Paper Technology Journal

News from the Divisions:
Engineering as the key competence.
Lang Papier PM 5 – 16 months ofsuccessful operation.
Schongau PM 9 – an investment
for the future.
New orders from the People’s Republicof China.

11

SAICA 3 PM 9 – fastest paper machine
for Corrugating Medium.
Nipco – 25 years of system know-how.
Paper Culture:
Another type of Global Player.

Contents

EDITORIAL
Foreword

1

Highlights

2

NEWS FROM THE DIVISIONS
Voith Paper Fiber Systems –not only a new name for the Stock Preparation Division

6

Fiber Systems: Engineering as the key competence
and main part of the services of Voith Paper

8

Fiber Systems: Official opening of the world’s most modern recycling line
for liquid packaging board

13

Fiber Systems: Super startup of the stock preparation and groundwood bleachinglines for PM 3 at Haindl Papier, Augsburg

14

Paper Machines: Lang Papier PM 5 – The new online concept for SC paper
16 months of successful operation

18

Paper Machines: The DuoFormer D – a success story

23

Paper Machines: Schongau PM 9 – Installation of the latest technology for new
SCB-Plus quality from 100 % DIP in 56 days … an investment for the future

28

Paper Machines: New orders from the People’s Republic of China

33

Paper Machines: Laakirchen PM 11 – a challenge for SC-A plus papers

36

Paper Machines: Procor – a challenge for Voith Brazil
New production line for corrugating medium and test liner

38

Paper Machines: Modern Karton – successful startup of high-techwhite top liner machine in Turkey

40

Paper Machines: SAICA 3 PM 9 – latest paper machine for corrugating medium

44“ahead 2001 – Challenge the Future
Comprehensive Solutions for Paperboard & Packaging

49

Paper Machines: New developments with the TissueFlex™

50

Paper Machines: Fibron Machine Corp. –Voith Paper’s total machine threading specialists

54

Finishing: Nipco – 25 years of system know-how concentrated in Krefeld

58

Service: The Cera Family – hard coatings for high demands

62

Voith Fabrics: Spectra – a family of composite press fabrics

66

PAPER CULTURE
Another type of Global Player

70

Frontispiece:
Heidenheim Fencing Centre,with participants in the
27. Summer Olympics
in Sydney – Schongau PM 9.

1

Dear Customer, dear Reader,
Since this is the first issue following the closing of our business year 1999 / 2000,
it is appropriate to quickly review the events during this period.
The Scapa plc Group’s integration is, for the first time, fully reflected in the Voith
Group’s consolidated figures and has had a correspondingly substantial and positive
impact on the overall business volume we perform with the Pulp and Paper Industry.
The strong growth, however, is not only due to acquisitions, but has also been
supported by the excellent demand for our well-appreciated core products andservices.

Hans Müller,
President and CEO
Voith Paper

Voith Paper and Voith Fabrics together had an order intake of 3,200 million DM(_ 1,630) and sales of DM 3,000 million (_ 1,530). The growth rate corresponds to an
impressive 30 %, when compared to the previous business year.
The past year has been particularly demanding for our Voith Paper team as we startedup a total of 15 new production lines representing a record number in the history ofVoith. These machines are equipped with new technology, such as the TQv former, theTandem NipcoFlex™ press concept and new former concepts for the board andpackaging industry. Also, the world’s fastest corrugating medium machine has been
started-up successfully and in record time.
Much of the confidence that customers show towards Voith is based on the allencompassing process know-how that the Voith team has amassed over the years.
This is also supported with a worldwide service network, which now includes
Voith Fabrics, that is second to none in the field of pulp and paper.
We want to take this opportunity to express our appreciation to our customers
worldwide and look forward to a continuing good relationship.

Yours sincerely,

Hans Müller
on behalf of the Voith Paper Team2

HIGHLIGHTS

Startup highlights in 1999/2000

Fiber Systems
Recovered paper stock preparationlines and systems for graphicalgradesSAPPI Fine Papers, Mobile, AL, USA.
Appleton Papers, W. Carrollton,
OH, USA.
Bowater, Catawba, SC, USA.
Kimberly-Clark de Mexico, Morelia,
Mexico.
Chapelle Darblay, Grand Couronne,
France.
Koehler, Kehl, Germany.
Rio Pardo Industria de Papeis e
Celulose, Santa Rosa do Viterbo,
Brazil.
Compania Suzano de Papel e
Celulose, Suzano, Brazil.
Fabrica de Papel Ledesma, Jujuy,
Argentina.
Condat, Le Lardin St Lazare, France.
Papierfabrik Hermes, Düsseldorf,
Germany.
Haindl Papier, Augsburg, Germany.
Norske Skog, Skogn, Norway.
SOPORCEL, Lavos, Portugal.
Papierfabrik Utzenstorf, Utzenstorf,
Switzerland.
Quena Newsprint Paper, Kous,
Egypt.
Gebr. Lang, Ettringen, Germany.
Daehan Paper, Chongwon, South
Korea.
PanAsia Paper Chongwon,
Chongwon, South Korea.
Aspex 3, Indonesia.

Recovered paper stock preparationlines and systems for board andpackaging papers
Paperboard Industries, Toronto,
Canada.
Papel Misionero, Misiones,
Argentina.
FS-Karton, Neuss, Germany.
Cartonnerie de Pont Audemer,
Pont Audemer, France.
Papierfabrik Schoellershammer,
Düren, Germany.
General Company for Paper Industry(RAKTA), Alexandria, Egypt.
SAICA 3, Zaragoza, Spain.
Pfleiderer Teisnach, Teisnach,
Germany.
Sande Paper Mills, Sande,
Germany.
SCA Packaging Obbola, Obbola,
Sweden.
Genting Sanyen, Bantig Selangor,
Malaysia.
Ruby Macons, India.
Asia Kraft, South Korea.
Recovered paper stock preparationlines and systems for tissue
Kimberly-Clark de Mexico, Ecatepec
de Morelos, Mexico.
Kimberly-Clark, Mobile, AL,
USA.
Kimberly-Clark de Mexico, Ramos
Arizpe, Mexico.
WEPA Papierfabrik, Giershagen,Germany.
Fabrica de Celulose e Papel daAmazonia, Belem, Brazil.

Sepac-Serrados e Pasta de Celulose,
Mallet, Brazil.
Klabin Kimberly, Cruzeiro, Brazil.
Sangyong Paper, Yongi-gun,
South Korea.
Kimberly-Clark, Philippinen.
Fort James Nederland, Cuijk,
The Netherlands.
Waste paper stock preparation lines
and systems for other grades
Sihl Landquart, Landquart,
Switzerland.

Paper machines
Graphic papers
Quena Newsprint Paper, Kairo,
Egypt.
Produits Forestiers Alliance,
Donnacona, Canada.
SOPORCEL, Lavos, Portugal.
Haindl Papier, Schongau, Germany.
Perlen Papier, Perlen, Switzerland.
August Koehler, Kehl,
Germany.
Papierfabrik Hermes,Düsseldorf,
Germany.
Board and packaging papers
SAICA – Sociedad Anonima Industries Celulosa Aragonesa, Spain.
Republic Paperboard Company,
Lawton, USA.
Zhuhai Hongta Renheng Paper
Product, China.

Modern Karton Sanayi ve Ticaret,
Corlu, Turkey.
Shandong Rizhao, China.
TissueSan Francisco, Mexicali, Mexico.
Occonto Falls Tissue, Occonto Falls,
USA.
Cascades Services and Achats,
Rockingham, USA.
Installations and rebuilds
Fort James, Kunheim, France.
Roman Bauernfeind Papierfabrik,
Frohnleiten, Austria.
Patria Papier & Zellstoff,
St. Gertraud, Austria.
Lövholmens Bruk, Sweden.
Cartiera Tolentino, Tolentino,
Italy.
Zellstoff und Papierfabrik Rosenthal,
Germany.
SCA Fine Paper, Stockstadt,
Germany.
Union Industrial Papelera, Spain.
Smurfit Towsend Hook, Snodland,
Great Britain.
Mondialcarta, Diecimo, Italy.
Daio Paper Corporation,
Mishima PM 5, Japan.
Daio Paper Corporation,
Mishima PM 6, Japan.
Daio Paper Corporation,
Mishima PM 7, Japan.
Daio Paper Corporation,
Mishima PM 8, Japan.
Bosso Carte Speciale Mathi,
Canavese, Italy.

3

FS Karton, Neuss, Germany.
Ahlstrom Corporation, Kauttua,
Finland.
Moritz J. Weig, Mayen,
Germany.
Nagoya Pulp Gifu Mill, Japan.
Longview Fibre, USA.
Atlantic Packaging, Canada.
Consolidated Papers, Wisconsin,
Rapids, USA.
Consolidated Papers,
Kimberly, USA.
Schoellershammer Industriepapier,Düren, Germany.
Ziegler Papier, Grellingen,
Switzerland.
Munkedals, Sweden.
Japan Paperboard Industries,
Soka PM 1, Japan.
Koa Kogyo, Fuji PM 6, Japan.
Nippon Paper Industries, Yufutsu,
Japan.
Nippon Paper Industries,
Ishinomaki, Japan.
Champion Papel e Celulosa,
Mogi Guacu, Brazil.
Champion International, Sartell,
USA.
Usinede Condat Le Lardin,
Condat Map, France.
Trierenberg Holding, Tervakoski,
Finland.
Fabrica de Papel Ledesma, Jujuy,
Argentina.
August Koehler, Oberkirch,
Germany.
Peterson Scanproof,
Norway.

Coating technology
Repap New Brunswick, Miramichi,
Canada.
Zhuhai Hongta Renheng Paper
Product, China.
StoraEnso Corbehem, Corbehem,France.
StoraEnso Research, Imatra,
Finland.
Papelera del Aralar, Aralar, Spain.
Champion Papel e Celulosa,Brazil.
Dong Ying Xie Fa Paper Industry,
China.
SCA Finepaper Stockstadt,
Stockstadt, Germany.
Steinbeis Temming Papier,Glückstadt, Germany.
Georgetown, USA.
Bastrop, USA.
Fabrica de Papel Ledesma, Jujuy,
Argentina.
SOPORCEL – Sociedade Portuguesa
de Celulose, Lavos, Portugal.
VPK Oudegem, Oudegem, Belgium.
Perlen Papier, Perlen, Switzerland.
Kanzan Feinpapiere, Düren,Germany.
SAICA – Sociedad Anonima
Industries Celulosa Aragonesa,
Spain.
Burgo Stabilimento di Chieti, Chieti,
Italy.
Winding technology– Sirius
Haindl Papier, Schongau,
Germany.

SOPORCEL – Sociedade Portuguesa
de Celulose, Lavos, Portugal.
Perlen Papier, Perlen, Switzerland.
Produits Forestiers Alliance,
Donnacona, Canada.
SAICA – Sociedad Anonima Industries Celulosa Aragonesa, Spain.
– Pope reel winders
Roermond Papier, The Netherlands.
Haindl Papier, Schongau,
Germany.
Holmen Paper, Hallsta, Sweden.
Modern Karton Sanayi ve Ticaret,
Corlu, Turkey.
Papierfabrik Hermes, Germany.
August Koehler, Oberkirch,
Germany.
Quena Newsprint Paper, Kairo,
Egypt.

FinishingJanus concept
Haindl Papier, Schongau, Germany.
Produits Forestiers Alliance,
Donnacona, Canada.
August Koehler, Kehl, Germany.
Perlen Papier, Perlen,
Switzerland.
Ecosoft calenders
Holmen Hallsta, Sweden.
SOPORCEL – Sociedade Portuguesa
de Celulose, Lavos, Portugal.
Quena Newsprint Paper, Kairo,
Egypt.
Portals Overton, Great Britain.

Dong Ying, China.
Papierfabrik Hermes, Düsseldorf,
Germany.
Boading Banknote, China.
Sun Paper, China.
Calenders
Perlen Papier, Perlen, Switzerland.
Sun Paper, China.
Paper roll cutting machines
SOPORCEL – Sociedade Portuguesa
de Celulose, Lavos, Portugal.
Quena Newsprint Paper, Kairo,
Egypt.
Twister/ Roll Handling
SOPORCEL – Sociedade Portuguesa
de Celulose, Lavos, Portugal.
Quena Newsprint Paper, Kairo,
Egypt.
Steinbeis Temming, Temming,
Germany.
August Koehler, Kehl, Germany.
Maul Belser, Nürnberg, Germany.
Klabin, Brazil.

Automation
Perlen Papier, Perlen, Switzerland.
Charles Turner, Bolton, GreatBritain.
Gebr. Lang, Ettringen, Germany.
Huatai Paper, Dawang,
Dongying City, Shandong, China.
Haindl Papier, Schongau,
Germany.

4

HIGHLIGHTS

Recent large orders

Fiber Systems

Recovered paper stock preparationlines and systems for graphicalgradesKimberly-Clark de Mexico,
San Rafael, Mexico.
Stora Enso, Wisconsin Rapids, WI,
USA.
International Paper, Pine Bluff, AR,
USA.
SAPPI Fine Papers, Mobile, AL, USA.
Appleton Papers, W. Carrollton, OH,
USA.
Kruger Newsprint, Bromptonville,
QC, Canada
Bowater, Catawba, SC, USA.
Daishowa, Quebec City, QC, Canada.
US Alliance, Coosa Pines, AL, USA.
SP Newsprint, Newberg, OR, USA.
Kimberly-Clark de Mexico,
Naucalpan, Mexico.
Madison Papers, Alsip, IL, USA.
West Linn Paper, West Linn, OR,USA.
Steyrermühl, Steyrermühl, Austria.
Pan Asia Paper Korea, Seoul, South
Korea.
Pan Asia Paper Thailand, Bangkok,
Thailand.
Papierfabrik August Koehler, Kehl,
Germany.
MD Papier, Plattling, Germany.
Papierfabrik Utzenstorf, Utzenstorf,
Schweiz.
SAPPI Lanaken,Lanaken, Belgium.
Huatai Paper, Shandong, China.
Fabrica de Papel Ledesma, Jujuy,
Argentinien.

Recovered paper stock preparationlines and systems for board andpackaging papers
Cartones Ponderosa, San Juan delRio, Mexico.
Longview Fiber, Longview, WA, USA.
Propapier, Burg, Germany.
Genting Sanyen, Bantig Selangor,
Malaysia.
Papierfabrik Schoellershammer,
Düren, Germany.
SCA Packaging New Hythe,
Aylesford, Great Britain.
Leipa Georg Leinfelder, Schwedt,
Germany.
Sande Paper Mills, Sande,
Norwegen.
Kappa Graphic Board, Hoogezand,
The Netherlands.
SAICA 3, Zaragoza, Spain.
CMPC, Puento Alto, Chile.
Rizhao, China.
Swiecie, Poland.
Cartiera Niccoli, Carbonera, Italy.
Companhia do Papel do Prado,
Tomar, Portugal.
Klabin Fabricadora de Papel e
Celulose, Lajes, Brazil.
Propal, Cali, Kolumbien.
Santa Clara Industria de Pasta e
Papel, Candoi, Brazil.
Celulose Irani, Vargem Bonita,
Brazil.
Orsa Celulose e Papel, Itapeva,
Brazil.
Citroplast – Ind. e Com. de Papeis e
Plasticos, Andradina, Brazil.
Recovered paper stock preparationlines and systems for tissue
WEPA Papierfabrik, Giershagen,Germany.

WEPA Papierfabrik, Müschede,
Germany.
Oconto Falls Tissue, Oconto Falls,
WI, USA.
LPC Group, Leicester, Great Britain.
Carta Fluminensa Ind. e Com.,
Rio de Janeiro, Brazil.
Papeles Industriales,
Santiago de Chile, Chile.

Paper machines
Graphic papers
SCA Graphic Laakirchen,
Laakirchen, Austria.
Jiangxi Paper Mill, Nanchang,
China.
Japan Paperboard Industries, Geibo,
Japan.
August Koehler, Kehl, Germany.
Minfeng Paper Mill, Jiaxing, China.
Board and packaging papers
Rebox, USA.
Visy Paper, Australia.
Papeles Cordillera/CMPC, Chile.
Oji-Fuji Mitsui, Bussan, Japan.
TissueCopamex, Mexico.
Installations and rebuilds
SCA de Hoop, Eerbeek, The
Netherlands.
Longview, USA.
Moritz J. Weig, Mayen, Germany.
FS Karton Neuss Mayr Melnhof,
Neuss, Germany.
Oudegem Papier, Dendermonde,
Belgium.

