nextlevel
by Voith Paper — N° 01.2018p.

08

Service works best in
close partnershipp.

20

Innovation in Brazil
has a real edgep.

28

The global pioneers
are choosing tissue

rollingout thenext
generationof tissue

02 Editorial

Editorial

Content 03

Content
Zoom
04 New directions
Maximizing cleaning with aground-breaking jet system

News
06 A quick round-up
From the world of Voith Paper
07

innovate
A look at key trends

World-class technology is highly valued
all over the world, and so too are innovative services. Both are at the core ofVoith Paper. These are the pillars thatguarantee a more comfortable journey
for our valued customers on a global
scale. But don’t just take our word forit. In this issue of nextlevel, we areproud to present a number of individual
customer journeys from all grades andstages in the papermaking process.
Through their personal insights, you
can discover how we help to drive theirsuccess to the next level.
As you will read, personal trust
plays a crucial role in all of these journeys. Whether in China, Brazil, Swedenor Germany, only through a trustfulrelationship can such success be realized over the long term. Trust leads totailored solutions, to pioneering innovations and business models that are
more sustainable and eco-friendly. We
trust you will enjoy the read!

Andreas Endters
CEO, Voith Paper

08 The Servolution has begun
A true partnership of expertise,engineering and interests
14 Make no assumptions
What’s the next big thing – andhow do you know? Foresight
management plays a role
16 A talent for textiles
An engineer with a passion for
fabrics provides tailored solutions for press felts and fabrics

19

transform
An overview of change

16

20 Open for tissue trials
Facts, figures and experiencesfrom inside the state-of-the-art
Voith Paper Tissue Innovation
Center in Brazil

The passion behindthe launch of Infinity

26 Follow in our footsteps
A manufacturing breakthroughfor decorative papermaking
28 A worldwide impression
Take a trip to tissue pioneersfrom around the world
32 It is time for tissue
What is driving the growing
demand for tissue paper?

33

08

20

Mutual interests lead tosustainable optimizationreflect
A round-up of expert views

34 A fresh, focused perspective
Personal and valuable insightfrom CEO Andreas Endters
38 Top of the line
A new invention takes care ofold headaches
40 A greener potential
Two experts outline their visions
for sustainable papermaking
43 Q&A
Could hand-hygiene habits
explain health trends?

The focus of this issue: tissue
paper and Voith innovations.
Explore how we support
our customers to achieve clear
differentiation in this highly
competitive market.

28
nextlevel N° 01.2018

N° 01.2018 nextlevel

Different cultures: individual
solutions with one supplier

40

Best practice ingreen production

Global trends intissue and trials

04 Section

Zoom 05

New directions
Paper machines using recycled fiber need to continuously clean
dryer-section fabrics. As conventional cleaning systems use only one
direction of high-pressure water jets, contamination can remain
within the surface pattern and structure of a fabric. However, thenewly launched CleanLine Extract4D uses four directions of water jets,
which directly contact and remove more of the contamination. As aresult, the dryer fabrics have cleaner surfaces and retain moreof their permeability for better drying efficiency and runability of the
sheet, and so improve the overall performance of the paper machine.

Maximize cleaning
The innovative design of the CleanLine Extract4D
ensures that the water jets are aimed directly at
the contamination – on the fabric surface, inside thefabric structure and through the CMD voids.

06 News

Section 7

News
A quick round-up

Smart pioneer in the paper industry
Sun Paper, one of China’s leading papermakers, has successfully implemented the Voith
Papermaking 4.0 project on PM 31, increasing
the efficiency, productivity and quality of its paper production process. The smart package isprovided by OnEfficiency Strengths, which
maximizes the machine’s full potential with anumber of tools. The OnV VirtualSensor allows
Sun Paper to forecast paper strength, while
the ComCore software platform acts as thecontrol base. In addition, the OnEfficiency
Cockpit, Voith’s operating system, works toeliminate incorrect dosages and reduce secondary effects. Thanks to the project’s success, Sun Paper is now planning to install the
Papermaking 4.0 package on two new Voith
XcelLine paper machines: PM 36 and PM 37.

“The integrated
logistics
Papermaking
solution is agame-changer
for theOnEfficiency
industry.”
Strengths

4.0
ComCoreThe modular
automation
platform.

Russia’s Segezha Group has celebrated thesuccessful start-up of their new Voith XcelLine
PM 11 – the first complete paper machine in
Russia since Soviet times. The new PM 11 willproduce 110,000 tons of unbleached sack kraft
paper at a design speed of 800 m/min, resulting in an increase in production capacity of
30%. “We have created a modern production
facility capable of manufacturing products withhigh added value within the country,” says
Kamil Zakirov, the Segezha Group President.

OnEfficiency
Cockpit
The gateway toreal-time datavisualization.

OnV VirtualSensor
Estimating values
with high reliability
and accuracy.

A smartcombinationof tools

p. 18

innovate

John Fox,
President and CEO of merQbiz ®

Paper sacks

110,000
tons

p. 07

A closer look at innovative technology,
people and solutions

One-stop shop for recovered paper
Officially launched in March 2017, merQbiz isan online marketplace designed to improve theway buyers and sellers of recovered paper dobusiness. Now, Voith continues to expand its
digital agenda and extend the range of its
trading platform for recovered paper. For thispurpose, merQbiz has announced C.H. Robinson as the exclusive logistics provider for theplatform. The collaboration brings unmatchedfreight capacity, competitive real-time pricing
and a powerful supply chain network to theplatform. “C.H. Robinson’s capabilities are aperfect complement to the merQbiz digitalplatform. Together, we aim to provide unmatched logistics capacity, increased options
and real value for our customers,” says
John Fox, President and CEO of merQbiz.

Why so blue?
The vibrant blue is truly eye-catching. But it is the functionality of this coater backing roll cover that is catching realinterest in the paper industry. OceanCoat is the newly
launched coater backing roll cover from Voith for
demanding applications. Thanks to the blue color, any coveroverheating can be spotted and dealt with quickly. What’smore, the special advanced material ensures aperfect fit on the blade coater, leading to longer grinding
intervals. And, because the OceanCoat cover is very easy toclean, your machine can be back up to operating speed
faster after a sheet break. In combination with the SkyCoat
coater blades, you can shift your coating performance tothe next level. True blue is the new black.

merQbizwww.voith.com/rollcovers

N° 01.2018 nextlevel08 innovate

innovate 09

Servolution

The Servolution
has begun

A targetedcommitment to
tailored service
solutions.

1

Phase

AssessIdentify needs,
potential andtargets.

A true partnership ofexpertise, engineeringand interests is thebest way forward inpapermaking. Discover
how services are
evolving to support
manufacturers toincrease productivity
and efficiency.

