2

A Royal Event for
Board andPackaging Papers

In early May 2001, under the motto“ahead, Voith Paper invited the
manufacturers of board and packaging
papers to Vienna to exchange theirexperiences and opinions.

The author:
Nicole Schnait,
Paper Machines
Board and Packaging

The list of the more than 400 participants reads like the ‘Who’s Who’ of
the board and packaging paper industry:
Over 250 top international managers
from the board and packaging paper
sector, as well as representatives of
institutes, technical universities
and representatives from the media
had accepted the invitation to come to
Vienna. A total of 40 countries wererepresented – from Australia to Canada,from Japan to Chile.

Lunch was served in the newly renovatedroof foyer of Vienna’s Hofburg Palace.

Vienna’s Hofburg Palace provided a royalsetting for the conference. In former times,
the Hofburg Palace was the emperors’ winterresidence. Today it houses the offices of theAustrian Federal President, the Spanish
Riding School, the National Library, several
museums and a modern conference centre.
More than 350 guests from 40 countries
attended the conference held in the ‘Großer
Redoutensaal’.

Otto Heissenberger,
President of the Board and Packaging
Paper Machine Division,and Dr. Hermut Kormann,
President of J.M. Voith Aktiengesellschaft, Heidenheim.

3

4

On the evening before the conference,
Otto Heissenberger, President of the Board andPackaging Paper Machine Division, welcomed theguests at a reception held at the Ferstel Palace.

A ‘gemutlich’ evening at a ‘Heuriger’ withtypical ‘Schrammel’ folk music is an absolutemust in Vienna.

The evening’s entertainment was anexperience enjoyed by everyone. In therelaxing atmosphere, many attendees
also found the time to discuss futureplans and projects.

Three years had passed since the last“ahead Customer Conference was held in
1998, focusing for the first time on the
topic of board and packaging papers –and it was time for an update.

 What are the possibilities of multi-ply
and multi-layer concepts, when aresuch concepts used today and what
advantages do they offer for the production of certain board or packaging
paper grades?

Many investments were made by Voith
Paper during these three years, mainly
to strengthen its process competence.
Today, papermakers have to re-think andoptimize their complete production
process to assure that their products are
geared to market requirements at optimum cost effectiveness.

 What can be done to follow the trend
towards higher speeds and lower basis
weights of packaging papers? What
are the possibilities to boost production while enhancing quality when
producing board?

Some changes were clearly visible, suchas the acquisition of the Scapa group,
which considerably strengthened theVoith Paper Service Division and madeVoith Fabrics one of the major manufacturers of paper machine clothing.

In other areas, such as research and development, Voith Paper has also focusedon strengthening its process competence. The following topics were interlinked throughout each paper being presented at the “ahead 2001 Conference:

 How do the raw materials used, thestock preparation equipment, thepaper machine components and following process stages interact with
one another during operation of aboard or packaging paper production
line and how can such interaction be
utilized to achieve an optimum
product?

 How do investment cost and operating
cost correlate, and how can amachine’s total cost be minimized?
The papers focused both on concepts for
new production lines and on possible
upgrading through rebuilds. Moreover,
several “smart solutions” were presented, allowing the papermaker to achieve
lasting improvements in machine performance with small investment budgets
and minimum amortization times.

Highlighted on the agenda were the papers on new reference plants. During“ahead 1998, several new components
and machine concepts specifically developed for board and packaging papers had
been presented, such as the gap formers,
DuoFormer™ Base and DuoFormer™ Top.
This time, five customers demonstrated
how these concepts had successfully
been put into practice, giving current figures to substantiate their reports.

Some of the production lines discussed
have revolutionized the industry: PM 9 at

5
The spouses’ programme included a visit to
the imperial apartments in the Hofburg and the
Porcelain Manufactory Augarten.

SAICA 3 in Spain, the fastest paper machine for corrugating medium, constantly
reports new speed world records. The
new production line for gypsum-grade
paperboard, Lawton, Oklahoma, USA, isthe world’s first paper machine fittedwith two gap formers. The fact that the
shoe press technology has also gained afirm foothold in the production of board
was demonstrated by a report on the
BM 3 rebuild at Mayr-Melnhof, Frohnleiten, Austria.

The guests’ expectations were high, andthe participants this year were twice as
many as during the “ahead 1998 Conference. The numerous positive reactions,the pleasant atmosphere during the conference and the fact that the large conference room was packed full until the last
paper was read, showed that the Vienna
conference was worth visiting.

In closing, a small, but unique, thankyou gift was presented. Each participant
received a ‘take-away’ paper machine.
The simple design, absolutely maintenancefree and environmentally friendly, was received
with great enthusiasm.

“ahead on the Internet:
All papers and the best photos of the conference
can be found on the “ahead homepage:
Simply download at: www.ahead.voithpaper.com
The papers presented at the conference can also
be requested from:Ms Sigrid Hrebacka, Fax: +43 27 42 8 06 25 48
E-mail: sigrid.hrebacka@voith.com

6

Our guests’ opinions

Ing.
Henk Lingbeek
SCA Packaging De
Hoop, Netherlands

product. It was a highlight for me not
only in technical respects, but also because it focused on the tasks of our
product.

It was an excellent conference, and what
I liked especially – I also attended theconference three years ago – was the
combination of topics: not only technicalissues, but also some dealing with marketing, final products, Voith Paper's philosophy and organization.

... Whether I will come again? Yes, ofcourse, we already agreed yesterday that,
if things go on like this, Voith can holdsuch a meeting every week!

Peter Reichler
Amcor Australasia,
Australia
Dipl. Ing. (FH)
Manfred Stemmer
Cascades Arnsberg
GmbH, Germany
My general impression is a very positive
one, we gained new ideas and thoughts,
and moreover, it was a good opportunity
to talk with many colleagues.
What impressed me most was the professionalism of the presentations.
...An important thing is that people withpractical experience were present, reporting about their experiences...
...What I also liked very much, as I comefrom the folding boxboard sector myself,
was the first paper giving entirely new
aspects of the publicity value of ourI think it was a very impressive conference, you have picked a beautiful location, even the weather is impressive.
What pleased me more than anything else
was the quality of the presentation andthe information provided...
... It was very pleasing that the information was prepared in a way that even the
non-technical people, such as myself,
could understand...
... The paper on investment and operating
cost yesterday and of course the two presentations of the new mills in Turkey and
SAICA were most interesting!…
...I do have to express my appreciation of
the Voith team – they have done a fabulous job!

Pekka Mauranen
KCL, Finland
I come from the Finnish research institute KCL and have to admire your team.
Listening to all of the papers about thedifferent products, I realize how deep
their expertise is in this field.
I think Voith has done extensive theoretical research and development work andhas applied the results in practice on thepilot machine and in customers’ mills…
...Of course, the location is very impressive, this imperial palace...
...I think it's a world-class conference!

T.S. Ong
Genting Sanyen,
Malaysia
The conference was well organized, and I
think the topics were well chosen, particularly on the first day. The quality of thepapers, in general, was good – ’they were
presented by many of the young people. I
think there is a bright future ahead because Voith is capable of renewing itself
with these young specialists...

N e w s F R O M Stoffaufbereitung
THE DIVISIONS

7

Stock preparation – the key to ensure
the productivity of newsprint and SC paper
machines
The Federal Republic of Germany holds
a top position in Europe with regard to
the use of secondary fibers for the manufacture of paper and board products.
The rate of utilisation of recovered
paper is presently 62%. For Germany,
this ratio is expected to be increased
further, which will lead to a further
reduction in fresh fiber usage.
The author:
Harald Selder,
Fiber Systems

It is known that the largest quantities ofrecovered paper are used in the field of
packaging papers. In this product sector,
signs of maximization have already become apparent, so that in this sector no
increase in the use of recovered paper
is to be expected. A higher percentage
can therefore only be achieved by raising
the secondary fiber usage for graphicalpapers.

What is the present situation in the useof recovered papers in the field of graphical papers?
Fig. 1 shows the relative recovered paper
contents for the most important graphical, wood-containing paper grades. The
abscissa in this diagram represents thequality whereas the ordinate stands forthe price achieved with these products.
The red field describes the average, relative recovered paper content used inthese products.
Today, the standard newsprint paper isusually made from 100% deinked pulp
(DIP). The same applies for upgradednewsprint. In the SC paper sector, 40%of secondary fibers are used on average,
and for LWC papers, approximately 25%.
A similar percentage is also used for thehigh-grade coated papers.

8Fig. 1: Content of deinked pulp inwood-containing printing papers.
Fig. 2: Number and relative weight of advertisinginserts in newspapers.
*Relative weight =Weight of inserts
x 100
Overall weight (newspaper + inserts)

Fig. 3: Trend in paper grades used for magazinesand change in inorganic content of DIP.
German deinking furnish:
50% ONP, 50% OMG.
1
HWC
MWC

75

LWC

Price

MFC

50

STIN
SC
SIN

25

IN

Rel. content of deinked pulp [%]

100

NEWS

Quality
2
80
Japan

30

70
Japan

25

60

15
10

40
30
20

5

10

Relativ weight* [%]Germany

50

Germany

Number of inserts

20

100

50

80

40
SCA Papers

60

30
Ash content

40

20
LWC Papers

20

10

1990

1995

2000

0
2005

Content of anorganic substances [%]3

Relative content [%]The recovered paper grade, which isavailable in sufficient quantities in Germany and of satisfactory quality uniformity, suitable for the higher-quality,
graphical papers, is the deinking furnish.
This deinking furnish is collected in theform of a household collection grade by
the recovered paper trade, and it‘s thenseparated into brown and white paper
fractions in sorting plants.
The resulting white paper fraction consists of approximately 50% old newspapers and 50% magazines and is supplied
to the paper mills as deinking furnish.
The paper composition of this deinking
furnish is subject to continuous change,
which the stock preparation engineers
have to take into consideration. In thisarticle, we will point out the most essential changes in the deinking furnish composition, which have an influence on thedeinkability and the DIP quality.

0

0

0
1985

Recovered paper:
quality and availability

Today, the daily newspapers include approximately 2-5 advertising inserts per
paper. These inserts are in most cases
printed on SC and LWC papers. The
printing process is mostly sheet-fed offset with integrated heat-set drying. Dueto this heat-set treatment, many problems have to be reckoned with when it
comes to deinking. The quantitative shareof these inserts is approximately 10-20%
of each newspaper, as shown in Fig. 2.
In Japanese daily newspapers up to 30
inserts per distributed paper can befound. In this case, the inserts have ashare of 70%. In Japan, statutory regulations limit the advertising space in daily
newspapers, which explains this highpercentage of inserts.
Such a high share of inserts is not to be
expected in Europe. However, a further
increase in the number of advertising inserts in daily papers is to be reckoned
with. Local and regional advertising is notof interest as yet for the electronic media,
and it will remain a domain of print advertising for now and the near future.
Another change can be noted for themagazine paper grade. Approximately
15 years ago, the principal paper grade
for magazine production was LWC paper.
Today, the predominant paper grades
used for magazines in Germany are theSC paper grades suitable for roto-gravure
printing, as can be seen from Fig. 3.
About 70% of the magazines publishedin Germany are presently printed on SC
papers.
This situation must be expected tochange again. The reason is the new generation LWC papers. These papers arecoated and calendered in an online
process. In this way, production costs
can considerably be reduced. In addition,
the quality of these papers is equivalentor even superior to that of the corresponding SC papers. Consequently, there
will be more LWC papers in the deinking
furnish in the future.
From Fig. 3, it is also obvious that a constant rise in ash content can be noted in
the deinking furnish. This rise is theresult of continuously increasing ash
contents in LWC and SC papers, and on

Fiber Systems

9– Higher final
product requirements– Quality decrease ofrecovered paper– Reduction of fresh
water consumption– Runability– Productivity
4

Fig. 4: Runnability- and productivity-related
variables.
Fig. 5: Simplified block diagramm of analyzed
system.

the other hand of rising ash contents in 5
standard newsprint papers.

Loop I

Drum chest
Coarse screening
Flotation I

For the macro stickies determination, thepick-up method, developed by Voith Sulzer was used. And, the micro stickies
were determined with the laser opticalparticle counting method developed by
BASF.

Fine screening
Thickening I
Disperging I
Loop II

Along with the higher percentage of magazines in the deinking furnish, more adhesive glue and more hotmelts are automatically fed into the stock preparation
systems. These substances are thesources of the macro stickies, which willcause many upsets on the paper machine
if not sufficiently removed. In addition,
large quantities of coating binders andcoating additives are included in thecoated papers. It is from these substances that the micro stickies originate
resulting in serious runnability and availability problems on the paper machines
if their removal is not satisfactory. Thissituation will require systematic countermeasures in the future (Fig. 4).

analysis focused on establishing thechange in the macro and micro stickies
area. For reasons of completeness, thedevelopment of the chemical oxygen demand and the anion-charged substances
was also established.

Drum pulper

Flotation II
Thickening II
Make upwater from PM
Disperging II

H2O2
NaOH

In the following section, a thorough description is given of the results obtained
regarding the macro and micro sticky behaviour.

Bleach tower

Results
In addition to the usual targets of opticalbrightness and cleanliness, which are
aimed at in the stock preparation
process, the separation of detrimental
substances in the recovered paper mustalso be increasingly considered in the future. As fresh water usage in paper production is reduced, this subject becomeseven more important. The remainder ofthis article describes solutions for thecontrol of detrimental substances in thestock preparation system. The control
strategies are integrated with plans for
optimizing paper machine operation.

Process modules for controlling
detrimental substances
In order to be able to fight detrimental
substances effectively, it is necessary todefine those modules integrated in stock

preparation systems with regard to theseparation of detrimental substances. For
this reason, the results of a detrimental
substances analysis will first of all bepresented.
The system chosen for the analysis(Fig. 5) consists of a 2-loop process forthe production of DIP for SCB papers.
The first process loop includes the drum
pulper, coarse screening, flotation I, finescreening, thickening and disperging I.
The second process loop contains flotation II, thickening and disperging II. Disperging II is combined with peroxide
bleaching. No process water cleaning isconnected, neither in the first nor in thesecond process loop. Only the make-up
water from the paper machine, which iscarried over to the stock preparation, is
run through a microflotation. The system

Macro stickies
The first reduction in macro stickies
worth mentioning occurs in coarse
screening, as shown in figure 6. In flotation I, no macro stickies are removed.
With 85% removal efficiency, fine screening is by far the most effective processmodule. A further reduction in macro
stickies can be noted in both disperging
systems.
The total sticky loading was reduced from11510 mm 2/kg b.d. to 192 mm 2/kg b.d.
which corresponds to a total reduction of
98.3%.
Micro stickies
The change in micro stickies area in eachprocess step presents a completely different picture from that of the macro
stickies. The screens do practically noth-10

After pulping= inlet coarse screening

11510

4.71* 1010

Inlet flotation I

4000

1.02* 1010

After flotation I= inlet fine screening

4849

8.44* 1010

After fine screening

725

9.19* 1010

After thickening I(MC+HC)1180

3.78 1010

After disperging I

600

4.23* 1010

Inlet flotation II

436

9.77* 1010

After flotation II

520

6.32 1010

After thickening II

580

3.01* 1010

After bleach tower

330

3.43* 1010

Headbox PM

192

6.26* 1010

Fig. 6: Change in macro stickies area in theanalyzed deinking system.
Fig. 7: Change in number of micro stickies in theanalyzed deinking system.

*

Fig. 8: Effectiveness of stock prep process units
in removing substances detrimental to runnability
and productivity.
Fig. 9: MultiScreen fine screen optimized
for macro stickies removal.
Rotor– Multiple blades– Adequate pressure pulses
Screen basket– C-bar™ technology– High precision of slot width
Housing– Conical design– Fishmouth accept discharge*0
4 *1010
8 *1010
0
4000
8000
12000
Number of micro stickies [n/kg b.d.]
Macro stickies area [mm 2/kg b.d.]6
8Process blocks
Coarse screening
Flotation I
Fine screening
Thickening I
Disperging I
Flotation II
Thickening II
Disperging II
No influence7

Macro stickies Micro stickies

COD

Low improvement

Medium improvem.

