twogether
Paper Technology Journal

23

India’s surging economy I Shandong Huatai Paper breaks
another world record I Revolutionary pulping concept

CONTENTS

4

Report4 India’s surging economy
10 Voith Paper in India

20

26 Exemplary teamwork –Shandong Huatai Paper breaks anotherworld record

28 “Perfect Fit” –Burgo Sora PM 1 rebuild

Technology
12 Guangzhou Paper deinking system –First-class stock for several paper
machines

16 The IntensaPulper –a revolutionary energy-saving pulping
concept

20 Shandong Huatai Paper –Voith paper machines now meet half ofChina’s newsprint needs

31 Aracruz Celulose banks again on
Voith Technology

34 Mitsubishi HiTec Paper –Energy management: a masterable

48

Miscellaneous
19 ahead07 –International Voith customer conference
for the board and packaging paperindustry

65 “Life Cycle Partnership” presented
in China –High interest in lasting partnershipchallenge

38 Maxau PM 6 VariTop winder –All high-performance promises fulfilled!

41 Handling bigger and heavier rolls –No problem with Voith Finishing logistics

44 Voith DriveCommand –a major spin to totally integrated
paper machine automation

48 PrintFlex PRO –Voith Group news
66 Energy from active breakwaters
67 Voith Industrial Services
implements OPM

67 Voith Water Tractors will soon
escort the biggest cargo vessels into
the world’s largest container port

For the finest possible pressing

52 Effective forming fabric concepts –for economical paper and board
production

56 NipMaster and NipSense help papermakers improve machine runnability

59 Profile Maintenance Program utilizing
Virtual Reference Grinding (VRG)

62 High Technology on a Roll Part 1
64 New Service Center now also in Chile

2

Culture69 Paper bridge supports Chinese
clay soldier

Regular features
3 Editorial
72 Highlights
76 Imprint

23 I 2007 I Voith Paper I twogether

EDITORIAL

Dr. Hans-Peter Sollinger
Member of the Corporate
Management Board Voith AG
and President of Voith Paper

Dear customers,

nate all process components by

Voith Paper Environmental Solutions

Dear readers,

applying our comprehensive paper-

works out innovative process

making know-how.

concepts for environment-friendly

2006 was another excellent year forresource-conserving paper mills.

Voith Paper, with numerous new

A significant step in this direction is

The resulting high customer benefit

machines and rebuilds that rapidly met

the new Voith DriveCommand systemin terms of economy sets an impor-their production goals after only athat optimally integrates processtant benchmark for the future. Our

short commissioning and optimizationcompetence and drive automationnext twogether magazine edition willphase.

know-how. The article on page 44

address this subject in detail.

of this issue tells you more about
This issue of twogether magazine

Voith DriveCommand.

reports on some of those startups, for

In closing, I would like to draw yourattention to an important event thisexample the extremely successful

Another important aspect is to focus

spring: ahead07, our international

commissionings of Huatai PM 11 andincreasingly on operating cost effi-

customer symposium for the board

PM 12 as well as the Guangzhou

ciency, primarily with regard to ener-

and packaging paper industry, will be

Paper secondary fiber stock prepa-

gy, water and waste disposal. Apart

held from May 9 to 11 in Vienna.

ration line.

from the steep rise in energy costs,

I look forward to welcoming you there!

freshwater consumption is also a
What is the secret of these successes

significant cost factor in papermaking

that pay off so well for our custom-

today. And above all in Germany,

ers? The answer lies in Voith Paper’s

waste disposal costs are becoming

overall system competence. This

unbearable.

enables us to support our customers
with successful project realization

To support our customers in this area,from beginning to end. Our primary

Voith Paper has founded a newgoal thereby is to keep project costs

division dealing with precisely theseas low as possible by minimizing cost-problems: Voith Paper Environmental

ly interfaces, and to optimally coordi-

Solutions.

23 I 2007 I Voith Paper I twogether

on behalf of the Voith Paper Team

3

REPORTREPORT

India’s surging economy

REPORT

With a population of over one billion, a growing middle
class with greater purchasing power, skilled labour in the
millions, and growth rates exceeding eight percent –the booming Indian economy is competing with that of its
north-eastern neighbour China. In fact the world’s two
most populous nations are now neck and neck in therace for global market leadership. Analysts are alreadyheralding the “Asian century”, and at any rate there is no
doubt that both India and China have become magnets
for the global economy.

The land of Gandhi, so long over-German exports to India rose to theIndia is well on the way from a one-shadowed by China, has now ad-

record level of 4.2 billion Euro in 2005,

time Cinderella to the new starvanced to one of the world’s top ten

28% higher than in prior year, whileof Asia. But the path to stardom is

economies. According to the World

imports from India rose by 15 percent

thorny: according to World Bank esti-

Bank, India’s GNP rose in 2005 to

to 3.4 billion Euro. Above all themates, 35 percent of India’s people

785.5 billion US dollars. More andGerman machine industry is favoured

still have to live on one dollar or lessmore foreign investors want to profit

with orders from India: machinery

per day. Above all the rural districts

from this surging economy in future –deliveries rose by 43 percent in 2005

have yet to benefit from India’s eco-including Germany’s industries.

to 1.5 billion Euro. And in the first

nomic boom, which is of course con-

Direct investments by German com-quarter of 2006, bilateral trading be-

centrated on the cities.

panies in India have doubled in only

tween the two countries surged evenone year, and about 1,500 of themmore steeply: German exports rose

Foreign companies in India also haveare already positioned there.

again by 46 percent and imports byproblems to overcome. The economic

30 percent!

reforms cautiously launched by theAfter decades of economic isolation,

Indian government in the early nine-

Indian trade is now booming. Exports

Our most-quoted example of India’sties, as a first step toward global

rose by 23 percent in the fiscal year

business success is in the IT and callmarket opening, are still in progress.

2005/2006 to 103 billion USD. Ger-

center segments, where turnoverBecause in contrast to the authoritar-

many is India’s fourth most importantrose by 31 percent in 2004/2005 to

ian Chinese government, the world’s

export customer after the USA, China

28.2 billion USD. But software is notlargest democracy (as India calls

and the United Arab Emirates.

the only area where India has longitself) has to reach agreements andadvanced to international leadership:

make compromises – which slows

Trading volume between India anddevelopments are extremely promis-

things down considerably.

Germany surged by 22 percent ining above all in the pharmaceuticals,2005 to 7.6 billion Euro, and may

biotechnology, automobile, aero-

According to the World Bank, above

even exceed ten billion Euro in 2006.

space and food industries.

all the poor state of infrastructures

6

23 I 2007 I Voith Paper I twogether

REPORT

A market offering enormous
opportunities –
also in the paper industry

and the bureaucratic decision-making

Although the Indian elephant is lag-processes are hampering India’s prog-

ging behind the Chinese dragon,

ress. While new airports and high-some analysts are already betting on

ways are springing up all over China,

India in the medium to long term.

the world’s largest democracy is tak-A study published by the Deutsche

The many obstacles still to be over-ing much longer to improve commu-

Bank in May 2005 forecasts that bycome in India are outweighed by the

nications. India already has 3.5 mil-

2020, India’s economic growth will be

opportunities. And this also applies tolion kilometers of roads and high-faster at 5.5 percent p.a. on average

India’s paper industry: a glance at theways, but their state of repair is often

than any of the 34 national econo-

statistics is enough to show up its

so bad that average speeds are lim-

mies investigated. Likewise in theenormous potential. Global paper con-ited to about 50 km/h.

opinion of the US investment banksumption per annum is currently 55 kg

Goldman Sachs, India may well

per head of population on average,

China’s freeway network had alreadyexhibit the fastest economic growth

ranging from 320 kg in the USA andreached nearly 30,000 kilometersin the long term.

already 36.4 kg in China – to only

by 2005, but India still has less than
2,000 km.