Segezha Pulp & Paper Mill,
Segezha, Russia.
Cartiera di Carbonera,
Camposampiero, Italy.
Neusiedler, Kematen, Austria.
Stora Enso Magazine Paper,
Reisholz, Germany.
Nippon Paper Board Geibo, Japan.
Georg Leinfelder, Schrobenhausen,
Germany.
Irving Paper Mill, Canada.
Zaktady Celulozy i Papieru“Celuloza”, Swiecie, Poland.
Inland Empire, USA.
Tohoku Paper, Akita, Japan.
Indah Kiat Serang, PM 3, India.
Indah Kiat Serang, PM 6, India.
LPC Leicester, Great Britain.
Kolicevo Karton Proizvodnja
kartona, Slovenia.
Stora Enso Imatra, Tainionkoski,
Finland.
Stora Enso, Uetersen, Germany.
Newark America, Fitchburg, USA.
Papierkombinat Archangelsk,
Russia.
Technokarton Mayen, Germany.
Copamex, Mexico.
Steinbeis Temming Papier,Glückstadt, Germany.
Inland Empire, Millwood, USA.
Kruger, Corner Brook, Canada.
Westvaco Corporation, Evadale,
USA.
Sappi Fine Paper, Stanger, South
Africa.
Felix Schoeller, Weißenborn,
Germany.
Koa Kogyo, Fuji, Japan.
Hokuyo Paper, Nayoro, Japan.
Daio Paper Corporation, Mishima,
Japan.

5

Oji Paper, Tomioka, Japan.
Hokuetsu Paper Mills, Niigata PM 7,
Japan.
Hokuetsu Paper Mills, Niigata PM 8,
Japan.
Willamette Industries, Hawesville,
USA.
Grünewald Papier, Kirchhundem,
Germany.
Steyrermühl Papier, Austria.
Burgo Stabilimento di Chieti,
Italy.
Julius Glatz Papierfabriken,
Neidenfels, Germany.
Jinjiang Paper, China.
KFPC-Celucat, Brazil.
Cartiera Nicoli, Carbonera, Italy.
Schoellershammer Industriepapier,Düren, Germany.
West Linn Paper, Oregon,
USA.
Mingfeng Special Paper, China.
Inland Empire Paper Company,
USA.
Champion Papel e Celulose,
Mogi Guacu, Brazil.
Haindl Papier, Schwedt, Germany.
Productora de Papeles Propal,
Propal PM 1, Venezuela.
Productora de Papeles Propal,
Propal PM 3, Venezuela.

Papierfabrik August Koehler,
Oberkirch, Germany.
Papierfabrik August Koehler, Kehl,
Germany.
Sappi Muskegon, USA.
Neusiedler, Kematen, Austria.
UPM-Kymmene, Kaukas, Finland.
Modo Paper Hallein, Hallein,
Austria.
Sappi Fine Paper, Stanger, South
Africa.
Felix Schoeller, Weissenborn,
Germany.
Sant Joan Les Font, Torraspape,
Spain.
Montananesa, Torraspape,
Spain.

Coating technology
Papelera del Aralar, Spain.
StoraEnso Veitsiluoto, Finland.
StoraEnso Kabel,Germany.
Cartiere Burgo, Verzuolo,
Italy.
Oji Paper, Oji, Japan.
CNTIC Trading, Rizhao, China.
Mitsubishi HiTec, Hillegossen,
Germany.

– Pope reel winders
Papierfabrik August Koehler, Kehl,
Germany.
SP Newsprint, Newberg, USA.
Roman Bauernfeind Papierfabrik,
Germany.
Frantschach Swiecie Spolka
Akcyina, Swiecie, Poland.
Shandong Rizhao Wood Pulp,
China.

Winding technology– Sirius
Papierfabrik August Koehler, Kehl,
Germany.
SCA Graphic Laakirchen,
Laakirchen, Austria.
Shandong Chenming Paper,
Chenming Shouguang, China.
Jiangxi Paper Mill, Nanchang,
China.
– DuoReel
Stora Enso, Uetersen, Germany.

FinishingJanus concept
UPM-Kymmene Tervasaari,
Finland.
SCA Laakirchen, Austria.
Chenming Shouguang, China.
Ecosoft calenders
BlueRidge Paper, USA.
Rizhao, China.
Oji Paper, Japan.
Linan Jinjang, China.
Visy Paper, Australia.
Yang An, China.
Papierfabrik August Koehler, Kehl,
Germany.
Mitsubishi Hillegossen, Bielefeld,
Germany.
Fabriano Miliani, Italy.
Century Paper, Pakistan.
Calenders
UPM Kymmene Kaukas,
Finland.
Felix Schoeller, Weissenborn,
Germany.
BlueRidge Paper, USA.
Rizhao, China.
Arkhangelsk, Russia.
CMPC – Procor, Chile.
Frantschach Swiecie, Poland.
Supercalenders
Ahlstrom La Gère, France.
Twister/Roll HandlingGreat Northern Paper, USA.
SP Newsprint, USA.
Bacell, Brazil.
Papierfabrik August Koehler, Kehl,
Germany.

Maul Belser, Nuremberg,
Germany.
Roto Smeets, The Netherlands.
Biegelaar & Jansen,
The Netherlands.
StoraEnso Hagen,Germany.
Roll cutting machines
CNTIC Trading, Rizhao,
China.

Automation
JSC Solikamkbumprom, Solikamsk,
Russia.
UPM-Kymmene, Kaukas Paper Mill,
Lappeenranta, Finland.
Daio Paper, Mishima Mill,Iyomishima City, Japan.
Sonoco, Hartsville, South Carolina,
USA.
Sonoco, Rockton, Illinois,
USA.
Westvaco, Evadale, Texas,
USA.
Yibin Paper Industry Group,
Yibin, China.
PT Pabrik Kertas Leces,
Probolinggo, Indonesia.
StoraEnso Fine Paper, Uetersen,
Germany.
CMPC – Procor, Puente Alto Mill,
Chile.
Pachisa, Chihuahua, Mexico.
Mitsubishi HiTec Paper Bielefeld,
Bielefeld, Germany.
SCA Graphic Laakirchen,
Laakirchen, Austria.
Modo Paper Hallein, Hallein,
Austria.

14Super startup of the stock preparationand groundwood bleaching lines for PM 3
at Haindl Papier, Augsburg

The author:
Andreas Heilig,
Fiber Systems

As a leading European producer of print-

For the new PM 3 line, Haindl therefore

ing papers from woody and recycledawarded Voith Paper Fiber Systems,

grades, Haindl Papier decided in 1998

Ravensburg, Germany, in December 1998

after an intensive test and planninga design planning contract covering thephase, to invest about 800 million DM

entire process, control and instrumenta-

in their “New Dimensions” PM 3, onetion engineering for stock preparationof the most ambitious and innovativeand groundwood bleaching. In close

projects in the paper industry. Designed

teamwork with the Haindl engineers,

for an output around 400,000 tonnes

Voith Paper worked out a 3-loop stockp.a., this machine produces LWC offset

preparation system with intensive water

paper with basis weights ranging fromcleaning, and rejects and sludge treat-

39 to 70 g/m 2. Haindl regards thement. This stock preparation line, with an

furnish mix of 25% each recycled paper,

output capacity of 380 t/24 h, uses recy-

groundwood, virgin kraft pulp and pig-

cled furnish consisting of mixed house-ments as revolutionary.

hold collection grades.

The Haindl corporate philosophy is to in-

Compared with conventional lines using

creasingly use recycled paper even for

two loops, this system has a third loop

superior grades – naturally without sacri-consisting of a thickener followed by di-ficing product quality, and improving it

lution with clarified water. As a result, thewherever possible. This can only bestock preparation and paper machine wa-

achieved, however, with highly sophisti-

ter loops are very well separated, thus

cated process technology including thefreeing the paper machine very effectively

appropriate water treatment and rejects

from troublesome colloids and dissolved
contaminants.

and sludge disposal systems.
12Fiber Systems

15

Fig. 1: Partial view of the storage towers andbleaching pipes.
Fig. 2: First-stage LC fine screening with 0.2 mm
C-bar™ slotted basket.

Fig. 5: Foreground: Disperger I with screw press
and heating coil above. Background: Disperger II.

Fig. 3: HTD 700 disperger.
Fig. 6: One of the four Deltapurge water cleaningmachines.

Fig. 4: Flotation I and II: primary cells on theright, secondary cells on the left with stickies
flotation. Service accessibility of the entire line
is exceptionally good.

Fig. 7: Polymeri additive processing for watercleaning and sludge treatment.

The main quality-related stock preparation 4
processes were supplied by Voith Paper
Fiber Systems as follows (Figs. 2 to 5):
I Flotation I, 2-stage with forward feedfrom the secondary stage
I LC slotted screening with 0.2 mm
C-bar™ technology
I Stickies flotation as fine-screening end
stage (new patented concept)
I Disperging I
I Flotation II, 2-stage with forward feedfrom the secondary stage
I Disperging II.
Our joint venture partner meri, Munich,Germany, was responsible for all the water cleaning systems consisting of four
Deltapurge

machines

Polymeri

additivewithassociatedprocessing

plants5

6(Figs. 6 and 7). meri also supplied the rejects treatment and disposal plant including magnetic separators, two shredders,compactor and sedimator.
3

7

16
Production setpoint
Total losses

SP

Consistency
x SPR
OUT
WC
x

SPA
DC

SPR
FC

Pulping
Hole screening

SPR
FC

Power control
specific
Delay

WI

Consistency

M

M

DC

FC

Flotation I
Slotted screening
Thickener I

x

x
SPR

EC

LC

Disperger I

SP SPASPR SPR

M

M

DC

FC

DC

FC

FC

Flotation II
Thickener II

Losses

x

SPR
WC

Delay

WI

WI

x

HC

Power control
specific
Bleach time

WI

x
SPR

EC

LC

Disperger II
Bleach I

OUT

SP SPR
DC

Thickener III

M

FC

M

M

DC

FC

Bleach II
Storage
Finished StockIntake

PM 3
PM 2

PM 3
Water loop 4
Water treatment

Effluent
Sludge intake

Water treatment

8

Water treatment

The 2-stage high-consistency peroxideters to be set with a single control organ

Another important reason for the smoothbleaching section for groundwood, with a(Fig. 8).

progress of this entire project was the
exceptionally good cooperation with thecapacity of 300 t/24 h, is located next tothe stock preparation line. The necessary

Thanks to the high degree of automation,

Haindl Augsburg project team (Figs. 12

connections and preparations for future

not only is line operation simpler andand 13).

addition of a third bleaching stage weremore reliable, but Haindl’s requirement

already taken care of at the planning

for a single control desk on PM 3 for the

One of the main reasons for such a per-stage.

stock preparation line as well as the pa-

fect stock preparation line startup, how-

per machine was also met (Fig. 11).

ever, was several weeks of software trials
prior to commissioning. Every single one

For the first time at Haindl Augsburg, thepatented Voith Paper engineering concept

During the design phase, interferenceof the 1384 control circuits was simulat-

AP 2000 (“Advanced Process”) was ap-

checks were continuously made on theed and thoroughly tested.

plied. After thorough investigation by

3D simulation system. This largely avoid-

the Haindl specialists, this concept was

ed time-consuming modifications during

Despite the high demands and pressure

systematically implemented in a largely

erection work. Furthermore, the high-pre-of time, this enabled the commissioning

closed-loop and very highly automatedcision isometric drawings supplied byteam, with the support of deinking spe-

process.

Voith Paper enabled the piping subcon-

cialists from Schongau and Schwedt, totractor to deliver largely in the prefabri-pump finished stock from the storagecated condition.

tower to the PM after only one week of

The entire new stock preparation line cancommissioning in mid-May 2000.

thus be run up with a single “Main start”
command in only 20 to 30 minutes, andEarly in the design stage, representatives

shut down again including flushing.

of Haindl and the trade association close-

With this innovative technology, Haindl

Another highlight in user-friendliness is

ly checked the 3D model for plant acces-

has set yet another milestone in theircertainly the production regulation sys-sibility, maintenance-friendliness and op-

long and successful recycling tradition.

tem, which enables the precise parame-erating safety (Figs. 9 and 10).

And as so many times in the past, it wasFiber Systems

17

9
10
11
12

Fig. 8: Production control diagram
for the new PM 3 deinking line in
Augsburg.
Fig. 9: CAD 3D model at the design
stage of Augsburg PM 3 DIP line.
Fig. 10: Overall view of the DIP line
immediately after commissioning.
Fig. 11: Central control desk bothfor the DIP line and PM 3.
Fig. 12: Part of the Haindl Augsburg
and Voith Paper Fiber Systems
Ravensburg commissioning teamfor the DIP and groundwood
bleaching lines.

our privilege to play a role in this devel- 13
opment. To us this is not only a matter ofpride, but also of obligation. We look forward to continuing our decades of deinking partnership for the ongoing successof Haindl Papier.

Fig. 13: Bernd Schindler (left),machine design group leader, and
Wolfgang Krodel, group leader
recycled paper and groundwood/bleaching, Haindl Papier, Augsburg.

18Lang Papier PM 5 –The new online concept for SC papers:
16 months of successful operation
In this age of the Internet and digital

Gebr. Lang GmbH in Ettringen set thetechnology, the global market demands

stage for a total of five online Janus

increasingly efficient machine concepts

technology installations so far. The big

for competitive low-cost paper produc-market success of the new SC-B gradetion and marketing. Voith Paper has

with a DIP content of 80 % played a key

taken up this challenge. With the newrole in the decision for their new PM 5,

SC online concept, we have set aagain supplied by Voith Paper.

decisive milestone in the development
process toward more efficient and
The authors:
Ingolf Cedra,
Rudolf Beißwanger,
Paper Machines Graphic

lower-cost production of high quality
grades. With the installation of the first
6-roll Janus calender in their PM 4,

Paper Machines

19

Fig. 1: Lang Papier PM 5.
Fig. 2: Process consideration as a whole…
Fig. 3: Offline-online comparison.

Project schedule

ing numerous tests at Voith Paper Heidenheim (pilot paper machine No 4) andAs shown below, the time schedule set

Krefeld (Janus facility) as well as on thefor this project was extremely tight:

existing PM 4 at Lang Papier, and also

End of May 1998: Machine order placed

for identifying any quality risks in con-with Voith Paper, start with the civil-

nection with the new production line.

work of the PM building.
December 1998: New building completed.
January 1999: Start of paper machine
erection.

Online versus offline –Demands on the online concept

July 1999: Start of commissioning.
22.8.1999: First paper production –A fair comparison of online and offline

earlier than planned thanks to thecalendering technology today shows acommitted efforts of the entire team.

significant cost advantage for online calendering (Fig. 3). However, offline calendering still gives the best SC qualities

System partnershipand printability due to the significantly
lower operating speeds. With ongoing

1

2
Lang Papier Optimisation
Voith Paper SGW DIP
1998

Due to the strategic importance of thisconsistant process optimization, SC-A+

project both for Lang Papier and Voith

qualities will soon be attainable by online

Paper, a technology partnership team wascalendering as well, provided that the fol-

founded at the same time as contract

lowing conditions can be met:

signing (Fig. 2). This team was responsi-

I Maximum overall line availability

ble for joint product development includ-

I Optimal overall process stability
3

Value (Gloss)

Optimisation
PM 5

Trials
XPM 4

1999

2000

Order

Start-up

50
40
Ecosoft
30
Online Janus MK 2

2x Offline Janus MK 2

20
System Partnership

10

33 %

72 %
Total Specific Costs per Year

100 %

20

4
5

I Defectfree web, minimize webbreaks
and running time losses

6

wire suction box with four opposite form-

I Symmetrical drainage for symmetricaling blades (D-section in Fig. 5), wet andsheet structure in the z-direction

flat suction boxes, wire suction roll and

I Maximal dry content after the wet

high-vacuum suction box. This arrange-

section, for gentle strength

Ambertec Formation [g/m2]

standard components: forming roll, top

ment of rotating and stationary drainage

I Consistently good MD and CD profiles

elements easily results in a dry content offor basis weight, fillers and moisturemore than 18 % into the press section.

content

Since the main SC characteristics are pri-

I Optimum moisture profile, both CDmarily determined during formation, gen-and sheet cross-section, with 10 %tle 2-sided drainage is extremely impor-initial moisture content into the Janustant. Forming performance as a function

calender.

of retention and blade drainage is shownin Fig. 6.

3.9
3.7
3.5
3.3
3.1
2.9
65
55
45
35
25
Total
Retention [%]

1000

600

200

2.9
3.0
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
over

Paper machine concept (Fig. 4)

The 4-felted Tandem-NipcoFlex press
section, used for the first time for these

1400
D-Unit Dewatering [l/min*m]

7

The most innovative components in thisgrades, comprises two shoe presses.

paper machine are the Tandem NipcoFlex

Thanks to the long shoe of the NipcoFlex

press section and the inclined Janus MK 2

roll, each of these ensures very long

calender for newsprint and SC grades.

dwell times in the press nip (Fig. 7).