9

Cationic demandHigh improvem.

Rotor

Inlet
Screen basket

RejectHousing

AcceptDilution watering in terms of micro sticky removal.
Whereas the flotation blocks possess aconsiderable separation ability. A high removal efficiency is produced in the thickening stages. But, the low micro sticky
level after the thickening processes cannot be maintained due to the highly contaminated process water that is subsequently used for dilution. At this point it
becomes noticeable that microflotation isneeded for cleaning the process water(Fig. 7).
Fig. 8 summarizes the efficiency of the individual process modules used in thestock preparation system with regard to
the separation of the investigated groupof detrimental substances.
The most effective process module withregard to macro sticky separation is finescreening. Voith Paper Fiber Systems
recognized the importance of fine screening for the macro sticky removal at an
early stage and now offers a most effective machine – the MultiScreen. This
screen (Fig. 9) is completely optimized
from “head to foot”.
Micro sticky control is most effective inthe flotation blocks and in microflotation
used for water cleaning. However, there
will always be some residual micro sticky
load carried over to the paper machine.

Fiber Systems
1300

11

11502%
Fig. 10: Correlation between build up of
detrimental substances in the PM white water.
absorption efficiency and fresh water usage.

0%

900

Absorbtion efficiency

Change in
detrimental substance [%]

1100

10%

700
500

25%

300

50%
75%

100

100%

0

Fig. 12: Strategy for control of detrimental
substances.
Process units relevant to macro stickies
Process units relevant to micro stickies
Process units relevant to COD
Process units relevant to cat. demand.

Source: BASF

7

14

21

Fresh water l/kg paper

10Collapse situation =renew process water

Feed quantity of micro stickies> rejected quantity

Feed quantity of micro stickies = rejected quantity

In order to ensure the runnability andavailability of high-speed newsprint andSC paper machines, it is absolutely necessary to control the level of detrimental
substances. There is a continuously increasing load of detrimental substances,and countermeasures must be taken to
fight this. Detrimental substances arecombatted most efficiently in the stock
preparation systems. The system suppliercan decisively help to reduce the load ofPaper machine

Minimization ofcarry over

Disperging II

Thickening II

Mikroflotation II
Flotation II

Thickening I

Fine screening

Flotation I

Mikroflotation I

Stock preparation

Disperging I

Summary and recommendations

Machine uptime

12

Coarse screening

If more micro stickies are fed to the paper machine than can be absorbed by thefiber material, the concentration in thewhite water circuit will continuously rise.
Eventually, a critical concentration isreached where slight changes in temperature and pH-value will induce the formation of macro stickies due to displacements in solubility. With a further increase in concentration, a collapse situation will be evoked. The paper machinemust be shut down and the process waterexchanged. This kind of situation willconsiderably impair paper machine availability (Fig. 11).

11

Concentration of hydrophobic
micro stickies in process water

In this case, the carried over micro sticky
load is to be bound to the fibers bymeans of fixing agents so that the leftover microstickies go out with the finished paper. The correlation between
absorption efficiency and changes in concentration dependent upon fresh water
usage is shown in Fig. 10. It can be notedthat a 50% absorption efficiency is required for maintaining a stable micro
sticky concentration in the white water
circuit (Fig. 10).

Fig. 11: Effect of hydrophobic micro stickies
concentration in the process water loop on paper
machine availability.

Optimum reduction in
detrimental substances

Fixing of residual detrimental substances
to the fibre and removal with the paper

detrimental substances by a corresponding module arrangement and by optimized process water management andcleaning. The aim should always be tokeep the carry over of detrimental substances to the paper machine as low as
possible (Fig. 12). This way, high concentrations of detrimental substances inpaper machine circuits can be avoided.

Consequently, deposits and contaminations of felts and screens can be eliminated. Another advantage of this control
strategy is the much reduced usage ofprocess chemicals during the manufacturing process. Fixing agents should only
be used after the reduction in detrimental
substances in the stock preparation system has been optimized.

12

New
Product

The author:
Wolfgang Mannes
Fiber Systems

EcoMizer™ –A new cleaner concept establishes itself
Hydrocyclones for the separation of
specifically heavy and/or light contaminants have been used in the paperindustry for about 50 years. After somesignificant innovations in the first
decades, the development of hydrocyclones came to a relative standstillin the recent past. Consequently, thedifficulties with these machines haveremained the same. The new EcoMizer
development now offers a solution to
many of these problems.

Fiber Systems

13

Fig. 1: Distribution of axial velocities in ahydrocyclone (result of numerical simulation
using the finite volume method).
Fig. 2: Backflow of thickened, contaminatedsuspension in the vortex center.
Fig. 3: EcoMizer™-Cleaner –Flow conditions at the rejects outlet.

Thickening behavior as a basic problem
Most problems with hydrocyclones canbe contributed to an elementary cause –the tendency of the fibres suspension to
thicken in the rejects. If this tendency is
not correctly assessed when designing acleaner plant, stock consistency increases in the final stages of a cleaner plant
will lead to operating problems and/or
excessive fibre losses.
However, apart from the uncertainty inthe design of cleaner plants, fibre thickening also limits the possible operating
conditions. A hydrocyclone only functions with the use of fibres while their
fluidation caused by rotation is guaranteed. If the rotation in the cone comesto a standstill, the cleaner becomesclogged. The restriction at the cone nozzle or a re-routing of the rejects on thecone end to a radial or tangential outlet,
will not allow any “pressing through” ofthe fibres.
This phenomena of rotation failure actually is the most common cause for operating problems on the hydrocyclone,whereas clogging due to individual,
large-size contaminants is rather an exception in the low consistency range.

Break-down of rotation and return flows
What causes the rotation in a hydrocyclone to break down? Since a fibre suspension is a viscous medium, it must be
constantly fed with energy in order tomaintain the rotation in the cleaner. The
more viscous the medium – as is known,
the stock consistency of fibres has a verylarge influence on the viscosity – themore energy is required for this.
In the hydrocyclone, energy is fed in with
the incoming suspension only and distributed downwards in the hydrocyclone
by the axial flow running along the cylinder and cone walls (Fig. 1). This energy
distribution depends on the volumetric
distribution of the inlet flow into the accept and reject flows.
The lower the volumetric reject discharge, the less energy reaches the bottom cone area. At the same time, thestock consistency, and thus the viscosityof the suspension, are at its highest in
the bottom cone area due to the thickening effect of the hydrocyclone. Therefore,
with low reject rates, failure of the referred to rotary motion may occur andconsequently lead to clogging of thecleaner.
The consumption of the kinetic energy inthe cone area is further intensified by anadditional phenomenon. As can be seenin Fig. 2, the basic pattern of a downward
flow along the cone wall and an upward
or back-flow in the vortex centre is alsopresent at the reject outlet.
With this backflow, the thickened rejectstock is returned to the cone where it further increases the consumption of kinetic
energy. In addition, contaminants, whichwere already separated, are once more
entrained upwards and in the worst case,may even reach the accepts.

vax (m/s)

1

9.65
6.89
4.12
1.36
-1.39
-4.16
-6.92

2
Cleaner cone

Backflow

Nozzle3

14Fig. 4: Problems with classical concepts forrejects dilution.
4

Low addition ofdilution waterHigh addition ofdilution water

Distributionof axial velocity

upwards

downwards
Contaminants settle backto the cone wall

The EcoMizer™ concept
The newly developed EcoMizer concept
offers a solution for these two problem
areas. The concept was derived from thefact that the basic flow pattern in the hydro-cyclone cannot be influenced. This isa consequence of the geometry and theusual distribution of the volumetric inlet
flow in a hydrocyclone. However, thedecisive idea is to “replace” the thickened
reject stock in the central return flow inthe lower cone by a clean filtrate or whitewater added from the outside (Fig. 3).
Thus, on the one hand, dirt is prevented
from being sucked upwards once again.
On the other hand, the injected filtrate
will mix in the cone with the surrounding
suspension, so that the stock consistency of the surrounding suspension will
also be decreased.

Danger of backflushing
the contaminants

In conventional concepts to decrease thereject stock consistency, the filtrate isusually added tangentially in the lower
cone area (Fig. 4). Although fibre recovery is thus fundamentally possible, withan excessive dosage of filtrate there is agreat risk that contaminants, already concentrated in the cone wall area, will be diverted to the vortex center at the point
where the filtrate is fed in. If these contaminants reach an area with an upward directed axial speed, flushing back of contaminants into the accepts may occur.
This risk particularly exists for contaminants which are difficult to separate,
such as dirt specks, since their specificweight differs only slightly from that offibres.

Comparison with traditional concepts

With the EcoMizer concept, however, theaddition of the filtrate is distributed overa comparatively large volume, actually
the entire lower cone area. Thus, it canbe dosed much better.

This type of dilution water addition has
several advantages compared to previous
concepts.

Furthermore, addition of filtrate is started
in the centre of the cleaner and fromthere continues outwards. The layers

near the cone wall, where the contaminants are concentrated, are not affected
at all by to the addition of dilution water,which also facilitates the dosage of thewater quantity.
Finally, the energy demand for adding thefiltrate is considerably lower than when it
is carried out via the cone wall. Depending on the pressure ratios in the hydrocyclone, even a vacuum may exist in thevortex centre, so that the flushing water
is sucked in from the outside without anypressure.
In conclusion, it is possible with the
EcoMizer concept to decrease the stock
consistencies in the reject outlet area
without any negative effect on separation
efficiency. On the contrary, due to thefact that the thickened reject stock is prevented from flowing back in the vortex
centre, and because of the lower stock
consistencies, the rotational speeds inthe lower cone remain high and the tractive forces acting on contaminants remain low. This means efficiency may
even be improved in certain cases.

15

Fiber Systems

Accepts

Fig. 5: Advantages of the new EcoMizer cleaner
concept.
5

 Higher operational reliability at lower
reject rates
 Reduced number of cleaning stages(2-3 in stock preparation,
max. 4 in the approach flow)
 Savings with respect to space requirements and additional investment costs forpumps and drives, piping and control
equipment Reduced energy consumption for pumping
 Improved dirt speck removal
 Efficient sand removal at considerably
higher consistencies than previously
possible New possibilities in the process design Reduced fiber losses through higher
contaminant concentration in the rejects

Inletof the rejects, the stock consistency inthe bottom cone area still remains lower
than with conventional cleaners. Withhigher inlet stock consistencies, newpossibilities result concerning thearrangement of fine cleaning and slotted
screening in recycled paper stock preparation systems.
Finally, contaminant concentration can
now be increased with continuous reject
discharge in the final stage to such an
extent as was previously only possible
with periodically rejecting final stages.
Through minor changes to existing systems, considerable reductions in losses
and thus a lot of savings in the currently
incurred disposal costs have alreadybeen achieved.

What advantages result? (Fig. 5)
The operating reliability of cleaner plants
is always increased by lowering the stock
consistencies in the lower cone area. In
addition, back flushing allows operationof a cleaner with lower volumetric reject
rates and lower reject stock consistencies. It is thus possible to design the following stages considerably smaller than
before. Consequently, the required number of cleaner stages is substantiallyreduced, providing large savings, both inthe overall infrastructure required for operating a cleaner system, as well as inpumping energy.
Higher separation efficiencies for contaminants, which are difficult to remove,like dirt specks, have already been mentioned. Alternatively, the cleaners can be
operated with higher inlet stock consistencies than before, while maintaining theprevious efficiencies. Due to the dilution

This list gives a first idea of the potential
inherent in the newly developed technology presented here. The improvements are
not just a small step forward, they are
more like a quantum leap.

Where are the limits?
Rejects

To be honest, we do not know yet. It will
surely be an exciting task for the future
to answer this question. In the almost
20 installations, which have gone into operation since the first application in aplant approx. 1 1/2 years ago, the limits
have not yet become evident. In mostcases, start-up caused no problems
whatsoever, enabling the customers to
profit immediately from the significant
advantages of a higher operating reliability with simultaneously improved accept
quality and/or reduced fibre losses by up
to 70 %.

Dilution

16

Get the most out of your fibre1
One-ply concept

Multi-ply concept
Topliner
Underliner
FillerBackliner

The author:
Dietmar Borschke,
Fiber Systems

Multi-ply sheet formation allows theboard to be provided with a great
number of special features by selecting
special fibres and mixtures for theindividual plies of the base board. The
type and intensity of fibre treatment of
the raw materials used, for instance byrefining, dispersion or by washing also
help to optimize the base board quality.
Finally, the basic processes of eachindividual paper machine influence properties such as sheet formation, fibreorientation, sheet compaction andsurface quality. The characteristics ofthe finished board are additionallyspecified by surface treatment processes such as sizing, coating colour application and calendering.

For illustrating different board production
strategies, Fig. 1 compares the classic
single-ply sheet forming concept withmulti-ply sheet formation on a four-ply
board machine.
Solid bleached board – typical for production in the USA – consists of a single

Solid Bleached Board(typical for USA)– fully bleached (kraft) pulp
– high freeness– high E-modulus/stiffness– high furnish costs– low investment costs

Folding Boxboard, White lined chipboard(typical for Europe, Asia)– fibre stock acc. to ply requirements– low freeness– bulk filler for high board stiffness– high investment and low furnish costs

ply and is usually produced frombleached kraft pulp. This simple sheet
formation is compensated by the excellent fibre properties of this long fibre
pulp, such as a high CSF freeness, thehigh E-modulus and the resulting highbending stiffness. In connection with adouble coating on the top side of the
sheet, the requirements of surface properties and cleanliness can be fulfilled witha simple paper machine concept. Relatively low investment costs are involved
vis-à-vis relatively high fibre costs.

shining through, striking through orpressing through of the filler material.
For the filler ply, stock mixtures of highbulk are required for a good board stiffness. Two to three top coats are usuallyapplied. The production of such a board
is connected with high investment costs
due to the sophisticated overall systemand paper machine configuration. The
economy in production is here decisively
determined by the selection of low-cost
raw materials for all plies.

Especially in Europe and Asia, multi-ply
sheet forming concepts are used to produce folding boxboard on the basis ofvirgin fibres or secondary fibres (white
lined chipboard). The specific stock
requirements with multi-ply board varydepending on the ply; for the concept
shown, a distinction between topliner,
underliner, filler and backliner is made.
Simply speaking, for the two outer plies
special surface and strength propertiesare required, which can be achieved withbleached hardwood pulp or high-quality
deinking grades. The underliner prevents

Current virgin and recycled fibre
potential
How can the development of bending
stiffness of the total base board be controlled by the characteristics of the filler
material? The technological comparison
can be limited to the presentation of freeness, bulk (specific volume) and elasticity modulus (E-modulus) in order to evaluate the possible suitability of the threemean fibre stock groups mechanicalpulp, chemical pulp and secondary fibre
grades.

Fiber Systems

17

Fig. 1: Example for baseboard forming concepts.
Fig. 2: Bulk versus freeness.
Fig. 3: Elasticity modulus versus freeness.
hardwood pulp
softwood pulp
deinked pulp (ONP, OMG)
rec. supermarket paper, household collection
TMP
SGW, RMP
CTMP

Fig. 4: Stiffness index for comparison of
filler stock.
E • v3
Stiffness index =1000
E = elasticity modulus [N/mm 2 ]v = bulk [cm 3/g]

2
3,0Bulk [cm 3/g]

The bending stiffness of a single-ply paper sheet is experimentally established inpractice with a two-point bending stiffness tester by bending a clamped paper
strip in the elastic range (DIN standard).
The established bending moment usuallyagrees well with the mathematically established bending stiffness (S), which isthe arithmetical product of the E-modulus(E) and the third power of the caliber (d)of a single-ply material divided by 12. If
the bending stiffness of multi-ply boards
is calculated, the Steiner formula is used.

