarm fire in the shelter of a cave andseen their own images as shadows or
dark silhouettes on the cave wall.

a allburning sun beating mercilessly 2
down from the sky.

The shadow is an elemental symbol of
the human psyche, showing, one could
say, the dark side of our existence. One
must, remember that in the colder regions of the world totally different associations are attached to shadows than inwarmer countries where the shadow is
the protector of life, offering shelter from

Something eerily outlandish, something
magical yet larger than life attaches tothe shadow, something incomprehensible
to our minds and reason. It is part of our
spiritual world. Mythologies in numerous
cultures depict the shadow as the domicile of the soul and the spirit: anyone
who has no shadow is dead.

Another phenomenon of the shadow is
the way in which it acts as our constantcompanion, our double. It follows us
silently, does exactly what we do – but
we never succeed in catching it.

Paper Culture

75

Fig. 1: Shadow-theater performer Norbert Götz
from Bamberg (Germany).
Fig. 2: A French-African co-production narrates
the African fairy tale “Sunjata”.
Fig. 3 to 5: Traditional shadow theaters in Asia –the figures and fabrics have remained almost
unchanged until today. (Fig. 3 China, Fig. 4 Java,
Fig. 5 India.)3

4

Origins of the traditional shadow play
Like paper itself, the birthplace of the
shadow play is in the Far East, thoughscholars argue over exactly where it first
appeared. China, India and Indonesia areconsidered as possible countries of origin, and of course it is conceivable thatshadow plays may have developed simultaneously from various roots.
The first written records from the Chinese Sung dynasty are about 1000 years
old, but the shadow theater’s origins almost certainly go back to a much earlier
date. Chinese mythology tells of a magi-

5

Fig. 6: Traditional shadow-plays in the Far East –Yasuaki Yamasaki: “The History of Du-Zi-Chun”.

cian who performed shadow plays around
100 BC, at the court of Emperor Wu.

That shadow plays emerged from thiscult can be regarded as certain.

The magician stretched a piece of cloth infront of a source of light and asked theEmperor to take a seat on the other sideof the cloth.

Even today, Indonesian shadow players
make a sacrifice to the gods before thestart of the play. These players have thestatus of a priest: they are invited to attend births, weddings and cremations,and to officially open a temple.

He then created a picture on the curtain
in which the Emperor was convinced that
he recognized his favorite deceased wife.
Numerous other records also refer tolinks between the cult of the dead andthe origin of traditional Asian shadow
theater.

In India, the play of light and shadow
also has its roots in religion. Parts ofboth the Remayana epic and the Krishnalegend are still performed in this way inSouthern India.

6

76

Fig. 7: German classic playwrightFriedrich Schiller in a “silhouette”
version.
Fig. 8: In 19th-century Paris the
shadow theater “Cabaret du Chat
Noir” was triumphantly successful.
Fig. 9: A cut-out by Ernst Moritz
Engert, the German expressionist,
dating from 1930.
Fig. 10: “Prinz Achmed” – a legendary figure by the German artist
Lotte Reiniger. She was the first
person in the world to make a fulllength animated shadow-play film. 879Chinese shadows in Europe

Black ink and white paper

For many years, European shadow plays
had only a secondary role to perform.
The technique reached Europe in the middle of the 17th century via the old traderoutes. However, to the Europeans, with
their one-sided intellectual approach, theintangible shadows meant very little. The
three-dimensional, “physical” character ofmarionettes and glove puppets appealed
more to them. The play of light and shadow spread through Persia, Turkey and theArabian cultural regions. The “ombreschinoises” (Chinese shadows) were initially referred to as “Italian shadows” inWestern Europe, indicative of the factthat the play had traversed the Alps via
Italy. Itinerant artists carried their stages
with them, and were able to easily set
them up almost anywhere. With figures
made of cardboard, parchment, string andwire, with cloth or paper as a sunshade
and with a suitable source of light, shadow theaters were extremely portable. In
due course, many such artists used the“laterna magica” (magic lantern), a precursor of today’s slide and film projectors.

In the mid-18th century, silhouette portraits became fashionable in France. Anyone who took pride in his or her appearance needed a portrait drawn in black ink
on white paper. A clever contemporary
even invented a special chair as a meansof ensuring an unquestionable resemblance between the silhouette pictures
and the persons portrayed. A frame witha glass sheet was attached to it and covered with greased paper. A candle threw
the light onto the paper in such a waythat the shadow was free from any formof distortion. The contours were traced
in, the inner area was filled with black ink
and in no time at all the resulting lifesize
portrait was finished. It could subsequently be scaled down by means of apantograph.
These black silhouettes on white paper
were not just popular in the drawing
rooms and salons of the upper classes.
In the 19th century, scientists tried to
draw conclusions on human characterwith the aid of this technique.

10

The “Theatre Seraphin” was founded in
Paris in 1772. A century later, the famous
shadow theater “Cabaret du Chat Noir”
achieved great triumphs. The all-roundgenius, Rudolphe de Salis, and thepainter, Henri Rivière, did not attempt tostage a major drama play with mobile figures. Their recipe for success was to fascinate the audience with impressive pictures accompanied by ingenious lighting
effects. With background music and daring texts, theirs was not slapstick but entertainment at a distinctly superior level.
European shadow theater celebrated its
heyday in the age of Romanticism. In
Germany Goethe, Brentano, Mörike,
Uhland and Kerner wrote and staged
shadow theater plays. At that time, playswith hand or body shadows and cut-out
silhouettes were considered by any bourgeois household to be in the best of
taste. In most cases, the early silhouettes
were cut out of white paper and glued toa black background.
Even in modern times, Polish farmers’
wives decorated their houses with col-

77

11

Festival on Voith Paper’s doorstep
In Southern Germany during the 1980s,
shadow player and teacher Rainer Reusch
decided to take stock of the shadow theater and its situation. He discovered thata few stages were still in existence. From
50 countries, he collected the addressesof more than 300 professional modern
shadow theaters, a figure to which numerous amateur stages had to be added.
However, the total is certainly below the1000 mark, whereas in Asia, according toexpert estimates, the number of traditional shadow stages runs in the tens of
thousands. During this research work theidea of an international shadow-theater
festival was born. In 1998 the world’s
only festival for contemporary shadow
play was launched in Schwäbisch Gmünd,
South Germany – on the doorstep ofVoith Paper, one might say. A year later,
the International Shadow Play Center was
founded in that town in cooperation withthe world federation ‘UNIMA’ (Union
Internationale de la Marionnette).

12

ored-paper cutout pictures. In China too,colored silhouettes are still very popular.
Fig. 11: Modern Frenchshadow theater – Luc Amorosand Michèle Augustin.

With the advent of film around 1900 –shadow plays can well be considered its
direct predecessor – the great days ofthis art form came to an end. In Europe,some stages eked out a more or less miserable existence as unfamiliar entertainment for children or a few enthusiasts. In
Asia, on the other hand, the shadow-play
tradition is still respected and cultivated.

Fig. 12: “In Xanadu” by
Larry Reed, USA.
Fig. 13: A razor cut by Prof.
August Holtgreve (Germany).
Our thanks are extended toReiner Reusch and theInternational Shadow Centerin Schwäbisch Gmünd formaking the pictures available.
13