The machine is thus based on the new

Decisive for mechanical drainage is the“One-Platform Paper Machine Concept”.

press pulse, the product of line force andWith a maximum production speed ofdwell time. At an operating speed of

1,800 m/min and a wire width of 8.9 m,

1,600 m/min this is almost twice as highthis is one of the fastest and largest SC

as in a conventional roll press. The dry

paper machines.

content of 54 to 57 % attained in SC production also means a very high initial wet

Thanks to narrow-zone Profilmatic con-strength, and therefore much less risk oftrol, the ModuleJet dilution headbox en-

mechanical overstress on the web.

ables extremely good basis weight crossprofiles for all grades. With accurate

For a further increase in dry content andtuned gap adjustment, fiber orientation

good control of the moisture profile, a

has been optimized to deviation toler-

profilable ModuleSteam unit is installed

ances within ± 3°. Suspension drainage is

between the two presses. Apart fromby DuoFormer TQ, well-proven for SC pa-these runnability factors, symmetricalpers. This incorporates the followingpress drainage on the top and bottom

Paper Machines

21

Fig. 4: Concept of PM 5.

Fig. 6: Formation versus D-unit and retention.

Fig. 5: DuoFormer TQ – D-unit, the quality tool.

Fig. 7: Effects of nip dewatering
I high dryness
I proper felt conditioning– good moisture profile– long felt lifetime.
Fig. 8: Water balance of a Tandem-NipcoFlexPress; SC 55 g/m 2, v = 1,520 m/min.
Fig. 9: Tail threading with Fibron.
Fig. 10: Janus MK 2 in operation using all nips.

sides ensures optimally 2-sided consoli-

duction in single-nip mode, thus saving 8

dation and an excellent sheet structure

expensive down time. The rolls can beaccordingly – indispensable for good

lifted from the frame by hydraulic cylin-

printability (Fig. 8).

ders into a convenient position for the

Uhle BoxNip

88 g/m2
1. Nip30 g/m 2

crane.

2. NipThe TopDuoRun single tier dryer section
comprises 38 dryers, and incorporates a

The advanced Sirius winding system en-

moisturizer for correcting the cross-direc-

ables excellent control of Nipload, webtion moisture profile at a very high initial

tension and center torque throughout the

web moisture content of the entering thewinding process including parent rollJanus calender.

change. To this purpose, the Sirius has a

18 % 290 g/m2 36 % 145 g/m2

40 g/m2

77 g/m2

primary and a secondary center wind asIn contrast to offline calendering, anothersist. As a world innovation, parent rollchallenge with the online concept is tailoscillation is now possible right on thethreading through the calender at pro-paper machine, which significantly im-

duction speed. Fibron transfer conveyors

proves the quality particularly of jumbo

are therefore used before and after thereels.

9

Janus calender, and ropes in the calenderitself (Fig. 9). Due to its different production modes for newsprint and SC grades–

single-nip

top/bottomorFindings during commissioning

multinipmodes – PM 5 makes particularly highIt was a new experience for the operating

demands on the transfer process.

personnel to set the low web tension

56 % 93 g/m2

required from a centre roll without any
The new Janus MK 2 has eight rolls andvisible draw. Commissioning of the Tan-is inclined at 45° (Fig. 10). This not only

dem NipcoFlex press was a big challenge, 10

facilitates tail threading, but above all en-particularly conditioning the four press

sures mechanical stability of the calender

felts. The correct interplay of high-pres-stack even at the highest speeds. Due tosure showers and Uhle box soon turned

the 45° inclination, 30 % of the roll massout to be critically important. In team-loading is already compensated. If re-work with the felt manufacturers, felt

quired, hydraulic compensation is also

qualities were improved over the first few

available to ensure a constant line force

months to meet the new requirements ofat all nips. A special advantage of thisthe tandem NipcoFlex press. Rapid felt

new calender generation comes into play

response for a higher dry content onwith PM 5: calender rolls not in use canstartup was found to be essential for

easily be changed during newsprint pro-secure web threading. With regular felt

22
11

Fig. 11: Moisture profile at reel.
Fig. 12: Basic data of PM 5 in 2000.
Fig. 13: LPT plus –trials for roughness-optimisationv PM = 1,450 m/min; 55 g/m 2; 31 % ash.
Fig. 14: LPT plus –trials for cobb-optimisationv PM = 1,520 m/min; 55 g/m 2; 31 % ash.
Fig. 15: Quality ranking of woodcontaining grades.
SC

Speed
[m/min]1,400-1,560

1,400-1,600

Basis Weight[g/m 2 ]40-48.8

45-55

Filler [%]10-15

Press Load[kN/m]

950+1,150

950+1,150
54-57

Janus Load[kN/m]

105-130

250 -380

Furnish

85% DIP
15% SGW

75% DIP
20% SGW
5% Kraftcondition monitoring and drainage moni-

1.40
Top Side
Bottom Side

1.35

25-32

Dryness a. Press [%] 49-51

1.30

Target

1.20
1.16

1.15

1.10

mization measures in the press andtransfer system, SC production speeds
were increased as follows (Fig. 12):

1.05

I December 1999

1,500 m/min

1.00

I February 2000

1,560 m/min

4

I July 2000

1,600 m/min.

MWC

SC quality

2

1

3

Quality “value”

LWC

8
Bottom Side
R2 = 0.9414

7

SC-Plus
SC-A

Ettringen PM 5

Top SideR2 = 0.9716

IN
News

250
300
350
Janus Linear Load [kN/m]

400

The following quality data have been
attained so far for the new SC-grade
produced by Lang Papier (LPT plus) at

SC-B
S-IN

5
200

1.14

1.10

9

6

data boxes (Fig. 11). After further opti-

1.24

1.25 1.23

1.14

cross-profiles were stabilized at 2-sigma
values of 0.18 to 0.30 % (abs.) on 816

1.26

1.15

toring at each felt location, moisture

15

10

Cobb-Unger 10 sec [g/m2]

14

13

Newsprint

PPS-10S Roughness [mm]12Super Improved
for Rotogravure

Improved Newsprint
Newsprint
Costs

1,520 m/min:
I Ambertec formation norm. < 0.40 √g/m
I Bendtsen porosity < 20 ml/min
I PPS-10S < 1.20 µm (Fig. 13)
I Gloss 45° (Hunter) > 45 %I Cobb-Unger 10 sec < 6 g/m 2 (Fig. 14)

Claus Palm, mill manager
at Lang Papier Ettringen,
had this to say aboutcommissioning the new
PM 5:“The future-oriented COMPACT PM 5 project represents a huge success forall of us. In record time, the world’s
most modern SC production line wasinstalled. Thanks to first-class team-work between Voith Paperand Lang Papier, we can
now produce high-quality
SC grades efficiently andcost-effectively. With thecommissioning of our new
deinking line in October2000 and the recommissioning of PM 3, our production capacity will double compared with 1998 to 560,000
t.p.a. We can thus look to the new millennium with assurance.”

These are the best quality figures everachieved in online SC paper production.
With ongoing product optimization, rotogravure printability will further improveto the point where supercalendered SC-A
paper is hardly any better (Fig. 15).

23

1

The DuoFormer D –a success story
The DuoFormer D has been an outstanding success ever since its market
launch in 1984. To meet rising demands
on paper quality – in particular withregard to formation and costs – theDuoFormer D is the optimal tool. It is
used for all mass and special grade
papers at production speeds up to
1,200 m/min. Last but not least: the
DuoFormer D is very effective for modernizing outdated formation concepts.
The authors:
Cordula Mraz,
Reinhard Leigraf,
Paper Machines Graphic

So far the DuoFormer D has been
installed in nearly 200 paper machines
worldwide, with wire widths ranging
from 1.5 m to almost 10 m.

The DuoFormer D concept
The DuoFormer D
The DuoFormer D (Fig. 1) is a hybrid former, i.e. the suspension is predrained ona fourdrinier section. Afterwards follows
the twin wire section with significant upward drainage. The top wire unit can be243

Vacuum
10 kPaSkimmer
Zone 1

Vacuum
15 kPa

20 kPa2

Zone 230 kPa
kPa
15
10
5
0

installed both on new machines and on
existing fourdrinier machines. The latter
is facilitated by the fact that the twin wire
path only deviates slightly from the fourdrinier wire line.
The twin wire section of the DuoFormer D
The top wire (Fig. 2) is fully cantileverable and has 4 rolls, of which the leadout roll is separately driven. The wire line
is arranged so that all rolls are located on
the inside. Only the high pressure shower
for wire cleaning is situated outside the
top wire.
The drainage section in the twin wire partof the DuoFormer D comprises a top wire
suction box, underneath this the formingbox in the bottom wire, and the transfer
box for parting the top and bottom wires.
The top wire suction box is mounted ona swivel arm together with the lead-inroll. It has three zones: the vacuum skimmer, the first and the second suction
zone. Whitewater removed through the
top wire is raised by vacuum over a weir
into compartments of the top wire suc-Transfer box

Recommended air pressuretion box inside which it is led to the driveside of the machine (Fig. 3).
Within the top wire suction box area isthe forming box integrated in the bottom
wire. This has ten forming blades which
are separately guided, i.e. they are notmechanically linked to the neighbouring
blades. Three of these blades are locatedin front of the top wire suction box, while
the other seven are situated between theblades of the latter. They are pressedagainst the wire by pneumatic pressure
hoses (Fig. 4).
The top wire suction box and forming
blades comprise an integral unit known
as the D-section.
Wire changing with the DuoFormer D
Since the top wire loop of the DuoFormer
D only has interior rolls and this former
is extremely compact, wire changing isvery simple. It is only necessary to raise
the top wire suction box and lead-in rollby spindle drives, and retract the forming
blades (Fig. 5). At the same time thestretch roll is moved to the wire changing

position. Then the top wire can be cantilevered and the intermediate parts ofthe drive side frame removed. Dependingon the width of the DuoFormer D, theouter high-pressure shower can either becantilevered as well, or it has to be removed. The predraped wire can then be
retracted.
Wire changing can be carried out by awell-versed team in less than one hour.
Positioning the top wire unit
To ensure optimal paper quality for various applications, such as LWC (30 g/m 2)
on the one hand or coated raw paper(110 g/m 2) on the other, the predrainage
section must be equipped in each casefor the specific drainage characteristics.
The length and arrangement of thepredrainage section elements are therefore optimized by computer methods foreach individual paper machine. This ensures that the suspension level and consistency before the twin wire section arewithin the right range for the specificdrainage behaviour.

Paper Machines

25

Fig. 1: DuoFormer D.
Fig. 2: Twin wire section of the DuoFormer D.
Fig. 3: Vacuums and pressing forces.
Fig. 4: Forming blades.
Fig. 5: Wire change position.
Fig. 6: Drainage effects.
4

5
Ceramic
Compound blade

Pressure hosemax. 20 kPa
Forming box

Drainage
Drainage capacity
The production speed of a conventional
fourdrinier section is restricted by limited
drainage capacity due to their limited
length, and by dandy roll spraying which
increases with operating speed.
Thanks to the additional top wire drainage, the DuoFormer D has a much higher
drainage capacity. No spraying occurs aswith the dandy roll. For this reason production speeds up to 1,200 m/min areeasily possible with the DuoFormer D.
This limit is set by turbulence occurringon the suspension surface in the fourdrinier section.
Drainage process in the twin wire section
In three drainage sections – the skimmer,
suction zone 1 and suction zone 2 – topside drainage takes place over a very
short distance from initial drainage tosheet consolidation. Drainage starts at
minimum pressure, passing through apressure pulse zone and ending undervacuum at the transfer box (Fig. 6).

6

Initial drainage through the top wire
starts before the skimmer blade, i.e. thefirst blade of the top wire suction box. In
this zone the top and bottom wires arebrought together on the first flexible formation blades. Whitewater is pressed
thereby through the top wire, removed by
the skimmer blade and drained upwards.
In suction zone 1 drainage takes place at
low vacuum. Drainage forces are mainly
applied by the blades, so that the resultant pressure pulses cause relative motion between the fibres. Flakes producedin the predrainage section are thus broken down again.
The higher vacuum in suction zone 2dries the sheet to the point where it isconsolidated enough to facilitate wire
separation on the transfer box.

P vak

Top wiresuction box

Formation
bladesPressure
pulsesremoved downward in the twin wire section. Most of it is removed by the Skimmer and drained upwards in suction zone
1, so that only very little water has to be
removed in suction zone 2.

Paper quality
Drainage quantities
Fig. 7 gives an overview of water quantity
distribution on the DuoFormer D. In thepredrainage section about 50 to 60 % ofwater from the headbox is removed. Onlya small part of the remaining quantity is

Particularly important for paper producers is a high product quality over the applicable range of basis weight and refining degree. This requirement is not met
by conventional hybrid formers with

26

forming roll or shoe. With the DuoFormer
D, however, drainage pressure characteristics depend only on the forming blade
pressing force. The flexible forming bars
can adapt to varying drainage conditions,i.e. various layer thicknesses, while theblade pressing force remains constant.
Formation
Fig. 8 shows a comparison of forming results over suspension thickness at thefirst blade, on the one hand with the rollor shoe type hybrid former, and on theother with the DuoFormer D. Not only isformation quality with the DuoFormer D
higher due to the shear forces applied by
the blades, but the operating range ismuch wider with excellent formation results. The suspension thickness corresponds thereby to the proportion of top
wire drainage in the former.

Fig. 9 shows the average formation improvement for wood-containing andwood-free grades after rebuilt to DuoFormer D. By far the majority of DuoFormer D paper test samples show
above-average formation quality, with
Ambertec values of 0.4 to 0.48 (g/m 2).
Particularly a comparison with typical results on fourdrinier machines shows thegreat potential for improving formation
by upgrading to the DuoFormer D.

√

Tensile ratio
With many grades, only a slight fibre orientation in the machine direction is desirable. The tensile ratio (machine to crossmachine direction) must therefore be as
low as possible. This is the case for example with copy paper, label and format
papers, as well as numerous special
grades.

Fourdrinier machines often produce aflaky sheet structure at low tensile ratio.
With the DuoFormer D, on the other
hand, a low tensile ratio can be set whilestill retaining good formation.
2-sidedness
One-sided drainage on the fourdrinier(filtration) causes enrichment of fines
and fillers on the upper sheet surface.
With the DuoFormer D this problem issolved by drainage in the twin wire section, which equalizes the fines and fillers
content of the upper and lower sheet surfaces.
The symmetry thus attained is impressively demonstrated by comparing ash
distribution in a fourdrinier section withthat in a DuoFormer D (Fig. 10).

Paper Machines

27

Fig. 7: Drainage components –Drainage quantities depend on basis weight andpaper grade.
Fig. 8: Formation and drainage pressure withvarious former concepts.
Fig. 9: Formation improvement by installing a
D-section.
Fig. 10: Ash distribution in the Z-direction.
Fig. 11: The DuoFormer D – a success story.
7

8
Skimmer(+)

First zone
Second zone

10-15 %

3-5 %Headbox: 100 %Variable drainage pressure
DuoFormer D

Formation improvement

15-20 %
5-10 %
Paper web3-5 %Forming box

Forming roll
R = 0.5 m
Forming shoe
R=3m

50-60 %(–)
2

6
4
Suspension thickness

Predrainage section

8 (mm)

9

10
Fourdrinier

DuoFormer D
20

40
30
20

15
10
80 g/m 2
Ash content 17.9 %5

Ash content [%]2050

Ash content [%]Formation improvement (%)

60

15
10
83.5 g/m2
Ash content 14.2 %

5

10
0

0
0
0,30

0,40

0,50
0,60
0,70
0,80
0,90
Ambertec formation before upgrading [√(g/m2)]0
20 40
Bottom side

1,00

60

0
20 40
Bottom side

80 100Top side

Rel. basis weight (%)

60

80 100Top side

Rel. basis weight (%)

11

180

140
120

References

100

Since the first DuoFormer D was commissioned in 1984, this forming concept
has proved itself again and again as extremely efficient. Nearly 200 DuoFormer
D units now in service bear witness tothis high efficiency, cost-effectiveness –and customer satisfaction (Fig. 11).