2,0

1,0

0

Bending stiffness: S = E • d 3 / 12 [mNm]

E-modulus [N/mm2]

5000
4000
3000
2000
1000
0

4

22
Stiffness index [10 -12m8/(s 2g 2)]

In Fig. 2, the bulk of different fibre stocks
is plotted against freeness (all following
data is taken from Voith Paper’s database). The freeness serves as an auxiliary
quantity to describe type and pre-treatment of the fibre stock. The areas marked
in colour of the mechanical pulp types
TMP, SGW and RMP cover a wide rangeof freeness with a high bulk of up to
2.5 cm 3/g. The bulk range will of course
be extended downwards by refining.
CTMP is probably the most versatile fibre
stock, the properties of which can be varied by changing the process conditions,such as chemical chip impregnation andthe intensity of refining. With high specific refining work, i.e. with decreasing freeness, the high bulk level decreases. Hardwood and softwood pulps with excellent
strength properties only have a low bulk,
which decreases further with more intensive refining. Secondary fibres, which
originally always consisted of a mixtureof wood-containing and wood-free recovered papers, usually show mean specificvolumes from 1.3 to 1.8 cm 3/g. Deinking
grades from newspapers and magazines

3

20
18
16
14
12
10
10

20

30

40

50

60

70

80

90

[SR]
Freeness

843

595

425

305

217

143

76

27

23

[CSF]

18

Fig. 5: Basic data for technological comparison offolding boxboard – White lined chipboard.
5
Folding boxboard

White lined chipboard

Bending stiffness

mNm

70

70

Basis weight

g/m 2

300

390

Board
Fibre material
Topliner

Bleached softwood pulp

White shavings

Bulk

cm3/g

1.4

1.6

Elasticity modulus

N/mm2

5500

3500

Basis weight

g/m2

60

60

Groundwood

Household collection

Fibre material
Bulk

cm3/g

2.2

1.7

Elasticity modulus

N/mm2

1500

2500

Basis weight

g/m2

180

270

Bleached softwood pulp

DIP

FillerFibre material
Backliner

Bulk

cm3/g

1.4

1.6

Elasticity modulus

N/mm2

5500

3000

Basis weight

g/m2

60

60

and a prepared mixture of supermarket
waste and household collections areshown here as an example.
An almost contrary picture is obtained
from plotting the E-modulus against freeness in Fig. 3. With increased refining,chemically pulped fibres show an impressive increase in fibre bondage capability,
which leads to high strength values at
low elongation, i.e. to a high E-modulus
of 5000 N/mm 2 and more, with softwood
pulps showing higher values due to theirhigher long fibre content. In comparison,
the mechanically pulped fibres show an
extremely poor result with low E-modulus
values. The great advantage of secondary
fibres becomes evident here. They cannot
only be produced at a more favourable
price, but often have technological advantages concerning the E-modulus andother strength properties in comparison
with mechanical pulp.
The actual stiffness potential of fibres
used as a filler material referred to in thispaper can be determined with a stiffness
index (Fig. 4). The chosen stiffness index
depends on the bending stiffness calculation and is independent of the basis
weight. The application of the stiffness
index is limited to the filler ply or singleply paper sheet.
It is noticed that in particular softwood
pulps can have the highest bending stiffness values, although their bulk is comparatively low. The bending stiffness of
single-ply papers from mechanical pulps
is extremely low. Secondary fibre stocks
cover a wide spectrum in the centre-field.
This diagram clearly shows why it is pos-sible even today for so different sheet
forming concepts and their especially tailor-made fibre recipes to co-exist in theboard sector.

Folding boxboard versus
white lined chipboard
Why it was even possible for secondary
fibres of a quite different type to substitute primary fibres in board manufacturing. An economical advantage is the low
production costs of secondary fibres due
to low waste paper prices and comparatively low energy inputs for their preparation. Recycled stocks of analoguous primary fibres rank technologically only alittle behind (for example when comparing market pulp and hardwood pulp).
An interesting technological and economical comparison offers the comparison
with the board grades of folding boxboard on virgin fibre basis and white
lined chipboard on secondary fibre basis(Fig. 5). The reference value defined hereis the bending stiffness, which is also
used as one of the most important sales
factors. It is specified as 70 mNm.
Here, folding boxboard consists of threevirgin fibre plies. The topliner consists of
60 g/m 2 bleached softwood pulp, the fillerof 180 g/m 2 mechanical pulp and thebackliner again of 60 g/m 2 softwood
pulp. The basis weight of the folding
boxboard is thus 300 g/m 2.
In order to achieve a comparable stiffness level for a three-ply white lined
chipboard with recovered fibres, the following model set-up can be used. In the19

Fiber Systems

Fig. 6: Total board stiffness – Influence on bulk
and elasticity modulus of the filler.
Fig. 7: Total board stiffness – Optimization of thefiller ply through remixing.

A major reason for the increased material
weight of the white lined chipboard is tobe found in the significantly low bulk of
the prepared household collection compared to the mechanical pulp integrated
in the virgin fibre board.
By which measures can the technologicalproperties of the filler stock, which are so
relevant for board stiffness, be improved? Fig. 6 shows the ideal properties
that the filler should have. The increasein board stiffness, on the one hand by increasing the specific volume of a fictitious filler stock and on the other hand,by increasing the E-modulus in the filler,
is shown in two diagrams. It becomes evident that for this board model, voluminous fibres for the filler ply are given
clear preference to a fibre material withhigh E-modulus.

Bending stiffness [mNm]

6
130

130

120

120

110

110

100

100

90

90

80

80

70
1,6

1,8

2,0

2,2

2000

3000

4000

5000

6000

E-modulus [N/mm 2]
Basis weight g/m2
Furnish60
Topliner White shavings
270
FillerHousehold collection
60
Backliner DIP

390 g/m2
70 mNmWhite lined chipboard
Initial board stiffness

70
1000

2,4

Bulk [cm3/g]

7
E-modulus
N/mm2

Bulk
cm 3/gWhiteshavings

3500

1.6

Householdcollection

2500

1.7

SGW

1500

2.2

TMP

1800

2.1

CTMP

2000

2.1

DIP

3000

1.6

100
Total board stiffness [mNm]

topliner, pulp is replaced by preparedwhite shavings of a high brightness. The
most favourable raw material, i.e. household collection, is chosen for the filler
ply. Deinking stock is used in the backliner. The assigned stiffness-relevantcharacteristics are given in Fig. 5. The
basis weights for topliner and backliner
remained to be 60 g/m 2. The model calculation for board stiffness shows thatthe basis weight of the filler had to be increased by 90 g/m 2 to 270 g/m 2 in orderto reach the stiffness value of the virginfibre board. The increased basis weightof the white lined chipboard with costwise much more favourable fibre components reduces the cost advantage of therecycled board. In fact, the costs for a
ton of finished stock (bone dry) for thewhite lined chipboard mentioned are only
half the costs for folding boxboard.

SGW
Top

CTMP
90
TMP
80

Filler

70
Household collection
0

20

40

60

Back
80

100

Mixing ratio [%]Based on the experience that all mechanically produced fibres such as TMP, RMP,
SGW and CTMP are destined for this application, Fig. 7 shows the possibility ofloosening the compact fibre structure of
the prepared household collection byadding mechanical pulp to increase thevolume of the filler ply mixture. The aim
is to increase the bending stiffness of thepreviously defined white lined chipboard.
The starting point (grey point on the leftof the diagram) is the board model white
lined chipboard with approx. 70 mNm total board stiffness. If increasing percent-ages of SGW, TMP or CTMP up to a mixing percentage of 100 % are added to thehousehold collection, decisively higher
board stiffness values will be the result.
This method is used in some board mills,
and no significant technological differences can be observed for the three evaluated mechanical wood pulps.
Fig. 8 shows the cost side of such a filler
ply optimization. The raw material costs
for the entire three-ply board described
are presented based on the average market prices of the year 2000. Adding the

20

Fig. 8: Total board stiffness – Furnish costs for
optimizing the filler ply through remixing.
Fig. 9: Influence of machine type on bulk increaseof recovered fibres.
8

9
20
CTMP

400
350

TMP
300
SGW
250
Household collection

200
0

20

40
60
Mixing ratio [%]80

White lined chipboard

Furnish costs €/ t

White shavings

460

Household collection

155

SGW

245

TMP

320

CTMP

460

DIP (ONP, OMG)

260

100

most expensive filler stock CTMP will result in highest finished stock costs forthe base board. In this example, the technological/economical optimum is foundby adding low-cost SGW or RMP. Therefore, these mechanical pulps are widelyused as filler material or as addition in
multi-ply board production.

Processes for enhancementof bending stiffness
In addition to the raw material selection,
an appropriate process technology represents a further tool to develop specific fibre properties and to optimize the board
product. Refining with proper stock-specific refining parameters may lead to adesirable strength increase, such as theincrease in plybond and the increase of
the E-modulus. It is, however, connectedwith a reduction in bulk of all fibre types.
The decrease in air permeability is more
dramatic, which is of importance for certain board grades, such as for instancegypsum board. With secondary fibres,
dispersion processes can influence bulk

due to fibre curling. However, this is also
accompanied by partially undesirable effects such as higher wet web stretch andshrinkage, higher porosity and adsorption capacity, lower static strength values
and lower dewatering resistance.
The two types of Voith dispergers, (highspeed disk disperger HTD and low-speed
kneading disperger KD) may cause fibre
curling, in spite of different operating
principles (Fig. 9). The volume and porosity increase after the kneading disperger
is considerably higher.
Fibres also show a different tendency for
fibre curling in the kneading disperger.
Various examinations also revealed thatwood-containing stock shows a high percentage of reversible curling (latency behaviour), whereas curling of wood-free fibres is irreversible to a great extent.
Therefore, the effectiveness of the kneading process cannot be generally predicted. Pilot plant trials carried out with thekneading disperger for an individual raw
material offer the board manufacturer apossible alternative.

Rel. change in bulk [%]Furnish costs of total board [€/ t]

450

15
Kneading Disperger
10
5Disk Disperger
0
-5

0

50
100
150
200
Spec. dispersion energy [kWh/t]

Conclusions
The wide variety of board structuring allows free choice of fibres, either virgin or
recovered. The fibre material has to be
selected according to the individual ply
requirements! Bulky fibre stock should
be used for the filler ply to increase thetotal board stiffness.
The lower stiffness potential of household collection used in the filler ply ofwhite lined chipboard must be compensated by higher grammage and/or remixing with mechanical pulp. Of course, thefurnish costs for white lined chipboard
from recovered fibres are significantly
lower than for folding boxboard from virgin fibres.
RMP/SGW are most suitable for the filler
stock. The kneading disperger helps toincrease bulk where fibres show a tendency to curl.

Presented on the Voith Paper Customer Conference“ahead 2001, Vienna, May 8 -10, 2001.

Paper Machines

21

Multi-Layer and Multi-Ply Concepts –Driving forces and advantages
The discussion of multi-ply/multi-layer
concepts is as old as the paper industry
itself. Though the limitations of modern
wet part concepts are quite different
from those of the past, the basic principles are still valid. In order to minimize
the total cost per net ton of paper, production and high fibre yield have been
the main driving forces for the development of advanced forming concepts.
This paper focuses on the reasons for
multi-ply/multi-layer technology fromthe past until today and introduces a
new multi-ply/multi-layer concept which
offers additional advantages.

The author:
Dr. Günter Halmschlager,
Paper Machines
Board and Packaging

in order to reduce the total cost per net
ton. But this will also reduce the quality
level.
In addition, the general furnish trend has
to be considered and may change the cycle time until the market quality level isreached. At this point at the latest, thequestion will come up how to speed up
the machine further and simultaneously
maintain the quality level.
In case the machine production is limited
due to the wet part, there are mainly two
options: add one more ply or switch to
the next forming generation.

Multi-ply cylinder mould formers
Paper quality and production
When installing a new paper machine, thelayout has to be done in a way that themarket quality demands can be fulfilledvery soon after start-up (Fig. 1). After optimization, a new paper machine normallyexceeds the quality demands, enabling
the papermakers to increase production

In cylinder machines, multi-ply forming
was required because of the very limited
production of one single former. The
operating window of a recent cylinder
mould former is shown in Fig. 2.
Production can be increased by adding
additional plies, as long as the operating1
Original machine layout

Quality

FurnishMarket demand

Machine speed
Fig. 1: Effects of machine “squeezing”.

22

Fig. 2: Basis weight pick-up of a cylinder mouldmachine.
Fig. 3: Forming concepts – Design limits forboard machines.
Fig. 4: Forming concepts – Design limits for
packaging paper machines.
2

speed is not a limiting factor. To overcome the speed limitation, an upgrade to
the next forming generation is required.

800
8-pliesbasis weight (g/m2)

600

However, such concepts still reach reasonable production levels for board
grades.

400

4

8

200

Forming concepts –design limits for board grades

1-ply
0

100

200
speed (m/min)

300

400

3

basis weight (g/m2)

900

700

The driving forces for multi-ply fourdriniers for the production of board havebeen speed, which means production,and sheet quality such as smooth formation and bending stiffness.

500

300

100

35

Forming concepts –design limits for packaging grades

800

300
speed (m/min)

The trend towards lower basis weights
and, at the same time, high productionlevels made gap formers the state-of-theart concept for packaging grades for new
machines and rebuilds. Similarly to thecylinder mould formers discussed before,
it is again the speed limit – in this case of
the fourdriniers – which is the main driving force for the next forming generation.

4
600
500
basis weight (g/m2)

Multi-ply fourdriniers combine the advantages of single fourdriniers with those ofmulti-ply cylinder mould formers. As
shown in Fig. 3, the operating window ofmulti-ply fourdriniers is much wider
compared to the cylinder mould formers.

400
300
secondary fibre
fresh fibre

200

secondary fibre

100
0
500

1000
speed (m/min)

1500

2000

Voith Paper introduced the gap former
technology as early as in 1992. In themeantime, 14 gap formers for board andPaper Machines

23

Fig. 5: Effect of multi-ply gapforming on strength.
Fig. 6: Single-ply sheet 200 g/m 2 (top).
Double-ply sheet 200 g/m 2 (bottom).
5

6

tensile strength MD [N]

250
200
150
100
50
0
100

1 former150

2 formers

200
basis weight [g/m2]

250

300

packaging grades are in operation, including the very first double gap former
machine worldwide. One further top ply
gap former is being delivered right now.

Fig. 4 further shows operating points (darkblue) of Voith paper machines already installed as well as layout points of recent
projects (light blue).

These gap former types have been specially developed for multi-ply board andpackaging papers. The high two-side
drainage capacity of the DuoFormer™
Base and DuoFormer™ Top results invery good sheets, even at highest production levels.

Apart from production, there are otherreasons which make a multi-ply gapforming concept attractive.

Fig. 4 compares the operating windowsof multi-ply fourdriniers (blue area) witha single-ply gap former and a double-ply
gap former. It can be seen that single-ply
gap formers (red graph) are very competitive in the medium speed range. A sheetwith 150 g/m 2 can be produced at a
speed of eg. 950 m/min with one gapformer only. Nevertheless, for very highproduction, a second ply is required.
The yellow graph shows the operating
range for a two-ply gapforming concept.
Such a concept allows to produce a highgrammage sheet even at high speeds.

The crosscuts as shown in Fig. 6 demonstrate the higher density in the centre ofa multi-ply gapformer sheet.
A multi-ply gapformer concept (Fig. 7)
ensures best formation and strength athighest production levels.

Strength is one of the decisive factors forthe production of linerboard. There is asignificant improvement in strength when
producing two plies instead of one ply.
Though the strength might be different
when using different forming concepts,
the multi-ply technology always gives aclear advantage.

Multi-ply / multi-layer technology

Fig. 5 shows the breaking length of a
100% OCC sheet for different basis
weights, using one or two gap formers. It
can be seen that the two-ply concept results in a clearly better strength at higher
basis weights. Sheet forming is enhancedwith better formation and lower z-orientation of the fibres, which will both help to
optimally utilize the fibre potential, thus
saving fibre cost.