“We hadmutual goals,
trust and
respect.”
Maryam Kazerani
Optimization Engineer, Voith Paper“My highest compliments go to thiscustomer and their team of operators,” says
Maryam Kazerani, Optimization Engineer atVoith Paper. “They are truly among the besteducated and most competent that I have everworked with in my career. We had mutual goals,
trust and respect and worked together at eyelevel to achieve an optimized boost to their production line.” The close teamwork was crucial.
“We were able to push the design of the paper
machine to its limits and achieve so much morethan even our expectations,” explains Kazerani.
“The operators celebrated every achievement. It
was a great feeling for everyone whenever we
topped the 1,000 tons a day mark.”
The customer in question is Varel Paper
and Board Mill, the renowned paper and board
manufacturer in Germany. And, according toKazerani, also one of the most ambitious,
forward-thinking and technologically advanced
companies in the industry. As Kazerani spentnextlevel N° 01.2018

N° 01.2018 nextlevel

Following the major rebuildof PM 4 at the Varel Paper
and Board Mill, the company
now has almost a completely
new machine, as only thepress section remains fromthe first rebuild step of theoriginal machine from 1989.
The rebuild itself took fourmonths, and then anotheryear was spent with Voith
optimizing the production,from stock preparation tocalendering. The rebuild
increased the design limitof 850 tons daily to 1,000.

2

Phase

TailorCustomize solutions
using the Voith portfolioof services.

3

tons

850

Phase

CommitSteer the project andoptimize production.

Expertise and commitment at Varel Paper andBoard Mill: optimized together with Voith.

Productivity
Services that bringtangible results
for the long term.

Pioneering role
The optimized
combination oftechnologicalsolutions and service
offerings.

over a year embedded in the team at the plant
during the rebuild of their Voith paper machine
PM 4, she has the inside view. Her long-termrole at Varel is a clear indication also of Voith’s
own commitment to a customer, longafter a paper machine has entered into operation. Such embedding is also part of an innovative service portfolio from Voith Paper.
A new wave of services“Right now, there is a need for an innovative
wave of services to complement the fourth industrial revolution, this technological shiftacross industries and consumer habits,” says
Erik Forsberg, Director Global Service Solutions
at Voith Paper. “As we hold a pioneering role indeveloping today’s technological solutions inpapermaking, we are also at the forefront of anevolution in service solutions for the industry.
We’re calling it Servolution. But it is not just a
new term. It is a win-win concept for customers
and Voith together.”
How does Servolution work in practice? It
effectively encapsulates Voith’s commitment toproviding an all-round service with intelligent
solutions that meet customer expectations. Essentially, the concept covers their entire needs,
from Equipment Services, which includes allparts and materials needed to keep a piece ofequipment efficient, Process Services, forknow-how transfer and optimizing customer
processes, and Integrated Partnerships, where
customers can outsource the full responsibility
for their service processes to Voith. With
nextlevel N° 01.2018

innovate 11

Ulrich Lange
Managing Director
Varel Paper and Board Mill

tons

1,000

10 innovate“A production capacityof over 1,000 net tons dailyis truly impressive.”
N° 01.2018 nextlevel

Mr. Lange, the optimization of the
PM 4 is complete. How satisfied are you withthe whole process? At the end of the process
the joint good result was important. Rebuilding
and optimizing PM 4 together with Voith set an
example in our market. Voith was an invaluable
support to us, particularly regarding production
trials, quality assurance and the development ofstock preparation, in particular for the various
paper grades that we manufacture on the PM 4.
We had carried out a number of trials on ourother Voith machine in-house, the PM 5, which
was installed in 2005, and therefore were able
to clearly define specific targets in advance forthe rebuild. The Voith team ensured that we
made rapid progress so that the whole project
was wrapped up quickly. Their expertise andknow-how made it an exemplary partnership,particularly regarding the stock preparation ofdifferent qualities of recycled paper.
And with the results? A production
capacity of over 1,000 net tons daily is truly impressive. To be honest, I believe that Voith
could certainly afford to be even more confident
about the potential performance of their paper
machines. We’ve shown that together we canpush the design limits and achieve outstanding
productivity results. The quality of our products
has been welcomed on the market and sells extremely well. We are now planning a rebuild of
the press section to complete the whole PM 4
to a new machine. We think Voith knows its
strong points and will make an innovative offer.
Our current production capacity on our two
paper and two board machines is 850,000 tons
a year. In five years’ time, we expect it to be
1 million tons.

12 innovate

innovate 13

Turn it up fortissueVarel, Kazerani was part of a fourth option:
Productivity Services, which offers innovativevalue agreements to ensure a mutual interest
in increasing productivity. Within such a transparent partnership, maximizing efficiency andreducing operational costs become a common
goal.
What’s your key performance indicator?
With Varel, the partnership evolved around thecompany’s decision to increase the production
capacity and product range of the existing Voith
PM 4, which had been installed at the mill in
1973. The sophisticated rebuild involved a major extension of the stock preparation system
and a complete modernization of PM 4 and its
paper machine control system. As part of theagreement, both stakeholders took on a shared
responsibility for a mutually defined target.
When a papermaker seeks to achieve abusiness-related key performance indicator or a
specific goal with fixed parameters – such as
paper quality or fiber yield – Voith steps up to
the challenge. “We focus on the customer business-related productivity concept,” explains
Forsberg. As part of the agreement with Varel,for instance, for every additional ton manufactured after the Voith optimization measures,
Varel would pay Voith an additional compensation. “And in the spirit of true partnership, weshare in the responsibility of reaching the targets, and are compensated according to thebusiness performance related to the improvement,” adds Forsberg. “When we understandthe costs, it helps to optimize the solution.”

As well as dedicatedsolutions for board andpackaging, Voith has thesolution for all paper grades,
including these typicalequipment services fortissue from the Voith OnSite
Services Package for
production optimization.

Servolution

TerraDry HHT
The Yankee cylinder coating for the highest
drying efficiency and the lowest energy
consumption.

OTR Precise
The measurement technology for reliably
identifying surface deformations on the
Yankee cylinder.

MiniGrinder
The compact grinder for the accurate removalof irregularities, old coatings and chatter marks.

SkySoft
The highly wear-resistant SkySoft creping bladewith ceramic coating ensures constant tissue
quality and helps increase productivity.

Discover the whole range of Servolution options for all paper
grades, including tissue, at www.voith.com/servolution

nextlevel N° 01.2018

N° 01.2018 nextlevel14 innovate

innovate 15

Make noassumptions
for example, where we look at patterns
in scientific literature.

Machine learning,
digital manufacturing
or new materials in
papermaking? What’s
the next big thing?
And how do you
know? To find out,
Timo Kalefe is keeping
a very close eye on
developing trends.

Mr. Kalefe, you are responsible for foresight management at
Voith. What does that mean? Essentially, my work is about getting to know
promising topics and trends from theoutset or earliest stages – and cruciallyabout not missing any developmentsthat may be relevant for the future ofpapermaking. It involves the carefulobservation of the megatrends of ourcentury. Of all kinds of social, political,
environmental and technological trends
and drivers. Foresight management isa mixture of analysis and evaluation oftrends with the goal of identifying, andthen eventually pursuing, the new, embryonic technologies or disruptive topics that could offer the most promiseand potential for Voith, and with it bringpapermaking to the next level for ourcustomers.