80
60
40
20
0
84

85

86

87

88

89

90

91 92 93 94
Year of Start-up

95

96

97

98

99 2000

Number of DuoFormer D

160

28

Schongau PM 9 –Installation of the latest technology for new
SCB-Plus quality from 100 % DIP in 56 days... an investment for the future
At the end of January 1999 Voith Paper
was awarded a contract by Haindl
Papier GmbH & Co. KG for replacing a
newsprint machine, in operation since
1962 at the Schongau mill, with a newmachine for producing high grade SCB
from 100 % recycled paper.
Haindl is one of the largest European
producers of wood containing roll-printing paper.
On three Voith paper machines, theSchongau mill produces about 650,000
tonnes of printing press paper per year.
Apart from standard newsprint, the wide
product range in Schongau increasingly
includes improved rotogravure or offset
printing grades. Standard newsprint
mainly comprises 80 % DIP and 20 %TMP. For the improved grades, exclusively DIP is used.

The author:
Gerhard Kotitschke,
Paper Machines Graphic

Targets with the new PM 9 installation
were as follows:
I Replacement of a 38 year old paper
machineI High grade SCB production from
100 % DIP
I Greater output
I Long-term workload security.
To ensure overall project cost-effectiveness, the old paper machine had to be
replaced as quickly as possible. Furthermore, the old machine had to be dismantled very carefully for sale to a customer
in China. As of May 2001, this machine
should be producing standard newsprint
from recycled paper again at Dongying
Huatai Paper.

1

The extremely short down time was only
possible thanks to the extensive preparations made prior to the shutdown of theold machine as well as during the outage:
I Assembly and commissioning of themain hydraulic aggregates
I Structural modifications to themachine buildingPaper Machines

29

30

2

I Pre-assembly of all machinecomponents in the suppliers’ works
I Tail transfer system design andconstruction to enable transfer tests
from the last drying cylinder to the
Sirius winder five days prior to production startup
I Intensive operator training
I Compilation of a detailed commissioning schedule with computer-supported
deadline monitoring
I Formation of eight working groups inteamwork with the customer for interchanging experience on comparable
installations, avoiding repetition oferrors, taking into account the operator’s system know-how, and successively improving the system

3

I Formation of a steering committee formaking all main decisions andensuring compliance with important
deadlines.

PM 9 machine layout (Fig. 2)
With a working width of 6,100 mm, PM 9
is not a particularly large machine, but its
design concept and operating speed of
2,200 m/min make it one of the mostmodern paper machines worldwide.
This new “One Platform Paper Machine
Concept” comprises the following components:

I ModuleJet headbox adapted to the new
Profilmatic MQ system, which almost
instantaneously adjusts the basis
weight by intervening directly in the
ModuleJet mixing units thanks to a
newly developed stock consistency
measuring sensor,
I DuoFormer TQv, a state-of the-art
vertical former concept for graphicalgrades,I Closed draw Tandem-NipcoFlex press
section for highest dry content, symmetrical drainage and secure web
control,
I TopDuoRun without exterior fabricguide rolls, with open draw after the
first drying roll,
I New moisture cross-profile control
concept – without rewetting – forSC paper production,
I Janus calender MK 2 inclined at
45 degrees with 10 rolls, divided into
two separate stacks,
I Sirius winding system with reeloscillator.
The DuoFormer TQv vertical former specially developed for PM 9 is not only
attractive, but also has a large forming
potential, great flexibility, and easy accessibility for cleaning and changing
wires and rolls (Fig. 3).
Based on operating experience with existing Tandem-NipcoFlex presses, the firstclosed draw press section was installedon PM 9 in Schongau.
Closed draw in this case means that between individual presses, and between
the press and dry section, only slight
constant velocity differentials are requiredwith no free web draw.

Paper Machines

31

Fig. 2: Machine concept of the new PM 9.
Fig. 3: DuoFormer TQv in new design.
Fig. 4: Tandem NipcoFlex press with free web
draw after drying roll 1.
Fig. 5: Janus MK 2 in operation.
4

This goal was reached by modifying thetransfer sections after the presses andproviding for a free web draw after the
first drying cylinder. A velocity differential here of 1.6 to 2.1 % generates the
web pre-tensioning required for ensuring
troublefree transfer to the first dryer
group (Fig. 4).
To meet the high demands for rotogravure and offset-heatset printability of
100 % deinking paper with PCC fillers, aJanus calender MK 2 inclined at 45 degrees was installed. This comprises
10 rolls in two identical stacks, with individual line force control (Fig. 5).

5

Design is not only a question of taste,
but also of style.
While the exterior design of the new PM 9
is truly stylish, its interior embodies thevery latest technology (Figs. 1 and 6).

56 days from paper to paper –a world record indeed

The Janus MK 2 is designed for a line
force range of 30 to 500 kN/m and amaximum FLEXITHERM roll surface temperature of 160° C.

Decommissioning and dismantling an entire paper machine ready for assembly at
a new location, replacing it with a new
high-tech paper machine, carrying out
extensive structural modifications, completely reshaping the periphery in part –and recommissioning everything exactly
on time – demands overall project planning right down to the last detail together
with a well-versed team.

Four steam humidifiers provide the additional moisture content and heating required for improved calendering results.

Long before the old PM 9 was finally shut
down, structural and assembly work was
in progress all over the place.
I Structural work commenced already inJune 1999 by building control rooms,

offices and social facilities alongside
PM 9. The building length was extended with an additional bay, at the sametime creating an erection opening forremoving the old components andinstalling the new ones. New concrete
foundations were installed for theformer and the Sirius winder.
I Between July and October 1999, completely new switch gear rooms werebuilt and part of the equipment
installed.
I A new hydraulics room was constructed.
I Already in September 1999 a start wasmade on connecting and commissioning the approach flow section and heatrecovery. This work included in particular replacing the deculator and vertical screens, installing a new heatrecovery system, and installing new
pulpers.
I The former exhaust aggregates were
installed and precommissioned.
I Large auxiliaries such as the lubricating systems, Nipco hydraulics, combihydraulics and thermo-oil system wereassembled including piping, then32
Design data of the new PM 9Paper grade SOG A top T (SCB-Plus)
Design operating speed v K = 2,200 m/min
Operating speed (phase 1) vB = 1,500 m/min
Basis weight 45 - 60 g/m 2
Ash content in paper 30 - 34 %Working width on pope roller 6,100 mm
Furnish 100 % DIP
Fillers Kaolin + PCC

Figs. 1 and 6: PM 9 in new design.
Fig. 7: PM 9 with Janus MK 2 and Sirius.

6

flushed and commissioned together
with the control system.
I The Sirius winder was installed without
reel magazine.

First
production
results
Dipl. Ing.
Artur Stöckler,
plant manager at Haindl Papier GmbH &Co. KG Schongau, assesses the project
execution, commissioning and initial
operating results extremely positively:
After exactly 56 days of rebuild time,
the new PM 9 went into service righton time at an operating speed of
1,330 m/min. From the first day on, it
has been producing SCB paper in nonstop operation. Haindl’s high demands
on operating speed, overall efficiency
and production output were significantly exceeded after only two months.
Thanks to the excellent cross-profile forhumidity, basis weight and sheet thickness, online production requirements
for SCB paper are ideally met. The low
mill waste quota, and above all the positive feedback from numerous rotogravure printers, confirm that this was
the right concept to choose.

Thanks to complete preassembly of all
machine sections including piping andwiring, limit switches, etc. in the Voith
Paper works, the paper machine erection
work in Schongau went ahead rapidly. In
some cases the main functions and motion sequences were already tested in theVoith Paper works.

7

The enormous strategic importance of
this project for Haindl Papier and Voith
Paper, the extremely short project completion deadline and rebuild time – despitedifficult conditions – demanded a quantum leap in cooperation between the paper machine supplier and the customer.
Even the first four months of continuous
operation demonstrated the great potential of PM 9 for quality and productivity.

33

New orders from the People’s Republic of China
More newspapers are printed in China

The Chinese government has therefore

today than in any other country – a sign

launched a comprehensive support pro-of the times. The People’s Republic now

gram for important priority and pilot pro-has a population of 1.4 billion, and withjects. Thanks to technical prowess andsteadily rising personal incomes, paper

successful tendering, Voith Paper has

and board consumption is growing

already secured several contracts in con-accordingly. Over the next five years,

nection with this ambitious plan.

demand is expected to double from30 to 60 million t.p.a. This applies toAmong these are some large new orders

all grades, but particularly coated andfrom Shandong Chenming Paper Holding

uncoated graphic papers.

Ltd. and Jiangxi Paper Co. Ltd. Bothcompanies are leaders in the Chinese paper industry.

34

Offline coating system for Shandong
Chemning Paper Holding Ltd.
With four JetFlow coaters at 4,635 mm
web width and 1,500 m/min operating
speed. Also two offline Janus MK 2
calenders with ten rolls each, at
4,600 mm web width and 1,000 m/min
operating speed. For single and doublecoated woodfree grades with basis
weights from 70 to 210 g/m 2.
Newsprint machine for Jiangxi Paper
Co. Ltd.
Incorporating Voith Paper key components such as GapJet headbox with
ModuleJet technology, DuoFormer TQv,
DuoCentri II press, TopDuoRun dryer
section and Sirius winder. For 7,000 mm
wire width and 1,500 m/min design
speed. Output 540 t/day of newsprint,
basis weight 35 to 51 g/m 2.
Total contract value: DM 210 million

On November 8, 2000 the China National
Technical Import and Export Corporation(CNTIC) signed two more large contracts
with Voith Paper. This reflects our fruitfulcooperation with this organization andVoith Paper’s outstanding reputation in“The Middle Kingdom”. The first of theseorders involves a complete offline coating
system, with coater and two Janus calenders, for Shandong Chenming Paper
Holding Ltd. The second order entails
newsprint and improved newsprint machines for Jiangxi Paper Co. Ltd.

35
These pictures give some impression of thecontract signing ceremony and subsequent gettogether in the impressive “Great Hall of thePeople”.

Agreements were also signed for pro-

The contract signing ceremony – held in

The commissioning of the new machines

duction technology transfer to state ma-

the “Great Hall of the People” with high-toward the end of 2002 and at the begin-chine-building companies. Voith Paper

level delegations from the Ministry ofning of 2003 will be a very special occa-

thus meets an important SETC require-

light industry and the State Economy andsion – seventy five years previously, inment for local production of paper ma-

Trade Commission (SETC) – was broad-

1929, the first Voith paper machine inchine parts and line components accord-

cast on Chinese TV and radio and head-

China went on line. It has been followed

ing to Voith Paper specification.

lined in the national press. This clearly

since then by numerous other machinesreflects the importance attached by China

for practically all grades. This just goes

This is an important contribution by

to upgrading its paper industry as part ofto show that global playing and long-term

Voith Paper to the partnership required

the enormous national effort toward apartnership are not a modern concept by

for modernizing China’s older paper mills.

modern and competitive state economy.

any means.

361Laakirchen PM 11 –a challenge for SC-A plus papers
In mid-October last year, the AustrianWith a design speed of 2,000 m/min andto replace the smaller and outdated PM 3.

company, SCA Graphic Laakirchen AG,

a web width of 9,650 mm, the new PM 11

The new PM 11 will be erected in a ma-ordered a new paper machine fromwill produce 240,000 t.p.a. of SC-A plus

chine room around 300 metres long adja-

Voith Paper. The purpose of this invest-

graphic papers with basis weights be-cent to the existing PM 10. The extensive

ment is to further expand the market

tween 52 and 56 g/m 2. The new machine,

structural work required is already well

position in high-grade SC-A plus maga-

to go on line at the end of May 2002, isunderway.

zine papers, and to enhance mill prof-

designed for a future capacity expansion

itability at SCA Graphic Laakirchen AG.

to 400,000 t.p.a.

The entire new PM 11 line is based on
the Voith Paper “One-platform paper

2Technical data of the new PM 11
Wire width: 9,650 mm
Product: SC-A plus, basis weights 52 to 56 g/m 2
Output: 240,000 t.p.a. (phase 1),
400,000 t.p.a. (phase 2)
Design speed: 2,000 m/min

After years of intensive planning, SCA

machine concept”. Unique worldwide,

Graphic Laakirchen AG received approval

this new concept impressively demon-

from its parent company, Svenska Cellu-

strates the pioneer role of Voith Paper inlosa Aktiebolaget (SCA), for a new PM 11

partnering the paper industry with future-Paper Machines

37

Fig. 1 : Location of the new PM 11(marked in blue).
Fig. 2: SCA Graphic Laakirchen today.
Fig. 3 : Board Chairman Michael Rogowski(standing in the centre) with his company
management and the SCA Graphic Laakirchen /Voith Paper project team.
Fig. 4: Ole Terland, Board Chairman of SCA
Graphic Laakirchen until October 2000, talking
with Michael Rogowski and Harry Hackl.
3

4oriented technologies. The great advan-

results. Our “One-platform paper ma-

The phase 1 concept of this new machine

tage of this modular concept is that it canchine concept” has now been imple-

is aligned to the reputed Laakirchen SC-A

be expanded and adapted according tomented for all main graphic grades, withplus quality. A big advantage of the Voith

production demands and paper quality

six new paper machines built on thisPaper “One-platform paper machine

requirements.

principle:

concept” is that in a later phase, the machine can easily be adapted to future

The forming system in PM 11 comprisesa DuoFormer TQv with ModuleJet headbox. Maximum dryness and optimal paper quality with minimal 2-sidedness are
ensured by a Tandem NipcoFlex presswith two double-felted shoe presses. Furthermore, PM 11 will incorporate TopDuoRun advanced dryer technology.
Minimal paper losses and optimal rollquality will be assured by the Sirius
winder, and the offline Janus MK 2 technology will ensure optimal calendering

I Palm paper mill, Eltmann, Germany:market demands.

newsprint
I Lang paper mill, Ettringen, Germany:
SC papers
I Haindl Papier, Schongau, Germany:
SC papers
I Soporcel (Sociedade Portuguesa de

For Voith Paper this order is testimony
to our pioneering achievements in the
SC-online sector, including for example
Ettringen PM 5 and Schongau PM 9. The
choice of this Voith Paper machine con-

Celulose), Portugal: woodfree copying

cept by SCA Graphic Laakirchen for first-

papersclass magazine papers represents a fur-

I Perlen Papier, Lucerne, Switzerland:
LWC offset papers
I SCA Graphic Laakirchen, Austria:
SC-A plus papers.

ther challenge in this direction.

38

Procor – a challenge for Voith Brazil
New production line forcorrugating medium and test liner

The author:
Nestor de Castro Neto,
Voith Paper São Paulo, Brazil

In May, 2000, Voith Paper was chosen
by Papeles Cordillera S.A., a CMPCGroup company, as the supplier of acomplete plant for production of Test
Liner and Two-layered Corrugating
Medium papers, within a basis weight
range of 90 to 300 g/m 2, using mainly
recycled paper and pulp in bales.

The CPMC Group is the second major paper manufacturer in Latin America andhas 16 paper mills spread over many
countries of the continent, producing
pulp, printing & writing papers, newsprint, tissue and packaging & board
papers. This traditional client has beenplacing important orders with Voith
Paper Brazil in recent years, amongst
which we can highlight the Procart project, installed 3 years ago and, that has
exceeded the guaranteed production, anda major rebuild of the newsprint machines in Inforsa mill, 2 years ago.
The project named Procor will be implemented in Puente Alto, Chile, where
CMPC have already 5 machines running,
the new machine will result in the shut
down of existing PM 9.The 5.5 m wire
width paper machine will have initial production capacity of 150,000 tons/year ata maximum speed of 1,000 m/min, and a
total capacity at future of 230,000 tons
p.a.
The contract with Voith Paper comprises
the supply of the total production line
including stock preparation system, thepaper machine, the auxiliary equipment,
electrification, cranes, piping, project

management, erection, start-up and follow-up after the start-up.
With globalization, the Latin Americancompanies have looked for the optimization of their structures, focusing mainlyon their core business. This change resulted in a reduction of their Engineering
Departments. Voith Paper has realized
this and has build up expertise to support
the paper industry in implementing acomplete paper production line. In thecase of Procor, Voith Paper as the main
supplier acts as the contractor for thewhole project with th following supply:

Fiber System
I Pulper for recycled pulp, including
pulper feeding
I Pulper for virgin pulp, including pulp
bale conveying system
I High density cleaning
I Deflaking
I Low density cleaning
I Broke system
I Water system.

Paper Machine
Headbox
One MasterJet F/B headbox with ModuleJet for the bottom wire and one MasterJet F/B headbox without ModuleJet for
the top wire.
Contract signing by the Papeles Cordillera andVoith Paper management:
Osvaldo S. Martin, Voith Paper São Paulo (on theleft); Antonio A. Ruiz-Clavijo, Papeles Cordillera;
Kurt Brandauer, Voith Paper São Paulo;
Pedro H. Barros, Papeles Cordillera.