In such a concept, the stock is fractionated as follows: long fibre long/short fibre short fibre.

In the following, a new concept using
three secondary fibre fractions will be introduced. If the multi-ply sheet is additionally stratified in the headbox, further
advantages for even better machine performance can be achieved.

The long fibre fraction is fed to the DuoFormer™ Base, which produces the top
ply. The long/short fibre fraction andthe short fibre fraction are supplied to a

24Fig. 7: Multi-ply/multi-layer gapforming concept.

7
MasterJet™ G

DuoFormer™ Basemulti-layer headbox in a DuoFormer™
Top, thus allowing additional sheet stratification.
Fig. 8 shows the location of the fractions
during the drainage process. The long/short fibre fraction is drained through theouter wire. The short fibre fraction containing most of the fines is drained
through the inner wire. Gentle drainage
by the forming roll helps to keep thefines of the short fibre fraction in the
sheet, which is desired for several reasons but especially for good plybond.
The long/short fibre fraction on the outerwire helps to reduce washout effects.
The sheet leaving the forming section has
been stratified as follows (Fig. 9):
 long-fibre top ply on the base wire
 short fibre fraction with high fines
content inside the sheet long/short fibre fraction as back ply on
top side.

MasterJet™ M2

DuoFormer™ Top

fibre sheet is more open and easier todrain compared to a short fibre sheet.
Since the long fibre fraction and thelong/short fibre fraction are located on
the outer sides of the sheet, the water
can drain with less resistance. This helps
to avoid sheet crushing in the press section, which is especially important forhigh production. Better drainage also increases wet densification, which is positive for the strength development.

low content of stickies. Therefore, thecontamination of the fabrics will be reduced, which is again a plus for runnability but also for cleanliness and maintenance.
The higher surface porosity of a stratified
sheet allows the steam to escape easier,which is the third advantage. Due to thefact that the sheet gets more open towards both surfaces, also the danger ofblistering and delamination is reduced.

Effects in the dryer section

Effects in the size press/SpeedSizer™

In the dryer section, there are also advantages related to the multi-ply/multi-layer
technology (Fig. 11).

High strength figures demand full starch
penetration. At high speeds, the dwell
time in the nip gets shorter and it is moredifficult to achieve full starch penetrationof the sheet.

With such a concept, the long fibre fraction is facing the dryer cans. Due to better bonding of the longer fibres in the
sheet, the dust development in the dryer
section will be reduced. Less dust will result in enhanced runnability and improved converting properties.

In the press section, the stratified sheet
structure makes drainage easier. Viceversa, the open surface of the stratified
sheet allows better starch penetration(Fig. 12).

Effects on the press work
Figure 10 shows a schematic sketch ofa press nip. As generally known, a long

The second advantage is that the long/short fibre fraction is facing the dryer
fabric. This fraction is very clean with a

Especially for high basis weights andhigh production, this effect is of advantage.

Paper Machines

25

Fig. 9: Sheet structure after couching.
Perfect location of fines– higher ply bond.

Fig. 11: Effects of a stratified sheet in the
pre-dryer section.
The long fibre fraction faces the dryer can surface– reduced dusting;
The clean short/long fibre fraction faces the dryer
fabric – improved runnability due to low stickies
content.

Fig. 10: Effects of a stratified sheet on thepress work.
More open sheet surface– better drainage– high wet densification.

Fig. 12: Effects of a stratified sheet in thesize press/SpeedSizer™.
Higher porosity on outer sides– better starch penetration (CMT, SCT)
– better ply bond in the centre.

Fig. 8: Two-layer gapforming.
Reduction of washout effect– higher retention.

8

long

9

long/short

long

short

10

long/short
short

felt

l/s
s

l/s

long/
short

s
l

short
long
felt

12

porosity

11

dryer fabricEffects on converting

Summary

The long fibre fraction on the surface
maintains a certain roughness required toachieve the desired sliding angle. Further,
the hot glueing properties will improve.
The glue can better penetrate into thesurface and develop a mechanical interlock with the sheet.

The main driving forces for the multiply/multi-layer technology have been
speed and production, but also quality.
This also applies to the latest board andpackaging gapforming concepts.
Though the additional advantages of astratified sheet are difficult to quantify,
this technology will improve the machine
performance and runnability as well as
the sheet properties required for further
converting and final usage. As a conse-

quence, the natural resources are utilized
more efficiently, which helps to protect
our environment, but also the total costs
per net ton of paper can be reduced, thusincreasing profits.

Presented on the Voith Paper Customer
Conference “ahead 2001, Vienna, May 8-10, 2001.

26

One Platform Concept

For years, the paper industry has
generated a steady stream of numerous
innovations. According to surveys,
Voith Paper is the most innovative paper
machine manufacturer in the world.
There is no end to the creativity anddrive at Voith Paper – there are plentyof ideas – but “Innovation takes
methodology”.

History
Voith Paper had already been building
large, fast and productive paper machines in the past.

Gratkorn 11 (Triple Star) was designed in
1997 for an annual production of 470,000 t
and is, therefore, still the highest-capacity
fine paper machine in the world.
With Dagang PM 1 and PM 2 in China,
1998 saw the delivery of the widest paper
machines in the world, with a wire widthof 10.5 m.
These three global references document
the state-of-the-art in the years 1996 to
1998. It is clear how new developments
were introduced piece by piece.

Challenge
Braviken PM 53 (1996 series) was thefirst paper machine in the world that
could exceed 1,800 m/min – thanks tothe shoe press.

The author:
Bernhard Kohl,
Paper Machines Graphic

Paper manufacturing is a complex
process, which must continuously meet
new demands. In many regions of theworld, the increased use of secondary
fibers is required; while on the other
hand, it is clear that the quality of recovered paper for recycling is decreasing.
The paper types are also undergoing constant change.
In order to reduce costs, ever-increasing
amounts of filler are used and, at thesame time, the basis weight is diminishing. Ever-higher yields and faster production are expected using ever-decreasing
amounts of fiber. The fact that quality demands are simultaneously increasing is
not surprising. This all creates enormouspressure to innovate, which can only
be successfully responded to through asystematic development, the One Platform
Concept.
The demands mentioned above cannot be
met simply by building faster and more
complex paper machines. These demands
can only be met if the paper manufacturing process is analyzed in context andcomprehensive solutions are developed.
The following examples show how complex the interrelationships are.

Two Examples of Challenges
1. Example: Use of Recovered Paper
for Recycling
Voith Paper can, without reservation, becalled a leader in secondary fiber preparation. Voith Paper has a long history ofexperience in the design and outfitting of
secondary fiber preparation facilities(dispersion, flotation and sorting), but
who decides how the finished preparedstock must look?
 How many dirt specks are permissible?
 How much ash is needed?
 How is the calenderability?
 How suitable is it for coating?
 Or, is this the maximum yield?
All of these questions can only be answered in the overall context of the manufacturing process and the end quality
requirements. This is precisely where the
One Platform Concept begins.

Paper Machines

27

Fig. 1: Challenges to the One Platform Concept.
Fig. 2: Extent of the One Platform Concept.

2. Example: Base Paper Requirements
A second example says: “In order to produce standard LWC paper, which is filmcoated and calendered online, what condition does the base paper have to bein?” It is not enough to define values
such as breaking length, smoothness,
oil absorption or porosity. The entire
process must be reanalyzed. Stock preparation, post refining and base paper production have to be viewed in context andoccasionally must also be tested. The result, however, can only be evaluated in
paper which has been coated, calenderedand printed.

1

Raw material

Paper Machine

Paper product

Recycled fibres

Productivity

Bulk / gloss

Quality of
waste paper

Online process

Filler content

Speed

Basis weight

Increased innovation pressure leads to

One Platform Concept2
Investment and production costs
Process

The fundamental principle of the One
Platform Concept is to view the individual
steps in context.

Technology
Automation
Raw material

Paper machine

The Three Basic Rules

Paper product andprinting process

Clothing One platform for all graphic paper
gradesIn order to permit a comprehensive development for a broad application field,
there must be only one platform.

Roll covers
ServiceContinuous paper product development

Definition
 Specific modules for the specificpaper grades
In order to cover the specific requirements of individual paper grades, there
are uniform quality modules that are
built into this platform:
1. Paper Contact Systems (clothing,roll covers, special machine elements)
2. Process Control Suitable for all raw materials
The One Platform Concept must be
suitable for all available raw materials.

The One Platform Concept means thecomprehensive solution of the statedgoal – the production of paper.
This includes:
1. A paper machine with all of the steps(from stock preparation to finishing)
2. Automation of the entire facility
3. Paper technology know-how

4. Optimization of the process
5. All paper-influencing surfaces(clothing, coatings)
6. And comprehensive service concepts.
What is special about this challenge isthe dynamics of the stated goal. Demands from the raw materials, market
producers and financial markets lead toever changing peripheral conditions,which must be considered at each startfor a solution.

28This is what new paper machines look like!
The persistent implementation of experience with
the One Platform Concept puts Voith Paper in aposition to offer optimal paper machines for any
desired type of paper.

Advantages
If all paper machines are built in accordance with the One Platform Concept, amaximum of experience assures a minimum of risk. This experience, from all of
the One Platform Concepts, is immediately available to all.
Operating experience from existing facilities can be used to further optimize individual components and developments. Experience from new facilities can be used
to increase the capacity of existing facilities that were placed in service earlier.
At the same time, this accumulated experience leads to improved production facilities with faster start-ups and higher production.
As a whole, the One Platform Concept
improves economy and simultaneously
minimizes risks in all investments.

The Proven Concept
With all of this experience in several
facilities for a wide variety of graphic papers, Voith Paper is in a position to offera proven One Platform Concept.
This cumulative experience was the basis
for the trust that convinced SCA Laakirchen and Myllykoski to each order a newpaper machine using the One Platform
Concept from Voith Paper.

Newsprint
Based on the above-mentioned elements,
ModuleJet™, DuoFormer™ TQv, TopDuoRun, EcoSoft™ and Sirius™, the TandemNipcoFlex™ offers an additional degree of
freedom. For very light paper grades (under 40 g/m 2), a smooth transfer belt has
advantages over felt, whereas the asymmetry in the surface can be compensatedfor in the calender.

DuoFormer TQv

Tandem NipcoFlex

Magazine Papers (SC)A Janus™ must be used as a quality module. Because of the high demands withregard to symmetry, the TandemNipcoFlex™ press must be equipped with four
felts. All other elements were already partof the newsprint concept.

DuoFormer TQv

Tandem NipcoFlex

LWC Papers
The quality module SpeedCoater™ is integrated for online coating. At the sametime, this includes the pre-calenderingand the end drying by a ModuleDryer™.
The other elements were transferred fromthe magazine paper concept.

DuoFormer TQv

Tandem NipcoFlex

Office Papers
These papers are likewise surface-treatedby the SpeedCoater™, but pre-calendering is not required. On the other hand,curl in cutsize papers needs special consideration. Therefore a CombiDuoRun isused. The remaining elements correspondto the basic newsprint concept.

DuoFormer TQv

Tandem NipcoFlex

29

TopDuoRun

Ecosoft

Sirius

TopDuoRun

Janus MK 2

TopDuoRun

Calender SpeedCoater

TopDuoRun

SpeedCoater

SiriusModuleDryer

CombiDuoRun

Janus MK 2

Ecosoft

SiriusSirius30

Why One Platform Concept?
Could you please give a short outline of
the One Platform Concept?
During the last 5 years, Voith Paper has
developed a completely new paper machinery concept for graphic grades. No
aspect of the paper machinery process
was left out. We have launched a new typeof production process onto the market.

A discussion with Dr. Hans-Peter
Sollinger, Voith Paper, on the
backgrounds, strategic targets andcustomer benefits regarding themodular One Platform Concept.

In this connection, we have tried to combine all the different concepts that existed for the different paper grades into an
optimal and modular basic concept
applicable to all papers. We call thismodular basic concept the One Platform
Concept.

Why has it been developed?
The reasons for the development of the
One Platform Concept were the increased
demands being made on the entire paper
production process from the fibre to thefinished paper. Due to the increased useof recovered paper for the reduction of
raw material costs with a simultaneous
deterioration in the quality of recovered
paper, new processes had to be developed. The trend towards online processes for the paper production made considerable investment cost savings possible.
Simultaneously, the demands on the end
product have increased and this meantthat we had to give intensive thought tothe end product and the printing process.
In particular, we had to consider the different quality requirements of the graphic
grades from newsprint and SC qualities
to coated woodfree and wood-containing
papers. While maintaining the modular

basic concept, this is achieved by developing the systems in contact with paper(fabrics, belts, roll covers and special
machine elements) and the process control with regard to the individual requirements. This means that the One Platform
Concept is a tailor-made solution whichtakes the local requirements and the customer’s production layout into consideration – like a tailor-made suit.

What are the goals?
The One Platform Concept by Voith Paper
is more than a development and designconcept. On the contrary, it is our company philosophy which resulted from thechallenges given by the market. It is the
key that allows us to reach our company
targets and to fully meet the requirements and wishes of our customers.
With the One Platform Concept, we havedeveloped a forward-looking, modern
concept on which we would like to establish all further steps in the years to come.
We feel that sticking to this basic concept
is of great importance when we consider
risk management. It provides our customers and us with the necessary security.
Fast, reliable and optimal start-ups, safeguarded with regard to quality and reliability, are the benefits that we see in the
One Platform Concept.
Our customers should already be able toproduce profitably during the start-up
phase. Despite the image gain, we wantto make projects clearly and persistently
more profitable with first-class projects

Paper Machinesand by a reduction in the project handlingcosts. This is an advantage which pays
off directly for the purchaser and for us
as well.

With all the experiences gained from various plants for different graphic grades,
Voith Paper is able to offer a proven One
Platform Concept.

When did you introduce the
One Platform Concept?

What was the response by the market?

It is not possible to state a definite datefor its introduction, it was introduced
step by step. On the basis of our worldreferences between 1994 and 1998 suchas Braviken, Triple Star and Dagang, forexample, we introduced this concept indifferent stages. Today, we speak of threestages:Basic Concept
1998 - 1999
Advanced Concept
1999 - 2000
Consolidated Conceptfrom 2001.

Have you already been able to use thisconcept successfully? If so where?
Yes! With the “Basic” phase plants, e.g.
Eltmann, we were already able to implement the best production start-up curvefor newsprint.
Likewise, with the plants of the “Advanced” phase such as Schongau, for example, where it was possible to attain thehighest specific production values of allcomparable magazine paper units during
the first 6 months.
In the case of Perlen, for example, (“Advanced” phase) we were able to produce
high-quality, online coated and calendered magazine paper right from the beginning, although Perlen had not had any
experience with coated paper before.

We were really surprised by the industry’s great interest in our One Platform
Concept. The combination – most modern concept and highest possible reliability – is of great concern to the paperindustry. In this industry, risk awarenesshas started to change considerably.
With the One Platform Concept, we fully
met the spirit of the times in the industry.
Concerning this concept, our sales department receives many words of encouragement from all sides of the paper industry. Races for daily records such as
speed (peak results) no longer count.
Nowadays, “quality tons on the reel” areimportant, throughout the year. Quotations of our customers underline this, forexample the one by a Finnish customer:“The production-oriented pulp and paperindustry competed for the most beautiful,largest and fastest paper machine. Somewhere in the speed range towards andabove 2,000 m/min, the target to produce
not only more paper but also to increase
profits was forgotten. This has to change
fundamentally.”

What can be expected in the future?
We will further develop the basic concept
for the One Platform Concept. At the moment, we are dealing very intensively with31

some innovative and very interesting
concept solutions. But some time willpass until we have developed them tomarket maturity and will be able to integrate them into the current One Platform
Concept.
But above all, we see our future tasks inthe further optimisation of the existing
One Platform Concept. There is still a
considerable potential in the optimisationand further development of process control and the systems in contact with paper, i.e. forming fabrics, pressing fabrics
and drying fabrics, as well as belts androll covers. The interplay between machine, systems in contact with the paper
and process control has a considerable
influence on productivity and productquality.
This is a continuous optimisation process
which we implement in close co-operation with our customers on their operating production units and on Voith Paper’s
pilot units, where we are supported by
the experts from Voith Paper and Voith
Fabrics.
Process optimisation plays an importantrole with Voith as the preferred processsupplier.
Voith offers the best prerequisites for
this:Voith is the only supplier who produces
all systems of a paper machine that arein contact with the paper and offers theprecondition to systematically implement
process optimisation with the One Platform Concept.

