Paper Technology Journal

Triple Star – A picturebook startup
in Gratkorn.
Brilliant two-sided coating at
2000 metres per minute.
News from the Divisions:
Winding technology for the next
millennium.

5International Paper Technology:
Tissue on the upsurge.
Paper Culture:
Ludwigslust palace – waste paper
recycling of a different kind.

Cover picture: PM 11 at KNP LEYKAM
in Gratkorn, Austria, the world’s mostefficient plant for the production ofhigh-grade wood-free coated paperwith basis weights of up to 170 g/m 2.
The plant’s overall conception –PM 11, Coater 11, calendering andwinding technology – is well ahead ofits time. The new reel dimensions with
3.6 meters in diameter and 120 metrictons or more in weight are impressive
too. See articles on pages 8 and 44.

Contents

EDITORIAL
Top 5, one team – introductory remarks from the management

2

HIGHLIGHTS
Startup highlights in 1996/97 and recent large orders

4

Triple Star – A picturebook startup in Gratkorn, Austria

8

Brilliant two-sided coating at 2000 metres per minute

12

Wire width 10,500 mm – two of the world’s largest paper machines for China

20

Mayr-Melnhof chooses Voith Sulzer technology for its first shoe press project

21

NEWS FROM THE DIVISIONS
Stock Preparation Division: Dispersion, stickies and optical cleanliness

22

Stock Preparation Division: New possibilities for water management

28

Paper Machinery Divisions: Ortviken PM 4 – success for a new concept

35Paper Machinery Divisions: A new former for top plies of packaging papers

38

Customer Information Meeting of the Paper Machine Division Board and Packaging

43

Paper Machinery Divisions: Winding technology for the next millennium

44

Finishing Division: Startup of the first Janus calender at KNP

50

Service: After-market service saves fiberlines

54

Service: Measurement and diagnostics join the team with DIAG S.A.

59

INTERNATIONAL PAPER TECHNOLOGY
Tissue on the upsurge

61

QualiFlex Contest – record after record

68

Active patent protection – in the interest of our customers

69

Paper Machine Division Board and Packaging under new management

70

Management of Voith Sulzer Papiermaschinen GmbH, Heidenheim, enlarged70

New office in Finland

71

PAPER CULTURE
Ludwigslust Palace – waste paper recycling of a different kind72

Stock Preparation
Graphic Paper Machines
Board and Packaging Paper Machines
FinishingService

Dear customers, dear readers!
To take the lead in quality, thanks to top technology, innovative methods and excellent
service! This was the vision when Voith Sulzer Papiertechnik was created. Unique inthis trade, its corporate structure, with five independently operating divisions, isoriented towards this target. The company’s comprehensive product range is unique
too: the entire technical equipment required by the paper and board industry, ranging
from woodyard handling to packaging logistics for the final paper product. Top 5,
one team, with everything from a single supplier.

Hans Müller,
President and CEO
Voith Sulzer Papiertechnik

Since its establishment, Voith Sulzer Papiertechnik has succeeded in boosting its
turnover by more than 25 percent – after adjustments for acquisitions – within only
three years. This is convincing confirmation of the wide acceptance of our objectives
and our company philosophy: to be a partner to the paper industry with efficientmethods and a competitive edge.
In this issue of twogether magazine you will find three interesting examples of how
our top technology enhances quality, efficiency and competitiveness: Gratkorn,
the world’s most advanced plant for the production of high-grade printing papers;
Brilliant Coating, the state-of-the-art test plant for innovative coating technology,
and Dagang, two large plants for the production of photocopy, writing and printing
paper for the Chinese market. In addition, you will again find numerous innovative
system components presented here, with examples of their performance andcontributions from the research and development areas. These have turned ourcustomers’ magazine into a popular technical journal with a worldwide readership.
I hope you enjoy reading your magazine and discover many interesting ideas within
its pages.
Sincerely yours,

Hans Müller

“Voith Sulzer Stock Preparation
is currently the world’s leading
supplier of paper recycling
plants. Thanks to strategic
alliances it is also the only
supplier which covers the fullproduct range from raw material

graphic paper machinery havesubstantially exceeded the previous year’s figures. In themature markets of the industrial
world we were able to secureinteresting orders for the modernization of existing production
facilities. For the future too, we
consider that there is considerable potential in modernization
work aimed at improving quality
and efficiency. We are prepared
to develop this potential together with you – our customers –“Thanks to the introduction by
the Finishing Division of its
Janus and Ecosoft machines,graphic papers in particular now
display even more excellent
surface properties. Considerably
improved optical surface values

our competitors. However, tocontinue to exceed our customers’ expectations, we must
continue to grow. We are doing
so with new Service Centers in
Brazil, and the U.S., and plans formore in the Far East and Europe.
No matter how many locations
we may have, it is essential that
we continue to view the Service
Division from the same perspective as our customer – «the only
Service Center I care about is the
one nearest my mill.» We must

The managers of Voith Sulzer Papiertechnik on the current situation
storage to the papermaking
machine, including all peripheral
equipment. This number-one
position spurs us on to offer
customers the latest innovations
and technologies. Our efforts arebacked by two large research
centers in the USA and inGermany. Today, more than
65 % of incoming orders are formachinery and systems of akind that did not exist until four
years ago, when Voith andSulzer merged their businesses.
This innovative synergy
represents a good basis for the
future – both for our customers
and ourselves.”

and to support you in yourefforts to produce your paper
product in an improved andmore efficient way.”
Dr. Hans-Peter Sollinger
Paper Machine Division
Graphic

Dr. Lothar Pfalzer
Stock Preparation Division

are expected to be achieved,
especially in the field of SC
papers, by the imminent
introduction of new machines.
In addition to the surface, thefurther processing of all paperand board grades needs
fundamental revision too. In
this area, we have again trodden
new paths with the introductionof Twister and Torowinder(reel cutting machines). Only
with technical/technologicalinnovations will we be able
to safeguard Germany as anindustrial base. The needs andrequirements of our customers,
who are involved at an earlystage, are always at the focal
point of our efforts.”
Dr. Dieter Kurth
Finishing Division“The consumption of board
and packaging paper is strongly
correlated with economic
growth. New production capacities will therefore be requiredin particular in the countriesof South East Asia. Westerncountries put an increasingemphasis on projects forenhancing the efficiency andquality of existing plants.
“By means of market-oriented
product development we havestrengthened and expanded ourleading position in all areas of
papermaking machinery technology. Pioneering innovations
have been introduced to themarket successfully. Thanks
to this excellent basis and apositive trend in Asia’s growthmarkets, incoming orders for

Our research and development
activities and the extension of
our sales operations as well as
cooperation with our joint
ventures in China and Russia
ensure optimum implementationof the investment targets of ourcustomers.”
Prof. Dr. Franz Silbermayr
Paper Machine Division
Board and Packaging“Customer Support – For us thismeans treating our customers astrue partners, delivering to theman ever-growing range of products and services. Our primary
goal is to offer these valueadded benefits in the fastest andmost flexible way possible. In
order to convert our goals intomeaningful actions, we realizethat we must also provide facilities which are as geographicallyclose to our customers as possible. That is why we alreadyoperate more Service Centersaround the world than any ofcontinue to be for our customers
a responsible and reliable local
partner, ensuring their competitive position in this great industry.”
R. Ray Hall
Service Division“Since Voith Sulzer Papiertechnik
was established, we have tried
to concentrate our joint capability
areas and expertise in paper
technology to support ourcustomers in their longing for
economic success. Given thistarget, we are fully aware of theneed for continuous improvement.
Only if we succeed in boosting
our customers’ own successas a result of our commitment
and cooperation can we claimthat we have accomplished thistask.
On the basis of the results
achieved so far, we are confident
that this unremitting challenge
can be accepted, and determined
to supply our customers with thepartnership and assistance theyneed.”
Dr. Hermann Jung
Finance and Controlling

4

HIGHLIGHTS

Startup highlights in 1996/97

Stock preparation
Waste paper processing systems
and subsystems for graphic papers
Georgia-Pacific Corporation,
Kalamazoo, Michigan, USA.
Papresa, Spain.
Stora Hylte AB, Hyltebruk,Sweden.
Papierfabrik Palm GmbH & Co.,
Eltmann, Germany.
Cartiere Burgo S.p.A., Verzuolo,
Italy.
Sepoong Co. Ltd., Sepoong,
South Korea.
Cartiere Burgo S.p.A., Mantova,
Italy.
Hansol Paper Co. Ltd., Chonju,
South Korea.
Australian Paper, Fairfield,
Australia.
Schwäbische Zellstoff AG, Ehingen,Germany.
Halla Pulp and Paper Co. Ltd.,South Korea.
Daehan Paper Co. Ltd.,South Korea.
Steinbeis Temming Papier GmbH &Co., Glückstadt, Germany.
Holzstoff- und Papierfabrik Zwingen
AG, Zwingen,
Switzerland.
Haindl Papier Schwedt GmbH,
Schwedt, Germany.

Waste paper processing systems
and subsystems forboard and packaging papers
Port Townsend Paper Corporation,
Port Townsend, Washington, USA.
Simplex Industries, Constantine,
Michigan, USA.
Saica, Spain.
Papelera del Nevado, Mexico.
P. T. Indah Kiat Pulp and Paper
Corp., Indonesia.
Knauf, St. Petersburg, Russia.
Papeteries Emin Leydier,
St. Vallier, France.
Peterson Moss A.S., Norway.
Rigid Paper Products Ltd., Selby,
Great Britain.
Danisco Paper A.S., Grenaa,
Denmark.
Europa Carton AG, Hoya,
Germany.
Moritz J. Weig GmbH & Co.KG,
Mayen, Germany.
Corenso United Oy Ltd., Varkaus,
Finland.
Thai Kraft Paper Ind. Co.Ltd.,
Thailand.
Papierfabrik Meldorf GmbH &Co. KG, Tornesch, Germany.
Papierfabrik Schoellershammer,
Düren, Germany.
Klingele Papierwerke GmbH & Co.,
Weener, Germany
SCA Aschaffenburg, Aschaffenburg,
Germany.

Waste paper processing systems
and subsystems for tissue papers
Nampak Paper Ltd., Bellville,
South Africa.
Carlton Paper Co. of South Africa(Pty) Ltd., Johannesburg, South
Africa.
Wepa Papierfabrik, Giershagen,Germany.
P. Krengel GmbH & Co. KG,
Arnsberg, Germany.
Waste paper processing systems andsubsystems for other types of paper
Munksjö Dekor, Unterkochen,
Germany.
Papeteries de Bègles, Bègles,
France.
Felix Schöller jr., Burg Gretesch,Germany.
Hunsfos Fabrikker, Vennesla,
Norway.

Paper machines
Graphic papers
KNP Leykam, Gratkorn, Austria.
Nippon Paper Industries,
Yatsushiro, Japan.
Nippon Paper Industries Co. Ltd.,
Iwakuni, Japan.
Sinar Mas Pulp and Paper
Industries, Sinar Mas, India.
Tianjin No.4 Paper Mill,
China.

Board and packaging papers
Mazandaran Wood and Paper
Industries, Sari, Iran.
Ningbo Zhonghua Paper Company,
Ningbo, China.
Zülpich Papier GmbH, Zülpich,Germany.
VPK Oudegem S.A.N.V., Oudegem,
Netherlands.
Visy Paper, Staten Island NJ, USA.
TissuePapierfabrik Albert Friedrich,
Miltenberg, Germany.
Wepa Papierfabrik, Müschede,
Germany.
Strepp GmbH & Co. KG, Kreuzau,
Germany.
Thrace Papermill S.A.,
Greece.
Asia Pulp & Paper, Pindo Dell,
Indonesia.
Bacraft S.A., Santo Amaro, Brazil.
Rebuilds
Sczetin Skolwin S.A., Poland.
Alliance Forest Products, Dolbeau,
Canada.
Sanku Paper, Fuji, Japan.
Stora Kabel GmbH, Hagen,Germany.
Felix Schoeller Jr. GmbH & Co,
Gretesch, Germany.
Haindl Papier GmbH, Walsum,
Germany.

5

Pulp & Paper Corp., Stone
Savannah River, Port Wentworth,USA.
Papierfabrik Palm GmbH & Co.,
Eltmann, Germany.
Carl Macher GmbH & Co.,
Brunnenthal, Germany.
Mondi Kraft Piet Retief Mill, South
Africa.
Zadklady Celulozy i Papieru S.A.,
Swiecie, Poland.
Cartiere Fedrigoni & Co., S.p.A.,
Arco, Italy.
Cartiera di Cadidavid S.r.l., Verona,
Italy.
Kitakami Seishi KK, Ichinoseki,Japan.
Takasaki Paper MFG Co. Ltd.,
Osaka, Japan.
American Israelian Paper Mills,
Hadera, Israel.
Montreal, Canada.
Ambro S.A., Suceava, Rumania.
Assi Domän Scaerblacka AB,
Scaerblacka, Sweden.
Stora Carton & Board GmbH,
Baienfurt, Germany.
Fritz Peters GmbH & Co KG,
Gelsenkirchen, Germany.
Patria Papier- und Zellstoff AG,
Frantschach, Austria.
Hiang Seng Fibre Container Co. Ltd.,
Bangkok, Thailand.
Korsnäs AB, Gävle,Sweden.
Aylesford Newsprint, Aylesford,
Great Britain.
PWA, Stockstadt, Germany.
Papierfabrik Mochenwangen,
Mochenwangen, Germany.
Europa Carton AG, Hoya, Germany.
Papierfabrik Doetinchem B.V.,
Netherlands.
Smith, Stone & Knight Ltd.,
Birmingham, Great Britain.
Sappi Europe, Blackburn,Great Britain.
SCA Packaging de Hoop,
Netherlands.
Assi Domän Carton AB, Frövi,
Sweden.

Liaoning Intern. Trade Corp.
Liaoyang, China.
Toprak Kagit Sanayii A.S., Toprak,
Turkey.
Hapa Verwaltungs AG, Hallein,
Austria.
Asia Pulp & Paper Co. Ltd., Dagang,
Singapore.
Pisa Papel-Imprensa SA,
Jaguariaiva, Brazil.
Fernandez SA Industria de Papel,
Amparo, Brazil.
Papel Prensa SA, Buenos Aires,
Argentina.
Westvaco Corp., Luke, USA.
Appleton Papers, West Caroltown,
USA.
Longview Fibre Co., Longview,
USA.
Torras Domenech, Spain.
Torras Sarrio, Spain.
Saica, Spain.
Mitsubishi Paper Corp., Hachinohe,
Japan.
SCA Finepaper, Hallein, Austria.
Chuetsu Pulp Corp., Nohmachi,
Japan.
Jujo Paper Board Tokyo Mill, Japan.
Oji Paper Co., Ltd., Kushiro, Japan.
Ziegler Papier AG, Grellingen,
Switzerland.
Votorantim Cellulose e Papel S.A.,
Piracicaba, Brazil.
Crown van Gelder Papierfabriken,
Holland.
Genting Sanyen Ind. Paper,
Malaysia.
SCA Wifsta-Östrand, Sweden.
Coating technology
SCA Fine Paper, Hallein, Austria.
Haindl, Walsum, Germany.
Tianjin Paper, Tianijn, China.
Westvaco Corp., Wickliffe, USA.
KNP Leykam, Gratkorn, Austria.
Felix Schöller jun. Papierfabriken
GmbH & Co KG, Osnabrück,
Germany.
Guanzhou Victorgo Ind. Comp. Ltd.
Shin Ho Paper Mfg. Co. Ltd.,
Seoul, Korea.

Stora Hillegossen, Germany.
Consolidated Paper, USA.
Champion International Corp., USA.
Kombassan Holding, Murathi,
Turkey.
Mead Corporation, USA.
Assi Domän Carton AB, Frövi,
Sweden.
Burgo, Sora, Italy.
Brilliant Coating Pilot SM 2,
Heidenheim, Germany.
Valchiampo Paper Mill, Italy.
Sarego Paper Mill, Italy.
Champion, Quinnesec, USA.
Mead Chillicothe, USA.
Winding technology– DuoReel
Forestiers Alliance Inc., Dolbeau,
Canada.
August Koehler AG, Oberkirch,
Germany.
Shin Ho, Daejeon, Korea.
Pratt Industries Inc., USA.
Hermanecke Papierne akciova
spolocnost, Poland.
Bacraft S.A. Industria de Papel,
Brazil.
Mazandaran Wood and Paper
Industries, Sari, Iran.
Zadklady Celulozy i Papiern S.A.,
Swiecie, Poland.
– Sirius/Sirius rewinder
KNP Leykam, Gratkorn, Austria.
– WindersConsolidated Papers Inc.,
Wisconsin, USA.
Fabryka Papiern Szczecin-Skolwin
S.A., Poland.

Supercalenders
Tianjin, China.
Yuen Foong Yu, Taiwan.

Ecosoft calenders
Halla, Korea.
Forestiers Alliance Inc.,
Dolbeau, Canada.
Berghulzer, Netherlands.
Appleton Papers, USA.
Sappi, Blackburn, Great Britain.
MNI, Malaysia.
Miliani, Hungary.
Votorantim Piracicaba, Brazil.
Ningbo PM 2, China.
Ningbo PM 3, China.
Cascades La Rochette, France.
Dae Han Paper, Korea.
Maltadecor, Poland.
Suzano Rio Verde, Brazil.
Arjo Wiggins, Great Britain.
Amotfors, Sweden.

Machine calenders
KNP Leykam, Austria.
Ningbo PM 2, China.
Ningbo PM 3, China.
Shin Dae Yang, Korea.
Hwa Seung Paper, Korea.
Ding Il Paper, Korea.

Rebuilds
KNP Leykam, Austria.
Haindl, Walsum, Germany.

Twister
Hankuk, Korea.
Halla, Korea.
Gebr. Lang, Germany.

FinishingJanus Concept
KNP Leykam, Holland.
KNP Leykam, Austria.
Gebr. Lang, Germany.
Shin Ho, Daejeon, Korea.
Oji Paper Co. Ltd., Kushiro, Japan.

Roll handling
Halla, Korea.
KNP Leykam, Netherlands.
Scheufelen, Germany.
Gebr. Lang, Germany.
Hankuk, Korea.

6

HIGHLIGHTS

Recent large orders

Stock preparation

Waste paper processing systems
and subsystems for graphic papers
Perlen Papier AG, Perlen,
Switzerland.
Papierfabrik Palm GmbH & Co.,
Eltmann, Germany.
Gebrüder Lang GmbH, Ettringen,Germany.
Steinbeis Temming Papier GmbH &Co, Glückstadt, Germany.
Felix Schoeller jun. GmbH & Co. KG,
Gretesch, Germany.
Drewsen GmbH & Co KG,
Lachendorf, Germany.
Papierfabrik Palm GmbH & Co.,
Aalen, Germany.
August Koehler KG, Oberkirch,
Germany.
Holzstoff- und Papierfabrik Zwingen
AG, Zwingen, Switzerland.
Stora, Corbehem, France.
Norske Skog Golbey S.A., France.
Soporcel Socieda Portugesa deCellulose S.A., Portugal.
Haindl Papier GmbH, Germany.
Munksjö, Unterkochen, Germany.
Halla Paper Co. Ltd., Korea.
Hansol Paper Co. Ltd., Korea.
Genting Sanyen SDN BHD, Malaysia.
Hunsfos Fabrikker, Vennesla,
Norway.
Parenco B.V., Renkum, Holland.
Papelera Peninsular, Spain.
Schoeller & Hoesch, USA.
Bowaters/Great Northern Paper,

East Millinocket, USA.
Felix Schoeller, Great Britain.
Waste paper processing systems
and subsystems forboard and packaging papers
Adolf Jass GmbH & Co KG, Fulda,
Germany.
Corenso United Oy Ltd., Varkaus,
Finland.
Portucel-Viana Empresa, Portugal.
SCA Packaging, Munksund,Sweden.
Schoellershammer GmbH & Co KG,
Osnabrück, Germany.
Smurfit Carton y Paper de Mexico
SA de CV, Cerro Gordo, Los Reyes
Ixtacala, Mexico.
Willamette Industries, Campti,
Lousiana, USA.
Union Camp. Corp. Franklin,
Virginia, USA.
Domtar Packaging Ltd., Red Rock,
Ontario, Canada.
Zinc National, Monterrey, Mexico.
Cia de Papel do Prado, Portugal.
Saica, Spain.
Europac, Spain.
Genting Sanyen SDN BHD,
Malaysia.
Hansol Paper Co. Ltd., Korea.
Dae Han Pulp Ind. Co. Ltd., Korea.
Waste paper processing systems
and subsystems for tissue papers
Kimberley Clark GmbH, Flensburg,
Germany.
Nampak Paper Ltd., Bellville,
South Africa.