6 kg p.a. in India!
India has the advantage not only ofpolitical stability under democratic

No wonder the experts reckon with

Over the next ten years India willconditions, but also of its populationsuch steep growth on this market.

have to completely modernize its in-structure. According to estimates, in

Above all the improving standard of

frastructures – highways, railways,

about thirty years India will overtake

living, adoption of western consumer

airports and harbours, power sta-

China as the world’s most populated

habits, and advances in basic edu-

tions, water supplies and telecommu-

nation. Furthermore, the average age

cation will lead to far greater paper

nications networks – at an estimatedin India is much younger: currently

consumption in India over the next

cost totalling about 440 billion USD.

one in three of the population is lessfew years. In fact a new class of in-

Here again, this is an enormousthan 15 years old, and only five per-creasingly prosperous consumers ischance for foreign investors.

cent are over 65.

growing up.

23 I 2007 I Voith Paper I twogether

7

REPORT

Biotechnology: an Indian growth market.

Modern India – Electronics City Campus in Bangalore.

All the relevant market studies there-

This steeply rising consumption isdoubling by 2015. This is not only

fore assume an annual increase of at

expected to cover all paper grades,

due to higher demand by the service

least 6 percent in paper consump-driven by a growing demand fromindustries for books, brochures andtion. In other words, paper consump-

the packaging, printing and foodreports, but also to the growing num-tion will likely more than double byindustries. Almost half the booming

ber of readers. Last year alone, the2015 to 12.5 kg per head of popula-demand will be for industrial grades.

National Readership Study 2006

tion. By then the national paper de-

A good many products in India arereported a newspaper and magazine

mand is expected to reach 12.8 mil-still sold unpacked in local markets

circulation increase of no less thanlion tonnes per annum. According toand small shops, but this situation issix million.

various studies, India will be expand-already giving way to the discountering its papermaking capacities by five

trend. The discount stores now spring-

India’s demand for tissue and toilet

million tons over the next ten years –ing up in India offer foodstuffs andpaper is also on the rise. Paper nap-a lucrative opportunity also for theother wares in colourfully attractive

kins, kitchen towels and cosmetic tis-

German paper machine industry.

carton packages, so that annual

sues have not been widely used so

growth of 7 percent is expected for

far in India. And it is sometimes still

packaging papers and board. Annual

difficult to find paper handkerchiefs

production of these grades is current-

even at drugstores. In the same way

ly around 3 million tons, but accord-

as toilet paper or diapers, they are

ing to the latest forecasts it will reachstill classified as luxury items – most-

4.2 million tons p.a. by 2010 andly imported either as raw material or

5.6 million tons p.a. only five years

finished product – and taxed accord-later.

ingly at up to 60 percent. India cur-10

15,0008

12,000

6

9,000

4

6,000

2

3,000

0
85

8

0
90
GDP

95 00 03 10 15
Demand20

Paper and board
Demand in 1,000 tons

GDP growth rate in %India: GDP growth rate;
Paper and board demand; Status 2005.

rently produces only 48,000 t.p.a. of
The steepest growth is expected bythese grades, but annual outputs ofexperts in writing and printing paper

122,000 and 251,000 t.p.a. are fore-

production, with demand more thancast for 2010 and 2015 respectively.

23 I 2007 I Voith Paper I twogether

REPORT

Every year six million more people in India read newspapers and magazines.

India hardly imports any significant

As in China, but more slowly, theWith tougher environmental laws,

amounts of paper: only three percent

trend in India’s paper industry is

scarcer raw materials and higherof the consumed paper comes fromtoward larger and more modern pro-energy costs, India’s paper mills will

abroad. But this does not apply toduction facilities. With so many small

be increasingly forced to invest in

newsprint, 91 percent of which ismills spread over the entire country,

modern energy-saving production

imported. The newspaper publishers

however, mergers in India are often

facilities. Currently, their energy con-prefer imported newsprint because ofdifficult or unprofitable. But the trend

sumption is relatively high at 6.4 toits superior quality, moreover news-

toward large mills will still take effect10.3 MWh per ton of paper produced,

print in India is relatively expensive

over the next few years.

as against the global average of 5.0

due to the high cost of energy andto 6.1 MWh. And the situation is simi-

the small production facilities. India’s

In order to enable profitable produc-

lar with raw materials consumption:

newsprint production is currently

tion and marketing, massive modern-

Indian mills use 2 to 2.4 tons of raw

about 680,000 t.p.a. and is expectedization will be unavoidable over thematerial per ton of finished paper on

to grow by about 5 percent p.a.

next few years. Numerous production

average, as against the global meanfacilities are outdated and no longerof 1.8 to 2.2 tons.

Rapid modernization expectedcompetitive on the international
market.

India’s paper industry is still dominat-

India will not be able to afford thissituation much longer: in view of the

ed by small to medium size compa-

For example, the average paper mill

ongoing deforestation here, timber isnies. There are currently 666 paperin India produces no more thanbecoming increasingly scarce.

mills in India, of which 568 in opera-

14,000 t.p.a. – as against the global

tion. Their estimated capacity isaverage of 42,000 t.p.a. Likewise the

Only about 20 percent of India is still

8.5 million tons per year, but domes-

operating speeds at Indian mills –afforested, as against 31 percent in

tic production is only 6.55 million

200 to 250 m/minute – are far below

Germany, but no sustainable plan for

t.p.a., because numerous small mills

the global average of 600 to 700 m/

widespread reforesting has been

are not working at full capacity.

minute.

approved as yet.

23 I 2007 I Voith Paper I twogether

9REPORT

Tamil Nadu PM 2.

Voith Paper in India
The Voith tradition in India goes backeighty years later into one of themills. This includes the fastest paper

more than eighty years. It was in 1924

world’s most promising markets.

machine in India so far (at Bilt Graph-when Voith Germany gained a foot-ics, formerly Sinar Mas Pulp andhold here by selling its first paper

Thanks to that early start, Voith Paper

Paper), commissioned in 1996. Almost

machine to Meenakshi Paper Mills in

is now extremely well positioned in

two decades earlier in 1978, Voith

Delhi. And according to the Escher

the Indian market.

had already delivered India’s widest

Wyss records, a paper machine waspaper machine so far, to Hindustan

already sold in 1905 to James Stuart

Already in December 1950 Voith

Newsprint in Kerala. And in 1995

in Chittagong, belonging at that time

signed an agreement with Larsen &Voith supplied Tamil Nadu Newsprint

to India.

Toubro Limited (L&T) Bombay, India’sand Papers Limited with the world’s

leading construction and technology

fastest and largest paper machine forIn those days India was known as thegroup. In 1960 this was converted in-paper from crushed sugar cane.

exotic land of maharajas, tigers andto a license agreement enabling L&T

diamonds. It was still a British colony,

to manufacture plant and machinery

In April 2000 L&T and Voith founded

the famous Gateway of India in Bom-in India according to Voith designs,

a joint venture with equal participa-bay (now known as Mumbai) had justwhereby critical key componentstion, and changed the company namebeen inaugurated, and in 1924 E. M.

were still imported from Germany.

to Voith Paper Technology Ltd with

Forster published his final master-registered offices in Kolkata. Voith

piece “A Passage to India”. Hardly

Over the years Voith L&T supplied aPaper Fabrics, a Group company withanyone would have guessed then that

good number of new machines, re-registered offices in Faridabad near

this mysterious faraway country wherebuilds, extensions and recycling lines

Delhi, is moreover market leader in

the Ganges flows would develop

for nearly all of India’s large paper

India for paper machine fabrics.