How does it work in practice? You need to have your eyes everywhere! It could be through monitoring research at relevant leading
universities or organizations, attending
conferences, meeting with peers fromoutside the industry, and of course
through talking to our customers. At
Voith we have developed our own processes based on five key pillars: Trend
Analysis, Technology Foresight, Customer Foresight, Consumer Foresightand Radical Technologies. Within eachpillar, we’ve broken it down into smaller
activities. At the start, Trend Analysis
encompasses everything that is goingon currently, and that is relevant fornearly every company, such as additive
manufacturing, raw material availabilityor CO² emissions. Bibliometric analysis
is one area within Technology Foresight,
nextlevel N° 01.2018

How do you know what topursue? At first it’s important not tostick to your existing assumptions. Thisis about leaving our own comfort zone
and getting inspiration from fields that
we had never thought of before, where
the approaches are completely different to our own. Nevertheless, we have
set up a clear process with defined criteria on how to evaluate the impact of
new trends and technologies and to
derive actions needed for us.
It sounds almost like a collaborative effort. In a way, yes, it is.
The world is getting more complex,
and business is full of complexities. It
is not possible to pursue all directions
or develop all emerging technologies

N° 01.2018 nextlevelalone. As Voith is already a pioneer in papermaking, having
developed core technology
over decades, it is very interesting for start-ups or providers of new technologies towork together with us. We
have a certain knowledge andcustomer base, and we can
support them in identifying newareas, creating a market or
technology. We’re very open tocooperating and using ourknowledge base to develop technologies and, finally, markets together.
Where does the paper consumer fit in to all this? We also exchange ideas with the customers of
our customers. Companies who areclose to end consumers, such as theRewe supermarket, Zalando online
stores or logistic companies, are important contact points for Voith. We
look at what’s happening at the end of
the supply chain as well, so we cansee what the future packaging requirements might be. How Amazon might
be bringing the goods to their customers in the future. We think beyond themachine sector.
What improves the cooperation with your customers in thiscontext? For all of us, it is definitely
crucial to integrate our customer’s
point of view into the identification andevaluation of relevant topics that drive
the future of our industry. For instance,
customers share their views with us,
either in joint trend workshops or surveys. We value this input highly!
Any other joint activities
with or for customers? Absolutely.
The analysis of megatrends, such as
the shift to digital, led to the identification and implementation of importantenabler technologies for customeroriented solutions. For example, ourcustomers can now explore our new
machines with virtual reality goggles.

Can you share a favorite
trend with us? There are a number ofchallenges ahead in papermaking – forinstance, in the area of energy andwater consumption. New decentralized
technologies may play an importantrole here in the future. Particularly fascinating is the trend towards paper replacing plastic. How can new technologies help us to do this? We are
keeping a close eye on this.

Take part in our online survey
and join in the trend analysis!
https://www.surveymonkey.de/r/7ZMBWG2

For further information, please contact
Timo Kalefe at timo.kalefe@voith.com

innovate 17

16 innovate

A global team developed the Infinity family, the next
generation in press felt technology. At the headof the product is Anne Klaschka, a seasoned textile
engineer with a passion for innovation.

A talent for

TextilesAnne Klaschka
The press felt expert
From an early age, Anne Klaschka
knew she would work in fabrics.
Ambition, a talent for the sciences
and a degree in textile engineeringbrought her to a career at Voith.

“New technologies
can be scary for a
lot of people, but
at Voith we all saw
the real potential.”
modular
optimized
consistenthigh-technextlevel N° 01.2018

N° 01.2018 nextlevel“The first time I walked into
the Voith production site, I was reallytaken by surprise. It was definitely notwhat I had been led to expect during
my university studies,” explains Anne
Klaschka, Global Product Manager
Press Section – Press Felt. “But I knew
it was where I belonged.”
The biggest surprise was the size,
speed and sophistication. At Voith, youhave machinery that you don’t normallysee in textile engineering. While in mostareas of textile production the weave
looms are generally around 5 meters
wide, when Klaschka joined Voith in
2004, Voith’s widest loom – in Düren,Germany – had a width of 32 meters.
Today, the machines are generally a lot
smaller, but also much more technologically advanced, as well as a whole
lot faster. At the production site in Kunshan, China, the yarn is fed into the
weave looms at 100 kilometers anhour. “It is like driving down the Autobahn,” says Klaschka. “Textiles on steroids is how I would describe it.”Taking on the challenge
Initially a tailor by training, Klaschka
started out in the fashion industry, but
she always knew she wanted to moveon to a more challenging environment.
She joined as a trainee, traveled theworld via various Voith locations andbuilt up an incredible network and expertise in press felt technology andusage. She helped design, create andlaunch the state-of-the-art Infinity
family of press fabrics, as well as the

production sites where the fabrics are
manufactured.
The family keeps growing
The Infinity family is recognized worldwide as the very best in highly durablepress fabrics for steady-state operation, used as seam and endless.
Thanks to its stable and uniform characteristics, the seam is the number
one on the US market. Recently, three
new Infinity family members joined theportfolio: Infinity reloaded with cable,
ToughLine and FineLine. As with theestablished members, these press felts
are based on a modular concept andcan also be tailored according to therequirements of the customer. Basedon customer and machine specifications – including machine condition,
speed, lifetime and performance –Voith application engineers make themost suitable recommendations.
Thanks to Infinity, anything is possible.
“This is what we foster at Voith. It
is important for the product life cyclethat you want to be one of the innovators, not the copier,” says Klaschka.
Together with her global team, she isdefinitely among the innovators. The
Infinity family was first developed at
the Voith US plant in Appleton. As thelead engineer, Klaschka was responsible for overseeing the developmentof new production methods andthe implementation of the machinedevelopment. The new Infinity family
required a complete overhaul of the
manufacturing method, from

18 innovate

The new additions
to our modular felt
concept

The true laminated structure of
the Infinity family ensures
excellent compressibility
resistance.

The Infinity Family

Section 19

Carfield Wang
Technology andProcess Manager

p. 19

transform

Michael Zhou
Application Engineer

An overview of key developments inthe papermaking industry

Ann WuQuality and
Design Manager

Fannie Tang
Operations Manager

Press felt conditioning upgraded
Blocked or distorted low-pressure nozzles in standard
lubrication shower systems lead to felt damage, unevenmoisture profiles and dangerously slippery walkways. In
contrast, FilmLube, the innovative felt lubrication systemfrom the Voith AdvancedPRODUCTS PressMax portfolio, isfitted with an integrated lubrication gap in front of the Uhle
box. This ensures constant, optimum and efficient water application over the entire machine width, a steady-state felt
performance and uniform moisture profiles. As an upgrade
product, it transforms the performance of any Uhle box.

Infinity reloadedwith cableThanks to the high-tech cabledyarn, the structure of Voith
Infinity seam and endless press
fabrics ensures better battfiber anchorage and allows
consistent performanceover the entire service life.
For all grades.

TEAMWORK
The global team of innovators
provide tailor-made technical textiles to order.

ToughLineThe newest concept in void
volume control. Designed
specifically for challenging
applications, Voith’s Infinity
ToughLine can withstandthe most extreme conditions. For
pulp and board and packaging
applications.