39

Sheet formation
A 29 m long bottom wire with drainage
elements and suction roll. A 10 m long
top wire, prepared to receive a DuoFormer D. Provision for a second 10 mlong top wire.
Press Section
A Tandem NipcoFlex press, the first of
the kind in Latin America, with 2 nips for
a 1,200 kN/m maximum load and 2 separate pick-up rolls, one between the wiresection and the press section and theother, between the first and the secondpresses.
Dryer Section
The first two TopDuoRun dryer groups ofthe pre-dryer section are equipped withvacuum rolls and DuoStabilizers.
The after dryer section is equipped with
DuoRun groups.
SpeedSizer
For size application on one or both papersides.

Hard Nip CalenderThis calender consists of a vertical tworoll arrangement, with heated bottom rolland EcoNip top roll, for a good paper surface quality.

I Electrification
I Instrumentation
I DCS
I QCS manufactured by Voith Automation

Reel
With reel spool storage for automatedtransport and change of reel spools.

Engineering

Slitter and Winder
Able to manage the whole paper machine
production and with capacity to produce
sets of up to 8 paper rolls.

Auxiliary Equipment
I Mechanical drive equipment
I Pumps
I Piping and valves
I Steam system
I Vacuum system
I HoodI Building ventilation
I Cranes
I Paper roll handling system

I Machine and system engineering
I Basic and detailed engineering for thecomplete plant
I Process, paper machine
I Project management
I Field management
I Procurement
The erection work on site is expected tostart in January, 2001; the commissioning in September 2001; and the start-up
is scheduled for December 18, 2001.
According to the Procor General Manager, Mr. Pedro Huerta Barros, this projectis the beginning of a new era for the
CMPC Paper Division, as they have plans
to develop this market all over SouthAmerica, installing similar machines inother countries.

40

Modern Karton –successful startup of high-techwhite top liner machine in Turkey
In 1998, EREN Holding, Turkey, decided
to extend their production capacities
in the field of corrugating medium,
testliner and white top liner and placed
an order for the delivery of a paper
machine with Voith Paper.

The author:
Adolf Wachter,
Paper Machines
Board and Packaging

The EREN group has more than 2,750
employees in a variety of business segments, ranging from textiles, cement, energy and tourism to paper production.
The paper manufacturer, Modern Karton,is one of the largest companies of thisgroup and one of the largest and most advanced paper mills in Turkey and Europe.

2

The paper mill is located in Corlu, theSouthern region of european part ofTurkey, approximately 90 minutes by carfrom Istanbul Airport.
Corlu paper mill has two other paper
machines: PM 1 (2,250 mm, 40,000 tons/
year) and PM 2 (2,500 mm, 60,000 tons/
year) produce fluting grades from recycled paper and straw pulp (from its own
production line).

The concept of the new PM 3
Fig. 1: Modern Karton in Corlu, Turkey.
Fig. 2: DuoCentriNipcoFlex press.
Fig. 3: Speedsizer film press.

PM 3 is designed for an annual production of 200,000 tons of fluting, testliner
and white top liner.

41

1

PM 3 is the most advanced paper machine in Turkey and is equipped withcomponents specifically adapted to its
production program: It is the first paper
machine in Turkey fitted with a ModuleJet™ dilution water control headbox;
also, the first shoe press ever used in
Turkey has been installed in Corlu.
Secondary fiber preparation system
Andritz AG, Austria, delivered a preparation system for recycled paper with a capacity of 750 tons/day and a deinking line
for 400 tons/day.
Wire section
The wire section has one fourdrinier wire
for the backliner and one for the topliner,
which produces the paper as a top wireagainst machine direction and couches
the topliner onto the backliner.
The stock for both layers is supplied
through StepDiffusor™ headboxes withpulsation attenuators, with the backliner
headbox being fitted with dilution water
control because of the higher basis
weight of the layer. This helps to achieve

excellent CD basis weight profiles since
the dilution water quantity can be adjusted individually across the machine width.
The top fourdrinier wire for the topliner isequipped with a DuoFormer™ D/K. In thishybrid former, approximately 30 % of theamount of water is drained through the
top wire, and the formation of the topliner is improved through individually adjustable loading pressures of the dewatering blades.
Press section
A DuoCentri NipcoFlex™ press was se- 3
lected for the press section. This complex
name stands for a simple, compact andproven Voith Paper standard concept for
packaging paper machines for the grades
and speeds mentioned above.
After the pick-up suction roll, the paper
web runs over a central suction press rollwith two press nips (approximately 100
and 120 kN/m).
The third nip is formed by a NipcoFlex™
shoe press with a line force of up to

1,200 kN/m. This design allows maximum dryness and optimum web run
without any open draws and thus excellent runnability.
During web threading, the full-width web
is taken off the wire, threaded throughthe press section and directed into thepress section broke pulper by a pneumatically loaded take-off doctor installed at
the plain roll of the NipcoFlex™ press.
For safety reasons, the doctor systemcomprises another pneumatically ad-

42

3

4
5

The after-dryer section comprises five
single-tier cylinders, with the first (bottom) cylinder being chromium-plated anda two-tier group. Again, performance andrunnability are ensured by components
identical to those described for the predryer section.
The entire dryer section (with the exception of the film press) is fitted with aropeless tail threading system, where thetail is transported through the dryer
groups by means of air nozzles located atjustable doctor used as cleaning doctor
to keep the roll clean and to prevent any
damage to shoe, press sleeve or felts
in case of any problems with the first
doctor.
Dryer Section
The first 14 dryers of the dryer section
are single-tiered. The proven DuoRun™
system with perforated dryer fabric rolls,
fitted with DuoStabilizer™ boxes for vacuum supply, ensures a smooth web run
at maximum speeds. The remaining cylinders of the pre-dryer section are divided

into two groups and are arranged in twotiers.
The rolls of these two-tier groups arearranged asymmetrically to provide sufficient space for stabilizer boxes. The taskof these boxes is to stabilize the web
when leaving the dryer.
The pockets between the dryers are aerated by blowing doctors which blow dry
air from the doctor back across the entire
machine width into the pockets, thus ensuring a controlled moisture discharge.

43
The most important data of PM 3:
Net production 200,000 tons/year
Grades: Fluting, testliner and white top liner
Furnish 100 % recycled paper
Machine width after reel 5,000 mm
Operating speed 1,000 m/min
Design speed 1,300 m/min
Basis weight range 90 -175 g/m 2

Ali Íhsan Aras,
Technical Coordinator,
on the PM 3 Project
It is our aim to produce high-quality
test liner and white top liner from 100 %low-grade waste paper. At the sametime, we want to produce low basis
weight fluting paper.
Fig. 4: PM 3.
Fig. 5: Dryer section.
Fig. 6: Final section.

the doctors. This system guarantees minimum threading times, greatly improves
the runnability of the machine and reduces operating cost (no ropes required).

CalenderA two-roll hardnip calender arranged upstream of the reel is used for surface
treatment.

Film press
A Voith Paper Speedsizer™ is used as
starch application unit. This film press,
with roll diameters of 1,300 mm, allows adefined application of starch, size or evencolor with a consistency of up to 13 %,thus saving drying energy in the afterdryer section.

Reel
A Voith TR 125 reel with reel spool magazine for four empty reel spools and fully
automatic change-over system permits
roll diameters of up to 3,500 mm.

Start-up

6

Shortly after start-up on July 29, 2000,
the machine produced salable testliner;
the white top liner grades produced wereof top quality even without major optimization measures.
Voith Paper thanks Modern Karton for thecooperative project handling and wishes
them all the best with their new PM 3.
Voith Paper looks forward to a good
cooperation with Modern Karton in the
future.

To achieve these targets, we have built
very sophisticated stock preparationlines for OCC and DIP and very welldesigned approach-flow systems withall the necessary auxiliary equipment.
This innovative machine has been producing top-quality paper at high operating speeds (up to 1,000 m/min.) rightfrom the start.
Now we have a production capacity of
200,000 tons per year for our customers in the corrugated case industry
located in Turkey and the Middle East.
Apart from that, the trim width of
5,000 mm we provide is an optimum
size for the corrugated case industry.
We are very proud of our state-of-theart machines.
The team of Voith Paper and the staff ofModern Karton at Çorlu have done an
excellent job.
Modern Karton thanks Voith Paper forthe good cooperation, which started
with the signing of the contract andlasted until start-up.

44

SAICA 3 PM 9 –fastest paper machine forcorrugating medium
The new PM 9, in SAICA 3, started up
on schedule in early October 2000.
Already during start-up, it became clearthat this new paper machine for the
production of corrugating medium sets
new standards for the future:

The author:
Helmut Riesenberger,
Paper Machines
Board and Packaging

On October 12, 2000, PM 9 started up
with a speed of 935 m/min at a basis
weight of 105 g/m 2. No other paper
machine for corrugating medium has
ever reached such a start-up speed.

SAICA – Spain’s major manufacturerof corrugating medium
Sociedad Anónima Industrias Celulosa
Aragonesa, (SAICA), is Spain’s largest
producer of corrugating medium and oneof Europe's leading manufacturers withan annual production capacity of 850,000
tons. The start-up of PM 9 increases
SAICA’s capacity by 350,000 tons to
1.2 million tons per year.
Fig. 1: SAICA in Zaragoza, Spain.
Fig. 2: Two-stage MultiFractor fractionation
system for a production capacity of 1,200 t/24 h.

In 1943, the first paper machine was put
into operation with an annual productionof 1,937 tons of corrugating medium.
Since then, SAICA has continuously madeinvestments and extended its production
facilities. The paper mill SAICA 1, consisting of PM 6 and PM 7, is situated directly in Zaragoza.
In 1992, SAICA 2, located approximately
25 km out of Zaragoza, started production with its PM 8. Already in May 1995,
the Board of Management decided tobuild a new paper machine for corrugating medium in SAICA 3, next to SAICA 2.
To follow the ever-growing trend towards
lighter paper grades, the new PM 9 was
designed for a basis weight range of 75110 g/m 2. On January 28, 1999, SAICA
placed the order for the delivery and installation of the new PM 9 for SAICA 3,
including the stock preparation system,with Voith Paper.

45

1

Already in the first days after start-up,
PM 9 managed to achieve its first speedrecord: With 935 m/min at 105 g/m 2, thestart-up speed of PM 9 was only slightly
below the design speed for this basis
weight range. Any other paper machinefor corrugating medium so far has neverreached such a high start-up speed.

SAICA PM 9 – the world’s fastest
production line for corrugating medium
The concept of the new machine sets new
standards in many respects. The wire
width of 8,100 mm alone is very impressive, but PM 9 far outshines other machines due to its enormous speed: The
new production line is designed for a
maximum operating speed of 1,450m/min. In comparison, the fastest paper
machines for corrugating medium currently run at approximately 1,050 m/min,
which means that PM 9 will run almost
50 % faster than the fastest productionlines for corrugating medium do now.

The stock preparation system

2

The stock preparation consists of twocomplete TwinPulp™ pulping lines, eachfor a pulping capacity of 850 t/24 h andeach with an 80 m 3 pulper supported bya Contaminex™ detrashing system.
This is followed in each line by two-stage
Turboseparator™ secondary pulping (2.4mm screenplate holes) together with rejects cleaners and final stage Combisorter™ hole screening (also 2.4 mm).
The full stock stream is then fed to a twostage MultiFractor™ fractionation system(0.2 mm slots) with a production capacity of 1,200 t/24h. The long fiber fraction
is passed through low consistency clean-ers and MultiScreen™ fine screening(0.15 mm slotted C-bar™ baskets) followed by thickening in disk filters, thendispersion and refining. The short fiber
fraction is low consistency cleaned andalso thickened in disk filters. The disk filters were supplied by Andritz AG, Graz/
Austria.
Both lines handle EOCC supermarket andhousehold recovered papers. In the future, one line will convert to handling recovered kraftliner and boxboard with aproduction capacity of 350 t/24 h.
Voith Paper’s supply responsibility also
included a rejects handling system fromthe joint venture partner Meri.
The design of the plant was developed inclose cooperation with the customer,
with the need for extremely high cleaning
efficiency and exacting end product quality being particularly important factors,
bearing in mind the recovered paper
quality used here.

46

3

Fig. 3: S.A.I.C.A. PM 9
Wire width: 8,100 mm
Design speed: 1,500 m/min
Production capacity: 350,000 tons/year
Grade: Corrugated medium, 75-110 g/m 2 .
Fig. 4: Start-up PM 9.
Fig. 5: SpeedFlow.
Fig. 6: The final section.

The complete paper machine was delivered by Voith Paper and basically comprises the following main components:
A MasterJet™ G headbox equipped with
ModuleJet™ dilution water control ensures optimum CD profiles. The dilution
water technology makes it possible touse the profile bar as a tool for adjusting
an optimal fiber orientation angle.
The DuoFormer™ Base, developed especially for the production of board andpackaging papers, is used for the firsttime in such a high-speed range. It ensures the optimum utilization of the fiber
potential in terms of strength and guarantees high, controlled drainage, as well
as excellent formation.
In the press section, the proven Voith
Paper shoe press technology is used:
Paper run in the DuoCentri NipcoFlex™
press is fully closed, ensuring maximum
dryness, good strength values, as well as
high runnability. The compact gap former

4
100

are equipped with DuoCleaners™ forcleaning the dryer fabrics.

80
Efficiency [%]The paper machine

A SpeedFlow™ is used to increase paper
strength values through surface sizing,
followed by an Airturn for contactlesstransfer into the after-dryer section. PM 9
is, thus, the first paper machine for corrugating medium equipped with the new
Voith Paper SpeedFlow™.

60

40

20
0
10.10

20.10

30.10
Period

10.11

20.11

design and shoe press configuration
reduce space requirements, which help
keep building expenses down.
Paper quality and runnability are central
features in the dryer section. The entire
dryer section uses a single-tier concept(TopDuoRun™) and is fitted with DuoStabilizers™. It consists of pre- and afterdryer sections. A ropeless transfer system and low-maintenance water jet tailcutters are installed for safe and rapid
web transfer in both dryer groups. The
first four groups of the pre-dryer section

The Sirius™ reel, also used for the firsttime for packaging papers, ensures precise and exact line force control over theentire rewind diameter, as well as maximum efficiency with roll diameters up to
3,900 mm and minimum paper losses
during rewinding.
Ahead of SpeedFlow™ and Sirius™ reel, aFibron system is used for rapid transfer.

Installation and start-up in record time
On February 12, 2000, installation beganwith the first stand of the after-dryer section being mounted on the foundation

47

5

Statement ofFrancisco Carilla,
Project Manager for
the SAICA 3 project6

During the last years,
there has been a continuous trend towards
reducing the basis
weight of corrugating
medium. When SAICA’s
Board of Management
decided to invest in a new mill for the
production of light-weight fluting, we
asked the major PM suppliers for references. Soon we noticed that the paper
machine we wanted did yet not exist
anywhere. After many trials on different
paper machine pilot units with different
forming and pressing concepts, wefinally chose Voith as the supplier forthe complete stock preparation line
and PM.

During the project development phase, there wasa continuous and intensive cooperation between the two project
teams, who both tried toprovide the best of theirexperiences in the various fields for designing
the plant.
Start-up was performed in a reallysmooth way, and our first impressions of
PM 9’s performance and runnability, as
well as its paper quality, are very positive. No big problems occurred during
the commissioning or start-up phase,and we feel that PM 9 will exceed the
project guarantees thanks to the deep involvement and cooperation of SAICA,
Voith and the other major suppliers of
this project.

48

7

8

Fig. 7: The management of SAICA andVoith Paper in front of the new PM.
Fig. 8: Helmut Riesenberger, project manager
of Voith Paper and Francisco Carillo, project
manager for the project SAICA 3.

rails. By mid-August 2000, the firstcheckouts, drive tests and electromechanical test runs were made; and on
October 4, stock was on the wire for the
first time.
On October 12, Spain’s national holiday
and probably Zaragoza’s most important
holiday, Virgen del Pilar, at 00.20, thetime had come: The first paper was
wound on the Sirius™ reel. As mentioned
in the beginning, the new PM 9 started
up with the impressive speed of
935 m/min and already on the following
day, salable paper was produced.
Although the installation phase had begun approximately two months later than
expected due to delays in civil engineering work, the deadlines for the end of theinstallation phase and for start-up wereboth met. This was only possible due tothe great efforts of the motivated teamsof both customer and supplier as well as
the intensive and excellent cooperation of
all parties concerned. Even after completion of the start-up phase, Voith Paper
will continue to take an active part in the
optimization of the plant.
Voith Paper thanks all persons responsible for the success of this project andwishes the SAICA group all the best with
its new flagship, the world record machine PM 9.