32

Innovative Paper Machine Design

Design is not everything, but without

It almost goes without saying, therefore,

pearance? So is there any further needdesign, everything is nothing!

that the special qualities of innovative

for aesthetic design? Maybe this would

As demonstrated by aircraft and auto-

products should be underlined by theirmerely comprise expensive cosmetics?

mobile design ever since streamlining

outward appearance.

It is because of considerations like this,was discovered, elegance and efficien-that plant development engineers havecy go hand in hand. And it is equally

An exception to this rule has been (andperhaps waited longer than others before

true that well-designed ergonomic

still is to some extent) large installations

integrating aesthetic design concepts into

products sell better – as initiated byin the capital goods and machine building

their complex projects.

the legendary “Bauhaus” designers

industries. Since their design focuses ex-

and architects.

clusively on the best possible cost/bene-

Those times are definitely over, however!

fit ratio, surely such perfection should

These days progressive manufacturers,

speak for itself in terms of outward ap-

also in the paper industry, no longer re-Paper Machines

33

The illustrations show artist’s impressions andcomputer simulations of the new Voith Papermachine design as first implemented on PM 9
at Haindl Paper.

gard good architecture in new plants or re-value-added, enhanced work safety anddesign. Paper machine design studies

builds merely as a space and cost saving

ergonomy, better handling and mainte-

have been also assigned both en bloc andadvantage. They deliberately employ goodnance. It furthermore brings material andin part to leading universities and techni-aesthetic design as a marketing tool forcost savings wherever possible, both incal institutions.

enhancing their corporate image. And thisplant construction and installation. Eco-applies inside the mill as well as outside.

logical aspects such as energy and re-Since the introduction of our “One Plat-

source conservation also play a growing

form Concept” of modular system com-role in good design these days.

ponents on an interlinking basis, all our

How can good design be defined? At any

designs are now checked for perfect inte-rate, it has nothing to do with superficial
cosmetics or fashion. Based on thor-

For some time now the basic develop-

gration of all modules. In this connection

oughly systematic aesthetics, it also in-ment team at Voith Paper has been as-

the opportunity arose to integrate such a

corporates greater product benefit andsessing important innovations for optimal

new and comprehensive design – for innovation has to be systematic!
Prof. Horst Diener and his colleagues
Dipl. Ing. Peter Koloch and Dipl. Ing. (FH)
Reinhard Frank of Designpraxis Diener in
Ulm partnered us with their competence

34

and experience in reaching this ambitious

The team’s first task was to integrate thegoal. Thanks to intensive dialogue be-

optical design of a typical Voith Paper

tween the Voith Paper development engi-

production line. In view of the plant sizeneers, the corporate marketing people

and complexity, an overall design con-and the independent design team, all

cept was first worked out and its imple-

tasks and implementation phases crys-mentation divided into short, medium

tallized step by step out of the detailed

and long-term measures.

situation analysis.
One of the first measures taken was on
Visualize quality – comprehensively andthe walkways, which greatly affect thehomogeneously! This summarizes theoverall appearance of the paper machine.

goal of the last few months’ work. Although all the individual sections of a

Together with the machine designers theVoith Paper machine such as the former,

walkway system at the former and press

press and dryer sections and reel section

sections was therefore revised, and divid-

work together outstandingly well, theed into two levels or “storeys” as far as

visual impact of each component has so

possible. The stairways at the former

far been treated relatively individually.

were integrated into a kind of staircase.

35

The result of this work is not only a more

Since the former and press sections getdeveloped which fits various machineorderly impression, but also easier ac-very dirty during operation, the personnel

layouts.

cess for operation and maintenance. The

have to spend a lot of time cleaning up to

walkways were fitted with panels, which

ensure efficiency and safety. This work

Whether walkway panels, exhaust hoods,

serve several purposes:

will be reduced in future thanks to large

splash guards or partitions – all these de-splash guards. These not only keep off

sign elements fit well together both opti-

They prevent dazzling by the lighting in-

the dirt, but also reduce noise. For wire

cally and dimensionally. Overall, theystallations, while also improving the ca-

and roll changing, the guards can easily

form the new image of Voith Paper ma-

ble run and access. As a welcome side

be moved or swung away like doors. To-chinery and are a protected part of theeffect, these panels provide enough sur-gether with the walkways, they also serve

Voith corporate design.

face area for clearly labelling each systemfor optically harmonizing the machinerycomponent.

complex.

Based on Voith corporate blue, the walk-

The splash guards on the former andful premiere on PM 9 at Haindl Paper, theways optically link the modular elementspress section are similarly installed in thedesign team is working on further ma-of the One Platform concept into a har-reel section, but for protection purposes.

chine concepts and going into greater

monious whole.

In this connection a new modular cladding

depth with regard to operational, mainte-and support element system has beennance and rationalization benefits.

Step by step the new Voith Paper design
is being implemented. After its success-36

Soporcel PM 2 inauguration ceremony
On October 18, 2000 Soporcel’s new
PM 2 production line was officiallyhanded over in the presence of politicaland industrial leaders including
Dr. Jorge Sampaio, President of the
Republic of Portugal, Minister of
Economy Mário Cristina Sousa, andState Secretary José Junqueiro.
The author:
Dieter Babucke,
Paper Machines Graphic

October 18 is a particularly important
date for Soporcel: on that date in 1984
their new pulp mill was inaugurated – according to former President Antonio
Ramalho Eanes “Portugal’s most important industrial project”. On October 18,
1991 their PM 1 went into operation. So
for Soporcel it is now a tradition to celebrate the company’s most important
events on October 18. They take it as agood omen for ongoing expansion in the
future.

37

President Sampaio congratulated theSoporcel management in his speech on
the company's successful growth so far
and this courageous new step into the
future, their strategy of cost-effectively
implementing the PM 2 project in tune
with Portuguese market capacities. Economy Minister Sousa emphasized that thesuccess and quality of Soporcel papers
and the capacity expansion now attainedwith PM 2 should not be measured intonnes alone, but rather as the result ofentrepreneurial vision and purposeful implementation.
Board Chairman Alvaro Barreto referred
afterwards to the special mission followed by Soporcel: the goal already set
in 1984 of integrating all production
processes as comprehensively as possible in the company’s environmental responsibility – ranging from sustainable
forestry to the finished paper products.
He pointed out that Soporcel is alreadyTechnical data of PM 2,
built on the “One Platform Concept”:
Wire width 9,350 mm
Web width 8,600 mm
Overall paper machine length 182 m
Grades: wood-free graphic papers
from 60 to 110 g/m 2
Annual output 400,000 t
Production speed 1,500 m/min at 80 g/m 2
Design speed 1,700 m/min

38

1

2

3

responsible for 55,000 hectares of forest
covering about 30 % of current raw materials needs, furthermore that thanks toa model agricultural programme, morethan one hundred thousand additional
hectares are being re-afforested in an
ideally eco-economical manner.
In this connection the Board Chairman
mentioned another notable company investment of exemplary character: overthe last few years Soporcel had spent
about 100 million Euro on state-of-the-art
clean-air technology and anti-pollution

measures. The company had attained astandard thereby which not only improves on the EU air pollution limits, but
is also much lower than main international benchmark levels.
For the 900 Soporcel employees, thisPM 2 inauguration was certainly a sourceof pride and satisfaction. But it was also
an important step toward breaking new
ground. “Our market expansion in theSouth European countries is notable, but
due to lack of production capacities weare only just starting to find our feet incentral and northern Europe. Our declared target is therefore not only tostrengthen our presence in the traditional
markets of Portugal, Spain, France and
Italy, but also to expand beyond thesemarkets. In terms of figures, we planover the next three years to increase ourmarket share in the European Union from
7 to 11 % for office papers and from 6 to
10 % for offset printing papers”, said
Alvaro Barreto. With 730,000 tonnes
annual output capacity, Soporcel is now
Europe’s leading producer of office papers.

39

4

In closing, the Board Chairman paid tribute to the PM 2 project team for theiroutstanding performance and excellent
cooperation with Voith Paper. PM 2 hadbeen implemented two months earlier
than planned, including a very modern,
gas-operated power plant with 67 MW
output, thus improving significantly on
the budgeted costs.
After reaching the final production speedof 1,500 m/min at 80 g/m 2 basis weight,
Soporcel PM 2 will be the fastest andmost efficient production line in theworld for wood-free graphic papers madeof eucalyptus furnish. Decisively important for the efficient planning and implementation of this project was the excellent cooperation of the Soporcel team,under Chief Executive Officer Luis Deslandes, with the Voith Paper project
team. Thanks to this partnerly teamwork
and constructive dialogue at all times,
even the most difficult problems in thecritical deadline situation typical of such
ambitious projects were solved to thecomplete satisfaction of all concerned.

During the year preceding this PM 2 inauguration, CEO Luis Deslandes was particularly honoured by being appointed
chairman for the next two years of the
FAO advisory committee for paper andforestry products. Congratulations! This
unique committee, comprising members
from more than thirty countries on allcontinents, supports the head of the FAO
in all matters concerning worldwide demand for forestry and paper products, including production aspects.
A detailed description of the Soporcel
PM 2 project is given in twogether 8,
pages 18-20.

5Fig. 1: Dr. Jorge Sampaio, President of the
Republic of Portugal, giving his address at theSoporcel PM 2 inauguration.
Fig. 2: Board Chairman Alvaro Barreto talking
about Soporcel's special mission.
Fig. 3: Luis Deslandes, CEO Soporcel,
and Hans Müller, Voith Paper.
Fig. 4: PM 2 reel section.
Fig. 5: Part of the stock preparation line.

40

Quena –
Successful start-up of the world’s mostmodern bagasse paper mill
Egypt’s largest mill for graphic papers

cal Luxor where papyrus paper was al-

and newsprint started up in December

ready made four thousand years ago. The

2000 when the first finished paper rollmill is right next door to a sugar factory,

was turned out by PM1. Meanwhile pro-which provides bagasse – or cane trash –duction output has developed according

as raw material for the neighbouring

to plan, meeting all expectations forstock preparation line.

high quality grades.
Quena Newsprint Paper Co. (QNPC) is a
The author:
Bernhard Häussler,
Paper Machines Graphic

privateinvestmentcompany

whoseshareholders include some of the largest
banks, insurance companies, sugar andfood industry organizations. HeadquarAt the beginning of 1998 Quena News-

tered in Cairo, QNPC has greatly expand-print Company, Kous/Egypt ordered fromed its activities over the last few years.

Voith Paper a complete production plantfor graphic grades using bagasse furnish.

This turnkey project was realized in an

Kous is located in Quena province, upperamazingly short time. The impressive size

Egypt, only about one hour from histori-of the Kous mill reflects the owner’s fore-Paper Machines

41

Fig. 1: Quena PM 1.
Fig. 2: The paper machine building at Quena
Newsprint Company’s Kous mill in Egypt.

been producing high quality graphic pa-

Kous mill the largest of its kind in thepers from bagasse – a very difficult raw

whole of Africa.

material to prepare and process. Smoothand successful commissioning was en-

Thanks to mature process technology andsured by Quena and Voith Paper engi-

the perfectly integrated functioning of allneers together with a team of experts

Voith Paper components, this plant oper-from Tamil Nadu in India.

ates smoothly and completely troublefree.

Tamil Nadu Newsprint and Papers Ltd.

1have been producing newsprint commer-

The ModuleJet™ headbox ensures an ex-

cially from bagasse in India since 1996

tremely stable basis weight cross-profile,

on a Voith Paper line. This was the firstwith an independently controllable fibre

time in the history of newsprint produc-orientation cross-profile. Optimal forma-tion that 100% bagasse had ever beention and runability are ensured by theused as raw material. Right from the be-

DuoFormer CFD gapformer, which en-

ginning of the Quena project, full advan-

ables active control of ash and fillers dis-tage was taken of the experience gained

tribution on the z-axis.

in India.
PM 1 is equipped with the extremely relisight and pride in future-oriented tech-

Quena will be producing in their new millable NipcoFlex™ shoe press technology,

nology for high quality products at com-

144,000 t.p.a. of graphic papers andfor maximum dry content after the press

petitive market prices.

newsprint with basis weights from 40 towith optimal sheet volume retention.

80 g/m 2. The furnish used will comprise

The TopDuoRun dry section ensures

70-85% bagasse. This makes Quena’s

unsurpassed

Decisive for this contract award were
Voith Paper’s outstanding references andtechnological leadership in machinery for 2
producing newsprint and graphic gradesfrom yearling bagasse. Voith Paper is the
only comprehensive supplier worldwideof this technology, covering both stock
preparation and paper machinery. Voith
Paper reference plants using bagasse furnish are operating in India, Indonesia,
Pakistan, Bangladesh and Iraq.
Ever since the Kous mill was commissioned in mid-December 2000, it has

dryingefficiency,

while

42

Fig. 3: SpeedSizer.
Fig. 4: The bagasse raw material depot.
Fig. 5: PM 1 reel section.
3

4

SpeedFlow™ and tandem soft-calenders
ensure perfect sheet surface quality.
Apart from the complete paper machine,
the Voith Paper scope of supply also included the entire stock preparation line,
the approach flow section, whitewater
systems and rejects processing.
Stock preparation is initially in four lines.
The first two lines process mechanicallyand chemically bleached bagasse pulp
respectively. The other two stock preparation lines process imported chemothermomechanical

pulp(CTMP)

andbleached pine kraft pulp (NBKP). These

Main paper machine data:
Design speed 1,300 m/min
Wire width 6,800 mm
Sheet width on poperoller 6,180 mm
Full paper reel diameter 2,800 mm
Max. weight of full paper reel 35 t
Production output 400 t/24 hMax. reeling speed 2,500 m/min
Max. roll diameter 1,500 mm

43

5

two bagasse and two imported pulp

The Voith Paper scope of delivery also in-and environment-friendly wastewater dis-

grades are combined in the mixing chest

cluded a TORO winder with roll transport

posal. Well-equipped servicing and main-withtenance facilities are also provided.

thenand packaging system, furthermore therefiner.

additives processing system with piping

Newsprint is produced here with about

and vats, and the overall process control

Due to the extremely tight schedule for

40 % mechanically and chemically pro-system. Our consortial partner Alstom

paper machine manufacture and pre-cessed bagasse, and 10 % each of CTMP

supplied the drive systems and all electri-

assembly, including all main line compo-

and NBKP. The graphic papers made here

cal installations including the DCS andnents, logistics coordination among thecomprise 75 % chemically processed

QCS systems.

suppliers was a large-scale operation.

recirculated

processed

throughbroke,
the

and
trim

Site erection was carried out by Egyptianbagasse and 25 % NBKP.
Electrical power is generated on site bysubcontractors with the support of Voith

The main components of the approachan oil-fired high pressure steam turbine

Paper supervisors.

flow section are a 5-stage cleaner and aaggregate. Pass-out steam is taken from

3-stage screener. A disk filter supplied bythis boiler for low pressure process re-Voith Paper took over all plant engineer-

Andritz AG, Graz ensure optimal fibre re-quirements. Modern water treatment anding, and was also responsible for the en-covery.

effluent systems ensure freshwater purity

tire scope of delivery including comprehensive technical installations inside thepaper machine building. Except for excavation and structural work, the complete
turnkey paper mill was thus delivered tothe customer’s full satisfaction.
A further paper machine is planned forthe future, and the necessary infrastructure is already installed.