FineLine

The finest seam on the market.
FineLine is our newest member of
the Infinity family for tissue,
specialty and graphic paper.

www.voith.com/infinity

repeatablestablep. 32

conventional weaving to the modern
high-tech fast manufacturing weave
looms. “New technologies can be scary,
because change is not loved by everyone, but at Voith we all saw the real potential. With the board completely behind us, we pushed through thechanges within a year. That is incredibly
fast for such a transformative shift.”
A global overhaul
Once the plant was on track in the US,
Klaschka relocated to China, and supported the global team in the redesignof the production plant in Kunshan,
which led to the doubling of the press
felt production capacity within a few
years. Seen from both an environmental and a production perspective, it
was a most radical upgrade. It is also
one of very few buildings in China to
be LEED * Gold certified and has gainedinternational acknowledgement forenvironmental best practices. The plant
produces a much more stable basefabric, extremely uniform and repetitive,
the ideal in press felts and fabrics.
“Repeatability is the goal andbackbone of every production line,”says Klaschka. “Every piece we produce on our weave looms is exactly
the same as any one before. This iswhat we have achieved with the new
weave technique.” About the sametime as the product launch in AsiaPacific, Infinity was rolled out globally.
Whatever customers need, wherever
they are, they can order a tailor-madetechnical textile to the highest of standards. Depending on how the rungoes, the applied design can be optimized according to the needs of thecustomer. It is a tailored operation.
“Textiles is definitely in my DNA,”
Klaschka admits. “If you are a textile
engineer at heart, this is where youwant to be. Voith brings out the passion in an engineer.” Fashionistas
might see it differently, but Voith textiles have a much cooler vibe.

tailored* Leadership in Energy and Environmental Design(US certification program for green buildings)

nextlevel N° 01.2018

N° 02.2018 nextlevel20 transform

transform 25
openOpen fortissue trials

open

The Voith Paper Tissue Innovation Center has along history and an excellent track record inproviding extensive testing opportunities all along
the entire tissue manufacturing process. Discover
the options on our state-of-the-art machinery.
Open, yet confidential. Comprehensive, yet
focused. Innovative, yet risk-free. While these descriptions appear contradictory, they all aptly describe
the set-up at the Voith Tissue Innovation Center (TIC)in São Paulo, Brazil, the most technologicallyadvanced tissue R&D center in the world. “We cover
the entire tissue manufacturing process, from stock
preparation to reel and every step along the way,”says Caio Penteado, R&D Operations Manager at
the TIC. “We have a long history, an excellent trackrecord and the best testing facilities. All within thekind of trusted and high-tech environment that customers demand for their own pilot trials.”São Paulo
Voith Tissue
Innovation Center
The R&D center can be set up to mirror
your real-life scenarios and conditions.
The trials with Voith expertise help
secure market differentiation.
The key to success is the ability totransfer results to your own mills.
Our customers have complete, directaccess to the machines during trials.

nextlevel N° 01.2018

Before you invest, prove it in practice
The Voith Tissue Innovation Center is completely
open to trying out whatever the customer wants interms of process settings. Yet everything that happens in the center remains absolutely confidential.
“When it comes to raw materials, or chemical makeup of a pulp, sometimes we don’t know exactly what
is behind the trial from the customer’s point of view,
but we can analyze the results, make informed comparisons and recommendations,” says Penteado. “We
follow clear trial agendas and target settings agreed
with our customers and are open to adapt our trials,
also completely on the fly, to suit the customer’s
specifications.”
This tailoring of trials is something that customers
really appreciate, as Magnus Bengtsson, development manager at Duni, the market-leader of ecoconscious premium tissue products, can confirm. In
2015, Bengtsson oversaw two successful trials ofVoith’s new TissueLev technology using the company’s
own pulp. “The personnel are dedicated, flexible andN° 01.2018 nextlevelsupportive. Whatever wishes we had, they ran the
set-ups accordingly,” highlights Bengtsson. “Theywere also excellent hosts, taking care of us on both apersonal and professional level.”
The positive experience and results led to Duni’s
decision to place an order for the TissueLev technology from Voith in the same year. “The pilot machineplayed a key role for our decision to install TissueLev
on two of our machines at our plant in Sweden.
Thanks to the trials, we were able to see that using
our pulp with TissueLev would get the result we werelooking for – increased capacity and the opportunity
to develop new eco-friendlier types of napkin tissue.
Crucial for the whole project was the open and transparent cooperation with Voith and the strong mutual
trust between us.”
Please feel free to contact Caio Penteado
to discuss your own individually tailored
trials at caio.penteado@voith.com

Located in Brazil and open for global customers:
the renowned Voith Tissue Innovation Centertransform 24

su
G
M lob
ar al
ke T
t is

21%

Kitchen towels

15%

Facial tissue

7%

Napkins
1% Other

Pulp
suppliers

Tissueproducers

Pluralis refiner fillings
For optimization of pulp refining
to your needs. Higher headbox
freeness results in machine speed
increase of up to 100 m/min.
Bulk increases by 3% to 5%
while maintaining tensile specs.

Looking for green?

Close to 150 trial
days per year
The Voith
IntensaPulper
reducesenergyconsumption
in the pulping
processby 20%.

With ATMOS, the Voith technology for structured
paper, you can go from conventional to ultrapremium qualities in a sustainable environment.
For all grades, uses and fibers, and also with 100%
recycled paper. Even ultra-premium production canbe awarded with energy-friendly certification.

Verify the compatibility ofyour processes and raw
materials with equipment
you are planning to acquire.

650°C

.4

6.
1

ld

4.

8

9
5.

W

or

l
zi
ra
B

Explore the potential in networking,digitalization and new services. Industry 4.0 isalready here, and we are preparing our pilot
center to show customers new, cool andinnovative technologies, such as OnCare AR,
which exploits augmented reality to increase
the real value of data by visualizing real-time
information on site.

na

5.

3

8.

7

9.

2

20

0
18
.

Papermaking of the futurehiToilet paper

C

56%

y

EMEA

an

Energy savingsin conventional tissue
production by using the
NipcoFlex T shoe press.

mSouth America

er

20%

World Tissue Consumption:
34.9 million tons*

2015 2025

G

North America

Different countries, demands and growth rates. Tissue makers
explore ways to differentiate their products from the competition.

27.1

With a single
trial dayin our pilot
machine, we
could supply
enough tissue
paper for12,000 people
for a wholemonth.

Asia

.7

15%

11%

24

33%

SA

32%

Annual tissue consumption per capita(kg/person)*U

Our insightsfrom the inside

Home of our pilot-trial
customerse

21 transform

2 liters

One roll of premium paper towel can absorb morethan 2 liters of spilled milk. A simpler towel product will
be able to absorb only half of that. To keep a soft sheet
strong, suppliers use multiple plies.

Highest temperature with the Voith Ultra Hood aroundthe 5.5-meter Yankee cylinder at the TIC, providing
considerably higher production capacity and lower
power consumption than standard hoods.

by length
In America andEurope, toilet
paper is soldby the numberof sheets.
Manufacturers
therefore look atways to reduce
fiber consumption.

Close to2,000 jumbo reels

Chemical
suppliers
produced annually in
our trials

by softness What is soft for you?
IntensaPulper
Part of the BlueLine
product range, theIntensaPulper ensures
excellent pulping
efficiency with virginfibers, high reliability andlower maintenance, and,as a result, securessignificantly lower runningcosts. TIC trials available.

TissueLev results forpremium specs

Taking care of customers
and internal R&D

50%
One roll –two liters of milk

50%
Optimized outcomes

External customers

Tighter environmental regulations and a tougher competitive environment areoften the trigger for customer trials on our complete high-speed pilot machine.

Average percentage of trials
carried out for customers*Source: RISI (www.risiinfo.com), 2015

The concept of softness depends onthe different cultures. Some like a soft
surface, others prefer paper thatdrapes like a cloth, while others lookfor fluffiness. Europeans preferstronger paper than Americans.