10

23 I 2007 I Voith Paper I twogether

REPORT

1,080
1.5
675.0
620.0
8.8
7.0
6.5
0.7

1,300
0.7
1,677.0
1,290.0
6.0
59.0
45.4
1.7

Comparative figures for India and China;
Status 2005.
483
Ballarpur Industries
367
ITC Limited 32
80
140
96
S.K. Bangur Group200
110
Hindustan Paper Corp.
240
40
Tamil Nadu Newsprint
76 25
Khanna Paper 114
140
60
Printing and writing
Andhra Pradesh Paper
180
Industrial grades
JK Paper150
Newsprint
Century Paper
0
100
500
200
300
400
Capacity in 1000 tons/year

Average mill size
(tons/year)
Averagepaper machine speed (m/min)Specific raw material
consumption (t/d)
Specific energy consumption(MWh/t)

India

World

14,00042,000200-250 600-700
2.0-2.4

1.8-2.2

200

Cartonboards
1.08 mio. t/a

Newsprint
0.68 mio. t/a
10 % 10 %

16 %
34 %

Corrugating
materials
1.95 mio. t/a30 %Printing andwriting paper
2.25 mio. t/a

6.4-10.3 5.0-6.1

India’s paper industry by global comparison.
250 221

Other p&b production
0.64 mio. t/aPaper and board production in India.
100

91%
172

9%

168

150
100
47

50

58

Production capcity in %China

Number of paper mills

Population (mio.)
Population growth (%/year)
GDP (US$ billion in 2004)
GDP per capita (US$)
GDP growth
P & B 2005 demand (mio. ton)
P & B per capita (kg)Forests (mio. ha)

India

80
60
40
20

0

0
upto 15 16-30 31-50 51-100 above 100
Capacity in tons/day

India’s biggest papermaking companies.

Number of paper mills in India (Total 666).

Under these circumstances, recov-

eral, and in particular for Voith as theered paper will become an increas-

pioneer in modern paper recycling

ingly important raw material – and thetechnology and as the leading sup-demand for appropriate plant andplier of appropriate technologicalmachinery will increase. Even now,

systems.

101-200

201-300
above 300
Capacity in tons/day

Production capacity distribution of India’s
58 largest paper mills.

recovered paper comprises 32 percent of papermaking furnish, with

In summary, India’s paper machinery

only 40 percent timber. Anothermarket is not growing as rapidly as in20 percent comprises agricultural

China, but it offers great potential in

by-products such as straw.

the medium and long term.

There is still great expansion potential

Apart from enormous business op-

for waste paper recycling in India.

portunities, India also offers industrial

Currently only about 20 percent ofinvestors several advantages:

India’s waste paper is recovered, asagainst more than 50 percent in Ger-

● A plentiful supply of well-trained

many. But India is now making great-scientists, engineers and techni-

er efforts to increase the systematic

cians;

collection of waste paper. This opens● English is widely spoken;

up new business opportunities for● A politically stable democracy;

the paper machine industry in gen-

● A dependable legal system.

23 I 2007 I Voith Paper I twogether

Contact
Christine Möllhoff
New Delhi
moellhoff@gmx.net

Chandra Sekhar Panigrahi
Managing Director
Voith Paper Kolkata
chandrasekhar.panigrahi@
voith.com

11

TECHNOLOGY

Guangzhou Paper deinking system –First-class stock for several paper machines
In February 2006, Guangzhou Paper ordered a stock preparation
system for improved newsprint from Voith. The state-of-the-art
system will replace the existing chemical pulp mill, and will provide
several paper machines with 650 t /24 h of finished stock madefrom 100 percent recovered furnish.
Guangzhou city is located in theRiver. Today, the mill finds itself inprovince of Guangdong South China,

the middle of a thriving metropolis.

renowned both nationally and inter-

It was, therefore, decided to relocate

nationally for its culinary variety andthe entire mill in phases over the next

often known as Canton.

few years in a new industrial zone
outside Guangzhou. As part of thisDuring the course of its eventful his-

relocation project, it was decided totory since the mill opened in 1936,

modernize the existing production

Guangzhou Paper has grown into one

facilities in order to also reduceof China’s largest and best-known

pollution.

paper producers. As it was common

12in the past, the mill is located next to

In addition to its high stock quality,

a watercourse, in this case the Pearl

this new line meets all the demanding

23 I 2007 I Voith Paper I twogether

TECHNOLOGY

MultiScreen
MSS fine-screen
system.

requirements and strict conditions

The scope of machinery supply is● DX disperger with direct heating

applying to production plants locatedcomprised of the following compo-

to remove printing particles fromin heavily populated areas.

nents:

the fibers.

● Two-stage Protector system for
From the signing of the contract to

HC cleaning with MultiSorter

Important stock preparation compo-

the commercial production, the entire

and CombiSorter for holed pre-nents for this plant, such as the flota-

line was delivered, installed and com-screening, and integral IC slottedtion deinking cells, were manufac-

screening with MultiScreen.

tured and supplied by Voith Liaoyang

missioned remarkably quickly in only
about 13 months, significantly earlier
than originally scheduled.

● HCH cleaner group for LC cleaning
with well-proven EcoMizer technology.

The order covered not only all stock
preparation machinery, but also basic
engineering for the entire line. Alsoin China.

● EcoCells for pre- and post-flotation
deinking, including pumps.

Voith’s proven and tested quality willcontribute to the customer’s longterm benefit.

● MultiScreens with C-bar baskets

included with the order was C&I sys-

and MultiFoil rotors for fine

Voith also supplied control field

tem engineering, operations planning,

screening.

instrumentation for all machinery

as well as erection and commissioning supervision.

23 I 2007 I Voith Paper I twogether● Thune disk filter for thickening,delivered.

with bagless segments.

13

TECHNOLOGY

EcoCell flotation system.

Immediately after the order was

After punctual delivery of the machin-

Now that the actual project phase isplaced, Voith process engineers andery, the erection work started in No-

over, contact between Guangzhou

C&I specialists started compiling all

vember 2005. Thanks to Guangzhou

Paper and the Voith team is as cor-necessary design drawings and doc-

Paper’s professional coordination,

dial as ever. This was very evident

umentation for setting up the deink-

and the excellent on-site teamwork

during the meetings and negotiations

ing system, consisting of:by all parties concerned, the entire

held in September and October 2006

● Basic layout drawings.

erection was easily accomplished onthat led to Guangzhou Paper placing● Stock and water balances includ-

time. Any required small adjustments

an order with Voith Paper for anothering piping and instrumentation

were completed rapidly and unbu-

deinking system.

diagrams.

reaucratically.

● Motor and equipment listings.

It goes without saying that only a● Vat and piping layouts.

Commissioning started immediately

completely satisfied customer would● Instrumentation specifications andafter completing erection work andplace such a large follow-up orderinstalling the electrical and C&I sys-with the same supplier.

dimensioning.
● Operations planning including soft-

tems. Here again, teamwork between

ware testing by DCS suppliers.

the mill personnel and Voith commis-

This new deinking system, with asioning engineers was outstanding.

planned capacity of 1,360 t / 24 h, will

With the system ready for start-up in

be one of the largest in the world.

March 2006, finished stock was sup-It will be erected on the new mill site

During the ensuing technical discus-

plied to the various paper machines

outside Guangzhou city and is due tosions held both in Guangzhou andjust a few days later, as planned.

go into operation by the end of 2007

Ravensburg, all further details were

Afterward, the only tasks remaining(see article on the right).

worked out between the partners’

were optimization tweaks to further

project teams.

improve results.