44

Perlen PM 4 “Pionier”
An illustrious inauguration ceremonyand open day

The author:
Bernhard Stützle,
Paper Machines Graphic

On Friday May 4, 2001 Perlen’s newpaper machine PM 4 “Pioneer” wasinaugurated. Starting at the wood yard,
visitors enjoyed a tour of the TMP anddeinking stock preparation line rightthrough to the finished paper rolldispatch. All points of interest wereposted along the route, including
auxiliary systems such as effluent
treatment, the in-house hydropower
plant and boiler room. Perlen Paper
personnel were on hand at every point
for answering detailed questions.

This comprehensive tour showed in particular how the PM 4 line is customtailored to specific market needs as wellas various logistics and infrastructure
factors:
 The production capacity of PM 4 isadjusted on the one hand to regional
furnish availability, and on the other
hand to local paper market capacity
within a certain radius.
 The uniformly high furnish quality
required for LWC grades was ensured
not only by rebuilding the modern TMPline already existing, but also with a
new post-treatment line precisely

45

1Fig. 1: Perlen PM 4.
Fig. 2: SpeedFlow.

adapted to these needs. Perlen is the
only paper mill so far where this concept has been realized.
 As another special feature, semifinished stock preparation capacities
for TMP and DIP are sufficient fornewsprint production both on PM 4
and on PM 5. This ensures a highdegree of flexibility and adaptability tomarket fluctuations.
 The new line is installed right in theheart of the existing mill, in the spacepreviously occupied by an old paper
machine.

2

46

3

The highlight of this one-hour tour was ofcourse PM 4 itself – already in commercial operation. More than five hundred invited guests were able to see for themselves the online production of “Perlentop” coated high-gloss offset paper. PM 4
lived up to its “Pioneer” name by producing nearly 500 tonnes of “Perlentop” in
24 hours without a single tear-off.
On the following open day, the same tour
was available to the public. Once again,
PM 4 production in shift operation wentsmoothly, undisturbed by no less than
thirteen thousand visitors filing continuously past the machine.
Operations were equally continuous at
the other end of the line in the restaurant
marquee, where visitors enjoyed the hospitality of Perlen Paper Ltd. The logistics

functioned perfectly – as would be expected of Perlen Paper – with a shuttle bus service to Perlen from the enormous parking
lot on the military airfield nearby, andeven a special train to and from Lucerne.
To celebrate the occasion, this special
train was pulled by Perlen Paper’s lovingly restored steam locomotive dating backto 1911 – a great attraction for visitors!
Right through the day, Perlen Paper Managing Directors Schaller and Maisch wereon the spot with their entire team to ensure smooth operations. Feedback from13,000 guests – including about one hundred Voith Paper technology people –was very enthusiastic.
Ever since the beginning of this project,
the Perlen-Voith team and a good manyother suppliers had been working intensively toward this inauguration highlight– with some astonishing achievements
since then as well.
In a system consortium comprising delegates from Perlen, Voith and partners,
Omya and Dow Europe, a good deal ofdevelopment work was done already before the order was received, together withextensive tests on pilot plants. The entire
team always worked together on thewhole process line, focusing above all on
stock preparation, coating and calendering. Overall results were regularly checkedby printing tests in practice.
The intensive preparations bore first fruitat the commissioning in September 2000.
After a brief start-up phase with newsprint, LWC was already being produced in47Fig. 3: Janus MK 2 and Sirius.
Fig. 4: Visitors to Perlen on open day.
Fig. 5: Reel section.
4

5

October 2000. The specified productquality characteristics – gloss, printability and press room runnability – were attained unusually quickly.
The very high yardstick set for overallmachine efficiency was not attained as
rapidly as planned. During the commissioning and optimization phase, however,
the entire well-versed team of experts
was on hand with all the experience they
had gathered during this project. Individual optimization steps were planned andimplemented in working groups, withsuch success that in the meantime production output is well above the start-up
curve. Daily outputs of around 550 tonnes
are in the vicinity of the calculated grossproduction output. In April 2001 theoperating efficiency of PM 4 had alreadyreached about 82 % – an excellent level

48

6
7

8

Fig. 6: Perlen’s veteran steam locomotive.
Fig. 7: The Swiss doctor and balloonist
Bertrand Piccard.
Fig. 8: Perlen Paper Managing Directors Schaller(right) and Maisch (centre) welcoming guests.
Fig. 9: A group of visitors admiring PM 4.

9

for a machine with on-line coater and online calender.
At the inauguration ceremony, a brilliant
address on Excellence was given by the
Swiss doctor Bertrand Piccard, who in1999 was the first to circle the globe
non-stop in a hot-air balloon in only
20 days.
He emphasized that this record-breaking
achievement was only possible thanks to
teamwork, and explained the success factors which such a project team must fulfil. For the Perlen PM 4 “Pioneer” team,this was an excellent opportunity to draw
parallels with their own work. For our ongoing teamwork in this system partnership, we shall pay particular attention to
one of Dr. Piccard’s principles: Nevergive up until you have reached the target.
It is certainly a realistic medium-term target not only to attain the specified performance figures with PM 4, but to exceed
them.

49

1

Kaukas PM 1 –A Finnish success story
In March 2000 the UPM Kymmene

1988. At the beginning of 2000, UPM

Corporation, Helsinki, Finland awarded

Kymmene decided to optimize this line,

Voith Paper a rebuild contract for paper

and placed their trust in Voith Paper.

machine 1 and coating machine 1 intheir Kaukas mill. In January 2001 thislarge Finnish project with a total invest-

Decisionment volume of 30 million Euro was
The author:
Klaus Hutter,
Paper Machines Graphic

crowned by successful commissioning

Decisive for the award of this order toright on schedule.

Voith Paper was not only the well-founded technical concept, but also the satis-

Case history

faction of UPM Kymmene with their JetFlow-F coating aggregates delivered by

The first production line at UPM Kymme-

Voith Paper in 1996. Other important

ne went into operation back in 1975. De-

grounds were the outstanding reputation

signed for manufacturing LWC and MWCof the DuoCentri-NipcoFlex press and therotogravure and rotary offset magazine

extreme compactness of the new Module-

printing grades, the machine had been

Coater, making it ideal for installation in

producing 2-sided coated grades since

the existing coating machine.

50

2

Locationper production as well as machine capacity. To achieve this, some innovative re-very high dry content with optimal
sheet volume.
 EnviroScan system for measuring

The UPM Kymmene Corporation’s Kaukasbuild measures were necessary:mill is located about 150 kilometres east

The paper machine operating speed was

humidity cross-profile after the pressof Helsinki in Lappeenranta. This compre-

raised by 300 m/min to 1,600 m/min.

section.

hensive plant incorporates the following

Simultaneous pre-coating was integrated

 Dryer section rebuild to the DryStar

facilities: sawmill, in-house power sta-

into the coating machine, whose speed

concept, for greater reliability andtion, chipboard, pulp and paper produc-

was raised to 1,800 m/min.

stability of ropeless end transfer.
 Complete new hard-nip calender withtion. About two thousand three hundred
people work here. The Kaukas mill has

The scope of supply included the follow-

thermo and Nipcorect rolls for cross-customers throughout Europe, its main

ing machine components and aggregates:

profile correction.
 Fibron threading systems for ropelessmarket being Germany.
Paper machine:
Rebuild goals and scope of delivery

transfer through the calender to the New bottom wire return to ensure

poperoller.

stable running in the wire section.

Coating machine: New PM press concept comprising a

 ModuleCoater installation comprising

The purpose of this rebuild was to further

DuoCentri-NipcoFlex press with shoe-a SpeedCoater coating aggregate andimprove the high quality of magazine pa-press in the third nip. This ensures aa ModuleDryer afterdrying section.

Paper Machines

51

Fig. 1: UPM Kymmene Corporation’s Kaukas millin Lappeenranta.
Fig. 2: Kaukas PM 1.
Fig. 3: NipcoFlex press section.
Fig. 4: Comparison: before and after rebuild.
3

4

Special features

Before rebuild

For the first time worldwide in an offline
coater,simultaneous

precoating

by

OMC 1

RR 1

PM 1

OMC 2

RR 2

PM 2

SpeedCoater has been implemented. The
ModuleDryer newly developed in teamwork with Spooner Industries enables
OMC 3

2-sided contactless drying over a very
short distance. With this Voith Paper
technology

application,

double-coated

MWC paper can be produced at theAfter rebuild
SpeedCoater with ModuleDryer

New: Calender

NipcoFlex Press

Kaukas mill in a single run instead of using two offline coaters as previously. Dueto the high resultant efficiency, the investment is very worthwhile.

OMC 1

RR 1

Relocated unwind
OMC 2

OMC 3

PM 1
DryStar Concept

RR 2

PM 2

52

5

Planning, design and installation

During the main installation phase, thecoating machine aggregates were thor-

Kaukas workforce grew by more than 800

oughly tested and coordinated.

The first building modifications were car-people, about 400 of whom from Voith

ried out only three months after receipt

Paper. Operating trials started before theof order. Rebuild planning and design

installation completion deadline, and thewascontrol system was tested for the firstcompleted

in

less

then

seven

months.

Commissioning

time under actual operating conditions.

Since January 2001 the Kaukas produc-

Two months before, FA tests had beention line 1 has been turning out double-

To ensure smooth and trouble-free instal-

carried out under dry conditions atcoated MWC paper in STAR quality. On

lation, all aggregates were works-assem-

Honeywell Measurex.

January 14 commercial paper production
was attained for the first time, at a speed

bled in Heidenheim and Krefeld. Almost
100 truckloads were required for trans-More than twenty commissioning engi-

almost as high as the top speed prior to

porting the components to Lappeenranta.

neers ensured that all paper machine andrebuild. Likewise in January 2001, thePaper Machines

53

Fig. 5: Kaukas coating machine 1.
Fig. 6: Layout of coating machine 1.
Fig. 7: The Kaukas project and commissioning
team.
ModuleDryer

SpeedCoater 2 x 8 g/m2

Blade
Coater 1

JetFlow F

6existing OMC

new Precoater

relocated unwind

7

mill production and speed records werebroken. Only three months after commis-

Statement by Pentti Hirvonensioning, an operating speed of 1450 m/min

Kaukas Project Director

was attained. Dry content after the press
section at this time was already more

The teamwork in handling and success-than 50%. The coating machine commis-

fully completing this project is an

sioning was also extremely successful,exemplary reference for future projects.

with operation for up to twelve hours

All the new components and modules

shortly afterwards free of any tear-off.

were optimally integrated in the existing
line, thus not only ensuring successful

The customer was very impressed withcommissioning, but already breaking our

the smooth and trouble-free installation,

mill production and speed records.

optimal commissioning, and perfect teamwork with Voith Paper.

58

Hürth PM 1 –The most cost-effective production line
for standard newsprint

At the beginning of March 2001 – only

months later on August 1, 2002, the new

18 months after starting up PM 5 at theline built on the “One Platform Concept”

100 % Myllykoski subsidiary Langhas to start producing standard news-

Papier in Ettringen – Myllykoski again

print from 100 % recovered paper.

decided for Voith Paper. This time as
supplier of the new production line for

The overall investment budget of 280

newsprint at the Hürth mill near

million Euro for this new production line

Cologne.

includes not only the paper machine,

The author:
Thomas Schaible,
Paper Machines Graphic

buildings and infrastructures, but also
the complete stock preparation line as
The Myllykoski project team finalized

shown in Fig. 1. The scope of supply cov-

their specification for the stock prepara-ers a new pulping and screening drum

tion and paper machine lines in a very

concept with a feeding system suppliedshort time: from mid-December 2000 toby B+G, hole and slotted screening, pre-the end of February 2001. Only 16

flotation and afterflotation, disperging,

Separator

Paper machine

LC screener

1

DAF 3
DAF 1

Rejects
handling

HW cleaner

Storage

Disk filter 2

Flotation 2

EP disperging

Screw press

Disk filter 1

Flotation 1

PM Loop

Loop II

LC screener // 0.15

Dumping tower

MC screener fl 1.0

HP cleaner

Drum pulper

Loop I

Save All
PM
spray
water

Sludgehandling
DAF 2

Paper Machines

59

Fig. 1: Deinking line, 2-loop system.
Fig. 2: Layout of Hürth PM 1.

2

Fig. 3: The contract signing ceremony (from left
to right): Harry Hackl, Dr. Hans-Peter Sollinger,
Thomas Nysten, Managing Director Myllykoski
Continental, and Bernhard Ludwig, Managing
Director Lang Utzenstorf.

3

Decisive for the award of this contract
was not only Voith Paper’s outstanding
system competence, but in particular theexperience with newsprint production
from 100 % recovered paper.
The concept for this new line was drawn
up to meet the following requirements:budget compliance without sacrificing
quality or existing standards; full integration of feedback and findings from previous projects for optimal copying effectwith additional plant components; theconcept must take full account of market
requirements on standard newsprint overand the entire stock/water loop system

plenty of recovered paper is available as

including rejects handling. Our joint ven-

raw material, and the end customers areture partner Meri is supplying the water/

not far away.

rejects handling systems, while the dewatering machinery is supplied by our

Hürth PM 1 comprises a ModuleJet head-licensee Andritz as consortial partner. In

box, DuoFormer TQv, Tandem NipcoFlex

addition to the paper machine Voith Paper

press, TopDuoRun dryer section, single

is also supplying the quality control sys-

soft-nip Calender and Sirius. Since thetem, sheet inspection and tear-off analy-

introduction of this concept, the newsis system, and all local controls.

paper machine already incorporates theeighth Tandem NipcoFlex press and the

The Hürth location was chosen for vari-fifth DuoFormer TQv – thus making it theous reasons: power, steam and water areseventh line in only two years to be built

provided here from a local power station,on the “One Platform Concept”.

the next ten years.
By using well-proven components, systems and process stages, the shortest
possible commissioning time should beensured and the design production output reached as quickly as possible. The
goal agreed between Voith Paper and
Myllykoski for Hürth PM 1 is to attain theworld’s best start-up curve for this kindof line.

60

1Kehl PM 2 –Large new production line ordered forspecial graphical grades
Eleven months after the successful

age on the thermoreactive paper surface.

commissioning of their new PM 6 forSince thermal printers and copying ma-

decor papers, August Koehler AG,

chines save considerable time and costs

Oberkirch again placed a large orderin office communications compared withfor expanding their Kehl mill: a newconventional printing methods, there is a

production line for thermo-papers.

growing demand for thermopapers. This
growth is likely to continue for some

The author:
Heinz Braun,
Paper Machines Graphic

Installation work on this new line has al-time, since the processing possibilities,

ready begun. Production is to start in

rapidity and flexibility of thermoprinting

only sixteen months’ time, and commis-

have not yet been fully exploited by any

sioning is scheduled for December 2001.

means.

That will mark the start-up of Europe’s
most modern and powerful production

It was only logical, therefore, for Augustline for non-impact printing papers.

Koehler AG as a leading producer of special graphical grades to expand their ther-Main data of Kehl PM 2:
Product thermal basis papers, 40-80 g/m 2
Web width on roller 4,200 mm
Design speed 1,500 m/min
Operating speed 1,400 m/min
Gross output up to 390 t/24 h
Production capacity about 120,000 t.p.a.

Non-impact or thermo-papers comprisemopaper production according to market

special wood-free grades which can be

demand. Decisive for their choice ofprinted thermally, and without contact asVoith Paper as supplier of this new pro-for example in inkjet printing. The printerduction line was our outstanding partner-

is heated electrically up to about 160° C,

ship recently in the planning, installation

at which temperature the inks combine

and commissioning of PM 6 for decor

with developers to generate a printed im-

papers.

Paper Machines

61

Fig. 1: The August Köhler AG Kehl mill.
Fig. 2: Coating machine layout.
Fig. 3: Layout of the new PM 2.