Internal R&D
Average percentage of trials
carried out for Voith R&D

nextlevel N° 01.2018

N° 01.2018 nextlevel

Developed and designed by Voith
Paper Tissue R&D, TissueLev is aninnovative add-on that achieves ahigher post-press dryness
compared with using just the shoepress operation. Retrofitted to older
machines, it can increase themachine speed and capacity for a
relatively small investment. The
higher dryness can be transferred
into a higher-quality soft tissue
paper with higher bulk and strength.
Achieving 4.5% higher solids
allows 18% more speed orenergy savings.

4.5%

Dryer material after press

Two years
350 m/min

Increase in machine speed

Duni developed a concept for its own
production line with Voith in São Paulo over
two years. Product development is now
ongoing based on the opportunities createdfrom the installation of Voith TissueLev.

by weight
In some parts of Asia, weight is more important – notlength. The rolls have to be very firm. Manufacturers lookfor ways to optimize production using less energy andapplying alternative fibers, such as bamboo or straw pulp.

transform 27“By solving a tricky problem
for one partner, we opened up
new opportunities for all.”Reinhard Leigraf
Process Technology Engineer for Special Papers at Voith

Hard to believe, perhaps, but at the heart ofthe most hard-wearing, water- and scratch-resistantlaminate flooring is a thin layer of décor paper. The
most attractive designs require a specialty paper thatmeets the highest demands, and not just for appearances. Absolute smoothness, easy impregnability,and high resistance to mechanical and chemical loads
are all necessary properties of such paper.
“Getting there requires a superior manufacturing
process, quite different to other paper grades,” says
Michael Haffke, technology manager at the Osnabrück
mill of the Felix Schoeller Group, the renowned specialty paper manufacturer based in Germany. The customers of Felix Schoeller require a quality of paper thatcan be impregnated with a special resin to create thecore of the high-pressure laminate. How the paper behaves in this step is important to the final results. “Anywaviness in the paper structure and the quality suffers.
When you get it right, the results are stunning,” explains Haffke. Thanks to a close cooperation with
Voith, Felix Schoeller has most definitely got it right.
The background
Over the years, as the machines speeded up, getting
their décor paper to continue to lie absolutely flat became an issue. Felix Schoeller called on Voith for theirexpertise and support. Reinhard Leigraf, Process
Technology Engineer for Special Papers at Voith, wasin charge of the investigative process. Using lightanalyses, Felix Schoeller and Voith found the root
cause. “The problem came from the heart of the paper machine: The turbulence generator within theheadbox,” says Leigraf.
To understand where the problem stems from, it
helps to take a closer look at décor paper for laminate

flooring. Achieving the high opacity level needed tocover the underlying layers in laminate requires a lotof titanium dioxide. In decorative paper, 20% to 40%
is necessary. Other specialty grades use maybe 10%
to 15% of a much cheaper clay. The better you candistribute this titanium oxide, the less is needed.
But it is not just about cost-efficiency – it also has
to be achieved without compromising paper quality.
This is why the design and functionality of the turbulence generator define the lasting outcome on the finished flooring.
“Paper with this high amount of titanium dioxide
has a very different rheology to graphic paper. We
found that it is not good to have too much turbulencein the headbox for décor paper,” explains Leigraf.
“So we designed a brand-new one, the MasterJet Pro
with ModuleJet.” The adaptions to the headbox resulted in a more homogeneous distribution of fibers inthe sheet and the desired quality of paper at the reelwith a very good basis weight profile.

w
o
l
l
o
F

r
u
in o
s
p
e
t
s
t
o
fo

Decorative paper for hard-wearing
laminate flooring and furniture
requires distinctive properties.
A close cooperation between Voith
and Felix Schoeller has led toa manufacturing breakthrough forthis particular specialty grade.

The outcome“This unique headbox design made such a difference
to our production that we have since ordered anothertwo,” confirms Hans-Christoph Gallenkamp, COO
Felix Schoeller Group. A happy customer makes ahappy supplier. And as Leigraf stresses, the same solution is now available for all manufacturers of décor
paper: “By solving a tricky problem for one partner,
we opened up new opportunities for all manufacturersof décor paper.” And not just for laminate flooring:
the same advantages are achieved for furniture surfaces and kitchen cabinet panels. Since the new
design was launched, more than eight orders havebeen placed from various manufacturers.

nextlevel N° 01.2018

N° 02.2018 nextlevel28 transform

transform 29

A worldwide
Whatever the preferred properties or cultural demands, Voith is
the respected and experienced supplier of complete tissue
machines and high-quality components, from stock preparation
through to finishing. We present the customers’ viewpoint.

impression
Capacity

220 tonsa day, per machine

this type of machine is that we canachieve higher bulk and softness without sacrificing strength. To support the
production of printed special-occasion
napkins, we have developed a proprietary process for bonding multiple plies
together. This process is offline fromthe tissue machine. The collaboration
with the various teams from Voith was
excellent and allowed us to prepare fora very tight installation schedule. The
commissioning and start-up was extremely helpful in identifying issues andworking to resolution in a very professional and timely manner.”

Tissue type

toilet paper

BrazilStart-up“A key benefit of thistype of machine isthat we can achieve
higher bulk andsoftness without
sacrificing strength.”
Ron ThiryVice President and General Manager at
Little Rapids Corporation

In October 2017, Voith concluded the start-up of the XcelLine
VTM 3 tissue machine supplied toLittle Rapids Corporation, the US tissue and specialty paper manufacturer. The new machine replaced thecompany’s old PM 3 at its Shawano
production facility in Wisconsin. Ron
Thiry, Vice President and General
Manager, is satisfied with the results.
“On this XcelLine VTM 3, we will
be producing dry crepe tissue gradesfor medical applications, such as products commonly found in US physician
offices and in medical procedure kits.
We will also produce tissue that isused in special-occasion napkins andpersonal-care items. A key benefit of

30 days
Tissue typemedicalapplications“The high-performing
Voith tissue machines
will provide excellent
productivity rates andthe best paper in Brazil.”
Fabio Prado
Executive Director for Consumer
Goods at Suzano Pulp and Paper

USA

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N° 01.2018 nextlevel

With an annual production
capacity of 4.7 million metric tons,
Suzano Pulp and Paper is one of thelargest producers of pulp and paperin Latin America. In 2017, Voith delivered and installed two complete
XcelLine tissue machines for thecompany. Within the Process Line
Package, Voith also supplies theauxiliary equipment and services.
Fabio Prado, Executive Director for
Consumer Goods, explains why
Voith was the preferred partner.
“Brazil’s toilet paper market is currently changing, as it is migrating fromsingle to double and triple sheets. This
trend, which has already taken place inseveral Latin American countries, isnow seen more clearly in Brazil. This
proves that consumers are increasingly
concerned about product quality. Consumers notice that besides quality, migrating to the double and triple sheets
really adds value for them. This is because the higher the product’s quality,
the lower its cost per use. Since con-sumption is measured per sheet, themigration from single to double sheet
brings nearly 10% of cost-per-use
savings. From double to triple sheet
provides an additional 10% savings.
Voith has been our partner for
decades. Along with the coordination
services for the supply of Voith’s
auxiliary equipment, we are absolutely convinced that the Voith highperforming tissue machines for oursanitary paper mills in the Brazilian
Northeast region will provide excellent productivity rates and the best
paper in the Brazilian market. That is
our strategy: to offer a product thatcombines high quality, higher softness, great efficiency, that can bepurchased in the most important
points of sale in the regions we cover. Our location allows us to improve
the supply of products in the Brazilian North and Northeast regions,where per capita consumption of
toilet paper currently represents lessthan half of the national average.”30 transform