49

2001

Challenge the Future !
Comprehensive Solutions forPaperboard & Packaging“ahead 2001 – International Customer
Conference of Paper Machine Division
Board & Packaging
Vienna, May 8-10, 2001
Under the title “Challenge the Future! –Comprehensive Solutions for Paperboard& Packaging”, we are delighted to invite
customers from all over the world tocome to Vienna from May 8 to May 10,
2001 to exchange information and discuss the latest developments in the board
and packaging paper industry.
During this meeting, our team and international guest speakers will present themost recent trends and solutions for a
successful future: Based on trend-setting
Voith Paper reference projects realized in
the past years, we will give you a surveyof the most advanced technologies usedin practice and their actual benefit foryour company, i.e. optimization of yourproducts while reducing at the same time
the total costs in the production process.
Enjoy with us and guests from all over
the world Vienna in the springtime for a
few days! Of course, we have worked out
an attractive supporting program for you.
– Please make an entry in your calendar
for the period from Tuesday, May 8, toThursday, May 10, 2001.
Our team is looking forward to seeing
you in Vienna.

If you are interested, please contact
Voith Paper Board and Packaging Paper
Division, St. Poelten, Austria:
Ms Liselotte Stamminger,
fax: +43 (27 42) 718 83,
e-mail: liselotte.stamminger@voith.com.
Further details will be given underwww.ahead.voithpaper.com(from February 15, 2001).

“ahead 2001 – Have a look to see what’s awaiting
you: Evening reception at Palais Ferstel (left),
Customer Conference in the Redoutensäle ofVienna’s Hofburg Palace (above), ‘gemutlich’ gettogether at Schreiberhaus (below), a typical
Viennese Heuriger.

50

New developments with the TissueFlex™
1

The author:
Thomas T. Scherb,
Voith Paper São Paulo, Brazil

2

Another successful application foralso permits the ability to work with dif-

TissueFlex™ Technology

ferent linear forces for different products.

The TissueFlex™ technology with the

In our twogether magazine No. 8, we

shoe press against the Yankee cylinder,

showed the TissueFlex™ with the shoe

is successfully making papers with highfor bulk gain. We are now presenting thebulk and softness on four operating

bulk and absorption gain optimization forunits. Three other units have alreadytowelling using TissueFlex™ technology

been sold, including two complete new

associated with patented forming fabrics

CrescentFormers.

from Voith Fabrics called DSP (Dimensional Structured Paper). We will also

With this new technology, it is possible

review the new and encouraging results

to choose between an increase of paperwith the TissueFlex™ incorporating thequality or cost reduction by saving fibers

shoe for dryness and production gains.

or by using more recycled fibers. On a machine rebuild, this means a payback peri-

Significant advancements in towelling

od of approximately one year. The investment costs are extremely low when com-

We already proved the bulk and softness

pared to the costs of other technologies.

gain with different tissue papers and decided to optimize bulk and absorption

Most evident is the extremely simple andgains. The TissueFlex™ configurationeasy operation. The flexible shoe fits to

associated with a DSP imprinting wire

the Yankee cylinder profile and eliminates

improves, even more, the bulk and ab-

the necessity of crowning the press. It

sorption gains.

Paper Machines

51

Fig. 1: DSP forming fabric.
Fig. 2: Tissue made with DSP.
Fig. 3: Bulk values.
Fig. 4: Water absorption speed.
Fig. 5: Specific water retention capacity.
Fig. 6: Functionality index.
3 kg/ton Kymene, 20% CTMP, 80% SW
7 kg/ton Kymene, 1 kg/ton CMC,
30% CTMP, 70% SW

The trials were conducted with a Crescent3

Former configuration at our tissue pilot
machine located in São Paulo, Brazil. The

The target was to combine the Tissue-

8,10
Bulk (cm 3/g)

up to 30 metric tons per day.

8,50

8,5
8,0
7,5
7,0

Flex™ effect of producing a less com-

6,5

pacted paper with the pattern created by

6,0

7,00

Suction TissueFlex TissueFlex
Press Roll
+ DSP

the DSP wire (Fig. 1). The pattern is characterized by small depressions in the

Water Absorption Speed
40 Sheets [s]9,0pilot machine is able to run trials in continuous operation, with a production ofConverted towels
Conventional
DSP 3 kg Kym/t + TissueFlex™
TAD

Towel 21.0 g/m 2

11
9
7
5
3

2
4
6
8
10
12 14
Geometrical Mean Wet Tensile/BW (gf/in)/(g/m2)(Fig. 2) – which, due to capillary forces,

immersed them in water for 60 seconds,

increase the absorption.

removed them, and left them for an additional 60 seconds before weighing.

There are two types of absorption measurements: “water absorption speed (sec)”

Each market uses one or the other mea-

and “specific water retention capacity

surement to evaluate their kitchen towel,(gH 20/gfibers)”.

however, both give a complete evaluationof the towel paper used daily by house-

Water absorption speed is very impor-holds.

tant. When you use towel paper to dry awet surface, and the absorption speed is

We define a resulting factor, called “func-

slower than the movement of passing thetionality index for towel”, which is thetowel over the surface, the surface

specific water retention capacity divided

remains wet. In our trials, we measured

by the water absorption speed. The high-the time required for 40 sheets, cut iner the water retention capacity, the bet-

3” squares, to become totally saturated

ter. The shorter the absorption speed, thewhen put in contact with the water.

better.

Specific water retention is also impor-

Fig. 3 compares bulk values of the Tissue-tant, since it measures how many grams

Flex™ with and without DSP wire, andof water, per gram of fiber, the paper willshows the additional bulk gain provided

retain for a certain period of time. In

by the imprinting wire.

our trials, we took two sheets, cut inConverted towels
Conventional
DSP 3 kg Kym/t + TissueFlex™
TAD

5

13
11
9
7
5

2
4
6
8
10
12 14
Geometrical Mean Wet Tensile/BW (gf/in)/(g/m2)

3
Functionality Index
for Towel [(g/g)/(s)]9” squares, folded them as bellows andSpecific Water Retention Capacity[gH 2O/gFibers]

paper – with more fiber around and lessfiber in the middle of the depressions

4

Converted towels
Conventional
DSP 3 kg Kym/t + TissueFlex™
TAD

2

1

0

2
4
6
8
10
12 14
Geometrical Mean Wet Tensile/BW (gf/in)/(g/m 2)

6

52

Fig. 7: After-press dryness.
50% HW, 50 % SW, V = 1,500 m/min
G = 16 g/m 2, Cold yankee and Hood.
Fig. 8: After-press dryness.
50% HW, 50 % SW
v = 1,500 m/min
Grammage = 12 g/m 2
Cold yankee and Hood.
Fig. 9: Bulk.
50% HW, 50 % SW
v = 1,500 m/min
Grammage = 12 g/m 2
Cold yankee and Hood.
7
Best Felt
Average Felt
Worst Felt
After-press dryness [%]41,5is an additional gain in dryness of 1.5%,

speed for towel paper obtained withcompared to tests made earlier using a

TissueFlex™ and DSP wire, in compari-conventional felt, Fig. 7.

son with towel paper produced on con39,5

ventional machines, as well as with TAD

A significant production gain using the37,5machines.

shoe for bulk is also possible, but only
on new machines, with a T rib, reinforced

35,5
33,5
31,5
30

8

90

120 150 180 210

TissueFlex Shoe for Dryness
TissueFlex Shoe for Bulk
Suction Press Roll

46

Fig. 5 does the same comparison, now

Yankee and if operated with higher line

based on the specific water retention, andforces.

Fig. 6 presents the final balance with the
60Line Force [KN/m]

After-press dryness [%]Fig. 4 shows values of water absorption“functionality index” factor, always as a

Last year we developed a new shoe forfunction of the geometrical mean value ofdryness, and production increased with

the MD and CD wet strengths divided byexisting machines without losing bulk.

basis weight.

The Yankee will still operate under conventional line forces as with suction

It is important to note that these are re-44
42

out the use of any absorption additives

The reason for the dryness gain is the38

and special fibers, and without using theasymmetrical nip, quick pressure drop

36

best embossing method at the conversion

and less rewetting of the sheet after the34

for this type of paper.

press.

40

32
30
50

100

150

200

250

9

3,7

TissueFlex Shoe for Bulk
Suction Press Roll
TissueFlex Shoe for Dryness

3,5
3,3
3,1
2,9
2,7
50

100

150

200

Line Force [KN/m]

250

The attached tables compare the results

300

Line Force [KN/m]

Bulk [%]

press rolls.

sults from the first trials conducted with-300

In addition to bulk gain, a significant

obtained with the two kinds of shoes to

production gain on new and existing

those obtained with the suction pressmachines can be expected.

roll.

With the shoe being used for bulk, we re-

The attached Figs. 8 and 9 show the dif-

ceived bulk and softness gains for the

ferences between the two shoes and thesame line force and without loss of after-

suction press roll, regarding the after-press dryness or production, comparedpress dryness and bulk, always in rela-to the conventional suction press roll.

tion to the line force.

Results achieved over a number of trial

With the shoe for dryness, a gain of 4%months show that, when using the best

after the press dryness was obtained.

suited felt for the TissueFlex™ and, at theThis represents a 16% gain of produc-same time, using the shoe for bulk, theretion, operating with conventional line

Paper Machinesforces (Fig. 8, with 90 KN/m). There was

53

TissueFlex x Suction Press Roll for conventional line forces:a slight loss in bulk compared to the sucLine Force = 90 KN/m

Bulk

handfeel

production

payback may occur in less than a year.

Shoe for bulk with
optimized felt

+++
++++

++
+++

+
=

In the case of a new machine with T rib-

Shoe for production

=

=

+++

reinforced Yankee, operating with higher

TissueFlex x Suction Press Roll for reinforced Yankees and higher line forces:

tion press roll (Fig. 9). In this case, theline forces, the gain of dryness afterLine Force = 200 KN/m

Bulk

handfeel

production

Shoe for bulk

=

=

+++

Shoe for production

--

-

+++++

the press may reach 7% (Fig. 8 with200 KN/m), however, there is a 10% bulk
loss in relation to the suction press roll(Fig. 9).
For some market segments, where bulk
or softness is not important, a gain of 7%
dryness after the press, which would also
be an approximate 25% gain in production, would have an extremely strong
economic impact.

Conclusion
The TissueFlex™ technology has proventhat it has much to offer. In the case of
towelling, the results will be further optimized through the continued development of other DSP wires and the optimization of embossing techniques. It isalso possible to have in the same shoepress, a shoe for bulk gain and a shoe fordryness gain. Depending on the product,
it is possible to change from bulk gain to
production gain in only a few minutes.
The same shoe press has two shoes fixed
on the same supporting beam. By rotating the internal beam of the TissueFlex™
roll, one or the other fixed shoe can bepositioned against the Yankee cylinder.

54

Fibron Machine Corp. –Voith Paper’s total machine threading
specialists
Introduces its revolutionary new, patent

Due to its new compact design and its

pending Vacuum Tail Transfer (VTT)

total package options, Fibron 3000 mini-conveyor and vacuum technologies formizes mill integration requirements, andthe next millennium.

simplifies installation and commissioning
requirements. For example, as shown in
Fig. 1, Fibron 3000 has only simple pow-

The author:
Allan Broom,
Fibron Machine Corporation,
Vancouver, Canada

The new Fibron 3000 is the most ad-er, air and control requirements from thevanced, compact VTT system ever devel-

mill.

oped, and is applicable for all paper andboard grades. Each patent pending Fibron

Its integrated control system provides the3000 conveyor will incorporate a revolu-

mill with a full range of input/output op-

tionary, high power, internal drive with ations including RS 485 & RS 232 Modbus

fully integrated control system and thePlus, Profibus DP, Interbus S and CT Net.

optimal vacuum source for each applica-

Most significantly, it provides completetion chosen from a complete range of

threading system automation and control,internal and external vacuum options.

including performance logging and re-See Fig. 1.

mote troubleshooting capabilities.

Internal Drive

Mill Supply

Fibron Supply
Internal Vacuum

Compressed Air
Control Panel
Push Button
Station
A/C

patent pending

Air Supply
Control Power

RS-322Integrated
SystemController

3 PH A/C Power
Speed Reference, Mill Interlocks
1 Profibus ™ DP
(I/O Options)
1 RS 485 & RS 232 1 Interbus S ™
1 CT Net
1 Modbus Plus™

1Paper Machines

55

Fig. 1: Fibron 3000™
“Fully Integrated Compact VTT”.
Fig. 2: “Stable Vacuum” with VTT Turbo™
Vacuum Concept. Pressured air generates
vacuum efficiently through an internal turbine.

It has been optimized for the slowest ma-

Transfer) conveyor threading technolo-tion of the vacuum levels down the con-chine speeds to the highest machinegies:

veyor during the threading process.

tional testing it has been proven at

VTT 2

Fibron employs each of the conveyor

speeds in excess of 3000 meters/minute.

VTT Venturi

technologies as required – both in combi-

Fibron 3000 has proven itself ready for

VTT Turbo

nation with each other – and in combina-

speeds available today, and under addi-

tion with other threading technologies

the next generation of paper and tissue
machines.

As part of the Fibron 3000 VTT package

such as ropes, to design the most reli-(also available with our standard VTTable, cost-effective threading solution.

Fibron 3000 is the most compact VTT

conveyor packages) Fibron is able to pro-conveyor threading system ever devel-

vide the optimal vacuum technology for

oped. This opens up a wide range of neweach application, by utilizing these three

online threading possibilities where a tra-specialized vacuum technologies. Thisditional VTT conveyor threading system

ensures every customer that they will beThis new, patent pending Fibron convey-

simply would not fit.

supplied with the best, most suitable

or utilizes an internal air turbine driven

VTT Turbo™ Fig. 2technology to meet their unique require-by compressed air to create stable, con-Fibron’s 30 years of experience and 4800

ments and to provide optimal system de-sistent vacuum. This technology gives

VTT installations worldwide have demon-

sign and performance.

reliable threading performance for all
grades, speeds, machine locations andstrated that optimal VTT solutions are notprovided by a “one size fits all” approach.

Each of these technologies generates sta-

configurations. With only a simple airline

As machine speeds increase and thread-ble and consistent vacuum levels alongrequired to generate vacuum, its com-ing

becomethe complete length of the conveyor. This

pact, energy efficient design makes it

more complex, Fibron responded with theis critical for optimal threading perfor-

ideal for all space limited applications. It

development of 3 new VTT (Vacuum Tailmance. There is no pulsation or fluctua-

has significantly lower compressed air

application

requirements

2“Turbo Vacuum Profile”

Under Pressure Levels

Entrained
Air

VTT Turbo™
Compressed
AirInternal Turbine

ExhaustCompressed Air
patent pending

56

Fig. 3: “Stable Vacuum” with VTT Venturi™
Vacuum Concept. Vacuum is created byentraining air through the belt with a Venturi.
3“Venturi Vacuum Levels”
Entrained Air

Under Pressure Levels

CompressedAir

VTT Venturi™

ExhaustVenturi Throat

Compressed Air

Compressed Air

patent pending

requirements than VTT Venturi and can

It is uniquely suited to tissue applications

The external vacuum fan has the lowest

be retrofitted into all existing Fibron con-as there are no rotating parts and vacu-

power requirement of all the vacuum

veyor boxes. Additionally a VTT Turboum requirements for tissue are lower.

technologies because it uses no com-equipped conveyor is self cleaning as it

Rotating parts are to be avoided as muchpressed air. This makes it particularly

exhausts through the return run of theas possible with tissue due to the dust

suitable for customers with compressed

conveyor belt.

and associated fire hazards. Additionally

air limitations.

VTT Venturi is also self cleaning as it exVTT Venturi™ Fig. 3

hausts through the return side of the belt

Only Fibron VTT conveyors provide sta-

thereby preventing any dust build-up.

ble,

consistentvacuum,handletailwidths from 50-200 mm, and deliver
proven, reliable threading for all grades

This new, patent pending Fibron conveyor employs compressed air and the “Ven-

VTT 2™

turi” effect to create a stable, consistentfrom 8 g/m 2 tissue to 850 g/m 2 board
and pulp. Fibron VTT conveyors are reli-vacuum throughout the length of the box,

Vacuum Tail Transfer technology, invent-able for all speeds from 35 mpm toalthough the high compressed air re-ed and developed by Fibron using an ex-

2,200 mpm, and for all machine locations

quirements limit the vacuum levels at-

ternal fan, has a proven record of reliablefrom the couch roll to the reel. A fulltainable.

threading for all grades, speeds and ma-

range of integrated accessory devices,chine locations. VTT 2 upgrades the orig-

such as tail rippers, deflectors, reel

Its compact size and reliable performanceinal VTT system by using 316 stainlessthreaders, calender shoes, stabilization

make it ideal for machine locations wheresteel construction, integrated low profile,trays and rope threading accessories, en-space is limited and where compressedhead and tail pulleys for improved belt

sure optimum full machine threading per-air supply is not an issue.

tracking and compact motor mounting forformance.

easier installation.