Copamex Planta Uruapan, Uruapan,
Mexico.
Copamex Planta Tissue Monterrey,
Monterrey, Mexico.
Oconto Falls Tissue, Oconto Falls,
Wisconsin, USA.
Genting Sanyen SDNBHD, Malaysia.
Dae Han Pulp Ind. Co. Ltd., Korea.
Waste paper processing systems
and subsystems for other grades
International Paper Co.,
Rieglewood, North Carolina, USA.

Paper machines
Graphic papers
Asia Pulp & Paper Co. Ltd, Dagang,
China. (2 PM)
Malaysian Newsprint Industries
Ltd., Mentakab, Malaysia.
Quena Newsprint Paper Company,
Quena, Egypt.
Soporcel-Sociedade Portuguesa deCelulosé S.A., Lavos, Portugal.
China National Technical Import &Export Corp., China.
Board and packaging papers
Modern Karton Sanayi ve Ticaret
S.A., Turkey.
Guangzouh Victorgo Industry Co.
Ltd., Victorgo, China.
TissueLontar Papyrus, Jambi, Indonesia.
Suzhou (2TM), China.
Hengan, China.

Goma Camps, LaRiba, Spain.
Oconto Falls, USA.
Rebuilds
Stone Container, New Richmond,
USA.
Kombassan A.S., Kombassan
Turkey.
Lee & Man Paper ManufacturingCo., Ltd., China.
Kartonsan Karton San Tic A.S.,
Kartonsan, Turkey.
Pakerin Pulp & Paper, Pakerin,Indonesia.
P.T. Lotar Papyrus Pulp & Paper,
Indonesia.
P.T. Pindo Deli Pulp & Paper Mills,
Indonesia.
Asia Pulp & Paper Co., Ltd.,
Suzhou, China.
D.D. Umka Fabrika Kartona, Umka,
Yugoslavia.
Nippon Paperboard Co., Ltd.,
Jujo Paper Board, Japan.
Eurocan Pulp & Paper Co.,Eurocan-Kitimat, Canada.
Papeteries de l'Aa, Wizernes,
France.
Roman Bauernfeind GmbH,
Fronleiten, Austria.
E.B. Eddy Forest Products Ltd.,
Espanola, USA.
Papierfabrik Hermes GmbH,
Düsseldorf, Germany.
Wisaforest OY AB, Pietsaari,
Finland.
Consolidated Papers Inc., Biron,
USA.
Parenco. B.V. Renkum, Netherlands.

7

Papierfabrik Utzenstorf AG,
Utzenstorf, Switzerland.
Adolf Jass, Fulda, Germany.
Hermes, Düsseldorf, Germany.
Arjo Wiggins Papiers & Couches,
Wizernes, France.
VPM Kymmene, Wisa Forest,
Finland.
Assi Domän Skärblacka AB,
Skärblacka, Sweden.
Marackeh Pulp & Paper Industries,
Teheran, Iran.
Miguel y Costas, Spain.
Saica, Spain.
Patria Papier & Zellstoff AG,
Frantschach.
UIPSA, Spain.
Icec Papcel a.s., Ruzomberok,
Czech Republic.
Zinc Nacional S.A., San Nicolas,
Mexico.
Westvaco Corp., North Charleston,USA.
Kruger Inc., Montreal, Canada.
LSPI, Duluth, USA.
Fletcher Challenge, Elk Falls,
Canada.
Fraser, Madawaska, USA.
Mead Corp., Rumford, USA.
E.B. Eddy Forest Products Ltd.,
Hull, Canada.
Orsa Fabrica de Papelao Ondulado
S.A., Itapeva, Brazil.
Fernandez S.A., Amparo,Brazil.
Klabin Fabricadora de Papel e
Celulosa, Piracicaba, Brazil.
Votoranim Celulose e Papel,
Votoranim, Luiz Antonio, Brazil.

Inforsa Industrias Forestales S.A.,
Nascimiento, Chile.
Fraser Paper Ltd., Madawaska,
USA.
Nippon Paper Industries,
Yatsushiro, Japan.
Nippon Paper Industries, Kushiro,
Japan.
Champion Int. Corp., Bucksport,
USA.
Consolidated Papers Inc., Duluth,USA.
Cia Manufacturera de Papeles y
Cartones S.A., Chile.
Hansol Paper Co., Ltd., Taejeon,
Korea.
Munksjö Paper, Fitchburg,
USA.
Chuetsu Pulp Co.,
Japan.
Calpasoro, Spain.

Venepal, Venezuela.
Quena Newsprint Paper Company,
Quena, Egypt.
Champion Int. Corp., Quinnesec,
USA.

Coating technology
Westvaco Corp. USA.
Mead Corp. Rumford,
USA.
Consolidated Paper Corp., Rapids,
USA.
Stora Kabel, Germany.
Consolidated Paper Corp., Stevens
Point, USA.
Consolidated Paper Corp., Biron,
USA.
APP, China.
Intermills, Malmedy, Belgium.
P.T. Pakerin Pulp and Paper,
Indonesia.
Modern Karton Sanayi ve Ticaret
S.A., Turkey.

– WindersGold East Paper, Jiangsu, China.
Dagang, China.
Gebr. Lang, Germany.

Winding technology– DuoReel
Gold East Paper, Jiangsu, China.
Votorantim Celulose e Papel,
Brazil.
Malaysian Newsprint Industries
Kuala Lumpur, Malaysia.
Inforsa Industrias Forestales S.A.,
Nascimiento, Chile.
Klabin Fabricadora de Papele
Celulosa, Piracicaba, Brazil.
Votoranim Celulose e Papel,
Piracicaba, Brazil.
Votoranim Celulose e Papel,
Jacarei, Brazil.

FinishingJanus Concept
Stora, Port Hawkesbury, Canada.
Supercalender
Daewoo, Korea.
Ecosoft calenders
Alkim, Turkey.

Boading, China.
K.C. Huntsville, USA.
Toprak, Turkey.
Votorantim Jacarel, Brazil.
Nan Ya Plastics, Taiwan.
3 M, Canada.
Munksjö Fitchburg, USA.
Poligraphico, Italy.
Victorgo, China.
Dagang, China
Dow Chemical, Switzerland.
Pap. del Centro, Spain.
Imperial, USA.
Inforsa, Chile.
Machine calenders
Kalamazoo, USA.
Modernkarton, Turkey.
Rebuilds
Millykoski, Finland.
KNP Leykam, Belgium.
Twister
BPB Davidson, Great Britain.
Pap. Peninsular, Spain.
Koehler, Germany.
Holtzmann, Germany.
Madison, USA.
UPM Walki Wisa,
Great Britain.
Roll handling
BPB Davidson, Great Britain.
Burgo Ardennes, Belgium.
MNI, Malaysia.
Biolomatik f. Biberist,
Switzerland.
Holtzmann, Germany.

8

TRIPLE STARA Picturebook Startup in Gratkorn, Austria

91

On October 12, 1997 – two weeks early“Thanks to the suppliers’ highly trained

Shortly after startup, this new paper ma-– the world's largest wood-free coatedstaff and first-rate cooperation, thischine (PM 11), designed for speeds up to

paper production line started up at KNP

startup was absolutely troublefree and1500 m/min, fulfilled all quality criteria

LEYKAM in Gratkorn, Austria. The paper

one of the fastest on record. Only six

including formation, tensile strength, andmachinery, coating and calendering

weeks afterwards, we already operate at

2-sidedness of ash content, fines distrib-

machines for this state-of-the-art plant1100 m/min over long periods”, reports

ution and smoothness. The technologicalwere supplied by Voith Sulzer Paper

production manager Manfred Tiefen-

concept was worked out in close collab-

Technology.

gruber.

oration between KNP LEYKAM and all2

10

suppliers, and confirmed by exhaustive

over a very wide speed range. The ma-

controllable nip conditions (see report

trials. As a result of this outstanding

chine is also equipped with a NipcoFlex

on page 44), which enables faultless

teamwork, the customer now has anpress, the leading technology in wood-

winding of the world's largest reels

innovation-rich machine capable of pro-free paper production, which ensures aweighing 120 tonnes, with a diameter ofducing 470,000 tonnes p.a. of high grade

high dry content with optimally high

3.6 metres.

coated paper.

volume. A combination of single and dual
dryer units permits excellent runability

Designed for an operating speed ofIncorporated in its latest version, thewith high drying efficiency. Further

1800 m/min, the coating unit comprises

Module-Jet headbox ensures a first-classattractions of this Voith Sulzer paper

four JetFlow F coaters, whose outstand-CD basis weight profile which can bemachine are a Speedsizer and two

ing uniformity is ensured by CD profile

controlled independently of fiber orienta-

Speedcoaters.

control. Since the Sirius winding concept

tion profile. And with the DuoFormer

is likewise used on the coating machine,

CFD, all requirements for ash and fines

The futuristic Sirius winding technology

reeling results are outstanding despite

distribution in coated grades are met in

used here represents a world innovation.

the high smoothness and low porosity offull. Furthermore, this Gapformer meets

The main feature of this concept is a mo-this triple-coated paper.

the most exacting formation demands

bile Senso pressing roll ensuring directly

113
Figs. 1 and 2: Photograph and schematic layoutof the new PM 11 in Gratkorn.
Figs. 3 and 4: The SM 11 coating machine(photograph and schematic layout), designed foran operating speed of 1800 m/min.
Fig. 5: The triumphant KNP-LEYKAM
project team in Gratkorn: K. Merzeder (left),Dr. D. Radner and M. Tiefengruber.

4This consistent use of the latest technology was followed up by installing two
Janus calenders. With higher steel rollsurface temperatures and polymer covers, this results in a paper surface withextremely low porosity and high gloss.
With all these innovations, the ***Triple
Star*** is indeed a concept of superlatives – a true quantum leap into thenext millennium!

The author:
Marion Nager, Corporate Marketing VSPT,
interviewed production manager Manfred
Tiefengruber, KNP-LEYKAM Gratkorn.
5

12

13

Brilliant two-sided coating at 2000 metres per minute –on the world’s latest pilot coater
Brilliant Coating was the theme of a big

This gala party started the first evening,

LWC paper coating in a single throughput

event last summer: the inauguration ofwith fireworks and a genuine Samba– at 2000 metres per minute!

Voith Sulzer Paper Technology’s newgroup flown in by our Brazilian people. A

pilot coater. Voith Sulzer Papiermaschi-

good many interesting discussions got

Our Brilliant Coating event was opened

nen GmbH invited coating specialists

underway here between old friends andby Dr. Hans-Peter Sollinger, CEO Voith

from all over the world to this historicalnew, so that by the next day everyone was

Sulzer Papiermaschinen GmbH. He drewoccasion – and some 200 of them arrived

well tuned in for six papers on “Brilliant

attention to the increasingly importantin Heidenheim on June 4 and 5, 1997

Coating Technology Today and Tomor-role of coating technology today, not only

from Europe, Asia, South Africa androw”. Then came the actual christening

for new installations but also for existing

the USA.

ceremony: a world premiere with 2-sided

machinery. Through systematic upgrad-14ing, the latter can hold their own very wellWorld Market Analysis for Coated Paper,

against tough international competition

and The Voith Sulzer Paper Technology

both now and in future – thanks to ongo-

Center Of Competence

ing innovations by Voith Sulzer Paper
Technology.

Coating technology manager Dr. Rüdiger
Kurtz started off by presenting a world

Guests were welcomed by Dr. Hans-Peter
Sollinger, CEO Voith Sulzer PapiermaschinenGmbH, Heidenheim.

That is why Voith Sulzer Paper Technolo-

market analysis for coated paper, includ-gy maintains a modern “fleet” of test facil-

ing a tour of the Heidenheim coating divi-

ities, including this high-tech coatingsion. He pointed out that Voith Sulzer

machine on which customer tests are also

Paper Technology coating technology

carried out. Last year it was again upgrad-specialists are not only to be found here,

ed to the latest state of technology, thus

but all over the world at our various cen-ensuring optimal testing facilities for ourtres – for example in Appleton USA, Sankt

paper industry customers.

Pölten in Austria, and São Paulo in Brazil.

To this purpose the existing No. 1 machineMarket Analysis for Coated Paper,

was extended to form machine No. 2,

and The Voith Sulzer Paper Technology

which can operate at speeds up toCenter Of Competence

2500 m/min (Fig. 1).

The world market for coated paper is
growing relatively quickly, at the same

With both machines together, Voith Sulzer

time demanding high value-added against

Paper Technology now has a test facility

tough competition (Fig. 2). Nevertheless,which is unique worldwide: paper can bemarket needs and production capacity arecoated simultaneously on both sides in

not always well balanced. Fig. 3 and fur-a single throughput at speeds up to

thermore subject to fluctuations and2000 m/min – which not only saves anrecession cycles typical of the consumer

enormous amount of testing time, but

goods industry (Fig. 4).

also makes coating quality much more
realistic.

Currently the market is dominated bylarge American, Scandinavian and Asian

Here is a summary of the papers given

corporations

under the general title “Brilliant Coating

against each other for technological lead-Technology Today and Tomorrow”:

ership. The size and speed of coatinginongoingcompetition

machines have thus increased dramatically (Fig. 5), and with higher production
rates the worldwide consumption of coating pigments and chemical additives isHighlights

15

A feast indeed, to delight the eyes and whet the
intellect… with brilliant coating and papers alike,innovative technology – and Samba dancing as“hands across the ocean” from VSPT Brazil.
Round-table discussions followed by first-ratepresentations the next day – an excellent way ofkeeping up with a fast-moving technology.

16

1Fig. 1: Pilot Coater
4 Coater stations
Maximum Speed 2500 m/min
Automatic Tension Control
Diameter of rolls 1000 mm
Paper width 800 mm
Maximum reel diameter 1500 mm
Core Size 3’’ and 6’’

also rising (Fig. 6). Due to the trend inalso for the traditional papermaking

aged about 19% over the last eight years

papermaking toward chemically neutral

regions of Western Europe and North(Fig. 7), and our goal is to increase thisprocessing and new coating methods, for

America. Demands on paper quality haveshare through product innovations. With

example, calcium carbonate consumption

risen enormously, however, so that new

regard to coated board, for example, we

has grown enormously and new ways oftechnologies

This

are treading new paths to eliminate theenhancing coating quality have arisen.

means that special attention has to be

drawbacks of conventional methods suchareindispensable.

paid to upgrading and modernization, in

as air-knife coating. By upgrading theAnalysis reveals a clearly positive paper

order to meet these demands with exist-

board coating machine at Assi Domän inmarket trend into the next millennium.

ing machines as well as new ones.

Frövilors to this new concept, we are
already well on the way. Only by looking toPotential consumption and growth figures
are promising not only for the emerging

The market share of Voith Sulzer Coating

the future with mature technology andmarkets of Asia and Eastern Europe, but

Technology in machinery deliveries aver-well-founded innovations, can paper andHighlights

17

Fig. 2: Annual Market Growth of Paper
Consumption. Worldwide 1993-2010.
Fig. 3: Supply/Demand Balance 1991-1998.
Fig. 4: Real (inflation adjusted) Prices/Tonnes(Value). Printing/Writing Paper Demand –Worldwide.
Fig. 5: Trends for Off-line Coaters.
2

95

97
19

93

19

19

97
19

95

100

Source Jaakko Pöyry 95

NorthAmerica

3
0
93

90

4

North
America91

Other Grades

Board
80

5

19

30
50
60
40
70
Share of Consumption 1993 [%]WesternEurope

6

19

20

7

91

10

Mill tons Coated Woodfree Papers
8

Coated MechanicalPapers

19

0

5.9
%

Sack Paper

0

4.8
%

Liner andCorrugating

1

Coated Woodfree2

3

CapacityCap. Change

DemandProduction= 0.7 %
= 8.3 %
= 5.4 %
= 3.4 %
= 7.8 %
= 5.3 %

WesternEuropeTissue3

Uncoated Woodfree

Unc.Mechanical
Coated Mechanical4

Newsprint

Market Growth [%/a]5Asia/Pac.
WE
NA
Asia/Pac.
WE
NA

19

Demand Split

Source Jaakko Pöyry 95

45
Demand
Value

160
-18 %

150
140
130
120

+64%

110
-16 %

100
90

Operating speed [m/min]

170

2500

Operating speed
Web width

16
14

2000

10

1500

8
1000

6
4

500

2
1997

0
1988

1990

1992

12

1800

Web width [m]Value 1988 = 100

1994

1996

1960

1970

1980

1990

0
2000

Source PTS

Source Pima`s Papermaker, Feb. 97

coating machines be built such as the newpaper machinery to coating and finishing.

to profit from our brilliant coating tech-

KNP-Leykam line. This produces 470,000

As impressively demonstrated at KNP-

nology.

tonnes p.a. of high quality triple-coatedLeykam, this is particularly reflected inwood-free paper, 9 metres wide at a speed

our on-line concepts.

Production Experience with the JetFlow F
Bernhard Kohl, technical marketing andof 1400 m/min. Both coating systems
used in this line – film coating andEvery year Voith Sulzer Paper Technology

project manager, reported on production

jet/blade coating – are based on years ofinvests substantial sums in research andexperience with the JetFlow F introduced

development work by Voith Sulzer. Ourdevelopment. Our new coating test facility

a few years ago by VSPT as the world’s

greatest strength lies in the comprehen-(Fig. 1) is good example of how well thisfirst jet coater. Since then the JetFlow F

sive papermaking know-how we haveinvestment pays off, and it is entirely at

has established itself as state-of-the-art

accumulated “twogether”, ranging fromthe disposal of our customers. We hopefor practically all paper grades and oper-

raw materials, stock preparation andyou will make the most of this new facility

ating speeds from 150 to 2000 m/min.

18

Fig. 6: Consumption of Coating Pigments
in Western Europe.
Fig. 7: Market Share for Coated Paper(1988-1995).
6

7
Total
CaCO3
KaolinTalkumOthersDemand in 1000 t

10000

Coating Heads

1000

19%
34%
17%

100
14%
10
1965

1970

1975

1980
1985
Year

1990

1995

2000

Source PTS

16%

Coaters

Voith Sulzer
ValmetJagenberg
BeloitOthers

18%
41%

11%

Total Number of Coating Heads = 412

16%
14%

Total Number of Coaters = 156

Source Jaakko Pöyry 97

By June 1997, there were already fourteen

The Speedcoater –Since it substantially reduces operating

JetFlow F coaters in operation both inQuality and Economy

costs, payback time on Speedcoater

online and offline machines. Experience

Harald Hess (Coating Technology) gave

investments is extremely short.

has shown that in all cases, the mills con-an interesting paper on the Voith Sulzer

cerned reap substantial benefits:

Speedcoater.
Developments and Trends

I Production increases averaging six

The sizing, pigmenting and coating appli-in Coating Technology

percent, since higher speeds can becations of this film coater extend up to

Dr. Michael Trefz, Coating Technology

run without affecting quality.

densities of 15 g/m 2 per side, with highR&D project manager, explained some of

I Far fewer web ruptures.

solids content. Furthermore, the Speed-

the current development goals and trends

I Much shorter setup times.

coater covers an extremely wide variety ofin coating technology. These include

I Higher coating solids content andgrades, ranging from wood-containing

wider and faster machines, heavier coat-

and wood-free printing/writing papers to

ing densities, higher solids content, andspecial papers and board.

of course on-line production concepts.

reduction of co-binders accordingly.
I Higher quality coating at higher

Since all these developments must natu-

speeds.
I No more coating errors

Advantages of the Speedcoater:ty, the emphasis is on implementing intel-(stiffness).
I Less thickening on the coater.
I Lower drive power consumption.

rally have no detrimental effects on quali-

I Extremely uniform printing image

ligent concepts into new processes.

thanks to contour coating effect.
I Low web loading.

The highest coating densities and speeds

The cost-effectiveness of the JetFlow F is

I Easy on-line installation.

are currently attained with blade coaters,

impressively illustrated by payback times

I Much lower investment, operating andand development work is now aimed at thelabour costs than off-line machines.

“magic milestone” of 2500 m/min. Film

ranging from 10 to no more than 22months (depending on application).