● Basic planning data for C&I
installation.

14

23 I 2007 I Voith Paper I twogether

TECHNOLOGY

Thickening system with Thune disk filters.

… and now Guangzhou Paper

flotation deinking cells, fine screening

has ordered anotherwith C-bar baskets, disk filters, screw

large deinking systempresses and dispergers, as well as
the entire additive preparation system

By signing the order in October 2006

and control field instrumentation.

The cordial atmosphere of the contract
signing ceremony on October 10, 2006
with the Guangzhou Paper management.
Among those present were the Chairmanof Yue Xiu Holding, and high-ranking
officials representing the municipality ofGuangzhou.

for another stock preparation system,
which also will be used for improved

As with the preceding order, Voith

newsprint, Guangzhou Paper has

will again be supplying basic engi-

again decided in favor of Voith.

neering for the entire line, C&I system

With a capacity of 1,360 t / 24 h fin-

engineering (including operations

ished stock, this will be one of theplanning), as well as erection andworld’s largest deinking systems.

commissioning supervision. Voith willagain supply control field instrumen-This latest investment signals thetation for all the machinery delivered.

Contacttransfer of Guangzhou Paper’s entire
mill capacities, including a complete

This follow-up order is solid proof

new paper machine, to the newof Guangzhou Paper’s confidence inindustrial zone outside Guangzhou.

Voith Paper deinking technology.

Leo Engelmann
Fiber Systems
leo.engelmann@voith.com

It confirms the excellent relations esVoith’s scope of delivery for the new

tablished between Guangzhou Paper

deinking system includes the pre-and the Voith Team during the firstscreens and cleaner systems, 2-stage

project.

23 I 2007 I Voith Paper I twogether

Reinhard Bluhm
Fiber Systems
reinhard.bluhm@voith.com

15

TECHNOLOGYTime after color injection

Conventional pulper

IntensaPulper

5 seconds

10 seconds

Mixing efficiency ofthe new IntensaPulper
compared with aconventional pulper.
These test results under identical conditions(stock consistency andpower consumption)
show mixing progress
5, 10 and 15 seconds
after color injection.

15 seconds

The IntensaPulper –a revolutionary energy-saving pulping concept
It has always been a matter of course for Voith to take Total Costof Ownership into account in new machinery design and developments. In times of sharply rising energy costs, energy-saving
machinery is even more important, and applies particularly to stock
preparation machinery.

This article examines the various

Influence of operating mode on

operating modes of pulpers defiber-energy consumption

ing primary fibers. A new development is introduced that uses only as

Primary furnish can be pulped either

much energy as actually required forin individual batches or in continuous

pulping. For example, significant

operating mode. Most pulpers forenergy savings can be attained with

defibering primary fibers today arethis pulper concept, which features

operated in batch mode.

a design that has remained almost
unchanged for decades.

16

23 I 2007 I Voith Paper I twogether

TECHNOLOGYThe new IntensaPulperwith eccentrically arranged
rotor and double cone bottom
for optimal mixing and flow
configuration.

The batch-pulping mode is usually

Continuous pulping is clearly moremeans, that in a batch-pulping mode,

preferred for throughputs below

energy-efficient. This operating modethe surface motion of the suspension

200 t / 24 h, or for complex mixtures

is suitable for throughputs exceeding

can almost cease when the stockof different kinds of primary fibers

200 t / 24 h, and it uses a relatively

consistency is high at the end of eachassociated with frequent changes ofstraightforward furnish mix. Continu-

pulping phase. On the other hand,product and/or color.

ous pulping consumes about 40%

there must be enough agitation in aless energy compared with the batch-

continuous pulper to draw the bales

Batch pulping involves unproductive

operating mode. Moreover, with a

into the rotor vortex – on no accountwork cycles, such as filling and emp-

suitable control strategy, the stock

can they be allowed to settle at the

tying of the pulper vat. A consider-consistency remains constant andbottom of the pulper. The optimal

able amount of energy and time issimplifies the overall stock prepara-agitation energy can be defined byconsumed that would otherwise betion process.

the coefficient of power to volume[kW/m3], which varies according toavailable for the actual pulping proAgitation and mixing

application and operating mode.

that of continuous pulpers. AnotherOptimal agitation is indispensable

Another important criterion for opti-

drawback of batch pulpers is stockduring every pulping phase, and only

mal pulping is the flow pattern on theconsistency fluctuations, due to dilu-

as much energy should be applied tosurface of the suspension. This istion during the intermediate emptying

the suspension as is actually required

much more difficult to evaluate, be-and flushing phases.

for the defibering process. This

cause it cannot be defined in terms

cess. The production capacity ofbatch pulpers is therefore lower than

23 I 2007 I Voith Paper I twogether

17

TECHNOLOGY

of a simple coefficient. Good mixing

The IntensaPulper rotor is therefore

Particularly for large throughputof the suspension requires frequentinstalled off-center. Since this alone

capacities, the resultant cost savings

rotor contact with the furnish bales,

optimizes mixing, no energy-wasting

can be substantial.

and in practice this is assessed visu-

baffles are required and more energy

ally. If, for example, a bale remains

is available for pulping.

Summary

too long in the pulper, it does not

An optimized transition from the hori-● A pulper defibering primary fiber incontact the rotor frequently enough.

zontal pulper bottom to the verticalcontinuous operating mode princi-

As a result, mixing is inadequate andvat walls enables further exploitation

pally consumes about 40% less en-

so is pulping. To ensure intensiveof flow energy for pulping. In the new

ergy than in batch mode because

mixing, most pulpers today have baf-

IntensaPulper, the transition from theunproductive energy-consuming

fles on the vat wall to break up thepulper bottom to the vat walls is

flow pattern by diverting the mainly

optimized with a specially designed● The IntensaPulper has an eccentri-

rotational flow inward toward the

double-cone bottom. The two conecally arranged rotor for optimal

rotor. The drawback is that flow inter-angles are precisely determined tomixing – without energy-wasting

ference entails loss of energy. This

simulate a low-loss, torosphericalapplies not only to the baffles, but

profile optimally diverting the flow

also to the pulper bottom design.

generated by the pulper rotor.

on a concentric circulation path for

Voith has been carrying out develop-

phases are avoided.

baffles on the pulper walls.
● The IntensaPulper bottom is flowoptimized with a double-conedesign.

ment work on both these compo-

Potential savings with thenents in order to make optimal use of

IntensaPulper

flow energy for pulping.

● Results: the eccentric rotor arrangement of the IntensaPulper saves
about 25% specific energy in batch

Performance tests on a 20 m3 Intensa-

pulping mode and increases pro-Energy-optimized agitation

Pulper, operating in batch mode,

duction throughput while achieving

through asymmetrical motion

showed a 26% reduction of specificthe same defibering quality.

and optimal pulper bottom

energy consumption [in kWh/t] com-designpared with the conventional pulper
previously used. Furthermore, pro-As a result of these developments,

duction output was 7% higher, with

the new IntensaPulper incorporates

the same defibering quality.

two important features:● The rotor is positioned eccentricallyin the cylindrical vat.
● The transition from the pulper

In absolute figures, this means thatan IntensaPulper with an output of
100 t / 24 h saves about 175,000 kWhbottom to the vat walls is flow-opti-

per year. This energy savings reduces

mized with a double-cone design.

operating costs significantly.