Paper Machines

Advantages of the Fibron VTT

57

Conveyor Technology Summary

Conveyor Family

GeneralFibron 3000™ VTTStandard VTT

Design speed

3,000 mpm

3,000 mpm

Conveyor box

Stainless SteelStainless SteelDrive Belt

None

Timing or V-belt

Drive Motor

5 kW (internal)

2.2 - 5.5 kW

timal system design and performance

Possible Speed Difference

Optimized between 0 - 50 % Optimized between 0 - 50 %for every application.

Integrated Control Systemyes

I Fibron 3000™ is the most compact
conveyor threading system available
on the market with a fully integrated
drive and control system as standard.
I Full range of technology to ensure op-no

I Full range of accessory products to improve overall threading performance.

Concepts

VTT Turbo™

VTT Venturi™

VTT2™

Vacuum Created by

Air turbine

Air Venturi

Fanwith over 30 years application exper-

Stable and consistent vacuum

yes

yes

yes

tise and 4,800 installations worldwide.

Vacuum levels (relative)

100 %

60 %

100 %

I Proven performance on all grades fromInternal vacuum source

yes

yes

no
150 mmI The only Vacuum Tail Threading expert

8 g/m 2 tissue to 850 g/m 2 board andConnection

3/4” hose

3/4” hose

pulp; on all machine speeds fromPower Consumption

15 kW compressed air

30 kW compressed air 7.5 kW AC motor

35 MPM to 2,200 MPM; on all machine

Self-cleaning

yes

yes

no

Upright conveyor

optimal performance

optimaloptimalVertical conveyor

optimal performancegood

optimalInverted conveyor

optimal performancegood

optimalSpace Limited Applications

optimaloptimalaverage

Full range of integrated

yes

yes

yes

yes

yes

yes

yes

yes

yes

yes

yes

yes

yes

yes

yes

50 - 200 mm

50 - 200 mm

50 - 200 mm

locations from couch roll to reel.
I Standardized

threading

procedures,with reliable threading regardless ofgrade, speed, crew or threading path.
I Reduced

downtime,

improved

rev-

enues.
I Improved operator safety.
I Improved machine efficiency; reduced
operating costs.
I Single point responsibility for totalmachine threading operations frompress to reel.
tional parameters.

Full range of integrated initial
tail delivery devices
Full range of integrated
conveyor tail rippers

integration

with

other

threading technologies for reliable, fullmachine threading.

deflectors and discharge shoes
Full range of integrated ropes

I In house engineering expertise to proeasy

stabilization devices

Full range of integrated

I Maximum flexibility in conveyor opera-

vide

Application

threading accessories
Tail width capability

Note: Optimal tailwidth for all conveyor threading is 100 - 150 mm

58

Nipco –
25 years of system know-how
concentrated in Krefeld
The market launch of the Nipco rollwith numerous Voith Group specialists

dates back to 1974. Its name – short forand our customers in the paper industry“nip control” – really hit the nail on the– thus focusing again on the main Nipco

head: for the first time this roll enabledapplication.

a controlled line load distribution.
Today, 25 years later, it is hard to
imagine modern industry without the

The Nipco Krefeld concentration process

Nipco roll.
Four years ago Voith Paper took over the
Nipco Paper business (Nipco technology
applications in papermaking) from De“Industry” in this connection mainly

Pretto Escher Wyss, Schio, Italy. Twomeans the paper industry, which is theyears later the Roll Technology division

primary user of Nipco rolls. It should not

was taken over from Sulzer Escher Wyss,

be forgotten, however, that the Nipco roll

Zurich. As a result, the entire Nipco

is also well-established in other indus-

know-how accumulated over 25 years istries. The printing industry, for example,

now concentrated in Krefeld.

uses a large number of Nipco press rolls.
The silver jubilee of the Nipco roll stands

The Nipco division in Krefeld

for 25 years of impressive developments,

The authors:
Eugen Schnyder,
Dr. Rolf van Haag,
Andy Theiler,
Finishingas reflected in numerous patents. While

Since April 1, 2000 all Nipco activities

the basic principle has never changed, in-have been concentrated in the Nipco divi-

numerable

beension, Krefeld. Apart from the existing

made during this time – and it goes with-improvements

have

Krefeld specialists, people now work hereout saying that more will follow. The

who were previously employed at the for-foundations have been laid for the future,

mer Nipco locations in Schio, Italy andand readers are invited to draw their own

Zurich, Switzerland. The division is sub-conclusions from this article.

divided into two departments, order processing and development/design:

It should be mentioned here that reference is specifically made in the following

I Order processing follows up each con-to Nipco technology rather than merely to

tract from receipt of order to design

the Nipco roll, which is a “means to an

and manufacture, final inspection andend”. Nipco technology includes the envi-

forwarding. This also covers the asso-ronment in which the Nipco roll operates.

ciated hydraulics systems includingThis is the reason for our close teamwork

valve aggregates, and coordination

59

1with the control and automation systems. All Nipco rolls undergo comprehensive testing.
I The development/design department
provides all necessary system design
tools, continuously optimizes existingroll concepts, and works out new approaches for meeting future needs.
Several test rigs are available for systematic component testing.

Nipco technology for the paper industry
The basic principle of Nipco technology
has remained unchanged ever since thefirst Nipco roll was invented in the earlyseventies:
Support elements
The rotating sleeve is supported by a rowof hydrostatic elements mounted on abeam inside the roll (Fig. 1).

Fig. 1: Hydrostatic
support elements –the core of Nipco
technology.

60

3
300

300

250

250

Line load in N/mm

Line load in N/mm

2

200
150
100
50
0
-400 -320 -240 -160 -80
080160Distance from roll center (cm)

240

320

400

200
150
100
50
0
-400 -320 -240 -160 -80
080160Distance from roll center (cm)

240

320

400

These hydrostatic support elements are

I Line loads from 1 to 550 N/mm

Drive capacity

max. 980 kW

controlled in zones or individually to gen-

I Various sleeve system designs

Roll speed

max. 2,800 rpm

Web speedmax. 3,000 m/min

Nipco rolls normally have 12 to 14 sup-Roll diametermax. 1,120 mm

erate a prescribed line load distribution in
the roll nip.

port element zones, while Nipcorect rolls

Bearing centreline

Wider, faster and even more sensitive

have 30 to 60. The real difference be-spacingmax. 12,500 mm

To meet increasingly demanding market

tween the classical Nipco roll and the

Axis length

max. 16,000 mm

requirements, new generations of Nipco

Nipcorect roll, however, is that each indi-

Hydrostatic oil supply

rolls have been developed on an ongoingvidual support element in the latter has

system for up tobasis.

its own oil supply. This is thanks to a

Oil tank capacity

specially designed pipe-bundle oil distrib-

A dynamic test rig for rolls with flexible

ution system (Figs. 4 and 6).

sleeve systems is also available (maxi-

For example, the classical Nipco roll has

60 zones
max. 1,000 litresmum web width capacity 3,500 mm).

been adapted to higher operating speeds
by modifying the oil feed system, bear-

Precise point-to-point control

ings and seals. At the same time the pa-

Since each support element can be indi-

Revitalizing old Nipco rolls

permaker’s dream of perfect cross-profile

vidually controlled, the Nipcorect roll

The entire technical data of all Nipco sys-

control has come true thanks to develop-

enables precise point-to-point cross-pro-tems delivered since production began

ment of the Nipcorect roll (Figs. 2 and 3).

file correction over a range of almost

are stored in the Nipco division’s data-

0 N/mm to 550 N/mm.

base. Particularly for rebuilds and modernization, this enables customer needs

Modular design
Nipco technology is based on a modular

Focus on quality management

to be met rapidly and efficiently. For ex-

system. This enables the same basic

All Nipco and Nipcorect rolls undergo aample, existing Nipco rolls can be con-module to be used both for the Nipco andtough testing programme before delivery.

verted into Nipcorect rolls. Old Nipco

the Nipcorect roll, with the following

To this purpose, our roll test rig has justrolls have been revitalized in this way fortechnical data at the present time:

been modernized (Fig. 5). It is now

twenty years or so. New elements and in-equipped with extensive data recording

terfaces can also be fitted according to

I Roll widths from 1,600 to 10,000 mm

systems for the following operating para-need during rebuilds, which are super-

I Operating speeds from 1 to 2,500 m/min

meters:vised by the same team responsible forFinishing

4

Fig. 2: Line load profile at low nip loading.
Fig. 3: Line load profile at high nip loading.
Fig. 4: “Small” Nipco rolls.
Fig. 5: Test rig for web widths
up to 10,000 mm.
Fig. 6: “Large” Nipcorect rolls.

5

6

processing new orders. This ensures that
customers always benefit from the latest
Nipco technology.

Summary
Krefeld is now the focal point for morethan twenty-five years of Nipco knowhow, thus making optimal use of existing
expertise in all prior locations. Based on
the numerous Nipco rolls delivered forvarious applications, our Voith Paper
team can offer customers tailoredsolutions to meet their specificneeds. This synthesis of the various
Nipco technologies also forms a solid
basis for ongoing product development.

61

62

1

The Cera Family –hard coatings for high demands

The author:Dr. Hasso Jungklaus,
Service

The Voith Paper service centre in

In conventional press concepts today, theLaakirchen, Upper Austria offers a wide

open web run after the central press roll

range of hard coatings for paper

is often a bottleneck preventing any fur-machine rolls. Known as the Cera

ther rise in speed and efficiency. In manyfamily, this range was alreadycases the web tear strength at this pointdeveloped since 1994 under the former

is less than the tensile force required atcompany name Scapa Rolls or Scapa

someKern. The best-known family member isfrom the roll surface. Adhesion forces be-

CeraLease, which has revolutionized

tween the sheet and roll surface must

sheet output on the central press roll in

therefore be reduced to facilitate sheet

more than 300 installations worldwide.

separation without flapping. While these

After the paper-related activities ofrequirements were originally met by the

Scapa Plc. were taken over by Voith

granite roll, the limits of this material

Paper in July 1999, ceramic coatings

soon became apparent at speeds above

production and development were1,000 m/min with the additional use ofconcentrated in Laakirchen, also

steam blower boxes for better profilingserving the US market from Neenah,(Fig. 2).

Wisconsin and Portland, Oregon.

speeds for separating the web

Service

63

Fig. 1: CeraLease in daily use.
Fig. 2: Granite has its limits.
Fig. 3: Granite microstructure.
Fig. 4: Surface energy of press roll covers.
Fig. 5: CeraLease surface topography according
to paper grade.
Fig. 6: CeraLease S – surface smoothing byanti-adhesive material filling.

60
40
20
Hydrophobic Hydrophilic
Surface energy [mN/m]

The good sheet separation with granite 5rolls is due to alternating hydrophilic/

6
Decorative paperhydrophobic zones generated by the material structure (Fig. 3). Although this is
still taken as a benchmark today, modern
ceramic covers can substantially extend
the associated grinding intervals of 3 to
6 months.
CeraLease press roll covers (Fig. 1) with

LWC

their unique oxide ceramic material meetthe highest demands on sheet separation,
scrapability, smooth running, cleanlinessand form stability. This particularly ap-

CeraLease S is a further development ofplies to the latest development, Cera-

the well-known CeraLease ceramic press

Lease S. The CeraLease coating has anroll cover. While the oxide ceramic mate-even higher surface tension than granite(Fig. 4), with a particularly high polar
component. This enables rapid and uniform wetting of the roll surface, thus
reducing separation forces. A coating
topography tailored to the respective paper grade and machine operating speed(Fig. 5) supports this effect.

Newsprint

rial remains unchanged, the surface issmoothed by an anti-adhesive fluoride
polymer filling after grinding and prior tofinishing (Fig. 6). The object of this further development was to reduce coverdeposits, thus extending operating periods and improving sheet separation. Thisversion also improves on the original

60
30
0
80

Hydrophilic

60

Ceralease

Granite90

GR

Hydrophilic

120

90

Polarity [%]4

TopRock

3

Edge angle

2

64

Fig. 7: CeraSize with edge reinforcement.
Fig. 8: The Cera family members for various
applications.
Fig. 9: CeraLease coating by high-performance
plasma spraying.
7hydrophilic / hydrophobic

microstructure

characteristics of the granite roll.

press conversions where outdated concepts are replaced with modern shoepresses.

The “S” filling has resulted on reference
installations in up to four times longer

In sump type sizing presses, another ver-service life and 15% less tensile force

sion of the CeraLease cover has proved

compared with conventional CeraLease

itself well as an alternative to hard rubber

covers. The first field tests have been go-

rolls – the CeraSize. Thanks to the oper-

ing on continuously since the end of

ating characteristics of ceramic covers,

1998.

even the service life of softer rubber rolls
is greatly extended. A stainless steel edge

8
CeraLease

Central press rolls

In more than 300 installations worldwide,

protector incorporated in the CeraSize

CeraLease coatings are now first prefer-enables the smallest possible face radiusence for granite replacement rolls. Thisfor clean pocket transfer without the risk

cover is used on 80 % of the fastestof under-surface corrosion (Fig. 7).

CeraSize

Sizing press rolls

CeraVac

Suction rolls

Sachsenpapier Eilenburg, ANL Aylesford,

All the coating types available in the Cera

CeraVent

Grooved press rolls

Haindl Schongau, Schwedt and Steyrer-

family for various applications (Fig. 8)

mühl, StoraEnso Kvarnsweden, etc.). For

are manufactured in the same way: bycoated raw paper production, operating

thermal spraying of molten ceramic ortimes of several years have been attained

metal powder or wire on to the rotating

without trimming (Sappi Gratkorn, Sappi

roll surface. Since the hot particles – atEhingen et al), and wear resistance istemperatures up to 2,000° C – solidify

outstanding even on smaller machines

almost instantaneously on the surface offor decorative grades (Munksjö Unter-the roll, it is heated only insignificantly tokochen, Köhler Kehl, Technocell Osna-less than 70° C (Fig. 9).

CeraGrip

Pretensioning rolls

CeraClean/-Guide

Guide rolls / scraper bar

CeraDry

Drying roll

CeraCalCalender rolls

newsprint machines (Holmen Bravikken,

brück, Malta Dekor Pocznan, etc.). Recently, Scandinavian SC paper producers

Other highlights in the Cera family in-have also reported considerably lessclude CeraVent and CeraVac covers.

wear and tear with CeraLease S cov-

These hardmetal anti-wear coatings are

ers compared with competitive

ideal for all kinds of suction roll or
grooved press roll (Figs. 10 and 11), op-

products.

erating in the “naked” condition without
Based on their excellent

rubber or polymer cover. This can greatly

track record, CeraLease

extend the service life of bronze sleevescovers are also being

on suction screen rolls, for example,

used for numerous
9since far less trimming is required.

Service

65

Fig. 10: CeraVent wear-resistant coating forgrooved press rolls.
Fig. 11: CeraVac protects suction or vacuum
press rolls against corrosion and wear.
Fig. 12: CeraCal in a Mol calender for finishingdecorative paper.

The Cera family members CeraGuide,

10

CeraClean and CeraDry comprise dirt-repelling coatings for all paper machine applications – ceramic coatings for the screen
section, paper and felt guide rolls in thepress section, and scrapable teflon-filledhardmetal coatings for the drying rolls.
The surface finish of a hard thermo-roll
decisively

affects

paper

gloss

and

smoothness, particularly in the latest soft
calenders. The CeraCal coating centre in
Laakirchen meets this requirement perfectly, particularly with market-leader
productsfordemanding11

applications

such as on-line SC paper calendering orcoated art paper calendering (Fig. 12).
Thanks to an innovative materials/process combination enabling coating particle sizes in the smallest microscopic
range, coating smoothness is maintained
over long operating periods even under
the heaviest loading.
In summary, tailored roll covers can substantially enhance paper machine efficiency. With rising production speeds
and higher availability demands, not onlyis resistance to wear and corrosion more
important, but also optimal roll surface
quality and life. The successful trackrecord of our Service division in roll cover developments forms a solid basis formeeting the demands of the future. In
this sense, the Cera family of Laakirchen
will continue to grow both in quality andquantity.

12

66

1

Spectra –a family of composite press fabrics
Design of press fabrics

which is a success on one position, could
fail on rather a similar position.