I Significant raw material savings.

coaters are very attractive from the point

Highlights

19

Fig. 8: The front line of know-how: our speakers.
8of view of cost-effectiveness and produc-

tivity with wider webs, easier block

The new Brilliant Pilot Coater

tivity, but still suffer from drawbacks withchanging and faster setup, without any

for speeds up to 2500 m/min

regard to film splitting and operating

significant new demands on paper quality.

Against the background of the foregoing
papers, Ingo Gottwald gave some details

speed. The goal of developments in thisconnection is to overcome such prob-

Offset printing paper still has to be opti-

on further development of the Voithlems, thus enabling higher coating densi-

mized above all for better tear strength

Sulzer pilot coater. The flexible arrange-

ties at higher speeds.

and registration precision. For waterlessment

offset printing, particularly good pick

between individual aggregates make thisOnline technology trends are likewise tak-resistance is required along with ink opti-

truly a universal test facility.

en into account by Voith Sulzer withmization. Demands in the electrophoto-

numerous development projects, includ-graphy sector are increasingly on optimal

After partaking of luncheon in good com-

ing a new Speedsizer generation.

surface quality, controlled porosity andpany with the VSPT pilot machine itself,

conductivity,

andcombination

possibilities

surfaceour guests were able to witness theory

requirements for indirect printing with

unfolding into practice before their eyes.

The Future of Publishing and Demands

liquid toners. The main improvements

For the first time ever worldwide, they saw

on Paper Quality

expected for inkjet printing paper area pilot coater start up and proceed forth-

Guest speaker Armin Weichmann of MAN

good absorption and better ink compati-with to coat both paper sides simultane-

Roland Printing Machinery Ltd gave an

bility.

ously at a speed of 2000 m/min.

ments in printing technology and resul-

The future will therefore bring all kinds of

The test was run with LWC raw paper attant demands on the paper industry.

challenges, which can only be met suc-

36 g/m 2 basis weight, and a coating ofcessfully

teamwork

10 g/m 2 each side at 64.6% solid content.

As far as rotogravure printing is con-

between everyone concerned – printers,

This gala premiere was fittingly concluded

cerned, trends are toward higher produc-

papermakers and machinery suppliers.

with a standing ovation…

withspecificinteresting overview of future develop-

through

close

20

Wire width 10,500 millimeters –two of the world’s largest paper machines for China

With about 1.2 billion inhabitants today,
China accounts for roughly a quarter ofthe world’s entire population. It was thishuge country whose advanced civilization gave us paper of the kind we use
today. Today China is working with visible success on the expansion of its overall economy and infrastructure. And
paper is part of this effort – whether as ameans of information and communication within the county itself or as anexport item to its neighboring states inAsia.
In the multi-national state of China withits 56 recognized ethnic groups, languages and dialects, more than 2000 national, regional and urban daily newspapers as well as some 8000 weekly ormonthly magazines are published, quite
a few of which have a circulation easily
exceeding a million copies, since the Chinese are enthusiastic newspaper readers.
Today the People’s Republic of China is
responsible for more than one third ofAsia’s entire paper consumption. Experts
reckon that in Asia in general and in China in particular, the demand for paperand board will continue to rise in the
coming years – regardless of temporary
economic crises and cyclical fluctuations
afflicting some of the countries. Thanks
to its economically realistic and cautious

expansion strategy, China itself has so
far remained largely unaffected by sucheconomic turbulences and continues toinvest into its future – including among
other things an efficient and powerfulpaper industry.

In the face of fierce competition, Voith
Sulzer Papiertechnik won the contract tosupply Asia Pulp & Paper Co. Ltd. withtwo papermaking machines for the production of writing and printing paper.
The two plants will be erected in the

Highlights

21

Mayr-Melnhof chooses
Voith Sulzer technology for its
first shoe press project

Europe’s leading manufacturer of wastepaper-based folding boxboard, the Austrian Mayr-Melnhof AG company, whichis quoted on the stock exchange, decided in late 1997 to have a significant rebuild carried out at its Frohnleiten mill.
The investment project concerns the wet
end of BM3, which is already one of theGroup’s most efficient machines. The
aim of this rebuild is to improve board
quality and increase output.

Dagang area in the province of Jiangsu.
With a wire width of 10,500 mm and an
operating speed of 1500 m/min, they areamong the world’s largest papermaking
machines. Operation is scheduled tostart early in 1999.
The decisive factor in securing this order
was the innovative overall concept, withadvanced system components provided
by Voith Sulzer Papiertechnik to meet thehigh quality requirements and the preferred production and weight range, andlast but not least to ensure the availability
and reliability of the required machinery.
The concept includes ModuleJet headboxes designed specifically to improvethe basis weight profile, CFD DuoFormers
with flexible dewatering elements, NipcoFlex presses for the lowest possible
moisture content and Speedsizers andsoft calenders for correct surface treatment. In addition, the delivery program
comprises the entire equipment fromwinding and slitting technology to auxiliary elements such as hood, steam andcondensing systems and lubrication,
drive and the electrical equipment.
In China the name Voith has a pleasantsound. Highly significant: the fact thatthe order awarded to Voith Sulzer
Papiertechnik was accompanied by asecond dramatic supply contract for
China in which another Voith Group company – Voith Hydro – is largely involved.
After decades of thorough preparation,planning and testing work, China is
about to start building the project of the
century: to tame flooding of the Yangtze
River and to use it for environmentallycompatible energy generation. The“China Yangtze Three Gorges Project”(see computer simulation at bottom left)
is to become by far the largest hydroelectric generating plant in the world
and will – with the last construction
phase completed – have an output of
18,200 megawatts.
This capacity roughly equals the output
of today’s 22 most powerful coal-fired
power stations, which, however, emit
100 million tons of CO 2 into the air. For
this reason China has deliberately decided to utilize this ecologically more sensitive hydrodynamic power source to coverits industry’s growing energy needs.
Voith Hydro will supply the turbines
for this gigantic hydroelectric power
plant project, of which the first generating set is scheduled to start operationin 2003.

With the decision to replace the secondpress by a NipcoFlex press, Mayr-Melnhof has taken an innovative step forward.
This technology, which has been successfully used in graphic paper machines, is now gaining ground for board
machines as well. The NipcoFlex press
helps to increase output by reducing the
moisture content after the press section,
while retaining the bending stiffness ofthe board.
Sheet formation of the filler, which currently takes place on 7 suction formers,
will be replaced by 2 fourdriniers (TopFormer F), one of which with a hybrid
former (DuoFormer D). The Stepdiffusor
headboxes that have already proven successful on the topliner and backliner
wires of BM3 will be used also in the
new sheet forming system. One of the
new headboxes is equipped with dilution
water CD profile control, the ModuleJet
SD, and the other with a central distributor. Voith Sulzer Paper Technology’s
scope of supply also includes the rebuilt
and new parts of the approach flow
system. This major modification of the
sheet forming system results in an improvement in formation. The use of the
DuoFormer D in the filler line will permit
the smoothness of the base board to beenhanced.

22News FROM THE DIVISIONS

Stock Preparation Division:
Dispersion, stickies and opticalcleanliness
The reduction of dirt specks and dispersion of stickies are two classical functions of dispersion. As regards dirt speck
reduction, dispersion still makes a vital
contribution. However, to alleviate theproblem of stickies, screening has been
improved in recent years. The reason isthat just reducing the size of stickies
results in them building up in the system, now that water and stock loops are
increasingly being closed. Screening isan effective tool here. However, despite
success in the screening out of stickies,
dispersion will remain indispensable infuture for white paper grades and highquality packaging papers.
The purpose of this article is to review
the influence of machine design aspects
and operating parameters on stickies
dispersion and on the improvement of1

HTD disk disperger
P max : 2500 kW
Q max : 700 t/24 h
V Rotor/Stator : 50-60 m/s

optical properties. Based on the manydifferent functions of dispersion and thespecific requirements of the end products, a general recommendation for theuse of disk dispergers or kneading dispergers is made. Finally, different disperger systems are compared as regards
their economic viability.

The two machine concepts
Basically, there are two types of dispersion machines: disk dispergers andkneading dispergers. The main differences between them relate to the shapeand circumferential speed of their rotors
and stators (Figs. 1 and 2).
Voith Sulzer is the only machine supplierin the world who has been producing
both machines for a very long time andStock Preparation

23

Fig. 1: HTD disk disperger.
Fig. 2: KD kneading disperger.
Fig. 3: Tasks of dispersion – newsprint.
2

has therefore been able to accumulate
unbiased experience of both concepts.
Both machines permit a throughput of 30
to 700 t/24 h each. In addition, the disk
disperger is designed for operation under pressure at temperatures of up to
130°C. Apart from stickies and dirt speck
reduction, the two machines handle other important tasks in the stock preparation process. These are shown in Fig. 3,
using a system for newsprint production
as an example.

3

PM

LC
LC-Sortierung
Screening //0.35//0,35

Disk
Scheibenfilter
filterFlotation II

Bleaching,
Bleiche, ox.ox.

Dispersion
Dispergierung

Scheibenfilter
Disk filter
PresseAufgaben
Dispergierung am Beispiel Zeitungsdruck
Objectivesderof Dispersionn Restliche
Stickies
dispergieren
DispersionSchmutzpunkteof residual dirtund
specksand stickies
bzw.
flotierbar
machenor makethem flotatablen Verbliebene
Druckfarben
ablösen
Detaching residual
inks fromfibresn Bleichhilfsstoffe
einmischen
Mixing in bleachingchemicalsn Katalasen
zerstören
und Keimzahl
reduzieren
Destructionof catalases
and reductionofn Fasern
technologisch behandeln
microorganisms
n Influencing fibre properties
Aufgaben der Dispergierung – SonderfallnStrichgrießzerkleinern
SpecialObjectiven Breaking down coating grit

HW
ST-Cleaner
Cleaner

PM-LoopPM Loop

Loop IILC
LC-Sortierung
Screening //0.15//0,15HW
ST-Cleaner
Cleaner

Flotation I

MC
MC-Sortierung
Screening B1.2
ø1,2

Protector
ProtectorsystemsystemPulpingAuflösesystemsystemLoop I

Einflußgrößen
Parameters
nn MaschinentypType of machine–– Scheiben-Disperger
HTD disk dispergerHTD–– Knet-DispergerKD
KD kneading disperger
nn Spez.
Spec.Dispergierarbeit
dispersion energy
nn Temperatur
Temperature
nn Stoffdichte
Consistency
nn Garnitur
Fillings

Stickies dispersion
Closure of water and stock loops inevitably leads to a build up of stickies ifthese are not removed from the system.
Using the latest screening technology,
a level of stickies removal efficiency canbe reached, at least in some brownsystems, which is sufficient for problemfree operation of the board machine. In
such cases, the dispersion of stickies is
not required.
With high quality packaging paper, however, we continue to regard stickies dispersion as a useful feature, with graphic
grades it is indispensable. Following finescreening, a certain size spectrum of
stickies is still present and this represents a disturbing feature with graphic
grades, one which is inadequately eliminated by flotation 1 or washing. Dispersion secures a better stickies removal efficiency in post flotation and improves
the runnability of the paper machine andthe quality of the end product. Apartfrom operating parameters, such as specific dispersion energy, temperature or
stock consistency, the choice of the right24

Fig. 4: High temperature disperger system.
4

plant provides an ideal basis for this purpose (Fig. 4).
Influence of the type of fillings
The type of fillings also has a certain influence on stickies dispersion. Voith
Sulzer has been offering cast fillings forsome years instead of the milled ones
previously used in its disk dispergers.
Cast fillings are typified by a particularly
favourable cost-performance ratio, in addition to the usual long service life.
An evaluation of old and new test datashows that the cast fillings as opposedto the milled ones have a somewhat lower scatter range for the stickies area reduction 3 . A rather better average result
was also achieved.

dispersion machine in particular plays adecisive role in effectively combatting
the problem of stickies.
Influence of the type of machine
Experience particularly from North America shows that a kneading disperger cannot disperse stickies as efficiently as adisk disperger. Certain mills in whichkneading dispergers alone are used forwood-free office waste paper have had tocontend with enormous stickies problems, regardless of the particular designof kneaders used 2 .
Influence of operating parameters
As a general rule, higher stock consistency, temperature and specific dispersion energy have a beneficial effect on
stickies dispersion. This is true of all
waste paper grades. Specific dispersion

energy has a particularly great influenceon stickies dispersion.
For efficient stickies dispersion, it is sensible to warm the stock at least up to thetemperature where the stickies soften.
The operating temperatures of 70-95°C
usual for disk dispergers are generally
adequate for the stickies found in European waste paper grades.
On the other hand, for furnishes which
are particularly hard to disperse such as
AOCC, temperatures > 100°C may be appropriate. However, as high temperature
treatment also results in strength
losses 4 , a test trial should definitely be
conducted to enable a comparison of theadvantages and drawbacks for a particular stock. The new high temperature disperger system in the Voith Sulzer pilot

Optical cleanliness
Another principal task of dispersion is toensure good optical characteristics. To
improve optical cleanliness, several
processes take place in the dispersion
system.
I Dirt specks are detached from thefibres and so made flotatable.
I The flotatability of existing free ordetached dirt specks is improved bychanging the size spectrum.
I Dirt specks are reduced in size to
below the visibility limit.
I Often, bleaching chemicals (H 2 O 2 )are mixed in.
The biggest influence on optical cleanliness is obtained by the specific disper-

Stock Preparation

25

Figs. 5, 6, 7: Dispersion of dirt specks:
influence of specific dispersion energy.
O Disk disperger 90°C
I Kneading disperger 90°C
( Kneading disperger 45°C.
Fig. 5: 50% newspapers, 50% magazines withconventional printing inks after Flotation 1.
Figs. 6, 7: Office waste with laser print after
Flotation 1.
5

sion energy, machine type and, in thecase of some stocks, temperature. Herethe type of fillings and stock consistency
tend only to have a limited influence.

Reduction in dirt speck area
(B >50 mm) [%]

100
80
60
40
20
0
0

30

60

90

120

150

Spec. dispersion energy [kWh/t]

6

On the other hand, for ink particles from
non-impact printing processes, thekneading disperger gives a slight advantage over the disk disperger in reducing
the overall dirt speck area (Fig. 6 and 7).

Reduction in dirt speck area
(B >50 mm) [%]

100
80
60
40
20
0
0

30

60

90

120

150

Spec. dispersion energy [kWh/t]

7100
Reduction in dirt speck area
(B >150 mm) [%]Influence of machine type and specificdispersion energy
As shown in Figs. 5 to 7, the choice ofmachine type for optimum dirt speck
reduction depends on the stock. With
conventional, oil-based printing inks, theresults obtained with the disk disperger
are rather better than those reported withthe kneading disperger (Fig. 5).

80

In addition, the illustrations clearly showthat dirt speck reduction increases withrising specific dispersion energy. Thisapplies in principle to all white stocks
but not to brown grades. For brown
grades, homogenization of the stock isgenerally improved only to an insignificant degree when the specific dispersion
energy is increased above 40 to 50
kWh/t.
Handsheets from brown stock before andafter disk or kneading dispersion showthat for the same specific dispersion energy both machines operate with approximately the same efficiency.

60
40
20
0
0

30

60

90

120

Spec. dispersion energy [kWh/t]

150

The two machine types are also equallysuited as mixers for bleaching chemicals.
There is no known influence of specificdispersion energy on mixing quality 4 .

Temperature influence
The influence of temperature on the reduction of dirt specks is particularly apparent in the case of the kneader which
can be operated in the 40 to 95°C inlet
temperature range. Fig. 5 shows that for
conventional printing inks, hot operation
brings distinct advantages over operation
without heating. This operating mode
also has certain advantages as regards
dirt speck detachment for a post-flotation stage.
For non-impact printing inks too, the hot
kneading disperger process is again
somewhat more effective as regards the
reduction of all visible dirt specks, i.e. allparticles with a diameter larger than
50 Hm (Fig. 6). On the other hand, withthe reduction of dirt speck areas for particles >150 Hm (Fig. 7) corresponding tothe old Tappi Standard, the best results
tend to be obtained with the cold kneading disperger. This explains why manykneaders are run at process temperature
for this type of stock in North America
where the reduction of the dirt speckarea is generally assessed according to
the Tappi Standard.
Technically, it is also possible to run
both the disk disperger and the kneading
disperger without heating. However, unlike the kneading disperger, in the caseof the disk disperger, the increase in
SR freeness is higher at the lower temperatures. Therefore, the disk disperger
should only be run cold in special casessuch as HC refining. On the other hand,
the SR value does not change in the caseof the kneading disperger, regardless ofthe temperature at which this machine isrun (Fig. 8).

26

Fig. 8: Influence of dispersion temperature on
the SR value. Office waste, W spec. = 80 kWh/t.
O Disk disperger
I Kneading disperger
Fig. 9: Dispersion of dirt specks.
Influence of temperature. 20% office waste,
40% newspapers, 40% magazines.
Disk disperger, W spec. = 60 kWh/t.

I Reduction in dirt speck area

O Breaking length--- Breaking length before dispersion

8

Temperatures >100°C are generally chosen to ensure high bacteriological cleanliness 5,6 . As temperature rises, the dirt
speck area reduction is somewhat
greater (Fig. 9). Fig. 9 shows however,that the breaking length drops significantly as the temperature rises. A test
trial can demonstrate how the strength
values of a particular stock change as
temperature rises.

Change in SR value [SR]

88

6
4
2
0
-2
40

50

60

70

80

90

100

Temperature [°C]9Reduction in dirt speck area
(B >50 mm) [%]

80

4.0

60
3.5
40
3.0

20
0
70

80

2.5
90 100 110 120 130
Temperature [°C]

Breaking length [km]

4.5

100

Recommended use and economy
Fig. 10 describes the resulting recommendations for use of the two types ofdisperger. In principle, we recommend at
least one disk disperger when stickies
problems are expected. The kneading
disperger is suitable for mills with two
dispersion stages, for operation at lower
temperatures and for stocks which react
sensitively to an increase in SR freeness.
Apart from the technological criteria for
decision-making, economic considerations also play a significant role in the
choice of the type of disperger. The economic study shown in Fig. 11 is intended
to help in reaching decisions. It illustrates the operating costs in DM/t dispersed stock for four typical Voith Sulzer
disperger plants. A depreciation periodof 5 years is allowed.
I Plant 1: Pressure dispersion systemwith screw press and disk disperger.
I Plant 2: Pressure dispersion systemwith double wire press, plug screw anddisk disperger.
I Plant 3: Same as plant 2, but for max.
90°C only, i.e. without plug screw andwithout pressure heating screw.

I Plant 4: Kneading dispersion systemwith screw press but no heating screw;
increase in temperature of max. 30°C
through steam heating possible in thekneading disperger.
As the summary shows, the bulk of theoperating costs are accounted for bysteam and electricity. Depreciation represents only a relatively small part of theoverall cost. This is particularly true for asystem run at 130°C.
As far as possible, a dispersion plantshould therefore not be run at a temperature in excess of 90°C. However, theadditional investment in a pressure
disperger system is soon recouped if aproblematic stock requires temperaturesin excess of 100°C even for short periods.
The capital costs of a plant with a screwpress (plant 1) and one with a double
wire press (including tear, ascending andplug screw) (plant 2) are comparable.
The decision as to the use of the mostsuitable dewatering unit should therefore
depend on technology considerations,the space required and the preferred operating mode.
A cold kneading disperger plant is by far
the most economical system albeit withslightly reduced dispersion of disturbing
substances. If quality differences in thestock require high temperatures for instance, the stock can be heated up by atleast 30°C in the kneading disperger
without the addition of a heating screw
by direct admission of steam to thekneading chamber.

Stock Preparation

27

Fig. 10: Application recommendations
for disperger machines.
Fig. 11: Typical dispersion systems –operating costs.
I Depreciation
I Fillings
I Electricity 0.11 DM/kWh
I Steam (stock temperature 90°C/130°C)
28 DM/t steam.
10

Applications

FurnishNewsprint
Board topliner

whitewood-cont.,
Disk disperger
wood-free

stickies

Tissuewhite

wood-cont., Disk disperger
wood-free
Kneading disperger

stickies
bulk

SC, LWC

white

wood-cont.,

Disk disperger +Disk disperger

strength properties
stickies

Market DIP

whitewood-free

Disk disperger +Kneading disperger

stickies +gentle fibre treatment

Toplinerbrown–

Disk disperger

optical and strength
properties,
stickies

Board filler

brown

–

Kneading disperger

max. bulk

Coated broke

white

–

Kneading disperger

gentle fibre treatment
at low temperatures

11

Recommended
machines

Remarks

Conclusions
Dispersion remains an important process
stage for the cleanliness of stocks fromwaste paper. However, operating parameters such as temperature, stock consistency and the choice of machine typehave a varying degree of influence on optical cleanliness and stickies dispersion.
This aspect must be taken into accountwhen systems are designed and operated. Voith Sulzer has many years of experience, both with disk dispergers andwith kneading dispergers.
The decision for a particular installation
should be based not only on such technological experience but also on the economic considerations of the different
types of plants.