transform 31

20tissue machines
SwedenChina

Capacity

30,000 tons
a year, per machine

Tissue typehigh-quality
napkins
Duni/Rexcell is the marketleader of eco-conscious premium
tabletop products. Over two years,
Voith and Duni developed a tailoredsolution for the company’s two
existing tissue machines using
TissueLev technology, the Voith
add-on that can be retrofitted to machines. After repeated trials in 2015,
confirming the promising results, anorder was placed in summer 2015.
Each rebuild took only 5 days at the

beginning of 2016, with only 4
weeks between the first and second
machine. Stefan Åbom, the Managing Director at Duni/Rexcell, highlights the keys to success.
“We manufacture paper for tissue
in one, two or three layers, between 15
and 25 grams per square meter and in
more than 30 different colors. Rexcell
tissue is exclusively used for tabletop
products, such as napkins. With our‘goodfoodmood’ initiative, we intend togrow into the world’s most attractive
provider of inspirational tabletop concepts. This ambition is carried by outstanding quality and premium products. Beside colors and designs, themost important feature for our endusers is thickness and softness/stiffness. The TissueLev technology developed with Voith improves all of thesefeatures, but especially the thickness.
Voith innovations support us by making
it possible to realize our ideas about
the next generation of tissue, which
improves the qualities appreciated byour customer, as well as increases ourcapacity on existing grades. I would
highlight three things. The professional“Voith innovations
support us bymaking it possible
to realize ourideas about thenext generationof tissue.”In 2017, four XcelLine
tissue machines were launched byVoith for Lee & Man, including TM 12.
The tissue machines are very flexible in production to meet different
needs of the end customers. The
tissue weighs between 13 to 17
grams per square meter. The annual
output of TM 12 is 60,000 tons, andthe wire width is 5,600 mm, while its
maximum operational speed is 2,000
m/min. During the start-up, from“stock on wire” to “paper on reel” ittook only 28 minutes. From the very
first parent roll produced, the tissue
was of saleable quality. Harry Ng,
General Manager, Lee & Man Tissue,and Alfred Lai, Operation Manager,highlight their positive experience ofworking with Voith.
“Cantonese customers in southern
China prefer tissues with a soft feel,
while in Chongqing, central China,

60,000 tons
annually“We’re impressed with their swift
response and professional service.
We’ve built up a good rapport over our
multiple cooperations. The team atVoith has tracked the whole process,handling machine-related issues in atimely manner, with excellent technology and high efficiency. Their support allows me to see their expertise. To sum
up, Voith Paper is a very good partner.”

Start-up

1 day
Tissue type

householdtissue paper

Stefan ÅbomManaging Director, Duni/Rexcell

cooperation between our companies.
The equipment, as Voith technology isat the leading edge. Finally, the people.
Our partnership shows how two organizations can work together, both supporting and challenging each other toreach our mutual goals.”
Harry Ng
General Manager of Lee & Man Tissue

nextlevel N° 01.2018

CapacityOver the past two
years, 20 Voith tissue
machines have beensold globally,
including the fastest
in the world witha steam heated highperformance hood.

N° 01.2018 nextlevel

weight is more important. As a result,
the tissue paper produced in the
Chongqing base is mainly targeted at
consumer groups in Chongqing andthe surrounding area, while the tissues
produced in Dongguan cover the consumer groups in Guangdong and nearby areas. We take measures to adapt
the production to local conditions.”“We’ve built up agood rapport
over our multiple
cooperations.”
Alfred Lai
Operation Manager of Lee & Man Tissue

32 transform

It is
time
for
tissueA combination ofchanging lifestyles and amuch better awarenessof health care is driving
the growing global
demand for tissue paper.
Ronaldo Parucker, Voith
Paper’s Strategic
Technology Manager
for Tissue, outlines his
vision for the future.

The tissue market is on a roll.
“So far, this is a paper grade that really
does not have an effective technology
replacement,” says Ronaldo Parucker.
With the biggest growth rate among thepaper grades, tissue consumption is
expected to grow by about 3.5% every
year for the next five years. Worldwide,around 37 million metric tons of tissue
have been consumed last year alone.
And with cultural habits in the use oftissue paper changing, and more than
50% of the world’s population still notusing toilet tissue, there is certainly
huge potential for further growth.
When it comes to facts and figures, Parucker has them all at hand.
More importantly, he also has an indepth knowledge of papermaking andtissue paper. Having joined Voith in1988, he is about to celebrate his 30th
anniversary at the company. His career
path has crossed continents, from his
native Brazil to China, and this year it
will take him to the headquarters ofVoith in Heidenheim, Germany, where
he will continue in his role as Strategic
Technology Manager Tissue, offering
his knowledge in terms of technology
placement to customers. He was appointed to this position in June 2017.
Supply chain and pain points
Parucker has played a key role in thedevelopment of tissue technology andhas an expert understanding of the
supply chain and customer pain points.
“We are seeing increased, tougher
competition,” he says. “On top of striving to be innovative with new products,
tissue manufacturers also have to deal
with increasingly stricter environmental
regulations, demands to reduce energy
and fiber consumption and to increase
everyday efficiencies in the entire value
chain. End consumers, particularly supermarkets, are constantly on the lookout for price advantages,” he confirms.
All without compromising on quality.
“Our customers need to differentiate themselves from competitors. By
increasing the quality of the paper, using different fiber sourcing, or by getting more flexibility out of the production lines to better compete in such anenvironment.” Voith, along with theStrategic Technology Managers, aims
to help customers meet these challenges head-on, with solutions that ensure more eco-friendly, cost-effective
and highly efficient operations.
“My main goal, together with thestrong support of the business linesand digital agenda, is to help our customers to be not just in the game, but
at the top of the game.”

nextlevel N° 01.2018

p. 33

p. 43

reflect

A round-up of views from thought leaders
on key trends and developments

Smart basket“Keeping track of your inventory for screen baskets
on a spreadsheet is not future-oriented,” says
Christian Gommeringer, Global Product Manager Screening
Products & Services at Voith. “The combination of a simple
RFID tag with a sophisticated database, however, mostdefinitely takes asset management and life-cycle tracking to
the next generation.” In the future, all Voith screen baskets
will be fitted with such a tag. Scanning the basket with areader device connected via Bluetooth to a smartphone ortablet enables a hassle-free updating of your own dedicateddatabase. The user-friendly cockpit solution provides
increased transparency on the supply chain for the wholeinventory of one mill – or even for corporate groups.

N° 02.2018 nextlevel34 reflectreflect 35“I take on the
responsibility
with a real senseof respect.”

A fresh, focused
perspective
Faced with today’s challenges,
opportunities and threats, how canpaper manufacturers secure theirsuccess in the future? Andreas Endters,
CEO of Voith Paper, outlines his views.