An eccentric rotor arrangement

In continuous operating mode, spe-in the pulper vat results in good mix-

cific energy savings with the newly

ing, thanks to asymmetrical flow.

developed IntensaPulper are similar.

18

Contact
Wolfgang Müller
Fiber Systems
wolfgang.mueller@voith.com

23 I 2007 I Voith Paper I twogether

SEMINAR

ahead07 International Voith customer
conference for the board and packaging paper industry“High Tech – Human Touch” is the slogan for Voith Paper’s ahead07
customer conference to be held this year from May 9 to 11 in Vienna,
Austria. Customers from all over the world are cordially invited.
In the fittingly modern Hilton Vienna

An attractive, service oriented fringe

Conference Center, Voith Paper will

program will also provide a relaxed

be focusing this time on the humanatmosphere with the opportunity for

aspects of the paper industry.

intensive experience exchange andServices and solutions, processes

interesting technical discussions.

aside from high technology, andknowing the customers’ wishes are

For more details, please visit:

the focal point of the conference.

www.ahead07.com

And as always, the latest Voith innovations will be reviewed as well.

23 I 2007 I Voith Paper I twogether

19

TECHNOLOGY

Shandong Huatai Paper – Voith paper machines
now meet half of China’s newsprint needs
Shandong Huatai Paper Company Ltd., China’s leading newsprint
producer, once again chose a Voith newsprint line: PM 12 wascommissioned at the end of October 2006. This article describes
its twin machine PM 11, which went on line at the end of 2005.

20

23 I 2007 I Voith Paper I twogether

TECHNOLOGY

Voith’s partnership with Huatai Paper

Since PM 12 started up in October

2005. This company belongs to thestarted 11 years ago with the delivery

2006, Voith paper machines produce

Huatai Group, active not only in pa-of high-tech components for PM 1.

no less than 1,200,000 t.p.a. of news-

per production but also in the chemi-This fruitful relationship grew with theprint in Huatai for the Chinese market

cal and printing industries, forestry,

delivery of the former Schongau PM 9

– nearly half the national output.

logistics and trading. About 4,400 of

in 2000. In July 2003, PM 10 was

the Huatai Group’s 10,000 employees

commissioned, a complete Voith pro-Shandong Huatai Paper –work for Huatai Paper, whose mills

duction line for high-grade newsprint.

steep growth

are located exclusively in Shandong

The outstanding high quality news-

Everything started in 1976 when Li

duction capacity of 1,200,000 t.p.a.

print produced on PM 9 and PM 10

Jian Hua, now President of Huatai

The Huatai management center isvery soon established its reputation

Group, was appointed production

located in Dongying, near Dawang.

on the market. The enormous demand

manager of a small paper mill infor this paper opened the way for fur-

Huatai. That was the beginning of an

Huatai Group owns 32.33% shares

ther investments (China’s newsprint

outstanding success story both forof Shandong Huatai Paper Co. Ltd.

needs have almost quadrupled overPresident Li and for his Huatai Group.

Forty percent of Huatai Group‘sprovince and currently have a pro-the last decade). Voith, as preferredassessed value is currently held by

supplier, received the order for PM 11

Shandong Huatai Paper Company

President Li Jian Hua. 27.34% by thein June 2004, and one year later forLtd., listed on the Shanghai Stockmunicipality of Dawang, 20% by

its sister machine, PM 12, in June

Exchange since the year 2000,

18 members of the company’s exec-

2005.

recorded 750 million Euro sales inutive management and 12.66% byDawang Group.

Shandong Huatai Paper PM 11.

23 I 2007 I Voith Paper I twogether

21

TECHNOLOGY

5
Beijing

Million tons

4

Dongying
Shandong3⌬ = 260 %Shanghai

2
1

Hongkong

1980 1985 1990 1995 2000 2005 2010
Newsprint demand in China.

Huatai in Dongying, Province Shandong.

EcoMizer cleaners.

Huatai PM 11 – a complete

Yellow River, offices and accommo-

production line without peer

dations, as well as a planned rail connection for transporting paper rolls.

Huatai PM 11, one of the most mod-Huatai deserves great credit for

ern newsprint lines in the world andachieving the rapid growth that haslargest in China, was very success-enabled completion of four large

fully commissioned at the end of thepaper machine projects in only five

year 2005 – less than 19 months after

years – future-oriented facilities em-

contract signing and four months ear-ploying the latest technology for first-

lier than planned – with the first pro-class paper production in China.

duction series of breaks-free jumbo

Customer Comment
Li Jian Hua
President andspokesman,
Shandong HuataiGroup management

rolls. All Voith Paper divisions – Fiber

Founded in 2002 with an eye to the

Systems, Paper Machines, Finishing,

future, the nearby Voith Paper Rolls

Automation, Rolls and Fabrics – took

service center is already supporting

part in this project.

the Huatai mill. This subsidiary has
proved a valuable partner for project

The close partnership between

execution in such areas as logistics,

Shandong Huatai Paper Co. Ltd. andcustoms formalities, roll servicing,

Voith, which deepened still further

and small repairs.

after the successful PM 10 project,made this greenfield mill project a

In June 2004 Voith was entrusted

success. So far, PM 11 has devel-with delivery of the complete news-

oped very well, as confirmed byprint production line that uses recov-“Voith Paper provides its customers withmarket reception of the excellent

ered paper furnish. Based on thethe latest technology and first-class ser-newsprint quality.

“One Platform Concept,” PM 11 pro-vice. During the course of time, our close

duces high-grade newsprint in a

teamwork has blossomed into a genuine

This turnkey production line wasbasis weight range of 42 to 49 g/m2

friendship between Voith and Huatai. The

installed in record time in a building

for color offset printing, with anextremely successful start-up of our Voith

erected directly behind PM 10. Its

production capacity of 400,000 t.p.a.

PM 11 newsprint machine, with a capac-

twin machine, PM 12, has now been

ity of 400,000 t.p.a., has not only madeinstalled parallel to PM 11.

22This machine has a wire width of
10,200 mm and a design speed of

Huatai Paper China’s leading newsprint
producer, but also consolidated our excel-

The impressively large Huatai mill site

2,000 m/min. The scope of supply

lent reputation.”includes a power station, pulp pro-also included the complete deinking

duction line, canal system to theline from the drum pulper to the

23 I 2007 I Voith Paper I twogether

TECHNOLOGY

EcoCell preflotation and afterflotation in double-decker mode, with Thune disk filter.
In the foreground is the first stage of the MultiScreen slotted fine-screen system.

Thune screw presses.

finished stock storage tower, includ-To ensure optimal and efficient proj-

cy of Chinese site erection contrac-

ing complete engineering, chemical

ect execution, several liaison andtors under Voith supervision, thepreparation, and automation. Voith

coordination meetings were held on

entire erection work was completed

Paper Fabrics delivered felts anda jointly established basis. The pro-in only five months.

wires for the forming section, press

fessional organization and excellent

and dryer section.

teamwork between Huatai and Voith

All planning documentation to ensurefrom start to finish were critical to thecorrect erection of the deinking line

success of this project.

machinery, piping, electrical installa-

Comprehensive control measures
based on the Voith quality manage-

tions, control systems and chemicals

ment system certified to DIN ISO

Due to the extremely tight paper

processing was prepared in close

9001, and compliance with the Huatai

machine manufacturing and pre-teamwork between the Huatai andinternal regulations, ensured trouble-

assembly schedule, including all

Voith engineers. This work was con-free manufacturing and delivery of allcomponents and civil works, this was

siderably facilitated by the previously

components. For subcontractors andanother very challenging project for

intensive cooperation during thein-house production, all quality con-

Huatai Paper and Voith. Comprehen-

PM 10 planning phase, which enabledtrol inspections were based on previ-

sive logistics coordination for all sup-fast decision-making and detailed

ously defined criteria and certification

pliers had to be mastered in a very

optimization based on existing expe-

plans.

short time. But thanks to the efficien-

rience.