30
130°C

130°C

Costs [DM/t]

25
90°C

20

90°C

90°C

15
50°C
10
5
0
with
plug screw
90°C / 130°C

1

2

without
plug screw
90°C

3

4

Literature
1 M. Geistbeck: „Abscheidung von Stickies
in der Flotation“, Wochenblatt für Papierfabrikation, No. 16, 1997.
2 L. D. Ferguson, R. L. Grant: „The State of the
Art in Deinking Technology in North America“,
presented at the 7th PTS Deinking Symposium
1996, Munich.
3 W. Mannes: „Dispergierung – ein wichtiger
Prozeßschritt zur Verringerung von
Sticky-Problemen“, Wochenblatt für Papierfabrikation, No. 19, 1997.
4 V. Niggl, A. Kriebel: „Dispergierung – derProzeßschritt zur Verbesserung der optischen
Eigenschaften“, Das Papier, Vol 10, 1997.
5 H. G. Schlegel: „Allgemeine Mikrobiologie“,6th Edition, Thieme Wissenschaft.
6 H. Selder: „Verbesserung der Sauberkeit
von Sekundärrohstoffen“, Das Papier,Vol 9, 1997.

28

Stock Preparation Division:
New possibilities for water management
Paper manufacturing is recognized today

during swelling of the fibres naturalas an environmentally friendly industry,hydrocarbons dissolve 2 . Along with vari-achieving the highest recycling rates.

ous paper additives they build up in the

However, if one looks at the paper pro-loop water and in some cases can devel-

duction process somewhat closer, it

op a relatively unpleasant life of their

becomes apparent that valuable water

own. For example, starch in loop water

resources are still being used

all tooeasily hydrolyzes into glucose. Acid-liberally. In addition, clean fresh water isforming bacteria leave behind volatileoften not available in the quantities re-fatty acids as a product of metabolism

quired and so for some mills reducing

and these can be the cause of badwater consumption has developed into aodours. The pallet of possible negative

question of survival.

influences runs from stickies formationright through to disturbing the formation

Fundamental Dependenciesof hydrogen bonds.

The basic relationship when closing up

The authors:
Dr. Michael Schwarz,
Dietmar Borschke,
Ralf Mönnigmann,
Stock Preparation Division

loops is illustrated in Fig. 1. The concen-

In the end, product quality is affected as

tration of all dissolved substances drasti-

regards strength and optical characteris-cally increases when specific effluent ortics. Fig. 2 provides an overview of the

fresh water volumes are reduced 1 . De-

size spectrum of these substances. In

spite heavily increased concentrations inadditionloop water as well as in effluent, the con-already mentioned, further ones may

centration of substances discharged withalso be found (lignin fragments, woodthe effluent decreases disproportionally,

extractthe more the loops are closed up. If nohemi-celluloses). Inorganic substances

water cleaning is provided for fulfilling a

are also present. The latter are mainly in-so-called “kidney function”, then in thetroduced with the fibre stock (e.g. man-extreme case of completely closed water

ganese) or they enter the system withloops, all undesirable substances pass

the fresh water (e.g. chlorine). Contrary

into the paper, apart from a small

to opinions still being heard today, addi-

amount leaving the system in the resid-

tives make no significant contribution

ual discharge.

to the load of disturbing substances

to

the

organic

substances,

substancessaccharides

and(for example, sulfate from reductive
Disturbing substances

bleaching).

In paper production, disturbing substances are predominantly fibre related

Separation processes

materials and in no case problem materi-

All previously discussed substances haveals with toxic relevance. For instance,

the unpleasant characteristic in common

Stock Preparation

29

Fig. 1: Accumulation of disturbing substances.
Fig. 2: Substances in the process water.
Fig. 3: Separation processes for removal of
disturbing substances.
Fig. 4: Flux through membranes for paper
mill effluent.
1

4

Spec. permeate flux [l/m 2h]

Load in the effluent

Concentration in the effluent / process

Micr

200

ofiltr

ation

160
120
Ultrafiltration

80

Nanofiltration

40
0
1

30
20
Specific effluent [m3/t]

10

2Particle size in mm

0.01

0.001
Molecular
range

0.1

1.0

Macro-molec.
range

Metal ionsSulfates
Chlorides

50

10

100

10 000Macro particles
60 mm

Viruses

3

4

5

6

7

Reduction coefficient

1000

that they cannot be removed in convenOnce they are dissolved they can only beremoved from the fibre flow through wa-

visibleter exchange 3 . The filtrates from washingand thickening machines still have to be

CarbonFillersblack
Coating particles
Poly- andCoating pigments
oligosaccharides
extractives
Hemi-celluloses

Surfactants

2

tional cleaning and screening processes.

Colloidal
particles

not visible with the naked eye
Ligninfragments
Monosaccharides

40

Fibressubjected to further cleaning.
Possible filtrate treatment processes are
outlined in Fig. 3 for the mentioned parti-

Bacteria

cle size spectrum. Microflotation ensuresthat flocks formed following chemical
3

pre-treatment can adhere to air bubbles
Particle range in mm 0.001

0.01

0.1

1.0

Molecular Macro-molec.
range
range

100

Colloidal
particles

1000

10000

Macro particles
60 mm

not visible with the naked eye
Separation process

10tion, right through to reverse osmosis

Screening

Microfiltration
Flotation

Dissolved Air Flotation (DAF)
Evaporation

operate using filter units that retain allparticles and dissolved substances larger
than the respective “pore sizes”. However, the selectivity of these processes is

Nanofiltration
Reverse osmosis

membrane separation processes frommicrofiltration via ultra- and nanofiltra-

visibleCleaning

Ultrafiltrationand thus flotate together with these. All

often not sufficient. Evaporation finallyseparates practically all substances relevant in paper production. The problem of

30

Fig. 5: Falling film evaporator.
5
VapourHeating steam

Heating
steam

Heating elements

Heating
elements

Circulation
flow

Circulationflow

Condensate

Concentrate

Feed

Condensate

Circulation
pump

Concentrate

volatile substances will be discussed in

Design, separation efficiencies, and ap-

clearing devices, comparable with thefurther detail later.

plication limits of membrane filtration

rotor foils of a pressure screen, today

Membrane filtration

have already been presented in twogeth-

allow higher retentate concentrations in

Membrane filtration processes are used

er No. 3. To summarize, the probably

the case of water containing a high levelin many areas of effluent treatment.

most significant disadvantage of allof solids 6, 7 .

Treatment of leakage water from rubbish

membrane filtration processes, namely

dumps, cleaning of toxic industrial efflu-

that the specific permeate flux is very

Evaporationent or sea water desalinization can below (Fig. 4), should be mentioned again

Incited here as examples. There are twohere. The result is very high investment

stances can be virtually completely sepa-

reasons why membrane filtration has notand operating costs and this principle

rated out. The condensate has fresh wa-

established itself in the paper industry.

does not allow more than a very small in-

ter quality and can therefore be re-intro-

For one, effluent from the paper industry

fluence on flow rates 4, 5 . In the past few

duced into the process. Multi-stage

is not loaded with toxic or other harmful

years, however, membrane filtration has

evaporation units have established them-

substances and the second reason is thatreceived new impulses in a different di-selves early on in the pulp industry. Be-

the already mentioned substances ofrection. With water containing a low

cause of its favourable efficiency factor

organic origin can be easily, quickly and,solids load, cross flow operation can be

and low energy requirement, the falling

above all, inexpensively decomposed

eliminated. With “dead-end” operation,

film evaporator (Fig. 5) is highly suitablebiologically. Biology however, cannot

ultrafiltrations, for example, can be oper-

for application in the paper industry.

remove the inorganic load of salts fromated considerably more easily and inex-

Evaporation and subsequent combustion

the treated water flow.

pensively today. In addition, mechanicalof concentrated substances in pulp pro-evaporationallnon-volatilesub-Stock Preparation

31

Fig. 6: Packaging papers: limited effluent.
COD load in kg/min.
Effluent: 4.0 m 3 /t, COD process water: 7500 ppm.
Fig. 7: Packaging papers: closed loop withintegrated biology. COD load in kg/min.
Process water to biology: 4.0 m 3 /t,
effluent: 0 m 3 /t, COD process water: 7700 ppm.

Water management and closing up loops

Fresh water

Using two examples, the following dis-

Approach flow
Paper machine

Stock preparation

6

WWI

cusses what level of loop closure can beachieved with today’s state of the art
technology.
WWII

Packaging papers
Particularly in the production of liner andfluting from recycled paper, long term

Biology
1. anaerobic
2. aerobic

Effluent

experience with totally closed loops
without water cleaning is available. The
problems associated with this are also
well known. By choosing appropriate

7

tion of chemical aids, careful process

Approach flow
Paper machine

Stock preparation

non-corrosive materials, excessive addiFresh waterflow operation and frequent cleaningintervals, such systems can certainly
demonstrate good runnability. However,papers manufactured in this way are

WWI

WWII

burdened

by

odour

and

RCT/SCT

strength problems can also occur 10, 11 .
With the high recycling quotas for packBiology
1. anaerobic
2. aerobic

aging

gradesandtheconsiderable

amounts of starch added into the produced paper, the continuous build-up ofduction provide a high energy potential

compounds such as acetic acid, etc.,

dissolved substances is bound to lead toand in paper production, the reduced ef-

must be separated. For instance, the ini-

system collapse. For this reason, allfluent volumes help offset the high costs

tially evaporated volume, mainly contain-

plants are currently designed either withinvolved. The processes are perfected

ing volatile substances, can be dis-an efficient system effluent discharge or

and operationally safe. The first applica-

charged as effluent (foul condensate).

with internal biological water cleaning.

tions with complete water loop closing

However, if effluent that has been biolog-

The calculated loads circulating in the(zero effluent) have already been re-ically cleaned is evaporated, then all thesystem are illustrated in Figs. 6 and 7. If

ported 8, 9 .

recovered condensate can be re-used. All

the system is operated with a specific ef-

highly volatile acids are degradable due

fluent value of 4m 3 /t, corresponding to

It should be added in this context thatto the long dwell time and aeration in theapprox. 5.7m 3 /t fresh water, a COD con-during the evaporation of heavily loaded

biology stage.

centration of approx. 7,500 ppm is pre-process water, highly volatile organic

sent in the effluent.

32

Fig. 8: Graphic papers: water management forlimited effluent. Spec. volume flow [m 3 /t].
Fig. 9: Graphic papers: water management for agreater degree of water loop water closure.
Spec. volume flow [m 3 /t].
Fig. 10: Graphic papers: water management for
zero effluent. Spec. volume flow [m 3 /t].
8

The Sankey diagram in Fig. 6 illustrates

Approach flow
Paper machine

Loop 2

Fresh
water

the circulating COD loads for this example. Because of the low concentration
gradient from the preparation loop to the
PM loop the circulating water volumes

SludgeSludgeLoop 1Stockpreparation

are the same 12 . The biology in this inDAF 2

Save allstance is “end of pipe”. It fulfills the soletask of cleaning the effluent prior to its

DAF 1

discharge from the mill. If the water loop

Rejects/sludge thickening

is completely closed, the COD concentra-

DAF 3
Effluent: 8 m3/t

Biologytion increases to 30,000 ppm or more.
Odour problems as well as reduced
strength properties are unavoidable under these conditions.

Approach flow
Paper machine

Fresh
water

SludgeSludgeLoop 1Stockpreparation

Loop 29

However, if biological process water
clarification for a specific effluent volume of 4 m 3 /t is integrated into a completely closed water loop, a COD concen-

DAF 2

Save allin the loop water (Fig. 7). Experience

DAF 1

shows that COD concentrations below

Rejects/sludge thickening
DAF 3

10,000 ppm are not problematic, the ef-

Ultrafiltration

Biology

tration of approx. 7,700 ppm is reachedfectiveness of additives is good andrunnability problems due to deposits or

Effluent

product quality impairment as already10
Approach flow
Paper machine

Fresh
water

Loop 2
SludgeSludgeLoop 1mentioned, need not be feared as long as
Stockpreparation

there is adequate cleaning and screeningof the stock flow. The biologically clarified water is additionally cleaned througha sand filter and can also be conditionedby the addition of flocculants. It is then

DAF 2

Save allfresh water at the paper machine. Experi-

DAF 1

ence has also shown that the processes

Rejects/sludge thickening
DAF 3
Biologyavailable for re-use as a substitute forcan be controlled well if there is efficient
Ultrafiltration

Evaporation

Effluent: 0 m 3/tplanning of the overall water management process 13, 14 .

Stock Preparation

33

Fig. 11: Results of advanced water treatment(lab tests).

The additional costs for subsequent

8 m3/t4 m 3/t

4 m3/t condensate

cleaning in the biology stage can be offset to some extent by simplified approval

Retentate
0.7 m3/t

1

procedures by the authorities, lower
costs for fresh water preparation as well
Biologyas the elimination of effluent discharge
levies. For some mills the decision to in-

3

4

Ultrafiltration

Evaporation

2
SludgeConcentrate< 0.1 m 3/t

No. Sample

TSS
[ppm]

pH

COD

Conductivity[mS/m]

Turbidity[NTU]

1Feed biology

100

8.1

3600

2520

310

2

After biology

10

7.7

320

2460

25

3

After ultrafiltration

B

7.7

130

2310

7

4

After evaporation

B

7.5

< 100

< 10

< 0.01stall a completely closed system cantherefore already be economically justified today.
Graphic grades
The possibilities of further closing up
water loops or completely closing themcally before being discharged from thetabolisms will unquestionably be carried

are now discussed using the production

mill. This design represents state of theinto the process water. Fig. 9 schemati-of newsprint from deinked stock (news-

art technology. Specific effluent volumes

cally illustrates that a partial flow frompapers, magazines) as an example 15, 16 .

of approx. 8 m 3 /t are achievable without

the biology stage is cleaned throughThe best basis for evaluating water man-compromising the process technology or

ultrafiltration, before it is routed into

agement is provided by a Sankey dia-

product quality. With a further closing up

Loop 2.

gram of the water volumes in circulation.

of the loops, the dissolved loop load in-

Detailed balancing of process relevant

Fig. 8 illustrates this for the citedcreases disproportionately as alreadysubstances in the water shows that loop

newsprint example. The process compo-

shown by the curve in Fig. 1. Associatedclosure up to approx. 4 m 3 /t can benents are blockwise combined into waterwith this are the well-known problems ofachieved. This remaining effluent volume

loops. Water routing consistently follows

reduced efficiency of the bleaching,is basically essential to flush out the salt

the counter current principle. Fresh wa-

deinking and retention aids, poorer opti-

load brought in with the recycled paper

ter is added only at the paper machine.

cal characteristics of the finished paper,and additives. The transition from these

Following filtration, white water II sur-as well as increased deposits on thecontemplations to the scenario illustrat-

plus is cleaned in the fibre recovery

paper machine. If one views the biology

ed in Fig. 10 is smooth. If a fully closed

stage and used as dilution water after thestage as providing highly efficient clarifi-

loop is required, a specific water volumestorage tower or in Loop 2 in stock

cation for disturbing dissolved or col-of approx. 4 m 3 /t must be evaporated.

preparation. Loop 2 supplements Loop 1.

loidal substances, then reuse of the bio-With optimum process design (no alu-

The filtrates from sludge dewatering andlogically cleaned water is a virtual

minium sulfate, no dithionite) a reduc-rejects thickening can be cleaned via amust 17 .

tion down to 2 m 3 /t is feasible. Due toseparate microflotation, if a partial flow

If, however, the flow from the biology

complex chemical interactions in the het-is routed back into Loop 1. The otherstage is directly fed back – even after ef-

erogeneous stock, influences upon thesection represents the actual system dis-ficient mechanical/chemical post clean-finished paper characteristics cannot,

charge. The effluent is cleaned biologi-

ing – then microorganisms or their me-

however, be exactly defined today.

11

34

Fig. 12: Rough estimation of water treatment
costs.
12

Investment costs
DM/m3/hOperating costs
DM/m3

Fresh water treatment

8 000

0.15

Biology

28 0000.30

Ultrafiltration („dead end“)

27 0000.30

Ultrafiltration (clearing device)

29 0000.45

Nanofiltration (spiral wound)

35 0000.90

Evaporation

90 0001.10

Treatment of biological effluent

Just how the most important parameters

Outlookchange over these treatment stages is

Even though effluent from the paper in-summarized in Fig. 11. The results

dustry as a rule is non-toxic and notshown here represent a cross section ofloaded with harmful contaminants, themany individual measurements.

further closure of loops to preserve fresh
water resources appears unavoidable in

Despite these undoubtedly impressive

the future. With packaging grades, eco-values, it must be stressed that addition-

nomic advantages today make the deci-

al investment and operating costs willsion to install a completely closed plant

occur for further water cleaning via

easier. New impulses have reduced themembrane filtration and evaporation, andcosts of membrane filtration and at thethese are offset only to a small degree bysame time the process has become oper-

the lower costs for fresh water prepara-

ationally more reliable. But despite this,tion and elimination of effluent discharge

a zero-effluent system for graphic grades

levies. Fig. 12 gives broad trend values

is still subject to considerably higher

for the described treatment processes.

costs. Due to the pressure for better
water utilization, membrane filtration as

In summarizing, it can be said that com-well as evaporation will continue toplete loop closure for high quality graph-steadily establish themselves. However,ic grades appears possible today, but it

the objective cannot be to demand ais associated with considerable addition-completely closed system at any cost,

al costs for the installation and operation

but rather to aim for an economicallyof the additionally required systems

justifiable reduction in water require-technology.

ment, tailored to each specific location.