Andreas Endters
CEO of Voith Paper

Andreas Endters, having
joined Voith Paper back in 1995, youwere appointed CEO in 2017. You
are clearly a real Voithian at heart.
How do you feel about the new re­sponsibility? To lead Voith Paper – asa crucial supplier and trusted partner
to the paper industry and an essential
part of Voith – is a big responsibility
which I take on with a real sense of respect. At the same time, we have highly
skilled and dedicated employees, excellent products and services, a uniqueglobal footprint and long-lasting customer relationships. This is a great basis
on which to grow our business and to
improve our performance and customer
satisfaction. I am thrilled to exploit
those opportunities together with myteam and our customers.
N° 01.2018 nextlevel

What are your concreteplans? Across the whole of Voith Paper
we are working hard to ensure that thevalue add of our products and services
for our customers is maximized. By
developing innovative processes, products and services, or by combining andaligning existing products and services.
With Papermaking 4.0, for instance,
we provide connected, smart solutions
which make the papermaking process
more efficient and stable. Essentially,
we want to offer a more comfortableand enjoyable customer journey. We
achieve this by redesigning or digitalizing processes, as we have done with

Digitalization
With Papermaking 4.0, we
provide connected, smart
solutions for a more efficientand stable papermaking
process.

36 reflectreflect 37

Key conclusions
drawn from over20
years ofexperience

our Voith Paper Webshop. Everything
we do needs to create value for ourcustomers.
Which critical trends are
driving innovation in paper manufac­
turing? Scarcity of recycled fibers anddeteriorating waste-paper quality is a
big topic today for our customers. Ourinnovative BlueLine stock preparation
systems and XcelLine paper machines
help our customers to cope with thischallenge by managing higher dirt contents, reducing fiber losses and securing paper characteristics at lower basis
weights.
In addition, our customers faceconsistent cost pressure. By increasing
the efficiency of the papermaking

Cost
process, we help to secure their competitiveness. Lower energy and water
consumption support not only the cost
perspective but also the true sustainability of paper as a green product.
Finally, our customers are in search of
qualified manpower and talent. With

Andreas Endters discusses the megatrends in the paper industry:from recycling waste paper to replacing plastic.

connected, smart solutions such as
Papermaking 4.0, state-of-the-art
training programs and support frompapermaking experts, we can help ourcustomers address this issue too.
And in the tissue industry
in particular? The trends for tissue areWith the increased efficiency
and quality in papermaking,we help customers secure theircompetitiveness.

improved product quality with the minimum necessary basis weight, combined with a reduction of energy input.
We have excellent products in thisarea, and we are consistently investing
into R&D in order to push this further.
Our consumer and market foresightshows that an increasing portion of tissue products are being traded online,
which puts brand differentiation at risk
and increases cost pressure. The business in tissue machines is increasingly
important to us, which is why we arefurther strengthening our activities inthis area. In the last 24 months, wehave sold more than 20 XcelLine tissue
machines across all regions. We havesome very successful, record-setting
start-ups to our credit.
What about growth oppor­
tunities? Our clear target is to growour process enhancement products
and maintenance and technology services, which help our customers to focus on the papermaking process. We
are growing our service footprint in order to provide those services close to
our customers. We have excellent
products for all paper grades in paper
machine clothing and roll covers thatnextlevel N° 01.2018

match perfectly. With Papermaking 4.0
we have a huge opportunity to makethe papermaking process more efficientand stable, and this offers tremendous
growth potential for Voith as a whole.
At the moment, I see a huge opportunity to grow paper as a truly green
product for packaging and board applications, which are booming thanks to

And Voith? You are re­nowned and respected in the indus­
try as pioneers in traditional paper­making across the board. Is thesame still true for the digital revolu­tion? By developing our product andservice portfolio further to be “4.0ready” and with the formation of ourVoith Digital Solutions Group Division,

TissueOur technology and expertisein tissue production
enables brand differentiationin an increasingly competitivemarketplace.

e-commerce. Since paper is based on
renewable fibers and is really biodegradable, it has a lot of potential to replace plastic. However, as I mentioned
before, virgin as well as recycled fiber
has to be available in reasonable quality at an economic cost to support thissubstitution. Our BlueLine stock preparation technology helps to make recycled fibers available with minimum fiber
losses in the most cost-efficient way.
Are paper manufacturers
open to opportunities via digitaliz­ation? Considering the pressures ourcustomers are under, I’ve observedthat they are extremely receptive to use
digitalization as a way to reduce theiroperating costs. But also as a way torespond to the loss of talent and skills,
a growing concern as the more experienced staff retire in greater numbers. In
each case, the opportunities and challenges are different, but overall ourcustomers are eager to explore thepossibilities. Accordingly, we have built
several trusted partnerships with customers around the world to support
them in exploiting the full benefits ofPapermaking 4.0.

we have created the prerequisites toshape the digital revolution actively. By
digitalizing our internal processes andby making the papermaking process
more efficient with Papermaking 4.0,
we are taking our customers to the nextlevel of performance. For instance,
when customers buy a new XcelLine
paper machine today, they can explore
their new machine in a virtual reality
space and really work with it virtually. In
the future, trainings will be performedby means of VR in the machine. The associated cost and time savings are incredible. If you don’t exploit the opportunities offered by digitalization, you arewasting your potential and will not becompetitive in the medium term.

N° 01.2018 nextlevel

Environment
Through lower energy andwater consumption, we also
support the truesustainability of paper asa green product.

reflect 39

How to make top-quality box board or
white top liner? With the newly launchedpaper machine wet end concept,
part of the Voith XcelLine, papermakers
can significantly improve paper quality
and productivity levels.
Do you ever pay attention to
the front and back of the cereal box?
The visual appearance is of utmost importance. It needs to have a surface
that is bright, smooth and of superior
quality for perfect printability – and to
stand out on the shelves. High-qualityboard or liner creates an eye-catchingproduct on the outside. Inside – where
functionality, not looks, is a priority –brown fresh-fiber or recycled fiber isusually used. As a result, board or
liner is frequently a multi-ply product.
“The current manufacturing process for quality white top test liner iscomplex and costly. But it is about tobe significantly improved,” says Johann
Moser, Strategic Technology Manager
for Board and Packaging at Voith Paper.
The innovation is for the wet end, andis based on a thoroughly customeroriented approach to problem-solving.
A brand-new wet end
State-of-the-art paper machines for
quality white top test liner production
comprise two wire sections. One forthe white top ply, one for the brownback ply. Both are combined, and further dewatering occurs down the tablethrough the brown back ply, which
ensures top-ply purity. Pressing is performed with a DuoCentri NipcoFlex
press section plus straight-throughpress, which is fitted with a smoothmating roll on top to ensure felt markson the white ply are less prominent. A
further dry content increase with thepress does not, however, materialize!
nextlevel N° 01.2018

N° 01.2018 nextlevel

The important point is good topography of the sheet coming out of thepress section. Alternatively, pressing isachieved with an inverted Tri-Nip-Press
with transfer belt at center roll andtransfer wire. So far, so complex.
Face down
A patented wet end concept can replace this complexity, and reduce
costs. By changing the layout of the
top ply and back ply wire section, perfect layer purity and high web dry content are secured before the web enters
the press section. Turning the web in
the wet end and placing the web on a
Voith transfer wire makes a difference.
At the transfer section, web dewatering may not occur, so no dewatering
elements are installed. Thanks to thisinvention, the white ply enters the
DuoCentri NipcoFlex press section
face down, in contact with the smoothcenter press roll. This gets ultimate initial surface smoothness plus high dry
content, as demanded by papermakers.
No more headaches
As such, the straight-through press, aheadache for every papermaker, or
the inverted press concept is no longer
required. After the press section, thewhite top ply faces the dryer-can surfaces, so dryer fabric marking cannot
occur. “It is this combination of an
inventive spirit at Voith plus sophisticated design that results in a significantly improved white top ply surface
quality,” concludes Moser.