Apart from design planning and engi-

 MasterJet G headbox anding. Particularly important here is a uni-

neering, this large new order also covers

DuoFormer TQv (vertical gapformer) inform, high quality coating, which is en-

substantial parts of the stock preparation

the forming section to ensure optimal

sured by a special coating aggregate de-line such as the charging, pulping and re-uniformity in the macro range (cross-veloped for this purpose by Voith Paper

fining aggregates, rejects handling andprofile and machine-profile) and micro

in teamwork with the customer. The joint

the approach flow section. Main focus isrange (formation).

venture signed between Voith Paper andon the new PM 2 and on the offline coat- DuoCentri-NipcoFlex press for out-

IHI, Japan, also enables in Kehl the firsting machine for thermal printing paper.

standing runability with high dry con-application of a curtain coater working

The scope of supply also includes the re-tent and high pre-coating smoothness

on the uniform 1:1 coverage principle.

on the reverse side for thermo printing.

August Koehler is the first paper manu-

reeler, paper roll transport system andpackaging machine.

 Single row TopDuoRun dryer section
for rapid drying and optimal availability.

ing speeds above 1,000 m/min for thisThe Kehl mill’s new PM 2 will set new EcoSoft softcalender after the predry-

special product – a pioneering milestone!

milestones in thermo basis paper produc-

ing section for efficient precalenderingtion.

and a uniform thickness cross-profile.

After commissioning, this new produc-

facturer to use a curtain coater at operat- SpeedCoater for good contour or in-tion line will be described in detail in one

To meet the high quality demands, thesulation coverage as basis coating forof the next editions of “twogether”. It willlatest components of the Voith Paper

thermo-printing on the reverse side.

certainly expand the position of August
Koehler AG in the high grade thermopa-“One Platform Concept” will be integrated
in PM 2:In the offline coating machine, the sheet

per sector and consolidate the company’s

is covered with a thermosensitive surfac-

market leadership in Europe.

2

3

62

1

... continuation.
Janus™ MK 2 for Schongau PM 9
Review: when our previous article on
the PM 9 rebuild in Schongau went topress, we were just about to embark on
one of the most demanding installationand commissioning projects ever undertaken worldwide. In only 56 days, notonly did an existing paper machine haveto be dismantled and systematically
packaged for shipping to its new ownerin China, but its place had to be taken
by a new line due to start production at
the end of June 2000.

The authors:Peter Herbrik,Franz-Josef Schmitt,
Christian Münch,Finishing

The new PM 9 is equipped with a Janus™
MK 2 – the most modern calendering
technology currently available on themarket. The concept was new, it had to
be installed and commissioned in record
time, and the start-up curve was dauntingly steep.
All technical preparations for this project
had been made in close teamwork between the customer and the supplier.
Standstill time was scheduled right down
to the last hour. All units had been commissioned previously next to the operating paper machine. In Krefeld a task force
team of designers, automation and production experts was on hand around theclock for fast response to unavoidable
surprises, as far as possible leaving
nothing to chance. All possible preparations had thus been made – but were
they enough?

Finishing

63

Fig. 1: The first paper roll produced by PM 9.
Figs. 2 and 3: Frame erection and roll installation.
Fig. 4: Regular commissioning conferences –outside in the sunshine whenever possible.
2

3

To put the reader’s mind at rest – the answer is yes. In Fig. 1 you can see the exhausted but happy commissioning teamnext morning on June 28, 2000, standing
in front of the first paper roll turned out
by PM 9.
Let us now go back in time, however.
Punctually on May 2, 2000 the old PM 9
produced its last paper roll and was
ready for dismantling. At the same timein Krefeld the 400-tonne Janus MK 2 calender was being dismantled and packaged in erection-friendly units for transport. The task of setting up the frames
was practised once again – for there
would be no time for mistakes later on.
Dismantling of the old paper machine
was not even finished when the end aggregate foundations for the new one werealready installed. And when the ModuleJet™ headbox foundations were poured,
the Janus MK 2 frame was already inplace. This high-precision teamwork between the customer and supplier, civil
works contractor and erection people was
fascinating indeed. By May 25, 2000 theJanus MK 2 had been completely in-stalled, ready for commissioning (Figs. 2
and 3).
Old hands at commissionings know only
too well what surprises they can bring –and Schongau was no exception. There
were not only surprises, mostly of theunwelcome kind, but also breakdowns
and extremely frustrating delays. But thesituation was always saved by the wellversed customer-supplier teams, who
had spent twelve months preparing themselves technically and getting to knoweach other personally. This disciplined
teamwork between the highly motivatedHaindl people and Voith Paper’s
expert commissioning engineers worked so perfectly,that even the most obstinate problem wassolved in the end.
Coordination was timeconsuming. Two commissioning conferences were
held every day between the customer, supplier and subcontractors(Fig. 4).

On June 8, 2000 the rolls were heated up
to 240 °C oil temperature, and on June
15 the Janus MK 2 hydraulic system wasoperational. On June 18 the drives wererun up to 2,200 m/min, and three days
later both stacks were closed for the firsttime at full speed and loaded to maximum pressure.
When the countdown had reached 96
hours to zero, the end aggregate transfer
system was started up with an unroll
stand specially developed for this project.

4

64

Figs. 5 and 6: Final optimization work by thetransfer team.
Fig. 6: Start-up curve of PM 9 in Schongau.
Figs. 7 and 8: The Janus MK 2 calender.
5

6

600

566,77 t

Production

TargetProduction [t/day]

500

400

300
Jul
Oct
2000
7

Jan
Apr
2001

Jul

This was when the transfer team cameinto play. Day and night they balanced
the commissioning parameters between
dryer cylinder 38, the Fibron vacuum
tapes, the rope guide system, the pullstack and the Sirius™ winder. In themeantime the sheet reached dryer cylinder 38 several times. By now, the commissioning preparations on the paper
machine were almost complete, and theJanus team would soon be able to transfer their first sheet (Fig. 5).

Oct

On June 28 the big day came. The sheet
was running at 1,330 m/min on dryer
cylinder 38 in the pulper. Everyone held
their breath when the commands “Janustransfer on” and then “Sirius transfer”
were given. The first shot was a bullseye!
The double blade cutter divided the web,and the first reel was soon wound...
although at first with a thickness of
250 mm (Fig. 6).
The next few weeks were demanding but
rewarding. The transfer system had started up with impressive precision, andcontinued to do its job reliably. As shownby the start-up curve for the first monthin Fig. 6, performance expectations weresignificantly exceeded. The paper machine efficiency already reached 78 %only two months after commissioning,
and improved to 85 % after six months.
At the present time, more than 500 tonnesof paper are being calendered in theJanus every day.
The roll change team performance wasparticularly outstanding. Even the firstroll change went precisely according toplan, and after a while, roll changes weretaking significantly less than the guaran-

65

8

teed time. Meanwhile, roll changing has
become a routine task.
Teamwork between the automation groups
was likewise exemplary. After intensive
preparations followed by FAT (Factory Acceptance Test) runs, the control system‚
process regulation and drive aggregate
teams were well harmonized and able tosolve all problems in a very short time.
Despite the very tight schedule, all thenecessary adjustments and improvements

were still completed during the commissioning phase. This achievement was only
possible thanks to optimal coordinationand the high motivation of all concerned.

from 100 % DIP must be complied with.
The quality team continues to meet regularly for jointly optimizing the paper quality parameters on a systematic basis.

What now? All working groups have been
dissolved since then except for the quality team, but the personal contacts madeare still in place. Over the next few
months, in well-proven teamwork between
the customer and supplier, the demanding quality criteria for SCB production

The Schongau PM 9 project has shownthat through optimal planning and close
cooperation with the customer, shortstandstill times and steep start-up curves
are possible. We pay tribute to all those
who participated in making this projectsuch a success.

66

1

New Service Center in Indonesia
On April 19, 2001 in the presencerisks for the customer – including timeof numerous customers, high-ranking

and cost outlay – through really profes-

representatives of the Indonesiansional services on the spot.

Ministry of Trade and Industry, and the

The author:
Martin Scherrer,
Service Center Jakarta

German ambassador, a new Voith Paper

The new service center, which has nearly

Service Center was inaugurated about

7,000 square metres of shop floor area to

60 km east of Jakarta. This is situatedstart with, already employs 50 profes-

in Karawang Industrial Estate, wellsionals, and medium-term expansion to aconnected logistically with the West

staff of around 100 is planned. The craneJavanese pulp and paper industry andsystems and the machine park, with mod-not far from Jakarta airport and harbour.

ern CNC turning and grinding centers,
multi-spindle boring machines and dynamic balancing units, can already handle
all roll types up to 15 metres long,

The opening of this new service center

weighing up to 100 tonnes and up to

underlines the importance attached by

2,000 mm in diameter. Capacity can be

Voith Paper to growth of the paper andadded at any time according to need.

board industry in South-East Asia, Australia and New Zealand, Taiwan, China

The entire Voith Paper coating technolo-

and South Korea. True to our principle ofgy, both in rubber and polyurethane, isfast and partnerly customer service on

already available here or possible at shortthe spot, this new center offers every-

notice. The new service center thus offers

thing required for professional customer

exactly the same processes, materials,

support – consulting and analysis, main-

quality and delivery logistics as all othertenance and overhauls, and in particular

Voith Paper service points in Europe or

fast service for wear parts such as rollAmerica. This also includes the former

covers and stock preparation line compo-

Scapa technology acquired by Voith

nents. The main goal is to minimize all

Paper in 1999. And in the near future, theService

67

Fig. 1: The new Service Center in Karawang.
Fig. 2: Mertin Scherrer welcoming guests at theofficial opening.
Fig. 3: Ray Hall holding his welcome address.
Fig. 4: Roll center.
Fig. 5: Indonesian women in traditional costumes
at the inauguration ceremony.
2

3

4mechanical roll service equipment will be

at all times. Thanks to close teamwork

explained the latest state of clothing

complemented by a Nipco test stand. Fur-with Voith Paper’s R&D people in North

technology. Since January 1, 2001 Voith

thermore, the new service center will

America and Europe, the latest state ofFabrics serves the Indonesian market

soon be offering comprehensive servicing

technology has now been transferred towith its own qualified staff instead of via

for anti-deflection rolls. So far most In-

Indonesia.

local agents.

this type to Europe or the USA for recon-

Guests invited to the opening of this new

The substantial investment made by Voith

ditioning. By the year 2002 the manufac-

service center were able to see for them-

Paper in this new service and support

ture of composite covers for calenderselves the impressive offering. Welding

center will consolidate and expand on arolls is also planned here.

specialists demonstrated how rotors forlong-term basis our fruitful cooperation

donesian customers had to send rolls ofstock preparation units are reconditioned

not only with existing customers in the

It goes without saying that field service isin Europe – a service also available in In-

growing South-East Asian paper andalso provided, such as vibration mea-

donesia in future. Voith Fabrics people

board industry, but also with new ones.

surements, headbox repairs, dryer section
repairs, roll changing assistance, andmobile roll grinding and thermal spraycoating.
Voith Paper is the only provider in theentire South Pacific region of such wideranging services on the spot. Not to beforgotten is the worldwide backing ofVoith Paper research and development
potential, which can be directly accessed

5

68

1

Voith Fabrics –A new millennium of paper machine
clothing: Quantum II dryer fabrics
Choosing a supplier to the dryer part ofGraphic Papers

a paper machine has become more criti-

The author:
Mark Hodson,
Voith Fabrics

cal as we enter the new millennium.

Investment in the European paper indus-

This is because modern dryer section

try during the year 2000 saw the start up

geometry has evolved with the increas-of the new machines of Haindl Augsburg

ing requirements for faster machine

PM 3, Haindl Schongau PM 9, Hermes

speeds, higher quality papers andPM 5, Soporcel PM 2 and Perlen PM 4.

better fabric lives. Voith Fabrics

Voith Fabrics is the only paper machine

continues to develop its dryer fabricclothing supplier to be chosen for the

product range in order to maximise

dryer part on all of these new machines.

fabric performance on both new and

The Hermes, Perlen and Schongau ma-

existing paper machines.

chines started up with 100% dryer clothing from Voith Fabrics.
In addition to the success on new machines Voith Fabrics have also supplied
clothing to major rebuilds of European

Fabrics

69
62.9

62

60.4

58
55.8
Fig. 1: Small Loop and In-line Spiral seams of
Quantum II.

54

Fig. 2: Modern dryer section geometry.
50
Quantum II
3High Speed
Fabric A

High Speed
Fabric B

Fig. 3: Air volume (mm 3/mm 2 ) of dryer fabricsurfaces.

paper machines. These include the rebuilt

Voith Fabric’s products were fitted on the

Quantum II gives effective transmittancedryer parts of Holmen Hallsta PM 2, Sappi

first sections of Aylesford PM 14 (9.95 mof under pressures to the surface of the

Gratkorn PM 9, Nordland Papier PM 4wide) and Augsburg PM 3 (10.40 m wide)

sheet for good sheet control. In addition

and Haindl Schongau PM 7. In April 2001

on 14th February 2001. The seams on

the available volume of air in the fabric

PM 7 started up with Voith Fabrics on thethese fabrics were meshed, seam wire in-surfaces is very low (Fig. 3) and this im-

1st, 2nd, 3rd, 4th and 5th single tier sec-

serted and finished by the machine crews

provestions together with a fabric on the 6th top

in less than fifteen minutes each. The

runnability. Quantum II is already running

position. Quantum II from Voith Fabrics

seaming process requires fewer people tosuccessfully at pilot machine speeds ofruns on the world’s fastest machines pro-join the fabric, leaving operatives free for2000 m/min.

ducing graphic papers.

other duties. Changing dryer fabrics canEase of installation and safety

both

tail

feeding

and

sheet

be very uncomfortable for machine crews

The success of Quantum II is repeated on

due to the temperature in the hood dur-the high-speed machines in Asia. The ab-

ing “crash shuts”. The ease of seaming

sence of seam mark in the paper was anmeans that the machine crew is in theimportant requirement of dryer fabrics

thehood for a shorter period of time and thatfor the start-up of the 1500 m/min PM 1

seaming aids used with the Quantum II

the machine is soon available to startof Malaysian Newsprint Industries in De-(Fig. 1) design enable the dryer fabric toproduction.

cember 1998. Quantum II fabrics gave

Improved

seam

technology

andbe easily installed on sections where

the best performance on the machine and there are narrow clearances within theare now running on 100% of the dryer
Fabric life, stability and performance

fabric run, either long or short length fabrics havesections. Several of these fabrics exceeded lives of 15 months and were still in

limited stretch rack movement,

Quantum II has a high material content

good condition when safely removed at access is limited for seaming.

and CMD stiffness. This is important be-planned shuts.

cause dryer fabrics on high speed sec2

tions (Fig. 2) have to be more stable than

In North America Quantum II is becoming

normal designs due toestablished as the high-speed fabric on
critical sections of the paper machine.

 short length or wear prone positions,

It has replaced other fabric designs at fabric return runs with no outside felt

Alabama River News PM 1, Madison Paperrolls,
 fitting allowances of only 1% andfabric extension during life limited to

PM 3, Appleton Papers PM 7 and the rebuild start up of Willamette Johnsonburg
PM 5.

1% with high running tensions,
 long unsupported runs between feltrolls
 high under pressures from sheet
control equipment.

The performance of Quantum II in Europe,
Asia and North America shows it to be atruly global product.