Literature
1 Schwarz, M.; Stark, H.: Thoughts on restrictingof water loops in paper production.
Wochenblatt f. Papierf. 112 [1984]
2 Hamm, U.; Göttsching, L.: Contents substances
in wood and wood pulp. Wochenblatt f. Papierf.
123 [1995], No. 10, 444-448
3 Schwarz, M.: Peripheral sub-systems for water,sludge and reject.
Wochenblatt f. Papierf. 18 [1995], 792 - 802.
4 Zaidi, A; Buisson H.; Sourirajan, S.:
Ultrafiltration in the concentration of toxic
organics from selected pulp and paper effluents.
Tappi Proceedings Environmental Conference[1991], 453 - 467
5 Pejot, F.; Pelayo, J.M.: Color and COD removal
by ultrafiltration from paper mill effluent. Semi
industrial pilot test results. Tappi Proceedings
Environmental Conference [1993], 389 - 395
6 Rochem company publication, Ultrafiltration
DT-UF Module system
7 Teppler, M.; Bergdahl, J.; Paatereo, J.; Damen,
H.: PM and BM White Water Treatment with
Membrane Technology. PTS Symposium“New Processes for loop water and waste watercleaning” [11/96] PTS-MS 21/96
8 Evaporation systems, AE & E compan publication
9 Kostinen, P-R.: New evaporation process withsynthetic film heating surfaces for treatment
of industrial waste water and leakage water fromrubbish dumps. Paper given at UTECH ‘96 on
26.2.96, Berlin, Seminar “Further waste watercleaning
10 Mörch, K. A.; Steinig J.; König, J.: Experienceswith a closed water loop in a paper mill.
Allgemeine Papierrundschau 110 [1986], No 44,
1532 -1536
11 Diedrich, K.: Operational experiences with aclosed water loop during production of
packaging papers containing waste paper.
Wochenblatt f. Papierf. 112 [1984], No. 4,
116 - 120
12 Borschke, D.; Selder, H. Schwarz, M.:
Processing technology for wrapping papers –State of technology and development trends.
Das Papier 7/8 [1996], 444 - 454
13 Paasschens, C. C. M.; Habets, L. H.; De Vegt, A.
L.: Anaerobic treatment of recycled paper milleffluent in the Netherlands. Tappi Journal [1991]
No. 11, 109 - 113
14 Suhr, M: Closed water loops in the paper industry using predominantly waste paper-state of theart technology? Paper given at UTECH ‘96 on
26.2.96, Berlin, Seminar “Further water cleaning?”
15 Siewert, WH.: System components for waste
paper processing, Wochenblatt f. Papierf. 16[1995]
16 Holik, H. and Pfalzer, L.: Development trends in
waste paper processing, Das Papier, 10 A [1995]
17 Mönnigmann , R.; Schwarz, M.: Waste water freepaper mill – Dream or Nightmare? Das Papier 6[1996] 357 - 365

35

1Paper Machinery Divisions:
Ortviken PM 4 –success for a new concept

The author:
Dr. Michael Trefz,
Paper Machinery
Division Graphic

Machine concept
In February 1996 SCA Graphic Paper,
Sundsvall, Sweden started up their PM 4
after an installation time of only fivemonths. This machine produces LWC offset printing paper according to a new concept which is so far unique. For the firsttime, all production stages are incorporated on a continuous online basis. Insteadof the two or three supercalenders neededby other producers for ensuring the gloss
and smoothness required of LWC grades,
the Ortviken machine delivers a finishedproduct.
This concept, unprecedented for speed
and quality, offers substantial advantages
over conventional LWC lines both withregard to investment outlay and operating
costs. Fig. 2 shows the differences
between conventional product lines andthe Ortviken PM 4. Classical LWC production lines comprise firstly a paper

machine, the output reels of which are
rewound before coating and calendering.
All time lost due to rewinding has to bemade up by a 15 to 20% speed increase incoating. The supercalenders used for final
finishing cannot keep up with such coating speeds, however, so that production
capacity can only be met by increasing
their number. Furthermore, any web
breakage or other trouble in the coating
and calendering zones holds up reeling,
and may even lead to paper machine shutdown. With an online machine such as
PM4 in Ortviken, all these problems are
eliminated since paper production, coating and calendering are integrated into a
continuous process. This great advantage
has its price, however:Since the overall efficiency is made up of
the individual machinery efficiencies –with no buffers or correction possibilities
between them any longer – every single

36Fig. 1: The wet section DuoFormer CFD.
Fig. 2: Conventional LWC production line
compared to an advanced concept.
Fig. 3: Development of a new coating technique.
2

3
Conventional LWC production line
Paper machine
Wet-endBlade coating

Coating machine

Dryingsection

C1S

Finishing

C2S

SC

re-reelingre-reeling

SC

Supercalenders

New coating techniquen Optimum base papern New coating formulationsn Advanced machine layout

New developed, advanced LWC production line
Wet-end

Dryingsection

C1S/C2S
one or two stations

line element must be 100% available.This
demanding requirement not only applies
to the machinery itself, but also to raw
material supplies and the operating team.
Likewise for the Voith Sulzer commissioning engineers and the Heidenheim andKrefeld specialists, starting up and optimizing PM 4 was a great challenge. Nevertheless, most of the extremely demanding guarantee data were fulfilled.
Process development
In order to implement this promising
online concept successfully, each individual component must be highly efficientand reliable. This was not possible withthe aggregates formerly available, particularly with regard to coating technology
which plays a key role. The need for minimal web stress and long doctor blade
cycle time had to be coordinated with highdemands on coating quality and a reliable
control strategy.
This problem was solved by developing
the Speedcoater. Spurred on by theOrtviken PM 4 project, the design draft

FinishingFilm coating

was matured in the record time of only six
months to the first prototype trials on our
test facility. And that was when the development teams of SCA Graphic Paper andVoith Sulzer Paper Technology began
their ongoing success story.

tions exceeding all limits known so far.
Even with this superlative technology, theraw paper characteristics and coating
recipes had to be optimized to achieve a
product quality comparable with that ofcommercial LWC offset printing papers.

Fig. 3 shows the main steps in developing
this new production technique for PM 4 in
Ortviken. Thanks to two years of intensive
collaboration, we were fully able to reachour quality goals with the new process.

During printing tests, the true benefits ofthis new concept were revealed. The
absolutely uniform coating contour
attained with the Speedcoater resulted inbetter coverage than with blade-coatedpapers. Combined with the high surface
temperatures in the soft-compact calenders, this led to extremely good printability.

The Speedcoaters on PM 4 are the first
VSPT coaters where sizing is predosedwith smooth doctor blades. Comparedwith conventional coating technology
using grooved blades, this extends cycle
times to a matter of weeks. Furthermore,coating thickness is easily kept constantby automatic control of application pressure.
In order to maintain the machine efficiency as high as possible, we decided to use
only one calender nip on each side. This
was achieved by installing two compact
calenders, which operate under condi-

Since only one calender nip is needed oneach side of the paper, not only are its
optical characteristics better, but it has ahigher volume than conventional LWC
grades.
Commissioning and operating
experience
Commissioning of PM 4 started at the endof January 1996. The month of February
brought plenty of teething troubles andPaper Machines371215 m/min
3258 m4060 GRAPHO LUX

controlling the application pressure of thesmooth doctor blades. This enables compensation of all fluctuations in coating
consistency. Furthermore, the roll andblade cycle times reach several weeks
even at these high speeds.

Fig. 4: Basis weight cross-profile.
4

1997-09-18 14:55
MV < L2 14:15:47

Våtände648QC444 GUSKGROP
S64975 Profilstyrning inloppslåda

18/ 9 13:43

14:56:23

1.0
g/m2
-1.0
2 Sigma

0.13

0.278

Max

0.15

0.39

Min

-0.18

Reglerinterv. 2-0.41
Senaste ingrepp 14:54:31

12000
Steg
0
Medelv Kvot
Torrvikt

36.5 %

100 %

Fukt

6.3 %

0%

Tvärsreglering
Till

Vänta
Fel
Avbrytoutage time due to the unfamiliarity ofnewsprint producers with this newprocess. Improvements had to be mademainly in the web transfer system and gas
supplies to the dryer and coating system.
The first significant LWC production
started when the machine was handed
over to the customer on March 8, 1996. In
the meantime all components were functioning reliably, and the operating team
had been trained to the point where regular operation was possible. Now began the
optimization phase, mainly aimed at fulfilling the paper quality guarantees.
To this purpose the Voith Sulzer Paper
Technology development engineers werein attendance, and together with SCA
Graphic Paper, two years of well-oiled
teamwork won the battle – all gloss andsmoothness guarantees were fulfilled.
The key to this success was the comprehensive and systematic procedure, whichis indispensable with such a complex
online machine. Our work was also assisted by the optimal measuring and control
systems provided.

Alla ställdon
Man

OffsetAuto

BV

Avblock

Lokal

Thanks to this, the effects on productquality of parameter changes in theapproach flow or wet sections could beestablished practically instantaneously.
The first production guarantee of 1000
tonnes per 48 hours was fulfilled on May
3, 1996, and the following month broughta further increase in efficiency.
During commissioning and the first few
months of operation, operating speed wasaround 1000 to 1090 m/min. In the meantime this has been increased significantly,
and at the time of writing the machine isoperating at 1240 m/min.
The maximum weekly output of highest
quality LWC paper is 4740 tonnes, corresponding to an efficiency of 85%. This
reflects the choice of coating process:while three to five web ruptures per day
are normal with online blade coaters forboth coating stations, the two Speedcoaters operated during the first year with
only 1.5 ruptures per day. Coating thickness, which is so important for final product quality, is automatically regulated byHigh quality coating cross-profiles are
ensured by selecting optimal roll covers,
and the cross-profile of the raw paper is
excellent thanks to the ModuleJet headbox. As shown in Fig. 4, the basis weightcross-profile has a 2-sigma value of only
0.15%.
Good 2-sidedness of the LWC paper product was an important design criterion.
By means of the soft-compact calender,
2-sided roughness in the 3-nip press iscorrected naturally by first calendering
the rougher side.
The secret of the high gloss achieved with
only one calender nip on each side of thepaper lies in the coating recipe and theextremely high surface temperature of thethermorolls. This also means, however,that the soft-compact calender has tooperate at the limits of present-day feasibility both with regard to temperature andline force.
After more than eighteen months of operation, the market trend in LWC paper has
also changed, in this case toward lighter
grades. Apart from the main productgrade at 60 g/m 2 basis weight, LWC
papers with a final basis weight below
50 g/m 2 are also produced now. Thanks to
its tailored concept and innovative Speedcoaters, this is no problem for theOrtviken PM 4.

38

1

Paper Machinery Divisions:
DuoFormer Top – a new former for top
plies of packaging papers
The newly-developed DuoFormer Top istions in the packaging paper sector,

a top-layer gap former that transfers

which permits producing also heavy

the advantages of the gap forming tech-grades with excellent quality at highnology relevant to packaging papers –speeds.

so far only available for base plies – toThe author:
Dr. Günter Halmschlager,
Product Development
Manager, Paper Machine
Division Board andPackaging

the production of separately-formed top

Based on the continuous increase in theplies. This paper describes the design

quality standards demanded of top pliesof the unit and the various technologi-

of packaging grades in particular with re-cal relations playing a part in achieving

gard to printability, coverage, and white-

the required product quality.

ness with minimum basis weights, Voith
Sulzer has developed a new gap former

With this unit, Voith Sulzer Paper Tech-for the manufacture of top plies.

nology rounds off its gap former spectrum and thus is the first paper machine

Existing former designs for the produc-manufacturer to offer gap former con-tion of top plies are based primarily on

cepts tailor-made to suit all applica-

conventional top wire solutions with orPaper Machines

39

Fig. 1 and 2: DuoFormer Top (pilot plant).
Fig. 3: Step Diffusor Headbox for top-layer
gap former.

2

without hybrid or semi-hybrid formers.
They give fairly good results in terms ofindividual paper characteristics but arelimited in terms of speed. As generally
known, the profiles achieved on theseformers are relatively poor compared togap former concepts. The high formation
quality demanded of top plies requires
low consistencies and jet-wire ratios
considerably in excess of 1.0. Only hybrid designs will deliver superior formation under these conditions.
The following aspects have been the driving forces for the development of thearranged with its slice facing the press

Headboxtop-layer gap former:

section and thus the direction of paper

Depending on the application, a single-

I high strength

run. Initial drainage takes place over anor multi-layer headbox is used. Its main

I enhanced formation

open forming roll with no vacuum ap-

parts are the distribution manifold, theI elimination of the speed limit

plied. The web is further drained on the

Step Diffusor block with ModuleJet SD

I high runability even at high speeds

wire suction box and transferred by the

dilution control, and the nozzle. Apart

outer wire to the couch-on roll andfrom the general requirements placed oncouched onto the base ply.

the headbox, a particularly important is-(> 1000 m/min)
I compact design

sue in the production of packaging paSheet Forming Concept

pers is to achieve good formation at low

The DuoFormer Top operates on the

MD/CD ratios. High-quality formation en-

principle of the DuoFormer CFD, a gap

sures superior coverage with a minimum

former design used for the production ofamount of virgin fiber in the furnish. Thebase plies of packaging papers. It is a

Step Diffusor headbox has the ability toroll-blade former featuring:

fulfil these demands.

I single- or multi-layer headbox
I forming roll without vacuum

Forming Roll

I jet discharge channel

The forming roll has an open surface andI wire suction box with integrated

is not vacuum-augmented. The drainage
pressure is adjusted by the tension of thesuction transfer box
I couch-on roll.

outer wire and determined by the roll

The paper runs in the same direction as

diameter. The forming roll ensures safe

the base sheet. This means that, unlike

wire support, which effectively preventsthe formation of top wire ridges. Due toexisting former designs, the headbox is3

40Fig. 4: Jet discharge channel and wire suction
box with suction transfer box.
Fig. 5: Detail from DuoFormer Top (pilot plant).
Fig. 6: Formation versus MD/CD, gap former/
fourdrinier.
4

6

Ambertec formation index g/m2

2

10

0°

fourdrinier1
gap former

0
1

2
3
tensile ratio MD/CD [-]4

the small radius of the forming roll, theessary to apply a vacuum to the jet

opposite directions, the split between de-portion of the stock jet going through thedischarge channel.

watering accomplished by the formingroll and the shoe can be optimized by ad-outer wire separates from the wire very
quickly. With other formers using a

Wire Suction Box

justing the two wire tensions indepen-

forming shoe (larger radius) as the pri-Web drainage is continued on the wire

dently of each other. On the shoe, themary drainage element, the jet stays

suction box which consists of a curved

drainage pressure can also be varied byclose to the top wire longer as it travels

shoe with 12 to 20 blades. Since theadjusting the vacuum level. The suction

along and there is the risk that the jet

forming roll and the shoe are curved in

box is divided into two suction zones,

does not penetrate the top wire evenly,

each of them supplied with a separate

causing CD profile variations. Drainage

vacuum. The second zone enhances theon the forming roll simplifies operation,

drainage capacity and simultaneously

as the exact position of the jet impinge-

forms an integrated suction transfer box

ment point is less critical.

which effectively transfers the web to theouter wire.

Jet Discharge Channel
Arranging the headbox at the highest

Couch-on Rollpoint of the former simplifies water flow

Similar to conventional solutions, thetowards the jet discharge channel. The

web formed on the DuoFormer Top is

portion of the jet going through the outer

couched onto the base ply by means of awire is captured in the channel very

couch-on roll. Since – due to the large

quickly and discharged on the drive side

couch-on roll diameter compared with

with minimal mist formation. In thisthe reversing roll – web liftoff can occur

area, jet energy and gravity are sufficient

only at very high speeds, the problem of
web liftoff is virtually eliminated.

to ensure efficient drainage, it is not nec5

Paper Machines

41

7
1,6

1,2
1,0

Fig. 7: Commonly used stock consistencies indifferent applications.
H Normal range.

0,4
0,2
0

kraftliner

0,6

testliner

0,8corr. medium

consistency [%]1,4Fig. 8: DuoFormer Top with different wrap
angles.

100%
100%
virgin fibre
waste paper waste paper

Fig. 9: Fines distribution over sheet caliper on
different former designs.

8

9

110°
30°

fourdrinier

hybrid former

gap former

top layer
gap former

sheet
forming unit

Technological Relations

blade drainage, since breaking-up of thein production with limited rebuild re-Formation

flocs will reduce strength. In practice, aquirements. The DuoFormer Top will of-Both the base-layer gap former and thecompromise has to be found between di-fer formation qualities similar to those of

new top-layer gap former with Step Dif-

lution (= consumption of pump powerhybrid formers.

fusor headbox give good formation at

and retention) and drainage capacity

low MD/CD ratios. Fourdrinier wires have(= installation cost and vacuum require-

Bond strength

to be run at large jet-wire ratios toment). Basically, in gap formers andAs generally known, bond strength de-achieve good formation values. This has

therefore also in the DuoFormer Top,pends significantly on the distribution ofa negative effect on the MD/CD ratio. On

larger percentages of virgin fiber require

the fines. Bond strength has been a key

gap formers, formation is far less depen-

considerably lower headbox consisten-issue in the design of the DuoFormer

dent on the jet-wire ratio than in conven-cies than waste paper.

Top. Drainage towards the paper side
couched onto the base sheet is very gen-tional solutions. The better coverage due
to better formation permits reducing theAt high basis weights this leads to jettle to prevent washing-out of the fines.

proportion of the top-ply basis weight inthicknesses which without lateral form-

No vacuum is applied to this side (Fig. 9).

relation to the total basis weight. The

ing gap sealing cause technologically un-

high fiber strength potential remains un-

acceptable cross flows. Therefore, lateral

It is also well-known that high stock con-changed.

sealing of the forming gap is one of thesistencies and low jet-wire ratios have acentral points under development.

positive influence on bond strength.

packaging papers the current trend – in

Due to the large range of applications,

A low jet-wire ratio can readily be set onparticular with virgin fiber – is towards

the top-layer gap former has been de-a top-layer gap former; but the use oflarger forming rolls. Good formation

signed for different degrees of forming

virgin fiber puts a limit to stock consis-

properties are to be achieved by usingroll wrap. This permits adaptation to thetency variation. As a whole, based on

low consistencies and a small amount ofdifferent furnishes and allows increases

drainage to two sides, the DuoFormer

In gap formers for the production of

42Fig. 10: Space required by various two-ply
sheet forming units. Dimensions for a 5 m widemachine based on same water capacity.
Fig. 11: Applications of DuoFormer Top.
10

~13 m

TopFormer F~8 m

DuoFormer D/K~4,5 m~3 m

DuoFormer D~11,5 mDuoFormer Top~8 m~5,5 m~5 m

11

DuoFormer Top. It is not yet known what
the upper speed limit of this former typewill be. In practical terms this meansthat speed increases are no longer limited by the former. So, if a top former is tobe placed onto a fourdrinier, a configuration like the DuoFormer Top will offer thebest potential for the future: The technological benefits of this design are also
evident at considerably lower speeds
and, on top of that, when at some later
Top creates optimum conditions for goodface properties of the top ply, for exam-time the fourdrinier is to be convertedbond strength characteristics.

ple for improving printability (top side)

into a base-layer gap former it will turnor for further increasing bond strength

out that opting for the future-oriented

Multi-layer technology(bottom side). It is yet to be shown if the

top-layer forming concept earlier has

The multi-layer approach of the base-lay-higher investment cost of a multi-layer

been the right decision.

er gap former, which has become state-

headbox for the production of top plies isof-the-art technology, can be transferredjustified.

Location and Impact on Machine
Performanceto the top-layer gap former. Using themulti-layer technique, it is possible to

Production speed

One of the most obvious features of astructure the top sheet in the z-direction.

Speed limitations of approximately 1000

multi-ply sheet forming section utilizing

Different furnishes or classified stock

m/min on fourdrinier machines or hybrida DuoFormer Top is that the top-ply

can be used. This helps optimize the sur-designs are eliminated by the use of aheadbox faces the direction of the basePaper Machines

43

Facts, trends and visions
in the Board and Packaging
Paper Industry:
Information meeting in Vienna
from April 28 to 30, 1998
Fig. 12: Pilot paper machine with
DuoFormer Top.

sheet. Its distance from the base-sheet

design is basically suited for all applica-

headbox depends on the drainage length

tions in which top wires or hybrid form-

required for the base ply. Since the innerers have so far been used for top-ply

wire of the DuoFormer Top is arranged

production. So, the DuoFormer Top isabove the drainage section of the basealso an option for the production of theply and runs in the same direction as theindividual plies of board, in particular of

base-ply wire, the space taken up by thethe top or back ply. Different angles of

top-layer gap former after the couching

wrap ensure the required flexibility.

point – between the couch-on roll andIn the production of board at low pro-the wire suction roll – is fairly small. In

duction speeds, the downward water

new plants, this reduces the length of theflow minimizes the danger of backflows

building. In rebuilds, it can be a decisivein the forming gap.

factor for the feasibility of the rebuild.
The top ply is formed over the unfinished

Outlookproduct. If fiber lumps, drops, or any

To find the optimum configuration forother disturbing particles drop onto theevery application, the DuoFormer Top

base sheet they will be covered by thewill be available for customer trials fromtop ply.

October 1997.

The inner wire does not run over blades,

Layout data:

resulting in reduced wire wear. The outer

Basis weight:

30 - 80 g/m 2

wire is longer as it runs over the vacu-

vb:

300 - 1400 m/min

um-assisted wire suction box. The por-

Wrap angle:

30 - 100°tion of blade drainage in top ply drainage

At the same time, research is under way

is very small, which apart from theto solve the long-existing problem of lat-strength benefits also extends wire ser-eral forming gap sealing in gap formers

vice life.

to permit the use of large headbox slice
openings.

Applications

It is crucial both for board and packaging

The DuoFormer Top has originally been

papers to achieve superior formation atdesigned for producing the top plies ofgood strength values. This requires low

packaging papers. But this new former

consistencies and less blade-induced
drainage.

Liner/testliner

Board

I white top
I mottled liner
I top ply

I top
I under ply
I filler ply

The new top-layer gap former extends
the speed range and thus the production

12

range of multi-ply packaging papers
based on the technological characteristics important for these products.