TopDuoRun, EcoSoft and Sirius.

23 I 2007 I Voith Paper I twogether

23

TECHNOLOGY

Key components of the Voith PM 11

Key components of the Voith
DIP stock preparation line for PM 11

High efficiency and product quality,
thanks to comprehensive automation• ModuleJet headbox• DuoFormer TQv with BlackStone S rubberroll covers• Tandem NipcoFlex press with G2000
polyurethane roll cover• TopDuoRun dryer section with CeraGuide
thermal roll coatings, 8 dryer groups(36 drying cylinders)• EcoSoft Delta calender with Vantis S calenderroll covers• Sirius reel (parent roll diameter 3,700 mm)• Tail transfer• Dryer hood
• Hydraulic and pneumatic systems• Central oil lubrication system• Spare parts• Erection supervision• Commissioning and operator training• Combi MultiSorter screen (1.2 mm hole diameter)in the first stage, and Combisorter with cleaner inthe second stage• MC slotted MultiScreen and MiniSorter• 4-stage heavies cleaner with HydroCyclean
and EcoMizer technology• EcoCell flotation I with 7 primary and3 secondary cells• 4-stage fine slotted screening with various
MultiScreens and MiniSorters• Thickening I with Thune bagless disk filter andThune screw press• Disperging with equalizing screw and
DX disperger, followed by oxidative HC peroxide
bleaching• EcoCell flotation II with 5 primary and2 secondary cells• Thickening II with Thune bagless disk filter andThune screw press, followed by reductive hydrosulphite bleaching and finished stock storage vat• Complete additives plant for the DIP line
• For internal water purification 3 Deltapurge
microflotation groups were installed by theVoith joint venture partner Meri• Components for the PM rejects system,
plus special control equipment and valves• Commissioning and operator training

The automation systems are aligned not only to thespecific product grade demands on PM 11, butalso to individual process requirements ranging
from raw material processing to end producthandling. They provide a uniform operating andengineering platform for on-machine control.

The scope of services agreed upon with the customer includes not only the entire process andcontrol engineering, but also erection contractor
support by the Voith erection supervisors.

The extensive factory acceptance test (FAT) prior
to delivery enabled fast and trouble-free commissioning of PM 11 according to the well-proven“Plug & Work” principle.

The key components of the tail transfer systemafter the dryer section comprise a dual highpressure water jet slitter, a TT3000 “Bullhorn”
transfer device, and 11 VTT turbo-transfer
belts.

24

Key components of the automation systems:
OnControl• On-machine control
OnQuality• OnQ ModuleJet, dilution water control with
Profilmatic cross-profile control software• OnQ ModuleSteam, steambox with Profilmatic
system• OnQ ModulePro, dual medium nozzle moisturizer
with Profilmatic system• OnQ ModuleNip, caliper and gloss control
with Profilmatic system• All MD profile controls
OnView• OnView information system with trending andreporting functions• RollMaster for optimizing paper roll winding
quality on reel23 I 2007 I Voith Paper I twogether

TECHNOLOGY

Key components delivered byVoith Paper Fabrics• PrintForm H series
Two sets of the Voith Paper Fabrics PrintForm H
series were ordered for the forming section of
Huatai PM 11. The first set, currently in service
on the machine, is performing well in terms ofrunnability and sheet quality.
The PrintForm H series fabrics were designed tocontrol the initial dewatering around the formingroll, pushing more water into the forming shoeand blades for improved sheet formation.
PrintForm H forming fabrics have resulted inhigh dryness at the press section intake, and lesswire marking compared with our competitors’
products.
• Dryer Fabrics
Due to our outstanding success with Huatai’s
PM 9 and PM 10, Voith Paper Fabrics is the preferred supplier of dryer fabrics for PM 11. The
first fabric is currently in service on the firstgroup, and is performing well, with good sheet
control and no marking.

Technical data of PM 11

The entire stock preparation line

Clearly, the Voith Paper “One Platform

planning was based on process tech-Concept” verifiably ensures not only

nology data derived from the Voith

the fastest possible commissioning

process flow chart and mass flow

and steeper start-up curves, but alsobalance.

full compliance with paper quality
guarantees for a rapid return on in-

All measuring and control equipment

vestment.

was specified, and precise documentation was compiled for programming

PM 11 produced paper for the firstthe stock preparation line process

time on December 31, 2005. After acontrol system. Its implementation

series of eight breaks-free jumbo rolls

was scrutinized down to the lastof saleable newsprint had beendetail by Voith specialists during the

produced, successful start-up wascourse of functionality tests (FAT).

officially certified one week lateron January 5, 2006. By the end of

The successful erection and commis-

January 2006, a continuous output

sioning was based on meticulous

of more than 950 t/day of first-classplanning of all activities in teamwork

newsprint had been attained at awith Huatai Paper and joint agree-

production speed exceeding

Design speed

2,000 m/min

ment on goals. Thanks to the trans-

1,650 m/min. The technical depend-

Wire width

10,200 mm

parent supervision of project prog-

ability and overall line efficiency, at-Max. untrimmed web width

9,580 mmress, all work was completed system-

tained so early, already approach the

3,700 mmatically and according to plan.

level expected after full optimization.

Parent roll diameter

Production capacity
1,210 t / 24 h
(at 1,800 m/min operating speed)

Based on the well-proven Voith

Raw material

project management, site- and com-

AONP, AOMG,
CONP, CMOW

missioning-management system, theerection personnel completed thefunction tests in teamwork with thecommissioning team. Here again, aswith all other Voith commissionings,
efficient execution was based on

Contact
Tianhong Lou
Paper Machines Graphic
Tianhong.Lou@voith.com

transparent and trustworthy teamwork with the customer’s engineers.
“Quality tons on reel and ramping up

Bernhard Häussler
Paper Machines Graphic
Bernhard.Haeussler@voith.com

production as quickly as possible,
making a good quality paper” – thiscommon goal was reached in lessthan 19 months after contract signing

Leo Engelmann
Fiber Systems
Leo.Engelmann@voith.com– another record in the Huatai success story!

23 I 2007 I Voith Paper I twogether

25

TECHNOLOGYExemplary teamwork –Shandong Huatai Paper breaks another world record
On October 31, 2006 Huatai Paper Company Limited’s new PM 12line in Shandong province started up successfully – in the recordbreaking time of only five months after commencing erection workon June 1. And on November 18 the customer already certified
commercial operation.
The Voith PM 12 line in Shandong

49 g/m2, PM 12 joins PM 11 as one ofproduces high quality newsprint for

the world’s largest, fastest and most

4-color offset printing. This new ma-

modern newsprint machines. Likechine is the identical twin of PM 11,

PM 11, it was built according to thedescribed in the previous article.

Voith “One Platform Concept”.