704Fig. 4: Paper contacting surface of Ultratherm.

paper grades. Ultratherm is constructed

in North America and Europe. North

from PPS monofilaments in both the ma-

AmericanMany sections of packaging machines arechine and cross machine direction. It isboard and packaging machines include

able to achieve good lives with dryer fab-available with the same smooth contact

Westvaco Evadale, Inland Rome and Unit-

rics that are made of polyester or modi-

area and aerodynamic surface of theed Corstac Reading. Enduro fabric perfor-

fied polyester material. However, higher

Quantum II

Thismances have exceeded the normal lives

steam pressures can lead to degradation

makes Ultratherm an ideal choice for theof polyester fabrics and thinner calliperof the fabric edges outside the sheet

new generation of high-speed packaging

100% PPS or 100% PCTA designs on

deckle and it is necessary to run fabrics

machines.

abrasion prone positions.

heat and hydrolytic conditions within the

Improved fabric life on wear prone

New generation of fabrics

dryer section. Steam groups within thesections

High temperature applications

fabricconstruction.

successful

installations

onwith PPS material at the edges to improve fabric life. PPS is unaffected by the

Dryer fabrics are an essential part of thedryer part can be up to 8 bar pressure
with cylinder temperatures of 160 °C

Voith Fabrics introduced their latest dryer

paper making process from the physical(320 °F). PPS material is also used when

product line of Enduro in autumn 2000. It

requirements of transmitting the drive

chemical conditions on the machine are ais primarily designed to resist wear frombetween cylinders to the reduction of

cause of degradation. Voith Fabrics man-poor felt roll conditions on hydrolysis

shrinkage at the sheet edges. Modifica-

ufacture several different PPS content

prone positions. Enduro is a unique dryer

tions to dryer fabric materials can be

fabrics including Ultratherm and Enduro

fabric construction that consists of large,

achieved ‘in house’ through co-operative

for sections with high-pressure cylinders,square PPS and PCTA machine direction

development at our SynStrand monofila-

depending on the severity of conditions

monofilaments. The design gives a signif-

ment extrusion facility. Trials on Voith

within the hood.

icant increase in the amount of material

Paper pilot machines ensure that fabricpresented to the fabric surfaces, resulting

designs are proven to work on new sec-

in better fabric lives on wear prone posi-tion geometry, prior to their installation

tions. Most applications are on machines

on the paper machine.

Maximum resistance to degradation

producing packaging grades of paper.
Ultratherm is an established product line

However the surface is smoother than theVoith Fabrics designers, application engi-

that provides ultimate resistance to thenormal coarse fabrics supplied to theseneers and service specialists are integrat-

highest levels of temperature and humidi-

applications, resulting in a finer, more

ing with Voith Paper as one team. This willty (Fig. 4). It is mainly supplied to pack-uniform contact with the paper. This also

provide a unique customer based influ-

aging machines, although its applications

makes the fabric suitable for other paper

ence, feedback and knowledge that will re-include writings and printings and coatedgrades. Enduro trials have been supplied

define the direction we travel in the future.

Paper Machines71

Fibron TT3000™ –Innovative tail threading at Lang Papier
has proven a success
It is known that the efficiency of tailthreading from the last dryer is often
impaired on paper machines producing
grades with a high filler content (e.g.
SC, LWC) due to an overstressed doctor
function in the tailing region.

High-pressure water-jet tailcutters being
operated at a very high cutting pressure(more than 900-1,000 bar) produce alarge quantity of cutting pulp at the takeoff doctor at high speeds.

The authors:
Sylvain Demers,
Fibron Machine Corporation;
Wolfgang Drefs,
Voith Paper
Paper Machines Graphic;
Jim Dadd,
Fibron Machine Corporation

New
Product

If the tailcutter is operated for a longtime, this build up of pulp at the doctor
results in adhesion of small paper shreds
at the doctor blade in the area of the cut.
These obstacles prevent the threading tailfrom stabilizing properly off in the pivoting tail threading element, the flip tray,
fastened under the doctor blade. Tailtake-off and transfer into the following
part of the threading system is therefore
unreliable and inaccurate. Tails with very
long and uncontrolled loops, called double tail, are often produced. In a very demanding threading path such as a ropetransfer system in an online Janus calender, this double tail often results in thedestruction of the actual threading tailduring threading due to the knockingaround, tear-off and adhesion it creates.
Alternative doctor blades, precise adjustment of the doctor combined with regularcleaning and regular blade changes only
resulted in slight improvements inthreading performance.

Additionally, in the event of a sheet
break, such time-consuming disturbances and cleaning at the take-off doctor distinctly extend the production
downtime and reduce system efficiency,
which is so important, particularly with
online paper machines.
To ensure constant, reliable threading
and an improvement in the entire threading process, especially on high-speed
machines with online Janus calenders, it
was therefore necessary to develop a new
method for the take-off of the threading
tail. This method is based on the basic
idea of taking the tail directly off the dryer
surface in order to be independent of any
malfunctions at the take-off doctor.
The concept of using the already known
principle of the so-called “Bullhorn” takeoff seemed to suggest itself as this principle had already been used successfullyon other similar applications.
This principle was already tested sometime ago at the last dryer of a production
machine. However, for lack of testingtime, sufficient flexibility of the testing
equipment and of a sufficient number oftests, this test did not produce any reasonable results.
It became obvious from this experience: that such a development could only be
implemented in the fastest and mostefficient way on a pilot stand which
simulates the real situation during therun-off of the paper sheet and cuttingof the threading tail as precisely as
possible at the last dryer of a paper
machine;72“Bullhorn”

Table with airfoils

1Fig. 1: TT3000™ foil configuration.
Fig. 2: TT3000™ in three positions.
2

was to use the new threading system on
the last dryer on PM 5 at Lang Papier in
Ettringen.

Store

The new test stand was designed for amax. operating speed of 2,000 m/min.
and comprised the following elements:
 An unwind device for feeding the test
paper with a roll diameter of 125 cm
and a roll width of 60 cm;

Ready A steel cylinder with pressure roll anddoctor, arranged above a pulper, forsimulating the last dryer;
 2 high-pressure water-jet cutting
nozzles cutting on the steel cylinder
for simulating the tailcutter;

The concept
 Threading to be independent of thedoctor function
 Threading at any machine speed
 No looping (double tail) during take-off Precise control of the threading tailduring take-off Functional reliability

The device
 Operationally reliable Few moving parts
 Self-cleaningThread Moisturizing nozzles for paper-sheet
conditioning; that a large number of tests have to be
conducted using real operating parameters and taking speed, paper quality, basis weight, etc., into account; that a functional reliability of almost
100% must be achieved under test
conditions before installation in a running paper machine can be released sothat the risk of a time-consuming
restoration of the old components andthe production losses resulting fromthis are minimized in the event of insufficient function.
At the beginning of November 2000 it
was decided to start a development project in the R&D center in Heidenheim. If
successful, the objective of this project A new, long Fibron conveyor aredesigned for installation at Lang Papier
PM 5;
 A test “Bullhorn” take-off device.
The test was set up to simulate the actual
installation situation at Lang Papier PM 5
as precisely as possible.
During the setup of the test stand, already existing components and machineparts from different Voith Paper locations
could be used to a large extent. Becauseof this, the development time was very
short.
The development of the new peeling-off
and threading unit was based on the following criteria:

Characteristics
 Immediate readiness for threading,
without time-consuming doctor
cleaning and other maintenance steps
 Safe initial tearing and separation of
the tail Simple operation
 Non-contact solution
 Maintenance-free Retrofittable on existing systems
possible
The construction of the test stand wasstarted in the middle of December 2000.
More than 400 threading tests were carried out and documented from the end ofJanuary to the middle of March 2001 by
the R&D team consisting of employees
from Voith Paper Coquitlam (Fibron),
Voith Paper Heidenheim and Voith Paper
Krefeld.

Paper Machines73

Fig. 3: Prototype TT3000™.
Fig. 4: Production unit installed at Lang Papier,Germany.

3

A great number of nozzle and Airfoil
arrangements were tested during this period.
The use of a high-speed camera with 500
single pictures per second turned out tobe invaluable for the documentation of all
nozzle and Airfoil arrangements and theireffects on the peeling-off and threading
process.
Only the evaluation of the high-speed
videos enabled us to fully understand thecomplex peeling-off process and thus to
optimize blowing sequence and blowing
time of the nozzles and Airfoils in the millisecond range.
The breakthrough with the threading
tests at the R&D center in Heidenheim
came at the beginning of March 2001. A
functional reliability of almost 100% wasreached at a test speed of 1,800 m/minwith the test “Bullhorn” take-off device(Fig. 3). Shortly afterwards, the manufacture of the final design of the “Bullhorn”
take-off device for installation on PM 5 atLang Papier was started. In mid-March
the device was pre-assembled in the R&D
center. The installation in PM 5 took
place on 26 March 2001 and the start-up
from 30 March 2001.
The final design of the “Bullhorn” take-off
device consists of a table with four different Airfoils (Curly Foil, Foil 0, Foil 1 andFoil 2) and two laterally attached nozzlesof the “Bullhorn” type. Fig. 1 shows thisarrangement.
By the explosion-like air blast from thetwo “Bullhorn” nozzles, the threading tailis initially torn at the side and then torn

through and lifted off the dryer. The new 4
beginning of the tail resulting from this isseized by the Airfoils in the table andguided to the subsequent Fibron conveyor. In this connection the “Bullhorn” nozzles and Airfoils are controlled according
to a sequence which was optimized in thecourse of the tests to minimize blowing
time and maximize control and guiding of
the threading tail. The duration of the entire blowing sequence is far below 1 second.
The new take-off device was launched
onto the market under the name Tear andTransfer 3000™ (TT3000™).
Fig. 2 shows the three positions of the
TT3000™: the park position, the readyposition and the threading position. Fig. 4
show the device installed at Lang Papier.
When the TT3000™ was started up on
PM 5, it turned out that there was an essential difference from the tests at the
Research Center in that the threading tailadheres much less to the dryer during
practical operation. Peeling-off of thethreading tail from the dryer was mucheasier, but the lateral tear-in and tearthrough of the tail necessary for the creation of a new tail beginning without aloop (double tail) was equally made moredifficult.
One of the causes of this phenomenon
was the initially extremely high cuttingpressure of 1,500 bar at the tailcutter. The
consequence of this was that the cuttingedges of the tail no longer rested flatly on
the dryer surface and that blow air could
already get behind the tail and peel it off
the dryer before it was initially torn. The

cutting pressure was reduced to 800-900
bar in the course of optimization.
The most important result after a total
period of 6 weeks of optimization with all
operating modes, paper grades, basis
weights and speeds:
The production downtime after a sheet
break has been significantly reduced, primarily due to the elimination of the timeconsuming disturbances and cleaning requirements at the take-off doctor.
Our customer, too, who has favored andsupported this new development, hasconfirmed the functional and operationalreliability of the new device.
Congratulations to the entire project teamfor a job well done and completed onschedule.

74

P a p e r C U LT U R E

Creativity with Paper
Despite the availability of plastics and awhole range of kits made up of perfectly
reproduced pieces, the good old technique of modelling with paper and card
is currently undergoing a worldwide
renaissance. Unlike almost any othertype of hobby involving personal skill
and creativity, it inspires dreams andflights of imagination in the hearts ofchildren and adults alike. Where were
the first ready-made sheets of model-ling card produced? In Esslingen, near
Stuttgart, there is a small museum
where visitors can admire treasuresfrom the early days of modelling paperand card printing.
An accurate model of a ship, the set of
Goethe’s Faust in miniature, a model ofthe human body that can be taken apartto show the various organs – what dothey all have in common? They are on

display at the J.F. Schreiber Museum inthe south German town of Esslingen, situated on the River Neckar. And they are
all made of paper or card.
The J.F. Schreiber Museum tells the storyof world-famous publishers J.F. Schreiber, still a going concern in Esslingen.
With its picture books, sheets of modelling card and children’s books with moving parts, this company has contributed

75

1

something significant to Germany’s cultural history.
When you enter the museum, which ishoused in a historic building on the edgeof the old quarter of Esslingen, you immediately feel you have stepped back intime. At the beginning of the tour, youcross a corridor with display cabinets
containing among other things paper reproductions of historical buildings andbattles from previous centuries. Next,
you enter an accurately reproduced lithographic workshop which gives you an authentic impression of the early history of
picture printing. At that time, new techniques such as lithography were giving
wide public access to visual reproductions of many different kinds. In a sideroom, there is a theatrical set reproducedin paper and, as you continue, you will
see examples from an extensive range of

Fig. 1: Everything is to scale in paper and card –whether it’s a historic castle, a crane portal, the“Imperator” express steamer, an aircraft or a
local tram on the Teltow line.

76

Fig. 2: The lithographic printing technique, inwhich illustrations engraved on steatite arepressed on to the paper, permitted long andtherefore inexpensive print runs.

3

Figs 3 and 4: “Pictures for Visual Instruction
from Esslingen” – accurate reproductions ofanimals and plants on boards for use in theclassroom.
Fig. 5: Paper theatres were very popular among
educated people at the turn of the century.
2

educational institutions. These “Pictures
for Visual Instruction from Esslingen”
were a decisive step in expanding the
publisher's list. They replaced the moreor less primitive visual aids then available
with accurate pictures. In 1850, there
were already 90 of these boards, illustrating trades, agriculture and aspects of theanimal and plant world. They also illustrated special geographic features of Germany, Europe and foreign climes. In themuseum, visitors have an opportunity tobrowse through draft designs that havenot previously been seen by the public.

sation in book production”. New printing
techniques such as lithography weremaking it possible to produce illustrated
books at considerably lower cost – andSchreiber was a master of this technique.
cardboard models, display boards used
for educational purposes and historicchildren’s books from the publisher’sarchives.
J.F. Schreiber – a revolutionary in thegraphic arts
Who was Jakob Ferdinand Schreiber?
The founder of the publishing house thatbears his name was born in 1809 andgrew up as an orphan. His talent for
drawing, which was discovered at an early age, led him to the art academy run by
Georg Ebner, where he worked as adraughtsman and illustrator. It was therethat he discovered an enthusiasm for the“new and amazing potential for graphic
and artistic creativity”. He was fascinatedby the problem of reproducing and distributing these creations in a relatively
short time.

The publisher’s business was originallyfocused on holy pictures and pictures ofthe saints. Schreiber was very successful
at marketing them.

Boards pave the way to a full
publisher’s list
In 1833, Schreiber began to publish
colour illustrations for schools and other5

From 1877 onwards, the paper theatrebegan its triumphant progress, becoming
extremely popular as a form of family entertainment. The museum has various selected examples on display and some ofthem can be purchased as reproductions.

Pictures of the saints
Schreiber grew up at a time when Europe
was being swept by a fashion for “visuali-

4

The publishing house had another success in 1892 with Schreiber’s four large
anatomical wall panels showing the human body with paper components that
could be disassembled.

77

6

Schreiber cutouts were later added to therange. These were handicraft and modelling patterns that could be cut out ofsheets showing interesting buildings,
cut-and-assemble pictures and activity
sheets. The range still includes modelmaking sheets of cars, aeroplanes andships. The museum has about 500 examples of these cardboard models.

The “Wurzelkinder”
and other picture books
Children’s books were an important partof the range. Perhaps the most famouson Schreiber’s list, and still a firm
favourite today, was “Etwas von den
Wurzelkindern” (“The Children of the
Root Bowl”) by Sibylle von Olfers. Thereis a special section of the museum devoted to it. The children of the title live underground – and that’s where they arein the museum too. In the “root bowl”,
children can experience the magic of the“little people” for themselves.

1904, when J.F. Schreiber installed an
American two-revolution printing press
made by Miehle. In the same year, colour
illustrations produced by the letterpress
technique appeared for the first time as amagazine. Colour printing went throughan intensive process of development at
the Schreiber company before and after
the First World War. In addition, a new
department dedicated exclusively to thecareful and perfect reproduction ofposters, brochures and advertising material by offset and letterpress printing forlarge-scale industrial and commercial
customers was set up.

The first high-speed printing machine inGermany
In 1832, Schreiber bought its first letterpress printing machine and in 1864,
Ferdinand Schreiber, the older of J.F.
Schreiber’s two sons, imported the firsthigh-speed lithographic press to Germany from France. They were soon able
to claim to be “the first printers in Germany to use the letterpress method for
lithographic printing”. Schreiber was on
its way to conquering a world market.The
extent to which technology dominates the
publishing business was also evident in
7

J. F. Schreiber has been having renewed
worldwide success recently with reprintsof pop-up picture books from the lastcentury, presenting as it were the ‘historyof the story’.
Fig. 6: In the “Root Bowl”, adults and children
can experience the life of the “little people”.
Fig. 7: Even in the computer age, children canstill be creative with paper.