Springtime in Vienna – this has always
been worth making the journey! Paperboard experts from all over Europe meet
there at the end of April. But they will not
be paying the city a visit merely to get toknow Austria’s capital from its mostbeautiful side during the most attractive
season of the year. Instead, growth anda sense of awakening of a different kind
will occupy their minds. Markets andtechnologies, facts, trends and visionsof their trade – board and packaging
paper manufacturing.
The Paper Machinery Division Board andPackaging invites European manufacturers to attend a meeting in Vienna
from April 28 to 30, 1998. First-handinformation on the latest developments
and future trends will be the main topic –backed by lectures from the researchworld and practical business areas,
question-and-answer sessions and an
exchange of views. A date worth noting!
For more details, interested persons arewelcome to contact the Paper Machine
Division Board and Packaging ofVoith Sulzer Papiertechnik in St. Pölten,
Austria.
Telephone: ++43 2742 806 2353,
Fax: ++43 2742 74307,
Ms Nicole Kreitmayer44

Paper Machinery Divisions:
Winding technology for the next
millennium – with Sirius
The paper industry today already de-therefore developed an entirely newmands reel diameters up to 3.80 m,

winding concept to cope with such de-which, at a machine width of 10 m,

mands. This concept was first imple-

means reel weights of up to 120 tonnes.

mented within the framework of thePaper finishing processes formerly car-large-scale Triple Star project of KNP

ried out offline are now being integrated

LEYKAM (Picture above).

into the paper machine itself. Online

The authors:
Matthias Wohlfahrt,
Roland Thomas,
Thomas Martin,
R&D winding technology

coating is now the rule, and online soft-

The Sirius reeling concept

calendering is no longer unusual. The

The Sirius reeling concept is presented

Voith Sulzer Janus concept has made on-here on the basis of the new Pilot Reel atline supercalendering a reality at speeds

the Voith Sulzer Heidenheim R&D center

up to 1500 m/min, and this has alreadyfor graphic papers.

been successfully implemented.

In addition to the new concept, the uni-

Due to the associated dramatic changes

versal and flexible design of the Pilot

in paper characteristics, today’s end sec-

Reel facility allows a wide variety of

tion

have

winding principles to be tested and thus

reached their limits. Voith Sulzer havealso basic research to be carried out.

andrewindingconcepts

Paper Machines45

Fig. 1: Pilot Reel – Sirius configuration.
Fig. 2: Sirius nip loading system.
Fig. 3: Pilot Reel.

Fig. 3 shows an overview of the new Pilot

1
Reel

Reel, and in Fig. 1 the Sirius winding

SensoRollconcept is shown with the test rig set up
for normal winding operations.
SensoReeling,
the heart of the Sirius concept
The heart of the Sirius winding concept
is the completely new nip loading system. In contrast to the pope reel, nipload is generated by the pivoted SensoRoll, while reel growth is compensatedby the reel system (Fig. 2).
The nip loading system is operated by ashort-stroke cylinder to enable extremely
fine adjustment of nip force. By thismeans, the force and travel components
are separated from each other. As a result, the masses which have to be moved
to apply the required nip load are kept
low. This avoids errors due to friction,
so that even very low nip load (down to
0.3 kN/m) can be precisely adjusted.
Since the SensoRoll is wrapped throughalmost 180°, the web tension and nipload are no longer linked. This meansthat web tension fluctuations can nolonger affect the nip load.
The Pilot Reel allows nip loads to be applied either by conventional means or according to the Sirius concept. Loading
can either be hydraulic or pneumatic, allowing differences in operating behavior
runnability to be investigated.
In the Sirius concept the reel spool generally has a center wind, but conventional winding systems can also be set up on

2

this Pilot Reel. This combination of innovative nip loading system with centerwind of the reel spool and web tension enables optimal control of reel structureduring winding.
The entire winding process, i.e. interplay
between web tension, nip load andtorque (center wind) is controlled by acomputerized reel hardness monitoring
system: the Voith Sulzer Rollmaster. Thissystem also keeps statistical records ofall main parameters.
3

46

Fig. 4: Strip pull-out test recorder chart.
Fig. 5: Principles of the strip pull-out method.
4

5

The radial winding tension is thus defined as:Stripwidth blength l

Area A subject to:perpendicular stress s N
perpendicular force FN
Paper reel

L N = F N /A =FZ
2H b zcz=c=

2H b z2H bThis means that to determine the radial
tension, it is only necessary to measure

Measured force Fz

Measured travelz = clamped-in
strip length

the gradient of the force/travel line on
the recorder plot, the coefficient of friction H between paper and steel (for thisconfiguration measured with H = 0.3)
and the tape width.

The design speed of the Pilot Reel iscured or developed in addition to the new

As shown in Fig. 12, the tape pull-out

3000 m/min, with a maximum reel width

test facility. These are described below.

method enables clear assessment ofof 2.50 m at 2.20 m diameter. In specif-

winding hardness, irrespective of edge

ic cases the rig can easily be converted

Measuring radial wound-in tension

face quality (important for the needle

for reel diameters up to 3.50 m.

Since conventional measuring methods

test method) and without interrupting thefor assessing winding structure were in-winding process (as required with theReel changing systems

adequate, Voith Sulzer applies a method

Parotest).

The Pilot Reel is designed so that allof measuring the actual radial tension

known reel changing concepts can bewound into the reel. As winding proceeds,

Reel winding structure simulation

implemented.

a paper-covered steel tape is inserted

programinto the nip between reel and reel drum

Together with a university institute, Voith

One of the main development goals is toat several diameters. When this tape isSulzer is developing a simulation pro-

implement new winding concepts for:pulled out afterwards, the force is plottedgram for prior assessment of paper reel

I perfect winding right from the first

versus distance as shown in Fig. 4.

winding structure. Using the finite ele-This measuring method is based on thement method and non-linear algorithms

I minimum paper broke

principle shown in Fig. 5.

for paper characteristics, this program

I optimum reel changing reliability.

The following equations apply:

computes the 3-dimensional reel struc-To this purpose, a modern high-speed

F Z = H2F N

ture from the winding torque, web ten-camera allows detailed analysis of allwhere 2F N takes account of forces acting

sion and nip load. It takes account of

web movements.

from above and below on the tapedead weight and centrifugal forces, air

L N = F N /A ¨ L N = F N /b z

inclusions and layer displacements.

New tools for improved winding
To gain a deeper knowledge of the wind-

As shown by the recorder plot, force iswinding structure much more accurately

ing process, further tools have been pro-linear to travel: F Z = c z.

than methods used so far, some of which

layerThis simulation model thus defines thePaper Machines

47

Fig. 6: Principle of friction measurement.
Fig. 7: Friction measurement results.
Force displacement plot for uncalendered LWC.
6

oversimplify the formulation of basic
Perpendicular force

physical effects.

Friction force = tensile force

First results with this simulation program indicate that the target of forecasting paper reel winding structure can be

Displacement
Paper stackreached effectively.
Paper grades naturally vary very widely,
not only with regard to standard values

7such as basis weight, caliper and densiPerpendicular force

ty, but also surface characteristics, compressibility, strength and rheology. Since
particularly

thelatterMean perpendicular tension 0.45 N/mm 2

characteristics

Perpendicular tension

strongly affect winding structure, andhence computation results, these values

Coefficient of friction

are carefully measured by appropriate
methods.

Frictional force

Determination of winding friction values

Displacement [mm]For this purpose we use an instrument
which measures coefficients of friction at

friction commences. The perpendiculardered LWC is clearly unaffected by per-the high tensions occuring during thetension increases during measurement

pendicular tension variation (Fig. 9),

winding process. This instrument was

because the paper surface area underwhereas it varies considerably with un-

developed

pressure decreases with increasing dis-calendered grades, not only LWC. As

strength testing device so that it mea-

placement.

shown in Fig. 8, the coefficient of frictionsures friction, perpendicular force and

The wide variation of coefficients of fric-at very low perpendicular tension is sig-

displacement.

tion according to paper grade is clearlynificantly higher than at the high perpen-

The measuring principle is shown inshown by comparing results between un-

dicular tension in the reel during wind-

Fig. 6. Fig. 7 shows the results obtained

calendered and calendered LWC. In Figs.

ing. For this reason, relevant paper fric-on uncalendered LWC. Plotted here ver-8 and 9, coefficients of static and dy-tion coefficients in winding technology

sus displacement are the perpendicular

namic friction are plotted versus perpen-must be measured at perpendicular ten-and frictional forces, the intersurface

dicular tension for these two grades.

sions of 0.4 N/mm 2 and above.

pressure calculated from displacement

Both static and dynamic friction are sig-

and perpendicular force, and the coeffi-

nificantly higher with uncalendered thanCompression measurement

cient of friction derived from perpendicu-

with calendered LWC. Furthermore, theThe compression characteristics of paper

lar and frictional forces. As shown, static

static and dynamic coefficients of friction

likewise have a strong influence on wind-friction first has to be overcome accord-

are much wider apart for uncalendereding structure. To check this, we convert-

ing to Coulomb’s law before dynamic

LWC. The coefficient of friction for calen-

ed a Ring crush tester to enable com-byconvertingatensile48

Fig. 8: Coefficient of friction versus
perpendicular stress for uncalendered LWC.
Fig. 9: Coefficient of friction versus
perpendicular stress for calendered LWC.
Fig. 10: Compression test setup.
Fig. 11: Compressibility comparison between
calendered and uncalendered LWC.
8

10
Perpendicular force

Coefficient of friction

Static friction

Dynamic friction
Paper stack

Displacement

Perpendicular tension

9

11

Static friction
Dynamic friction

Spring stiffness

Coefficient of friction

Calendered

UncalenderedCompressive stress

Perpendicular tension

pressibility measurements to be carriedmaterial characteristics in the 3-dimen-

In summary, this concept not only allows

out. As shown in Fig. 10, the basic prin-sional simulation program.

higher winding speeds, but also results

ciple is to measure perpendicular force

in outstanding reel quality.

as a function of increasing displacement.

Results

In Fig. 11, compressibility tests are com-

In the meantime, numerous tests have

Winding tests

pared between calendered and uncalen-

been carried out with various paper

The following selection of winding test

dered LWC by plotting spring stiffness ofgrades. Calendered LWC can be woundresults give a good impression of how

the paper versus perpendicular tension.

troublefree at speeds up to 2000 m/min,

the Sirius concept improves reel struc-

The calendered LWC is much stiffer – i.e.

and uncalendered LWC up to 3000 m/min.

ture.

less deformable – than the uncalendered

Thickly coated decorative papers, where

Fig. 12 shows the effect of reel center

grade. CD-profile irregularities in calen-

the slightest displacement can lead totorque on winding hardness (at constantdered paper therefore have a muchglossy zones, were wound and rewound

nip load), expressed as radial winding

stronger effect on nip force regulation,

several times without any problem. Even

tension versus reel diameter.

and hence on winding structure.

self-copying paper – where troublefree

Winding torque is clearly a very effective

With these tools and the results derived

winding has only been possible without aparameter for controlling winding hard-obtained, Voith Sulzer have gained a bet-

nip up to 800 m/min – can now be

ness. The corresponding center torqueter understanding of winding processes.

wound at speeds up to 1500 m/min withcurves are plotted versus reel diameter

This forms a solid basis for formulating

enhanced reel quality.

in Fig. 13.

Paper Machines

49

Fig. 12: Effect of reel center torque on winding
hardness and constant nip load.
Fig. 13: Reel center torque curves.
Fig. 14: Effect of nip load on winding hardness atconstant torque.
Fig. 15: Nip load curves.
14High nip load

High torque

Smith needle test
scale divisions S [-]Radial tension by the tapepull-out method12

Low torqueLow nip load

Reel diameter

Reel diameter

13
High nip load

Nip load

Reel center torque15

High torqueLow nip load

Low torque
Reel diameter

Reel diameter

The influence of nip load on winding

Summary

trouble-free at speeds of 2000 m/min,hardness (at constant winding center

The new Voith Sulzer Sirius concept

uncalendered grades up to 3000 m/min.

torque) is shown in Fig. 14, where wind-meets all foreseeable demands on wind-

Even highly sensitive grades such as

ing hardness in increments S of theing technology.

self-copying (carbon) papers can be

Smith needle test scale are plotted ver-wound at higher speeds and with en-sus reel diameter.

Thanks to the following features, higher

hanced quality. Due to improved reel

Likewise nip load is therefore an effec-

winding speeds are possible, and in ad-changing, broke is reduced.

tive parameter for controlling winding

dition to this, the results are also better:hardness. The nip load characteristics

I Reel center windWith the Sirius winding concept and ourused here are shown in Fig. 15 as a func-

I SensoRoll acts as loading system

new R&D tools, we can work out optimaltion of reel diameter.

I Decoupled loading and displacement

operating parameters for the papers ofReel winding structure can thus be con-are provided by two carriages

trolled very effectively by varying both

I Full-length nip load system with noour customers.
A simulation program using much more

the winding center torque and the niptransfer from primary to secondary

comprehensive algorithms and models

load between paper reel and reel drum.

zone.

than previously is currently under devel-

The best possible way to ensure optimal

Large reels up to 3.80 m diameter weigh-opment. In future this will allow 3-di-winding structure is therefore to com-ing up to 120 tonnes can be handled eas-mensional forecasting of paper reelbine these control parameters.

ily. Calendered papers can be wound

winding structures.

50
Design data
Width
Operating speed
Design speed
Line force
Temperature
Paper grade
Basis weight

4440 mm
800 m/min
1000 m/min
330 N/mm
130°C
wood-free coated150-400 g/m 2

1

Finishing Division:
Startup of the first Janus calender at KNP,
Maastricht, the Netherlands
The elements and technological principles of the Janus concept have been

Table 1Supercalender

described

Lehmann gloss[%]

73,7/76,8

Bekk smoothness[sec]

1468/877inmanypublications

andpapers. And since the Janus technology
centre was opened, hardly a week hasgone by without at least one test demonstration on customer’s paper to show thequality and output advantages of the
The author: Franz Kayser,
Productmanagement, R&D,
Finishing Division

Janus concept.

Roughness
PPS-10S[Hm]

Brightness/Y-factor [%]1,06/1,09
85.84/85.60

Basis weight[g/m 2]

250

Thickness

[Hm]

190

Specific volume[cm 3/g]

0.760

Finishing

51

Fig. 1: Offline Janus calender.
Fig. 2: Steam boiler.
Fig. 3: Heating rolls.
Fig. 4: Calender unwind system.

What has been missing so far, however, 2

3

is an actual production report. This article remedies the situation by reporting on
the first Janus calender startup at KNP
Leykam, Maastricht.
Fig. 1 shows the calender layout in thismill, for finishing wood-free multicoatedheavy grades to optimal gloss.
The supercalender used so far only
achieved the surface qualities shown intable 1, at speeds down to 300 m/min.

4This Janus calender at KNP Leykam comprises the following modular elements:
1. Janutec plastic rolls for all elastic rollposition
2. Direct steam-heated rolls with individual temperature control
3. Multizone Nipco top roll
4. Single zone Econip bottom roll
5. All hard rolls coated (partly chromed,

For PM 6 in Maastricht, two of theseline during the evening of October 21,

Janus calenders were supplied.

1996. The situation looked so promisingthat it was decided to calender the firstpartly with SUMEcal)
Since Janus technology was so new, andproduction reel on the next day.

6. Web rope loading system, thus

never used so far in production, it waseliminating the nip guards

agreed with KNP Leykam that the calen-

At 6 a.m. on October 22, 1996 the steam

der would be commissioned well before

boiler (Fig. 2) was fired up, bringing the

7. Cooling rolls in calender output

startup of the rebuilt PM 6.

heating rolls (Fig. 3) to 140°C. All rolls

8. Unwind system with flying splice

After the usual hectic procedures, e.g. forweb was threaded through the open cal-balancingender nips to the winding station.

were then cleaned again, and finally the

9. Sensomat Plus rewind system.

heating

loops

and

drive

motors, the first Janus calender went on

52

Fig. 5: Temperature measurement with IR camera.
Fig. 6: Gloss development in the Janus calender.
Fig. 7: Winding on the Sensomat Plus.
Fig. 8: Gloss measurement in the sample test
laboratory.
6

5

After having the web wrinkle free on the
Sensomat Plus roll, all nips were closed
and pressurized.
The calender was then run up to 400
m/min – 100 m/min faster than the previous supercalender. In the meantime, thisspeed has been increased still further to
700 m/min, with equally good calendering results.
With a specially equipped infra-red temperature camera, the high-gloss hot rolls(Fig. 5) were continuously monitored forcorrect temperature level and distribution.
The same procedure was adopted for allother Janus elements, supervised by
specialists in order not to lose any time.
Fig. 6 shows the result: a wonderfully
uniform gloss from nip to nip of theJanus.

78

53

Fig. 9: The proud team in front of the first Januscalendered paper reel.

This high gloss paper, extremely smooth

Table 2Janus 13/14

Supercalender 9/10

and difficult to wind, is handled without
problem by the Sensomat Plus winding
system (Fig. 7).
Eager to see if such excellent first
impressions would be confirmed in thelaboratory, the customer lost no time inchecking paper samples (Fig. 8). The laboratory test results are shown in Table 2.
Not only was calendering considerably
faster, with substantial improvements in

Speed
Line force
Temperature
Nips[m/min][N/mm]
[°C]

700
300
100
9

300
300
90
11/13

Lehmann gloss
Bekk smoothness
Roughness PPS-10 S
Brightness/Y-factor

[%]
[sec]
[Hm]
[%]

77,6/78,1
1675/1711
1,12/118
86,31/86,20

73,7/76,8
1468/877
1,06/1,09
85,84/85,60

Basis weightThickness
Specific volume[g/m 2][Hm][cm 3/g]

250
190
0,760

gloss and smoothness, but above all systematic application of the Janus principle

At the end of this memorable day, no

The customer was delighted with results:

resulted in extremely low 2-sidedness.

wonder the entire calender personnel

all calendering quality targets had notproudly had their picture taken in Janus

only been reached but even exceeded – atCompared with 3-4 points gloss differ-T-shirts with our commissioning engi-

higher operating speeds.

ence between the two sides on the super-neers (Fig. 9).

calender, 2-sidedness on the Janus calender amounts to only 1 point.
954Service Division:
After-market service saves fiber lines
1

The author:
Mark Tayler,
Service Division, USA

Domtar, Potlatch Mills Use Service
Provider Know-How for Pressure Washer Drum Replacement“patch-up” work. Some failed catastrophically. Over 100 of these pressure
washers were built throughout the world.

In the early 1990s pressure washers
were reintroduced in North America as acost effective way to increase production. Pulp would be washed in an enclosed vessel, thus able to wash fasterand more efficiently. Pressure washers
were offered in huge sizes to make themeven more attractive.

Partnership for a Solution
Domtar Inc. has a fiberboard mill in Red
Rock, Ontario. The mill has sought to atleast achieve some economies of scaleby installing a large pressure washer.
The washer performed well for a year orso, but maintenance and inspections
began to uncover stress fractures. Operational problems took down the line. A
solution was required, since the mill
faced further investment need in effluent
treatment and other areas of the mill.
Domtar needed an innovative, fast solution.

At first, the washers worked very well.
Operating at high rotational speeds andthroughput, customers were satisfied
with ROI. Unfortunately, after about two
years, structural problems developed insome of the washers. The washers began
to experience severe fatigue cracking,causing long down times and expensive

Their supplier of after-market service ofthick stock pumps and other pulp equip-

Service

55

Fig. 1: Pressure washer 4m x 11m.
Fig. 2: Pressure washer under construction at
Tristar.
Fig. 3: Pressure washer ready for shipment to
Potlatch.
2ment, Tristar Industries Ltd. of Vancouver, B.C., offered a solution using aunique relationship it had establishedrecently.
Tristar has been working with Dr. Mohamed S. Gadala at the University of
British Columbia’s Mechanical Engineering Department for a year or so on new
ways of using Finite Element Modellingto solve complex engineering problems.
Tristar would use their own know-how
on pulp washer design together with
their work with UBC to solve the pressure washer drum problems. Domtar
agreed and a project was born.

mate solutions to a wide variety of engineering problems. UBC uses the NISA
finite element analysis (FEA) package. To
develop the new drum, approximately
20 intermediate designs were considered
and 60 detailed models were constructed

Using Finite Element Analysis
The finite element method is a numericalanalysis technique for obtaining approxi3

at UBC’s Finite Element Modelling Laboratory.
Once the design concept was finalized,
Voith Hydro in Pennsylvania remodelled
the drum using the ANSYS FEA package

56

Fig. 4: Alternating stress summary for the
existing design.
Fig. 5: Alternating stress results of the new drum
design.