With a design speed of 2,000 m/min,26

a wire width of 10.2 m and a pro-

Voith, as single-source supplier, de-duction capacity of 1,210 t / 24 h atlivered the entire PM 12 production

23 I 2007 I Voith Paper I twogether

TECHNOLOGY

line – from stock preparation to paper

itself, two VariFlex two-drum winders

producer both in terms of quality androll wrapping and transport – thereby

with ElaGrip drum technology, and a

production volume. Shandong Huatai

eliminating delivery interfaces withfully automated robot-supported

Paper’s annual output of high quality

other suppliers. This was the main

paper roll wrapping machine includ-newsprint – no less than 1.2 million

reason for the incredibly short erec-

ing automated roll transport system.

t.p.a. per end of 2006, about halftion and commissioning time of only

Voith also supplied the comprehen-

China’s total production volume –five months: an impressive improve-

sive automation system for PM 12,

is produced entirely on Voith machin-ment over the previous times forcomprising on-machine controls,ery. Huatai Paper’s ongoing confi-

PM 10 (eight months) and PM 11

quality control system and data sys-dence in Voith reflects the close and(seven months). The average erection

tem. The entire Voith process know-

long-standing partnership between

and commissioning time for compa-

how was fully implemented in engi-

the two companies: a success story

rable non-Voith lines today is about

neering for the C&I, recovered paper

to be continued with the next PM 13

eight months.

and additives handing systems, andalready under discussion.

for the machine control systems.
The Voith scope of supply for PM 12

The next edition of twogether maga-covered recovered paper stock prep-

PM 12 is the fourth successive Voith

zine will include a further update on

aration, the approach flow section

line to start up in Huatai. It will enable

developments at Shandong Huatai

according to the Advanced Wet End

Huatai Paper to uphold its position

Paper, including a detailed report by

Process concept, the paper machine

as China’s number one newsprint

the customer.

23 I 2007 I Voith Paper I twogether

27

TECHNOLOGY“Perfect Fit” – Burgo Sora PM 1 rebuild
Burgo-Marchi placed the Sora PM 1 rebuild order with Voith Paper
Italy in mid January 2005. Only eight months later, involving only
30 days of shutdown, the rebuilt machine started commercial operation again in September 2005. And during the entire period since
this rebuild, PM 1 at the Burgo-Marchi Sora mill has met all expectations to the customers’ complete satisfaction. As an addedreference, this rebuild also incorporates Voith’s first transfer belt
application in Italy.

28

The Burgo-Marchi Group was createdgroup produces 3,230,000 t/year ofin mid 2004 by the merger of Cartierecoated paper, base paper and news-

Burgo S.p.A. and Cartiere Marchi

print. 85 percent of total output com-

S.p.A. With 27 production lines inprises the Group’s specialties of CWF

14 paper mills in Italy and 1 in Bel-

(Coated Woodfree) and CMR (Coatedgium, the group is at present the

Mechanical Reels) grades for maga-

main producer of graphic paper inzines, catalogues, inserts and othersouthern Europe. The Burgo-Marchi

commercial print products. In these23 I 2007 I Voith Paper I twogether

TECHNOLOGY

two segments the Burgo-Marchi

after rebuild is 1,300 m/min. Currently

a suction press roll in bottom position

Group commands a European market

the machine is only operating atwith Aqualis polyurethane cover, andshare of almost 14%.

950 m/min, but the design speed

a top press roll with grooved stainlessand planned production capacity ofsteel cover. The second nip compris-

Located in central Italy, the Burgo

140,000 t.p.a. should be reached

es a NipcoFlex shoe press, with

Sora mill has two paper machines forafter completing the second rebuild

NipcoFlex roll in top position and a

producing coated woodfree paper:

phase – on the dryer section and on-bottom press roll with grooved stain-

PM 1 in a basis weight range ofline coater – at the end of 2007.

less steel cover. Thanks to Voith’s

55-93 g/m2 and PM 2 in a basis
weight range of 100-150 g/m2.

first transfer belt application in Italy,
DuoSuction NipcoFlex press

The paper width at reel is 3,770 mm
on both machines.

the web is transferred to the dryer
section via the suction roll without

The main portion of the supply wasany free draws.

the new press section, with the folVoith’s scope of supply for the PM 1

lowing rebuild goals:

Three interchangeable suction rolls

rebuild included the following newcomponents:● 3-stage slotted screening system
and 4-stage cleaners● MasterJet II F headbox withtransfer the web in full width from the● PM efficiency enhancement byforming wire to the first dryer group,

eliminating free draws and reducing

without using a tail. After the firstmoisture content at the dryer

dryer cylinder, the whole web width

section intake

runs into the press rejects pulper.

ModuleJet dilution system and● Improvement of paper properties

Subsequently, the tail is formed byscreening technology to suitthanks to a new concept hardly

the tail cutter positioned under the● DuoSuction NipcoFlex press

ever used so far for paper ma-transfer foil at the dryer section inlet.

section with transfer beltchines with wire width less than

● DuoStabilizer boxes in the first

5,000 mm.

Not only does the transfer belt elimi-

dryer group.

nate free draw between the press
The new press section is distin-

section and dryer section, but it also

Sora PM 1 has a wire width ofguished by two nips and the absence

has the advantage of significantly

4,270 mm, and the design speedof free draw. The first nip comprises

reducing sheet rewetting.

All in all, the rebuild team can justifiably be proud of the results.

23 I 2007 I Voith Paper I twogether

DuoSuction NipcoFlex press.

29

TECHNOLOGY“Perfect Fit” rebuild results – not bad at all!

95.5

950
950
95.2
94.8
94.5
94.4

The machine was optimized rapidly,
900

and the advantages of the new press

850
800

section were obvious right from the800

beginning of the commissioning
phase.

750
94.0
Prior to rebuild

After rebuild

33

2.5

Thanks to the new press section

2.3

concept, the base paper smoothness

30

2.0

25

1.6

20
15

1.5

enabled a reduction of sheet porosity

1.0

and improvement of fiber orientation.
0.5

50Prior to rebuild0

Bulk is now higher than prior to the0
Prior to rebuild

After rebuild

Two-sideness of smoothness.

As confirmed by printing results, the
1,170

1200

1.0

Speed [m/min]

1.3

0.5

1000

finished sheet surface is more uniform thanks to an optimally blended

930

coating.

800
600
400
200

0
Prior to rebuild0
Prior to rebuild

After rebuild

Web breaks per 24 h.

After rebuild

Off-line coater speed.

120

160

145

100
70

60
40

IGT increase [%]

80

120

100

80
Piero Dall’Alba
Voith Paper, Schio
piero.dallalba@voith.com

40

20
0
Prior to rebuild
Porosity improvement.

After rebuild

Contact
Pierangelo Girardello
Voith Paper, Schiopierangelo.girardello@voith.com

100
Porosity [%]the dryer section intake is no morethan 48%.

1400

2.3

1.5

rebuild, and moisture content at
After rebuild

TSO

2.0

30

now exhibits no two-sidedness.
The subsequent optimization phases

10

2.5

The paper machine efficiency was improved over all speed ranges.

Paper machine speed.

MD/CD

Difference between wire sideand felt side [%]35

700
Prior to rebuild

After rebuild

Overall efficiency.

Web breaks/day

Results

1000

Speed [m/min]

Overall efficiency PM 1 [%]95.6

0Prior to rebuild

After rebuild

Printability.

23 I 2007 I Voith Paper I twogether

TECHNOLOGY

Aracruz Celulose banks again on Voith Technology
At the end of 2005 Voith’s 300th NipcoFlex shoe press was successfully commissioned at Aracruz Celulose in Guaiba, Brazil.
As part of a pulp drying machine upgrade, it considerably increases
the mill’s production output.