The design of press fabrics is the art oftranslating a customer’s demands for de-A mechanical component is normallywatering and runnability into a textile

specified by target values like dimen-

construction. This exercise must be

sions, material specifications etc., and it

based on hard facts, the Basic Machine

can be accepted or rejected with refer-

Data. The demands described by the ba-

ence to measurements. A press fabricsic machine data can however be met

can be described by weight, size, perme-with different felt designs. A felt does notability, caliper etc. When judging therun by itself, it is run by the machinequality of the fabric, the quality control

crew. Thus it is essential to combine themeasurements are however completely

hard facts with the preferences expressed

irrelevant. The only acceptable criterion

by the machine crew on how the felt shallto judge the quality of a press fabric iswork.

the performance in the paper machine. If
the performance of the press fabric

The authors:
Heikki Kuokka,
Hans Ragvald,
Voith Fabrics

Important parameters for the design ofmeets the expectations of the customer,press fabrics

the fabric is good. If it does not, the fab-

I Press loading (kN/m)

ric is bad. This means that we do not

I Roll hardness (P&J)

supply a textile product; we sell a func-

I Surface structure of roll covertion!

I Machine speed
I Press geometry

A need for something more

I De-watering distribution
I Fabric conditioning

Historically it has been a practice to

I Temperaturechange as few press fabrics as possible

I Type of paper (fillers..)

at the same time. This was based on the

I Type of fibre

fact that press fabrics needed “a running

I The Customer’s opinion!

in time”, while the de-watering was poor
until it reached good function and finally

Success is always based on co-operation.

tailed off. Felts were run as long as pos-This would explain why a felt design,

sible, until they almost fell off the ma-Voith Fabrics

67

Fig. 1: Elastomer layer.
Fig. 2: Spectra family.
Fig. 3: Sectioned view of a Spectra felt, showing
the various layers.
Fig. 4: Composite felts in nip– The polyurethane layer has a natural elasticity
in the Z-direction– High resilience even after a number of nip
passages– Less caliper losses compared to standard felts.

chine. Focusing more and more on effi-

polyurethane structure is used as the com- 3

ciency, the traditional way of running be-ponent with retained properties (Fig. 1).

came out-of-date. Machine shuts have to

The elastomeric layer can be placed un-

be as few as possible and well planned.

der or on top of a fabric or between twoMore felts, in some cases all felts, arefabrics or yarn structures (Fig. 2). Forchanged at the same time and it is com-harder nips and high speed, the layer ispletely unacceptable that the felt perfor-

normally placed between two yarn struc-mance tails off before planned shuts. The

tures (Fig. 3). The design of fabrics andtraditional felts based on woven bases

choice of batt fibres must still be done

and batts struggled to meet those de-with care, using all the available data frommands, as the bases and the batt fibres,

the press position in question. The poly-by all means, will be gradually compacted

urethane layer does not do the whole job.

through life. Stable base fabric designs
and coarser batt fibres combined withhard pre-compaction became one way toBatt fibres
Top fabricPolyurethane layer
Bottom fabricBatt fibres

4*The composite felts were launched as Spectra
in North America and as Olympus in Europe.
From year 2000 the global brand name is Spectra.

design a fabric with as stable characteristics as possible through life.
Retained properties through life

Standard felt before running

A more sophisticated solution is to incorporate a component in the felt, which

In order to test the retained properties

does not change its properties, even with

under well controlled conditions, a num-

numerous passages through a hard nip.

ber of comparisons were made using a

In the Spectra* concept an elastomericSpectra and a laminated Omega felt, de-Standard felt after running

signed exactly like felts, which have runon the same 3rd press position in a high2

speed newsprint machine.
Spectra 1+1

The excellent retained caliper for theSpectra design is clearly illustrated with
Spectra 1+1+1

SEM pictures in Fig. 4. After 250,000 nip
passages the Spectra felt has 84 % re-

Composite felt before running

tained caliper while the laminated felt has
79 % only. The polyurethane layer itself
Spectra Arcus 1+1+1

has 100 % retained caliper!
The retained properties for the Spectra

Spectra 2+1+1

fabrics have been proven in many cases.

Composite felt after running

68

Case 1: SC Magazine paper, 1400 m/min,

Lower vibration level

Recently, however, we were able torecord a Spectra trial in a very efficient

pick-up positionhigh speed newsprint machine:

When using competitor felts only three

Vibrations are the limiting factor for ma-

weeks’ life could be reached and the per-chine speed and felt life in many posi-formance still tailed off at the end of thetions. The felt is often the carrier of vi-

Case 5: Newsprint, 1600 m/min,life. The machine shuts were thus planned

brations, but quite often the source is to

3rd press position

after three weeks’ cycles. With a Spectra

be found elsewhere. Worn rolls or bear-

With Spectra in the 3rd press, the millfelt in the position, the first target was toings, misaligned shafts etc. may cause

reports a 0.9 % higher dryness after thereach the planned shuts with full efficien-

vibration, which sooner or later will mark3rd press. Additional machine clothingcy, but the ultimate target was to double

a pattern into the felt. The felt can never

was all standard designs for the machine.

the life. The first felt had to be changed

absorb vibrations, but with retained re-due to a machine related shut after fivesilience it will survive longer in a vibrat-weeks, but since it has been well provening nip.

that six weeks’ life could be achieved.

Further development of theSpectra concept

Examples of retained caliper have alreadyCase 2: LWC, 1450 m/min,been shown, and this has also been

As stated above, the use of the elas-

4th press position

proven in practice. One example was giv-

tomeric layer does not eliminate the skill

In this hard nip, with linear pressure of

en in case 2, but there are more:of developing and selecting the correct
combination of yarn and batt layers. The

150 kN/m, the felts had to be changed
after three to four weeks, mainly because

Case 4: Newsprint, >1600 m/min,Spectra concept is already in its presentof an increased vibration level. The first

3rd press position

state tested on the Tandem NipcoFlex

Spectra on the position ran for 47 days

In Fig. 5 a vibration trace from the on-line

configuration, with excellent performanceand the record has later been improved

equipment is shown. The period with low

at Perlen PM 4 and some promising re-to 56 days.

and even vibration level is when Spectra

sults on Lang PM 5. In order to optimise

ran in this position. The result has been

the composite concept for the Tandem

repeated many times since this first trial.

NipcoFlex concept, trials have been per-Case 3: Fine paper, 1400 m/min,formed on the pilot machine VPM4 in

1st bottom press position

Heidenheim. The new concept involves a

In this machine the performance of the
1st bottom felt has a major impact on theHigher dryness

combination of CMD and MD yarn layerswith the elastomeric layer (Fig. 6).

efficiency of the paper machine. With
competitor felts the performance tailed

In most cases the dryness out of theoff towards the end of life, resulting inpress section of high-speed graphicalPress felts based on MD and CMD yarn

lower machine efficiency. Already withpaper machines are not recorded. On-line

layers instead of woven bases have been

the first Spectra trial on the position, thesystems measuring both nip de-watering

available in the market for a long time.

performance was very good up to aand suction box de-watering are goodExperiences from layers in this direction

planned shut, and from used felt analysis

tools and so is the record of draw be-

are quick start-up times, high nip de-there was clear evidence of residual life.

tween the press and the dryer section.

watering and good imprints. With theVoith Fabrics

69

Fig. 5: On-line vibration measurements
high speed newsprint machine.
Fig. 6: Non-woven composite fabric.
MD and CMD yarn structures for:– Quick start-up– High nip de-watering– Good impression
Elastomer for:– Retained properties through life
– Quick start-up.
5

Added value

This clearly shows that the felt, which
gives the highest paper production, is

In many cases the Spectra composite

always the most profitable one!

felts will be heavier than the competing
textile felts, as the density of polyure-With the composite concept correctly op-

thane is higher than for polyamide. Thistimised for batt and base design, it willmeans a higher felt price. At the same

no doubt be profitable for the customer,

time the paper industry has focused

independent of the higher price of themuch on cost reductions, which means

fabric.

that that the pressure on the performanceof the Spectra felts has been hard. In
Spectra in 3rd press

many cases the cost for paper machine
6

clothing per produced tonne of paper
is used as benchmark. As shown in theexample below, this could be very mis-

Summaryleading.
The Spectra concept, with an elastomeric

CMD yarn structure
Elastomer
MD yarn structure

A newsprint machine is running a four-

layer included in the felt, gives excellent

week cycle for the press fabrics. During

opportunities for high pressing efficiency

this period it produces 22,000 tonnes ofand retained properties through life. The

newsprint. The cost of one of the press

concept is exclusive for Voith Fabrics.

felts was 30,000 Euro, giving a cost per
tonne of 1.36 Euro.

There are many cases of improved resultswith Spectra, including good retainedWith an improved fabric the production

properties through life, higher pressing

could be raised by 2 % to 22,440 tonnes,

efficiency and lower vibrations.

but unfortunately the felt was 60 % more
expensive, 48,000 Euro. This led to a

The Spectra concept is at present further

addition of the elastomeric layer, the felt

felt cost of 2.14 Euro per tonne news-

developed for optimum performance inproperties will be well retained throughprint, which might be regarded as a dis-

the Tandem NipcoFlex press section.

life and the quick start-up will be further

aster.
Since 1994 more than 5,000 composite

supported.
However, 440 additional tonnes of news-

felts have performed in paper machines

The experiences from the pilot machine

print resulting from an extra 18,000 Euro,for all kinds of paper grades. Trials havetrials are very encouraging and trials on

is a profitable deal as long as the extra

been made by our competitors, but so far

commercial machines will start in Janu-

cost per tonne of paper is less thannone of them has been able to copy theary 2001.

41 Euro, which is a very low target.

technology.

70

P a p e r C U LT U R E

Another type of Global Player
Nanking, Valencia, Havana, Seoul,
Sydney – Ralf Bissdorf’s destinations
and competition dates read like thoseof an extremely busy business manager.
Yet this amenable political science
student is “only” a sports fencer in the
foil discipline keeping up with his
tournament commitments.

and then overall victory in the World Cup,and as another spectacular moment into
the bargain a silver medal at the 27th
Summer Olympic Games (photo left) in
Sydney – these are the souvenirs which
the young man from Heidenheim hascollected to date on his trips around theworld.

Runner-up in the Junior World Championships in 1991, German Champion in
1995 and 1999, European Champion in
1998, first place six times in the World
Cup tournaments of the last two years,

The active spokesman of the German
Olympic fencing team, fondly called “professor” by his team colleagues, is sitting
opposite us with two other members of
the team. To his right is Imke Duplitzer:

71

2

Olympic Games 2000: the opening ceremony in the “Australia Stadium”, which with a capacity of
110,000 spectators is the largest arena in Olympic history, was completely sold out.
Imke Duplitzer, several times military world
champion in the épée discipline. 10th place
individually and 6th team place in Sydney.

she has signed up with the German Army,has several times been military world
champion in épée fencing, and no lesssuccessful with numerous World Cup
placings and German and European
championship titles. To Ralf Bissdorf’s
left at the table is Marc Konstantin
Steifensand, a chartered engineer for nuclear reactor safety and an enthusiasticépée fencer in his spare time. He has
been a member of the German nationalteam since 1997, and won the silver
medal at the World Championships in1999.

Marc-Konstantin Steifensand, silver medallist
at the 1999 World Championships. 22nd place
individually in Sydney.

72

Ralf Bissdorf won in the quarter-final against
the Hungarian Mark Marsi.

How is it that the sports association of a
town such as Heidenheim, with a population of only 60,000, can put up three
Olympic fencing participants at the sametime? Curious to find out more, we visited the “Heidenheim Fencing Centre”. Firstof all we were told that Heidenheim is regarded among insiders as the “Wimbledon of épée fencing”. The “Heidenheim
Cup”, which has been held here since
1953, is today the world’s most important and largest fencing tournament after
the Olympics and the World Championships. Some 300 of the world’s bestépée fencers regularly cross swords in
Heidenheim in the first week after Easter.
Following the Heidenheim Cup, the“Coupe d’Europe” event is held, in whichway, the strongest club teams in Europe
establish their annual winning team.
All this began more than 150 years ago.
In royal Württemberg, as in all Germany
at the time, there was a great deal of
freedom of expression, which due to thelack of political parties, was channelled
into athletic clubs and student associations in particular. In the annals of the“Heidenheim Athletics Community” of thattime there are already details of regularmeetings on a Friday with “fencing andexercises”, for instance the winter of1847. Even though the athletic clubs andtheir fencing sections were disbanded fora time after 1848 as supposed breeding
grounds for Republican activities, there
always remained a certain weakness forthe sport of fencing in Heidenheim, an
open-minded, engineering centre which
was increasing in importance with growing connections well beyond the state’sborders. Not without justification were
the inhabitants alleged to possess greatskills in precision technology, special
mastery of physical laws and lightningfast reactions.
Things really took off again around
1930, when the first state fencing tournament was held in Heidenheim. In 1950
came the national and international breakthrough. A legendary épée team brought
the title of the German team champions
to Heidenheim five successive times between 1957 and 1961. 92 German Champion titles, participation in 148 world
championships and eight Olympic Games
with excellent results in each case – thisis the extraordinary record that fencers
from Heidenheim have established since
1950.
“How is that possible? Can you earnmoney by fencing?” This consciously
provocative question causes some amusement in our table group. Given the sumsof money accumulated today by some of
the leading sports disciplines that makeexciting viewing, the reply of a memberof the management of the “Heidenheim
Fencing Centre”, who was also present at
our get-together, seems almost anachronistic: “No-one gets rich in our sport!

Even at leading international tournaments
there is neither starting money nor cash
prizes for the winners. Of course we aresponsored by the national and state fencing associations, but for the most part
we survive on a great deal of idealism,
improvisation, personal commitment andsupport from mainly regional sponsors,
who like the Voith Group of Companies,
feel traditionally attached to fencing in
Heidenheim.”
Ralf Bissdorf continues: “To take part in
the World Cup, we not only have toinvest a great deal of time in training
and preparation, but also contribute ourshare of the costs such as travelling expenses to the venues in every continent.
But if you’re really addicted to fencing,
the whole atmosphere of this sport andthe international contacts and friendshipsthat arise from it, you’re prepared tomake this sacrifice. It’s not just for the
chance of success! These are experiences, especially taking part in the
Olympics, that none of us would want tomiss and that remain a lifelong memory.”
This idealism deserves recognition forwhat has been set up, passed on andachieved. Behind the name “Heidenheim
Fencing Centre” and the smart new building on Virchowstrasse (photos at right),
is a national centre and a focus of regional achievement where eight internationally renowned trainers and a sports
physiotherapist look after some 200
fencers. The centre has three halls with30 fencing pistes, physiotherapy, bodybuilding and training rooms and a purpose-built, welcoming administration
wing. Adjoining this is a day-boarding
sport school which enables highly talent-

73

9

ed children and teenagers to combine
competitive sport with their regular education. At present 40 children are taking
advantage of this facility.
But let’s return to our Olympic participants. Their description of the stay in
Sydney underlines once again the enthusiasm which all three have for their sport.
Sydney was unique, from the opening to
the closing ceremony. The underlying
motto of water, fire, sun and a scenic interpretation of proximity to nature, thespirit and dream world of the Aborigines
proved to be utterly fascinating. Above all
the people: the easy-going nature of theAustralians, their friendliness and openhearted spirit.
When the small fencing team, on a stroll
through the city centre, missed their bus
for a punctual return to the Olympic Village in order to get ready for the next
event, a fisherman was only too happy tohelp: he spontaneously invited them on
to his boat and took them straight acrossthe bay and said with a smile how happy
he was to be able to help.

It’s a great thing that experiences of thiskind are still possible in the increasingly
commercialised world of sport. As a
global player we wish all three many
more sporting successes in the truest
sense of the word, similar friendly acquaintances throughout the world andfor the “Heidenheim Fencing Centre” tocontinue its activities as a source ofsporting achievement discipline that in an
Olympic sense truly unites people. Voith
will continue to support this work. A
worthwhile task, don’t you agree?
Manfred Schindler

Paper Technology Journal“twogether” is published twice annuallyin German and English. Contributions by
independent authors do not necessarilyreflect the opinion of the publisher.
Please address all correspondence andinquiries to the editor.
Published by:Voith Paper Holding GmbH & Co. KG
Editor:Dr. Wolfgang Möhle, Corporate Marketing,
Voith Paper Holding GmbH & Co. KG,
Tel. (++49) 73 21 37 64 05
Fax (++49) 73 21 37 70 08
P.O. Box 1970, D-89509 Heidenheim
http://www.voithpaper.com
Editorial coordinator:
Manfred Schindler, D-73434 Aalen
Design, layout and typesetting:
MSW, P.O. Box 1243, D-73402 Aalen
Copyright 2/2001:
No part of this publication may be reproduced
or copied by any means whatsoever without
the express permission of the editor.
Issue 11, February 2001.

2/2001/21 MA Printed on chlorine-free bleached paper manufactured with Voith Paper Holding machinery.

Newsmagazine for theinternational clientele,
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