Existing Design
Location Description

Stress* Location Description
MPa (ksi)

Stress*MPa (ksi)

h1

110.3
(16)

h1

journal/flangeintersection

81.4(11.8)

h3

shaft shoulder/68.9
hub plate weldment (10)e3end-plate/
hub weldment

18.6
(2.7)

s1

spoke/hubintersection

54.5
(7.9)

w1

end-plate/
22.1
web plate weldment (3.2)

s2

spoke/box
intersection

38.6
(5.6)

w8

web/boxintersection

13.8
(2.0)

d1

deck shell

17.2
(2.5)

d1

deck shell

17.2
(2.5)

l1

longitudinal
members

32.4
(4.7)

l1

longitudinal
members

13.1
(1.9)

f1

fly-rings

40.7
(5.9)

f1

fly-rings

27.6
(4.0)

shaft/hubintersection

to cross check and develop sub-models
to fine tune the design in sensitive stressareas such as weld access holes(“mouse holes”) and stiffness transition
regions.

New Design

Building the New Drum
Domtar, U.B.C. and Tristar worked together on the problem drum during thedesign process. The team brain stormed
potential solutions and physically measured all boundary conditions. Load cells
and pressure sensors were installed on
one washer during a mill shutdown to allow accurate measurement of all forceson the drum.
Tristar has been a provider of after-market services for pulp equipment since1974. The company has always rebuilt
thick stock pumps, low and high pressure feeders, make-up liquor pumps, top
separator screws and baskets, and vacuum drum washers.

*Reported stresses are un-averaged von-Mises intensity for level 5 torque, 129 kN.m (1,141,000 lb.in.)

Much of the company’s vast manufacturing resources were concentrated on the
Domtar project, including the latest in
CNC boring machines, lathes and criticalinspection work. Just six months after
the model and testing were complete,
Tristar was installing the new drum at
the Red Rock mill.
The new drum design has significantly
reduced the alternating stress levels.
In the critical first weld near the drive
journal, stresses were reduced from+/- 10 ksi to +/- 2.7 ksi. (The design basis values used by Tristar are +/- 4.5 ksi
for full penetration weldment and +/- 10
ksi for non-welded parent metal.)

45Service

57

Fig. 6: NISA Finite element alternating stresssummary – end component detail for new Tristar
drum design.

The Results
In order to relate the alternating stresslevels to equipment life expectations,crack propagation analysis was employed. Although this part of the analysis
is somewhat crude, on a comparative basis it provides a very reasonable tool toassess the life expectancy impact on a
reduction of alternating stress levels.
By using the material properties of 316L
stainless steel in black liquor and assuming an elliptical surface crack, the impactof reducing the alternating stress from+/- 10 ksi to +/- 2.7 ksi was comparable
to increasing the drum life from 9months to 90 years respectively.
To verify the accuracy of the finite element analysis, the Domtar drum was fitted with strain gauge rosettes mounted
on the end plate at a critical stress area.
The strain gauges were carefully protected with layers of foil and rubber laminated in place. Wiring was run through theidle journal to a rotary electrical connec-

6Service Center Tristar
I A world class aftermarket equipment manufacturing and reconditioning facility
providing innovative and responsive service to pulp and paper mill customers.
One of Voith Sulzer’s five Service Centers in North America

Located in Delta, British Columbia/Canada
I Under the stewardship of Ray Hall, Chairman of the Board
I The leadership team:
Samuel A. Young – President
Mark Tayler – Vice President Operations
Victoria Gochuico – Financial Controller
Marcos Ishii – Sales and Marketing Manager
Moe Kassam – Manager of Engineering and Quality Assurance
I The product lines:
include washer drums, thick stock pumps, and digester chip feeders.
I The market:
50% Canadian mills, 49% United States mills and 1% New Zealandand Australian mills.

58

Fig. 7: Fatigues cycles of the existing and new
Tristar design.
Fig. 8: Measured alternating stresses on Domtar
prototype drum during field verification.
Fig. 9: Rauma washer distribution by global
region.
7

8

6

2.5
alternating stress in ksi

a [crack length in inch]

4
2
1.5
1
0.5

2
0
-2
-4
-6

0
1.E+0.3

1.E+0.5
1.E+0.7
1.E+0.9
N [number of cycle]
Existing design
New Design

tor and fed through a data acquisition
system to a computer monitor for realtime viewing by the team The actuallevel observed was +/- 2.5 ksi – exceeding expectation for alternating stress.
The three drums shipped to Domtar havebeen running well. No unscheduled downtime has been recorded. Tristar andDomtar continue to monitor the drums’
structural performance by making spot
inspections.
Repeating Success
Tristar built on its Domtar success withanother of its after-market service customers – Potlatch Corporation at their
Lewiston, Idaho mill.
Potlatch also experienced reliability
problems with their pressure drum washer line. Six months after the Domtar project completed, Tristar was awarded a
project with Potlatch for two even larger
drums.
The Domtar drums measured 3.5 m indiameter and 8.0 m face length. The-80

0.2 0.4 0.6

0.8

1.0 1.2

1.4 1.6
minutes

9

49.2%
5.6%
23.4%

North America
Europe21.8%

Asia, Africa
Latin America

Potlatch drums were considerably larger– 4.0 m x 11.0 m. The scale up design
required a concerted effort in modifying
the models and subsequent design.

The Next Challenge
Implementation of the “Cluster Rules”
will force mills to eliminate emissions.
Today’s rotary drum vacuum washers
currently vent gas. The new laws will require mills to collect and scrub thesegasses before emitting them to the atmosphere. Because of the high volume of

1.8

2.0

2.2 2.4

2.6

2.8 3.0

gas and low concentrations of the contaminants, re-tooling mills with scrubbers
is cost prohibitive. Pressure washers
provide a solution. Tristar, which is a
subsidiary of Voith Sulzer, has applied
for and received patents in the U.S. andCanada for their new technology.
Because of their enclosed operation,pressure washers emit very little gas.
Their designed throughput is excellent
and washing efficiency is very goodcompared to conventional rotary drum
vacuum filters. Replacement of rotary
drum vacuum washers with pressure
drum washers would eliminate air quality
problems for the mill, while paying forthe project with increased production.

59

1Service Division:
Measurement and diagnostics join
the team with DIAG S.A.
What seems to be the trouble? Produc-in 1993 by the Centre Technique dution problems, excessive vibrations?

Papier (CTP), Grenoble. Its purpose right

Is your dryer section energy consump-from the outset was to provide diagnos-

tion too high? Or perhaps you simply

tics services for paper mills, draw upneed to optimize paper machine opera-

reports and make proposals accordingly.

tion? Whatever the case, troubleshoot-The DIAG team has thus accumulated a

ing and optimization both demand pre-wealth of process and product know-how

cise measurements – a speciality of thewhich is highly estimated by numerous

Voith Sulzer Measurement and Diag-paper mills.

nostics Service. With their impressive
range of equipment, our experts are

The Voith Sulzer Service Division mea-

ready for all eventualities.

surement and diagnostics teams canthus provide paper mills with valuable

The authors:
Andreas Arnhold,Measuring and Diagnostics
Service,Henry Giroud,
DIAG S.A.

As all boy scouts know, lending a helping

support in all areas, irrespective of prod-

hand means being prepared. No sooner

uct. This includes mechanical, thermo-

said than done: the Voith Sulzer Service

dynamic and hydraulic system trou-

Division promptly acquired a majority

bleshooting, production optimization andholding in DIAG S.A., a French company

preventive maintenance.

with headquarters in Grenoble. This not
only augments our human resources, but

In order to carry out today’s widely

also places more equipment at our dis-varied and often complex measurement

posal. And in particular, we can now lookassignments, portable data reading andmuch better after our south-west Euro-

processing computers are used exclu-

pean customers. DIAG S.A. was founded

sively.

60

Fig. 1: Thermographic view of reel temperature
distribution over machine width.
Fig. 2: For taking measurements inside a dry
section, heat-proof suit is required.
Fig. 3: Telescopic arm with sensors formeasuring pocket humidity and dryer surface
temperatures over machine width.
2

Together with our new partner DIAG,

latestVoith Sulzer Paper Technology can now

their disposal – sophisticated technology

troubleshooting

equipment

atoffer even better services with regard tospecifically designed for this application.

thermal energy management in paper
mills:A thermographic analysis is first made of

I Analysis and proposals for enhanced

temperature distribution on the reel inpaper quality and drying.

the cross-machine direction (Fig. 1),

I Energy optimization in the dry section.

since an unequal temperature distribu-

I Improvement of dryer section evapo-

tion indicates a non-uniform humidity

ration performance.

cross-profile. If the problem is verified inthis way, other measurements are thenA case study

carried out in the dry section – a job for

For diagnosing humidity profile prob-

which our service technicians often havelems, for example, the Voith Sulzer Paper

to wear heat-proof clothing (Fig. 2). CTP

Technology / DIAG specialists have thehas developed a special telescopic arm
for this task, with sensors for measuring
pocket humidity and roll surface temperatures (Fig. 3).
After carrying out dry-section measurements in this way and optimizing air circulation as a result, production outputs

With those multichannel computerized

have been increased by about 4% – apartmeasuring systems, all main data can befrom significant improvements in basis

measured at various machine settings

weight and reel humidity cross-profiles.

(e.g. at different speeds and throughputs) without significantly interrupting

Examples like this show impressively

production.

how we reach our goals: to help mill

Apart from sophisticated measuring andowners optimize production, reliability,

diagnostics equipment, we also possessmaintenance and cost-effectiveness. We

comprehensive know-how for drawing

do this with customized diagnostics

conclusions from results and making

techniques

recommendations accordingly, for exam-

paper technology know-how. With DIAG

ple with respect to:as our partner, the Voith Sulzer Service

I Increased efficiency.

Division has intensified their activities as

I Quality optimization.

mechanical troubleshooter and as tech-

I Environmental protection.

based

on

nological problem-solver.
3

comprehensiveInternational PAPER TECHNOLOGY

61

Tissue on the upsurge

The demand for tissue – as a collective

The tissue market worldwide

term for lightweight sanitary papers – isGlobal tissue consumption has been ris-

growing worldwide at above-averageing at 4.5% p.a. over the last eight years,

rates, bringing in its wake a growing

as against 3.5% for other paper grades

demand(Fig. 1).

forproduction

machinery.

Although this growth refers to quantities,

The authors:
Rudolf Greimel, Andritz AG, Graz;
Dr. Martin Tietz, Voith S.A., São Paulo

it is above all quality which is required.

There are considerable variations in thisQuality with tissue mainly means softness

development from region to region; for

combined with strength, but it also means

example in North America the annual risehigh volume, good water absorption, andis only 2%, while in Asia it is more thanbrightness. Even the recycled materials

7% and even reaches 10% in China. At

content affects buying decisions thesenearly 5%, Western Europe is slightly

days. No other product sells itself on theabove the world average.

shelf like tissue paper.

62

Fig. 1: Annual production growth.
Fig. 2: Global tissue market: consumption
to growth ratio in various regions.
1
Papermillion t.p.a.

million t.p.a.

For the coming years experts expect simi-

Tissuelarly high growth rates, with greater
regional differences. The higher the mar-300

ket saturation, the lower the relative

20

growth rates (Fig. 2).
200

Per capita tissue consumption (Fig. 3) is10

led by countries with a high standard of100

living. At the top of the scale are the USA
and New Zealand with about 20 kg p.a.,

0

1986

1990

1994

0

2000

and at the other end Africa with about 0.1
1986

1990

1994

2000

kg p.a. Global tissue consumption per per-Annual production growth

son averages 2.9 kg p.a.

5.0%

Tissue production largely follows con-

4.0%

sumption statistics. Since the volume toweight ratio of tissue paper is about three

3.0%

to four times higher than other paper
grades, long-distance transport is not

2.0%

cost-effective. As a result, less than 5% of
1.0%

total production is traded internationally,as against more than 20% for other

0
1986

1990

Tissue1994

grades.

2000

Paper in total

The key to rising tissue consumption is2rising
Predicted average annual growth
1994-2005 [%/ a]8standards

ofliving,growing

tourism and business travel, and steadily
China

7

rising hygiene standards.

Eastern Europe

6Other
5 AsiaAbove all for institutional and industrial
applications the so-called I & I sector-tis-4
Africa3

Latin America

Japan

Oceania2

Europesue paper is increasingly replacing textiles. There remains the large consumer

North America

sector, which includes face-towels, hand-

1kerchiefs, toilet paper and other hygienic

0
0

5

10
15
Per capita consumption 1994 [kg/ a]20

25

tissues, to name only the most important
products.

International Paper Technology

63

Fig. 3: Per capita on tissue consumption
in various countries, 1994.

Tissue paper: characteristics andcritical, since only a few seconds areproduction process

available during operation for influencing

Tissue paper basis weight is extremely

product quality.

New Zealandtherefore require two, three or even four-

All kinds of tissue machine are in use

Switzerland

layer sheets, which are volumetrically

today, including among the older ones a

Norwaysofter than single-layer products. Apartlarge number of Fourdrinier and suction

Finlandfrom surface layer softness, volumetricbreast roll machines.

low at 12 to 25 g/m 2 . Most applications

3
USA

Swedensoftness is very important for user-friend-

United KingdomJapanliness. At the same time a multilayer sheet

The quality of tissue produced on these

Germany

is stronger, and enables systematic con-machines is good, but their speed andAustriatrol of quality characteristics. This canhence output is limited. They were suc-Taiwaneither be achieved by multilayer forma-ceeded over the last twenty years by aAustraliation, or by subsequent lamination.

great many twin-wire machines, which are

Italystill among the fastest existing and pro-FranceMultilayer tissue paper has a better volu-

duce excellent results.

metric softness (crushability) as against

Spain
Greecesingle-layer products. Apart from surface

As a further development of twin-wire

Rep. Korea

softness (“velvet” feeling), this is impor-machines, the CrescentFormer is now

Venezuelatant for user-friendliness.

state-of-the-art for new installations.

MexicoHungary

Despite the low basis weight of tissue,

Pulp is introduced into the Crescent-Chilemodern plants turn out up to 40 tonnes

Former from above, directly between the

Polandper metre width each day. This demands

outer wire and the felt. When the wires are

Argentina

machine speeds of more than 1500 m/min,separated after the forming roll, the web

Singaporesometimes exceeding 2000 m/min. And

already lies on the felt, so that no pickup

Rep. S. Africa

since tissue machines are much shorteris required here.

than normal paper or board machines, theWorld total
Malaysia

web dwell time is likewise extremely

After this the web is dewatered mechani-

short, often less than 2 seconds – and incally on the Yankee roll in one or two

China

this time it has to be dewatered e.g. frompresses to about 40%, and then dried. The

Thailand

0.2% consistency to 95% dry content!

highest specific drying performance of

CIS

about 210 kg/h water per m 2 drying area

Philippines

BrazilAs far as speed is concerned, tissue

is only attained by combining the Yankee

Indonesia

machines are therefore the “formula 1roll with a high-temperature nozzle hood.

Rest of Africa

racing cars” of paper machinery. This

The main advantage of the Crescent-makes machine concept selection very

Former is extremely high product quality

kg/y/capita

5

10

15

20

64

Fig. 4 and 5: Tissue machine TM 22.

4

despite its attractive simplicity. In con-Not only do these machines differ withhand, operators must be in a position to

trast to the twin-wire former, the Cres-

regard to capacity, but also as far asreact flexibly to market needs – market

centFormer has no inner wire or pickup,

equipment is concerned. While state-of-trends hard to forecast at the present time

which not only makes it much less com-the-art key components are incorporated

may be decisive for failure or success inplex, but also prevents web damage.

in all versions, the TM15 and TM10 are

the future.

comparatively low-cost alternatives covFurthermore, sheet forming directly onering fringe requirements.

Voith Sulzer and Andritz meet these

the relatively soft felt results in higher

expectations with future-oriented con-quality tissue, i.e. more voluminous. And

An attractive range of machine types is

cepts, whose market popularity is certain-

as a welcome „fringe benefit“, the Cres-

thus available, all of which meet the peakly attributable to the innovative compo-

centFormer is rather more compact.

technology standards to which Voith Sulz-

nents described below:

er customers are accustomed.
Highlights of the new overall concept
The VSPT former family

Goals met by our new concepts

Multilayer headbox (Fig. 6)

Demands on new installations vary widely

VSPT customers expect modern machin-

In CrescentFormers the pulp jet from theas far as output is concerned. Due to lim-

ery to meet peak quality demands at very

headbox has to be fixed very rapidly

ited transport possibilities, a 50 tonne perhigh operating efficiencies. On the otherbetween wire and felt.

day machine is often adequate for regional requirements, while for an entire,densely populated country a 200 t.p.d.
plant may barely cover additional needs.
The VSPT CrescentFormer range has been
tailored(Table 1).

to

suit

these

requirements

Table 1:
Type

Width

OutputDesign speed

TM22

2.5 to 6.0 m

75 to 240 t.p.d2200 rpm

TM15

2.5 to 4.2 m

55 to 140 t.p.d1500 rpm

TM10

2.0 to 2.7 m

30 to 65 t.p.d1000 rpm

International Paper Technology

65

Fig. 6: Two-layer headbox.
Fig. 7: Two-layer tissue (different fibres on top
and bottom sides).
5

Layered sheet
Short fibres on Yankeeside
I Improved softness due
to softening influenceof the Yankee surface.
I Higher strength due
to fewer long fibres
being destroyed.

Doctor blade
Long fibres on Yankee side
I More homogenous sheet.
I Less dust in thecreping zone.

The new headbox design is optimized sothat extremely short jet lengths of lessthen 100 mm can be set. Since the felt is
so close to the lower headbox casing,undesirable air intake with the felt into theforming zone is eliminated.
6

With a 2-layer headbox, different fibre
qualities can be incorporated in individual
layers. Product quality and manufacturingcosts can thus be systematically influenced by the operator (Fig. 7).
If short fibres are used on the Yankee sidewitha2-layerheadbox,long-fibre

destruction during creping is reduced. As
a result, the end product is more voluminous and softer on the short-fibre side,and stronger on the long-fibre side.
By subsequent doubling with the twolong-fibre sides in the middle, both goals
are reached: a soft surface and a strong
middle layer.

7

66

Fig. 8: Microsections of top and bottom surface
layers.
Fig. 9: GapScan.
8

ning

systems–complementing

themechanical system – gives extremely precise nozzle opening data even at widely
varying interior pressures. Measuringcapsules installed in the upper and lower
walls, and also in the intermediate lamellaof multilayer headboxes, transmit continuous readings of the exact distance
between them. The operator thus has precise data at all times on flow conditions in
the headbox.
Suction press-roll with central vacuum

9(Fig. 10)
As an alternative to the conventional suction roll with vacuum on the operator side,a new patented concept is used with central suction from the drive side. This eliminates the movable ducting with side compensators used on older machines, aswell as the vacuum piping on the driveand operator sides. The uncomplicated,straightforward layout is possible thanks
to a roller bearing specially developed fortissue machines, combined with a new
drive design.

On the other hand, 2-sidedness can be

Whether in multilayer or single layer

reduced by running long-fibre stock onheadboxes, symmetrical flow in the Z

the Yankee side without subsequent dou-

direction – from distributor via turbulencebling. Since the 2-layer headbox has agenerator to nozzle outlet – is decisive for

Success through competence

fixed central lamella, the two layers can be

the outstanding results achieved withMore than ten new installations sold with-run at different speeds to improve sheet

VSPT headboxes. Experience has shownin two years reflect the high market

strength.

that our step diffusor headboxes canacceptance of our systems and machinery

operate at higher consistencies than oth-(Fig. 11). These include the four largest

ers – under identical conditions.

machines in Asia, which will be going into

Fig. 8 shows layer purity in the 2-layer

service in 1998. The VSPT centres ofheadbox, the two layers being differently
coloured to illustrate fibre density in the

GapScan (Fig. 9)competence for tissue machinery are

Z direction.