40 reflectreflect 41

A greener

potential
How can the papermaking industry move further towardsustainable manufacturing? Esko Uutela, Chief Editor
and Consultant at RISI, a forest-products research firm, andZhang Yulan, Deputy Secretary-General of the China National
Household Paper Industry Association, debate the options.

Worldwide, we’re seeing tighter
environmental regulations acrossall industries. How has thisaffected paper manufacturing?
Uutela: Compared to 30 years
ago, the current situation is a lot
better. Today’s higher environmental standards mean that theless eco-friendly mills are closing
and others are investing in theirenvironmental footprint.
Increased transparency in theindustry is also making a difference. The more transparent companies have to be about their
CO² emissions, the more they will
do to reduce them. The problem
is, we have many kinds of players
in the industry and not all are
required to make the necessarychanges. But government
authorities may still implement
further measures, as we’ve seen
happen in China.

Best practice starts
with sustainable raw
materials: the official
certification of forestsis the key to success,argues Esko Uutela.

nextlevel N° 01.2018

N° 01.2018 nextlevel

Zhang: Our national energy
conservation policies haveaccelerated the elimination of
outdated systems, allowing modern
machinery in the tissue segment toscale up. As a result, many lowspeed, energy-intensive cylindermachines have been phased out infavor of high-speed crescent andvacuum cylinder machines. Thismodernization trend is ongoing andaccelerating further. China’s official“Industrial Green Development Plan”(2016-2020) clearly requires that
papermaking and other industries
should be significantly cleaner by
2020, with a marked reductionof industrial sulfur dioxide, nitrogen
hydride, chemical oxygen demand
and ammonia emissions.

q &a

42 reflect

Uutela: As a forestry expert myself, I am
particularly supportive of the certificationof forests. Implementing official independent control mechanisms has been a very
positive step. As for technology, theclosed-loop system, which sees the reuseof process water instead of constantfresh water, has led to the biggest
savings in water consumption. In tissue
paper manufacturing, it is probably down
to 10% compared to 30 years ago.
I would also include the shoe press,
which has helped improve efficiency. In
principle, combined heat and power
plants could be an important building
block for more efficient papermaking. But
they require heavy investment.

What are the current bestpractices and measures?

questions andanswers

Why do some cities have
healthier citizens than others?
Hand-hygiene habits could
provide part of the answer.
Fanis Papakostas, chairman of
the European Tissue
Symposium, explains why.

Zhang: Key developments include high-speed
wide tissue machines, the shoe press, steel
Yankee dryer and heat recovery systems. Notably,
the increase of after-press dryness is one of themost effective means to reduce energy consumption. To further boost energy conservation efforts
and reduce operating costs, some paper manufacturers in China have converted from coal togas. Such measures optimize the use of energy,
and reduce overall operating costs.

Could the industry benefit froma significant disruption?
Uutela: For almost as long as this industry has existed, thebasic principles have remained more or less the same. Thismay be why I see no ground-breaking technologies. Andeven if there were, they would take decades to have an impact. Finally, I believe we should be watching what China isdoing in the tissue industry. It is already highly modernized
today, but is still investing heavily. In 20 years from now, thecountry will have the most modern technology on theplanet. It will change the industry.

Zhang: Digital will bring about animportant change in the industry.
By understanding concepts such
as Voith Papermaking 4.0 the automation of paper manufacturing
can create a much more stableproduction process and increase
product quality. This will bringabout a far-reaching change anda greater potential for “green”
papermaking.

IMPRINT Publisher: Voith GmbH & Co. KGaA, St. Pöltener Str. 43, 89522 Heidenheim, Germany Responsible for thecontent: Kristine Adams Editor-in-chief: Marion Jooss Editorial Board: Anna Dennerlein, Marijane Ludwig, Susanne
Speiser In cooperation with: C3 Creative Code and Content GmbH, Heiligegeistkirchplatz 1, 10178 Berlin, Germany.
www.c3.co Content Director: Klaus-Peter Hilger Editor Responsible & Author: Deborah Capras Copy Editor: Asa
Tomash Project Management: Marlene Freiberger Design: Katja Wohnrath (Art Director), Regina Fichtner (Senior
Graphic Designer) Photo Editor: Julia Fell Printer: C. Maurer GmbH & Co. KG, Schubartstraße 21, 73312 Geislingen/
Steige Copyright: No part of this publication may be copied, reproduced or otherwise disseminated, nor may any of
the content in it be used in part or in whole in other works in any form whatsoever, without express written permission of
the editor. Photos: Cover: Felix Brandl, p. 4 – 5, 19: C3 Visual Lab, p. 11: Shutterstock, p. 13: Dawin Meckel, p. 14 – 15,
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nextlevel N° 01.2018

What’s the best way to prevent the
spread of infection and germs? As our hands
are the number one transmitter of microorganisms, hand hygiene is crucial. Hand-washing withsoap and water is the single best way to reducetransmission rates of viruses or gastrointestinal
illnesses. But it is not enough. What people often
don’t realize is that proper hand-drying matters.
It is directly correlated with the spread ratio ofpotentially harmful microbes in society. Microbes
can remain on the hands after washing, anddamp hands can transmit germs more easily.
Single-use paper towels or electric
dryers? You absolutely get the best results withsingle-use towels. There have been many independent studies on this topic, comparing thepotential for virus dispersion using jet-air dryers,
warm hand dryers and single-use towels. Whenyou use any kind of towel to dry your hands, you
are doing a much better job. The microbes stickon the paper and end up in the trash. When you
use the jet air dryers, the germs get blown andsplattered all over the place, as water droplets
can stick to the surface of the dryer. Microorganisms can end up on various surfaces of
the washroom, on the floor and, unfortunately,on human beings.
What exactly have the studies
shown? During one peer-reviewed study, for instance, Professor Mark Wilcox of Leeds University
N° 01.2018 nextlevel

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discovered that bacterial counts in the air close tojet-air dryers were 4.5 times higher than aroundwarm-air dryers – and 27 times higher comparedwith using paper towels. This suggests that the
jet-air dryers should probably best be kept at leastout of health care settings, where the potential toinfect vulnerable people is higher.
Regarding the environment, is there
also a clear argument for using paper towels?
In Europe, the tissue paper industry has set its
standards and all serious companies have committed to only use certified renewable forestry,
recycling fiber or both. Simultaneously they all
are in a continuous improvements mode regarding total energy efficiency. Although it is notalways easy to calculate the total environmental
impact with accuracy. Manufacturing of jet-air
devices requires plastic material, metals and energy in use too. What we are absolutely certain
about, however, is the hygienic argument. And
that is definitely for single-use paper towels.

The visionary
starts with a clean
sheet of paper
and re-imagines
the world.
Malcolm Gladwell