This new development in electronic scan-

Voith Sulzer Brazil, São Paulo, and ourInternational Paper Technology

67

Fig. 10: Suction press roller.
Fig. 11: Recently received orders.
Fig. 12: Tissue technology test facility.
10

DS

11

FS

Voith Sulzer/Andritz CrescentFormers convince the tissue market world-wide
Tronchetti
Italy2700 mm2000 m/min
Tien Long
Taiwan3650 mm1800 m/min
Wepa TM 8
Germany
2680 mm2100 m/min
Thrace TM 3
Greece2550 mm1700 m/min
Strepp TM 5
Germany
5600 mm
2200 m/min
Pindo Deli TM 11
Indonesia
5600 mm
2200 m/min
Lontar Papyrus TM 1
Indonesia
5600 mm
2200 m/min
HenganChina
3650 mm
1650 m/min
Suzhou TM 1
China
5600 mm
2200 m/min
Suzhou TM 2
China
5600 mm
2200 m/min
Goma Camps TM 6
Spain
2860 mm1800 m/min
Austrian partner Andritz AG, Graz. The

Customer trials are another focal point ofSão Paulo centre serves customers in

our activities. Since many customers can-North and South America as well as

not afford their own test facilities, they

Australia, while our Asian, African andrent machinery from us, for example toEuropean customers contact Graz forcarry out trials with their own raw mate-their tissue machinery needs. These two

rials for new machinery concepts.

companies jointly operate a tissue tech-With a wide range of adjustment options,nology test facility (Fig. 12) in São Pauloprompt data recording and evaluation, our– a 1 metre wide high-performancetissue technology test facility is a valuable

machine with great flexibility for a wide

tool enabling customers not only to opti-

variety of customer trials as well as basic

mize existing plants, but also to design

development.

new ones on a reliable basis.
12

68

Ind

Sieg

ust

rie

pap

ier

x
s
liFle sQuesas Sleeve 995

er de

Pr

t1
nteeLasufzeit!
Co
8 Tag
30

QualiFlex Contest – record after record
Winne

r of thQuae l

Press

iFle

Sleev xes

Cont

53 mill

est 1
io
n nip

995

passes!

Voith Sulzer Papiertechnik is the world’s

Visy Paper of Sydney, Australia for the

only paper machinery supplier to manu-

QualiFlex sleeve on their machine No. 6

facture and market flexible press sleeves

which achieved 53 million nip passes.

for shoe-presses. With a package com-

r des
iFlex
QusaslSleeves

Siege

Pre

1996 !
tensNtipdurchgänge
CoMn
illione70

prising the NipcoFlex press and QualiFlex

In 1996 completely new standards werepress sleeve, Voith Sulzer offers a sin-set: with 70 million nip passes Perlen

gle-source solution for trouble-free com-paper, Switzerland, broke the world

missioning

record with a blind-drilled QualiFlex

andcost-effective

paper/

press sleeve. In the second category,board production.

Stone Europe Carton of Hoya, Germany
Based on a nonwoven yarn reinforcement

also broke the record with 516 operating

which is completely embedded in poly-days on the machine No. 2. For 1997

urethane, QualiFlex press sleeves areworld records are likely to be brokenhighly reliable and long-lived.

again with QualiFlex press sleeves – what
will the winners achieve this time?

The popular “QualiFlex Contest”, an annual event since 1995, offers a prize for
Sieg

er de

s

Qu

P r e s aliFles Sle x
eves
C
onte
5
16 Ta

ge L

st 1

aufze

it!

996

the longest QualiFlex sleeve service life.

QualiFlex B: more void volume for

One category is for service life in days,

higher dry content

another in terms of nip passes. The win-

The bigger the sleeve void volume, thener is awarded a special-edition Quali-

better the dry content and production

Flex T-shirt, together with a surprise.

output. Based on this simple formula,blind-drilled QualiFlex B press sleeves

The author:
Andreas Endters,
QualiFlex press sleeves dept.

Winner of the first QualiFlex Contest in

have a new drilling pattern as of autumn

1995 was Schoellershammer Industrie-

1997. The greater number of holes in-papier, Germany, with a QualiFlex sleevecreases the open surface area and thus

on their machine No. 5 which ran for

the void volume. Instead of 440 cm 3 /m 2 ,308 days. Second prize was awarded tovoid volume in future will be 500 cm 3 /m 2 .

QualiFlex B

Old

New

Hole dia.
Hole depth
Open surface area
Storage capacity

2.4 mm
2.0 mm22%
440 cm 3 /m 2

2.2 mm
2.0 mm25%
500 cm 3 /m 2

International Paper Technology

69

Active patent protection –in the interest of our customers
I Decisive for a consistent headbox jet

shape of the nozzle convergence isflow is the lamella tip thickness. If thiscritical for preventing spraying effects.

is optimized, product flaws such as
striping are prevented and optimal

Patent family DE 4 323 050 C1

coverage is ensured.
Patent family EP 0 681 057 A2

The author:
Helmut Heinzmann,
Paper Machine
Division Graphic,
Patent System

I Decisive for the dimensional stabilityof paper, linerboard, etc. is systematic
Due to more difficult conditions in the

I Decisive for the quality, geometric sta-adjustment of the basis weight crosspaper industry, such as the rising cost ofbility and service life of the lamella tip

profile and fiber orientation cross pro-raw materials, competition has become

is its mechanical design.

file in the individual layers.

Patent family EP 0 711 869 A2

Patent family DE 4 321 268 C2

much tougher. As a result, development
activities have to be intensified to meetgrowing demands on paper quality andproductivity – and these strategic developments must be protected by patents.
Among the most important development
work of Voith Sulzer Paper Technology
recently is in the field of multilayer systems and technology. The aim here is optimal distribution of raw materials in the
sheet structure, not only to improve paper characteristics, but also to reduce

As an innovative partner to the paper in-mill operating and investment costs.

dustry, Voith Sulzer Paper Technology

Some decisive elements of these devel-

invests in new technologies to the beneI Decisivefor optimal coverage is thefit of our customers. All these innova-

extracts from VSPT patent descriptions

flow path in the headbox nozzle. Par-

tions and developments are comprehen-

and applications.

ticularly at high flow velocities, thesively protected by taking out patents ac-

opments are illustrated by the following

cordingly.

70Internal topics
Paper Machine Division Board andPackaging under new management
Dipl.-Ing. Wolf-Dieter Baumann, the previous manager of the Paper Machine
Division Board and Packaging, will leave
Voith Sulzer Papiertechnik GmbH & Co. KG
with effect from February 28, 1998 to join
the Körber AG mechanical engineeringgroup in Hamburg, which is active
throughout the world in tobacco processing, paper processing and productionengineering. Mr. Baumann will start his
new career as deputy management
spokesman for PapTis Holding GmbH andwill become chairman of the board ofmanagement in mid 1999 at the latest.
It is also intended that Mr. Baumann
should later join Körber AG Group Boardof Management.

1992 he was appointed executive sales
manager by the Board of Management ofJ. M. Voith AG, St. Pölten, Austria, and later became head of the Paper Engineering
product division. In the course of thedivisional restructuring of Voith Sulzer
Papiertechnik, Mr. Baumann accomplishedvaluable organizational work in connection with the establishment of the Board
and Packaging Paper Machinery Competence Center. Mr. Baumann’s move toKörber AG will have no influence on therelationship between the Voith and Kör-

activities in the fields of technology,
sales and management took him to Germany, England and finally to the USA.
Otto L. Heissenberger is an experienced
expert in the board and packing material
machinery area: He will assume worldwide responsibility for the CompetenceCenter and the markets for this particular
product area. As of January 1, 1998,
Mr. Heissenberger has been appointed amember of the Board of Management of
J.M. Voith AG, St. Pölten, Austria, andManaging Director of Voith Sulzer
Papiertechnik GmbH & Co. KG in Heidenheim, Germany.

Management of Voith Sulzer
Papiermaschinen GmbH, Heidenheim,
enlarged
As of September 1, 1997, Harry J. Hackl
became head of the new Sales businessarea at Voith Sulzer PapiermaschinenGmbH, Heidenheim, Germany.

Mr. Baumann came to J.M. Voith GmbH,
Heidenheim, Germany, in 1981. From1985 on he worked for Voith Inc. in theUSA, and in 1988 took over the newly
established Voith office in Moscow. In

ber groups.
Otto L. Heissenberger, born in 1952, hasbeen appointed Mr. Baumann’s successor. Until recently he was Senior Vice
President of Voith Sulzer Papiertechnik’s
Middletown plant in the USA. Mr. Heissenberger started his career as engineer
when he joined the Andritz AG mechanical engineering company in Graz, Austria,
in 1977.
While employed by several of the Sulzer
Escher Wyss Group’s companies, hisInternational Paper Technology

Harry J. Hackl has many years of widespread experience in international plant
construction. For more than 20 years heheaded the cellulose plant business area
at Krauss Maffei in Munich and the companies which took over these activities
from Krauss Maffei. During this time hecooperated successfully with Voith andSulzer Escher Wyss on complete, integrated pulp and paper plant projects
worldwide.
In his capacity as a member of the boardof management of Voith Sulzer Papiermaschinen GmbH, Heidenheim, he will bein charge of sales of graphic papermaking machinery and complete plants.

er proximity to the customer, acting as acompetent discussion partner, providing
the right people for round-table meetings, networking projects within our
product areas, intensive observation of
the market – and of course, the mostimportant target, increasing our market
share in this country.
Since Finland joined the Common Market
it has opened its economy and become
increasingly attractive for foreign firms.
In the past few years many new papermaking machines have been installed.
A temporary decline in investments istherefore expected in the near future. But
much reconstruction work on a larger orsmaller scale is required to update older
machines and improve efficiency andquality. We are confident that with our
successful system components, thisarea will offer us some worthwhile opportunities.

New Office in Finland“You should have made this move earlier! But it’s great that you’re here at last.
Competition is what we need here in Finland. Alternative technologies and prices.
We’re not interested in discussing ourstrategies with some agent or other, but
directly with yourselves!”
This is how our Finnish customers reacted when Voith Sulzer Papiertechnik
opened its own office in Vantaa, Helsinki,
on October 1, 1997.
By expressing their needs and requirements in this way our customers havealso determined our new office’s strategy: Improved, more rapid service in clos-

71

Although Finland has a reputation as oneof the leading paper production countries, the following facts may surprise thereader:A total of 140 papermaking machines
scattered among 50 firms generate anannual domestic output of 10.4 million
tons of paper and board. Taking Finnish
companies’ production abroad into consideration, annual production exceeds
20 million tons.
In Finland the level of surface treatment
is very high. Nowhere else is the ratio
between paper coating machines and thecountry’s size is so high. The quality ofthe domestic raw material, the aboveaverage level of education and the expertise of Finnish paper makers are the keys
to this unique range of paper types.
With these resources, the Finnish paperindustry should face a secure future.
With UPM-Kymmene, Enso, Metsä Seria,
Myllykoski and Jaako Pöyry we have ourhighest density of so-called key customers in Finland. Although these companies are organized according to alargely decentralized competence structure, some major research institutions
and strategy units are located in Finlandand influence decisions worldwide.

Jörg Fischer, previously an executive at
J. M. Voith AG in St. Pölten, Austria, is in chargeof the new office. Manfred Kohrs, a material
technology expert from Ravensburg, Germany,
Kenneth Krook of the previous agents Telko,
Jouko Jokinen, who has moved from Appleton
Mills to Voith and Minna Siitonen as assistantcomplete the team.

The new office of Voith Sulzer Papiertechnik is located between Helsinki airport and the city center.
The address is
FIN-01620 Vantaa, Jaakonkatu 2,
Telephone +03 58-9-27 66 15-0,
Fax +3 58-9-27 66 15-11.

72

P a p e r C U LT U R E

LUDWIGSLUST PALACE
Waste paper recyclingof a different kind
Germany – the land of castles andpalaces. This is certainly one of the many
impressions that the foreign visitor –whether on vacation or on a business trip
– absorbs and takes home from the kaleidoscopic picture of Good Old Germany.
Heidelberg and Neuschwanstein are wellknown in Philadelphia and in Tokyo. In themeantime Sanssouci has also re-entered
the list of castles and palaces worth seeing. But when talking about the more significant palaces in Germany’s new Federal
States – who has ever heard of Ludwigslust Palace? For paper manufacturers

it is a real must to note the name and pay
a visit to the former residence of theDukes of Mecklenburg. The late Baroqueedifice is located about 80 kilometers eastof Hamburg. Surrounded by gardens
which are really worth seeing it harbors apeculiarity which has nowhere else survived the course of time both in dimension and quality: a magnificent interior
made of waste paper – or, to be more precise, of papier-mâché.
In the 18 th century, when the numerous
rulers of the German Particularist states

tried to emulate their grand French model,
almost all of them started to build theirpersonal Versailles palaces. Some ofthem inevitably ran out of money before
they could pay for valuable marble, finetimber and costly and complex stonedressing and plastering work. Duke Frederick of Mecklenburg (1717-1785) was
also stricken with a shortage of money.
His father Christian II Ludwig (16631756), who had a great passion for hunting, had started to enlarge his hunting
lodge near the village of Klenow, an area
abounding in forests and game. In 1754

73

Fine statues, a classic decorative interior –the astonishingly genuine-looking export
bestsellers made by the thrifty Duke of
Mecklenburg reveal their ingenious substanceonly at second glance: papier-mâché madeof recycled files from the State sovereign’s
administration and finance chancellery.

he ordered that “…from now on and in the
future the said location should be named
Ludwigs-Lust”. His son Frederick appreciated Ludwigslust likewise, though in hiscase a passion for hunting played only aminor role.
The tranquillity and remoteness of the site
suited his own modest character andpiety, an economical household, a marked
interest in the natural sciences and his
affection for etchings “from nature”. Frederick had studied the exemplary economyof the Netherlands and became acquaint-

ed with French architecture and landscaping. Ludwigslust was the perfect place to
combine his personal interests with model agricultural projects aimed at improv-

ing the rural structure. He resolved torelocate his residence from the city of
Schwerin to Ludwigslust and had thehunting lodge replaced by a completely
new palace that complied with his representative and social duties as State sovereign. Although the style of King Louis XIV
served Frederick as a model, the funds
available from the Duke’s “Sand andWood Purse” – the proceeds from selling
construction sand and felled wood being
his sole significant source of income –were far from matching the budget of the
Sun King.

74

Paper Culture

75
The Golden Hall of Ludwigslust Palace with its
sumptuous interior, its immense columns, vases,
wall decorations and the acanthus leaves on theceiling, all in the graceful splendor of late Rococo
style. All gold-plated ornaments are made of
Ludwigslust Board, a papier-mâché formula thathas not been completely deciphered until today.

How or by whom Frederick was inspired touse recycled waste paper instead of thecustomary expensive materials for his
new palace’s interior work has not been
handed down. At that time papier-mâché
was already used as material for small
items such as devotional pictures, dolls or
tobacco boxes. But to conjure up columns
several meters in diameter and the splendid interior architecture of a Baroquepalace from this material was an extraordinary venture even in this architectural
epoch of “aesthetic illusion”. If his plans
had not been realized with the kind of perfection that is still admired today, theDuke would have become the laughing
stock of most European Courts. The factthat he succeeded in marketing this idea
profitably verges on genius. After successfully demonstrating its manufacturing formulae, which even today have notbeen completely brought to light, the“Ludwigslust Board Manufactory” supplied numerous noble houses between
Vienna and Paris which – also sufferingfrom the building urge – had been in thesame dire financial straits as Duke Frederick himself.
But his plans had to be postponed for the
moment. With the Seven Years’ War Frederick the Great, Duke Frederick's famous

76

The Ducal gallery in the Ludwigslust court
church. Its artistic decoration and drapery is
resistant to woodworm and moths: everythingis made of papier-mâché. (Picture below).

namesake in the adjacent State of Brandenburg, not only put military pressure on
Maria Theresa and Austria. Prussia's
associated dynasties were unrelentingly
asked for “support”, that is to say a contribution to the war chest.
As a consequence, work on Ludwigslust
did start not until 1764. The Court Church
was the first structure to be built, between
1765 and 1770, and tested the idea of richdecoration made of papier-mâché on asmall scale. Gold-plated ornaments andtextile drapery with elaborate folds decorate the balustrade. But every single item
is made from waste paper! The six splendid candleholders including their 50 cm
high altar candles are of the same origin.
Ducal cost-awareness considered eventhe use of beeswax as too much of a luxury. A clever spring mechanism inserts
inexpensive tallow candles of any desired
size into the papier-mâché sleeves andpushes them upwards so that only their
flickering wicks are visible.

The masterpiece of Ludwigslust waste
paper recycling is in the true sense of theword the so-called “Golden Hall” in thecentral tract of the new palace which was
finally completed in 1776. Although time
has left its mark – in particular the temporary misuse after the Second World War
when the Red Army used Ludwigslust as
its local headquarters – the multiplestorey banqueting hall still reflects thespatial concepts of its owner in its architecture: elegant splendor, symmetricalLouis-Seize style, combined with the playful forms of the late Rococo period. Monumental columns, gold-plated ornaments,
brackets, cornices, vases, busts, door andmirror frames and decorative chandeliers
are all made from papier-mâché with thehelp of pre-cast plaster moulds, pressedor – in the case of the more complex rarities – modeled and painted fastidiously byhand.
During the reign of Duke Frederick the“Golden Hall” was primarily reserved forconcerts of church music performed by
the Ludwigslust Court Orchestra, one of
the most significant interpreters of its
time. Contrary to any assumption basedon its impressive splendor, the “GoldenHall” has never served as a venue forsumptuous evening balls. Guests wererefused admission to the gallery. This was
not to prevent them from having a closer
look at the papier-mâché ceiling ornaments: the Duke’s pious attitude did not
tolerate gay festivities and in no circumstances a view from the top into the – atthat time quite opulent – décolletés of theladies.
An English travel book of 1781 is considered the earliest documentation on Lud-wigslust papier-mâché. It was the firstbook to mention the twelve Imperial
Roman Statues, “made of pure board”,
which adorned the park during the summer. In the 1940s the figures became victims of the ravages of war, but by then
“Ludwigslust Board” had weathered windand storms for almost two centuries.
Numerous attempts to discover the secretof the manufacturing principle and durability of Ludwigslust Board, whether byworkshop espionage or by luring away thecraftsmen, all failed. Duke Frederick
entrusted the task of expanding the manufactory to his loyal lackey John Frederick
Bachmann, who kept the secret of theexact ingredients until he died in 1815.
Some records and receipts tell of theacquisition of large quantities of ethyl

Paper Culture77

Two examples from the Ludwigslust Board
Manufactory’s numerous bestsellers: La Frileuseafter Antoine Houdon (left) and the Venus deMedici after the original now in the Uffizi in
Florence. Both pieces were made around 1790.
Even today, after two centuries, these accurate
replicas in their deceptive terracotta or marble
never fail to impress their admirers.

alcohol, flour and bone glue. Waste paper– in particular old files and paper from thechancelleries of the Ducal Finance andState Administration – always constituted
the basic material from which Ludwigslust Board was produced. However,in the heyday of the manufactory thissource of material no longer sufficed. By
the end of 18th century Ludwigslust wasprobably the largest waste paper recycling center in Central Europe. This
assumption is backed by the fact that thelayers of glued waste paper found in theinterior of some of the busts prove to havebeen written on in several different languages.
In the beginning the Ludwigslust manufactory concentrated on architecturalneeds, ornamental elements and rosettes
for ceilings and frames and moldings forwalls, mirrors and doors. Later vases,
chandeliers and furniture were added tothe product range. To round things off,
renowned artists created replicas ofworld-famous statues, which were thenmodeled in complex processes fromnumerous layers of wet and glued waste
paper. Fine finish, polishing and colored
frames resulted in an astonishingly genuine marble or terracotta look. The “Venus
de Medici” and a bust of Martin Lutherwere among the export bestsellers of the
Ludwigslust manufactory.
It's worth saying again – Ludwigslust andthe chance of admiring the papier-mâchécreativity of bygone days are really worth
a visit, despite the fact that not all the rarepieces born of the ducal thrift have survived until today. It is a pity that nothing
has remained of the manufactory itself.
The visitor must make do with the resultsthat can be admired in the Court Church
and the Palace. Some of them have been
restored with loving care, while many other pieces still await proficient restoration.
Be that as it may: the paper enthusiast or
the paper maker will become aware of how
many diverse possibilities his working

material contains, a material which today
is considered common property and isalways available. And if waste paper's
perspectives really change in the era ofelectronic media, someone might comeup with a new (old?) notion à la Duke
Frederick. There is always a future forbrave and bright ideas.

2Paper Technology Journal“twogether” is published twice annuallyin German and English. Contributions by
independent authors do not necessarily reflect
the opinion of the publisher.
Please address all correspondence andinquiries to the editor.
Published by:Voith Sulzer Papiertechnik GmbH & Co. KG
Editor:Dr. Wolfgang Möhle, Corporate Marketing,
Voith Sulzer Papiertechnik 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.voithsulzer.com
Editorial coordinator:
Manfred Schindler, D-73434 Aalen
Design, layout and typesetting:
MSW, P.O. Box 1243, D-73402 Aalen
Copyright 2/98:
No part of this publication may be reproduced
or copied by any means whatsoever without
the express permission of the editor.

2/98/20 SDZ. Printed on chlorine-free bleached paper manufactured with Voith Sulzer Paper Technology machinery.

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