23 I 2007 I Voith Paper I twogether

First introduced years ago, shoe

NipcoFlex shoe presses for web

presses are now well established inwidths of 2,600 to 10,600 mm andthe pulp and paper industry. They

speeds of 50 to 1,912 m/min areare fitted to nearly all modern paper

operating worldwide to the complete

and board machines for practicallysatisfaction of users. In order to stay

all grades, as well as to pulp drying

one step ahead of ongoing customer

machines.

needs, a special NipcoFlex test unit is31

TECHNOLOGY

Customer Comment
Romeo Zanchin
Project Manager at
Aracruz Cellulose for
the Guaiba Project

All the project goals were fully attained
to our complete satisfaction. The agreed
delivery deadline, costs and dryed pulp
quality improvement targets were met infull. Voith’s valuable support of our training and qualification plan played a keyrole thereby in our success today. And it
was thanks to Voith’s outstanding teamwork as our partner in this project thatthe entire erection and commissioning
procedures were completed so rapidly

already undergoing trial runs at con-

Apart from the 15 percent productionand efficiently.

tinuous speeds of up to 3,000 m/min.

increase, this NipcoFlex shoe press

NipcoFlex shoe presses offer big ad-

has also enabled Aracruz Celulose to

All the components delivered by Voith are

vantages both with regard to produc-

reduce specific steam consumptionof first class quality, and the production

tion output and product quality. Voith

thanks to lower pressure in the drying

data have not only confirmed all guaran-

is the market leader in this segment

section. Moreover, basis weight has

tees but exceeded them: with a daily out-

with a share of more than 60 percent.

increased due to the higher dewater-

put of 1,250 tons and a sheet dryness of

The Voith NipcoFlex shoe press is theing capacity, and the improved run-more than 55% after the NipcoFlex shoe

most reliable and well-tried technol-

nability has reduced the number ofpress. These excellent results are of fun-ogy on the market.

shut-downs.

The 300th NipcoFlex shoe press that

In order to further improve the pulp

went on line at Aracruz Celulose per

web quality, basis weight cross-In particular, I would also like to empha-

end of 2005 is installed as part ofprofile control with an Aquacontrol

size Voith’s partnerly support both in thea pulp drying system. This is alreadydilution water system was installed.

preliminary stages of the project andthe second NipcoFlex shoe press

The water-loop, pulp and vacuum

during its entire execution. This included

installed by Aracruz Cellulose –systems were also optimized andanalysis of the financial aspects, practi-

a sure sign of the customer’s trust inmodernized with new piping, pumps

cal evaluations and on-site tests, andVoith pulp drying technology. It is

and motors. In this connection thedetailed investigations of alternatives.

fitted with QualiFlex roll covers, andDC system was replaced by AC

We look forward to continuing this friend-

plays an important role in increasing

motors with frequency converters,

ly cooperation with Voith.

production output of eucalyptus pulp

and new gear drives were installed.

from 400,000 to 455,000 t.p.y.

The scope of supply also included

damental importance to us in view of ourcapacity limitations in the drying section.

32

23 I 2007 I Voith Paper I twogether

TECHNOLOGY

Wire section (left) and300th NipcoFlex
Shoepress (below).

Aracruz Cellulose
eucalyptus plantation.

operator training as well as erection

The success of this project and theand commissioning supervision. For

customer’s satisfaction are impres-commissioning, Voith Fabrics sup-sively reflected in the commentary

plied first fabrics in the third dryer

below by Romeo Zanchin, Projectgroup.

Manager at Aracruz Cellulose for the
Guaiba Project.

Particularly notable are the social
arrangements made by Aracruz in the
Guaiba region. Together with numerous companies including Aracruz und
Senai, Voith supports thereby a “personnel qualification plan” training andadvancement project for pulp and paper industry employees in the locality.
This has enabled more than 500 employees in widely varied trades toundergo intensive training in a facility

Contact
Luis Fernando Porchia
Voith Paper Máquinas e
Equipamentos, Brazil
luis.porchia @voith.com

for which Voith donated the equipment and financed renovation of thepremises. Some of the trainees havealready been able to prove their newly acquired capabilities in connection

Angelo Giosa
Voith Paper Máquinas e
Equipamentos, Brazilangelo.giosa@voith.com

with the Aracruz project realization.

23 I 2007 I Voith Paper I twogether

33

TECHNOLOGY

Paper mill Mitsubishi HiTec Paper Bielefeld, Germany.

Mitsubishi HiTec Paper –Energy management: a masterable challenge
The importance of saving energy has long been recognized, but
only recently has it been taken so seriously in industrial circles,
including the paper industry. Since the steep rise in energy tariffs
recently, particularly last year, greater priority is being given again
to energy-saving measures. Such measures are typically taken inareas not necessarily belonging to everyday papermaking activities,
so expert support in these specialized areas can be very helpful.

34

23 I 2007 I Voith Paper I twogether

TECHNOLOGY

Such considerations and common

Based on this situation, joint discus-

process water heating. Then thediscussions on the subject led tosions were held to define the focal

spray water would no longer have to

Mitsubishi HiTec Paper Bielefeld

points for study and evaluation. It

be steam heated.

placing an order with Voith Paper

was found that with so many inter-

Heidenheim for an energy savings

faces between the PM 3 steam/con-

2. Currently the condensate from PM

study. In order to attain the biggest

densate system and other process

1 and PM 3 is cooled down frompossible savings in the shortest

zones, the study would have to beabout 90 °C to 65 °C for processing

possible time, this study focused on

further extended in some cases in or-

purposes before utilization in thethe PM 3 steam and condensate

der to make a realistic assessment.

power plant. Instead of wasting thissystem in Hillegossen – a notoriously

thermal energy in the existing coolingenergy-intensive area offering highFirst of all the individual study points

tower, it can be utilized in two differ-

optimization potential accordingly.

had to be defined. Apart from as-

ent ways:pects like exhaust and condensate● either for heating the building in

System concept

heat utilization and tank insulation,

which coating machine 3 is installed

the PM 3 heating system also had to● or for heating the PM 3 whitewater.

On two paper machines and several

be investigated. The object here wascoaters, this mill produces special

to study and optimize the individual

The more cost-effective of these twogrades such as carbonless paper,

heater operating modes.

alternatives is worked out below.

papers and cast-coated labels. In

Investigations carried out and3. The analysis results showed con-2005 the Stadtwerke Bielefeld GmbHsolutions proposedsiderable heat losses from the clari-thermal paper, high quality inkjet

built a combined cycle power plantfied filtrate tanks – located outside

on this site to supply the mill with

1. The Sulzer blower exhaust, cur-without thermal insulation. Hereelectricity and steam.

rently unutilized, is ideally suitable foragain, the investment required forms

PM 3 wire section.

23 I 2007 I Voith Paper I twogether

35

TECHNOLOGY

HP steam

LP steam
PIC

PT

HP steam

PIC

PT

PIC

PIC

PT

PT

Heating group B

Heating group A

Heating group A

PDT

PDIC

Condenser

Features● Vapor utilization in the same
heating group● High pressure steam
required● Inefficient energy utilization● No pressure drop required

Heating group B

PDT

PDIC

Condenser

Separator

Separator

PM 3 heating system – Elimination of the 12-bar line,
current condition.

Features● Vapor utilization in thenext heating group● Only low-pressure steam
required● More efficient energy
utilization● Pressure drop required

PM 3 heating system – Elimination of the 12-bar line,
cascade system.

a basis for estimating the cost-effec-

energy-intensive high-pressure steam

tiveness of corrective measures.

is tapped from the turbine to drive

Results

the thermo-compressors and for the

Cost/benefit assessments were car-

4. An important part of this study fo-

steam registers of the hood supply

ried out for each measure as men-

cused on the energy balance of theair. This reduces the power generated

tioned, based on budget price figures

existing PM 3 heating system. It wasby the steam turbine. As an alterna-

for any investments required. The de-soon apparent that the operatingtive to the thermo-compressor sys-tailed results were as follows:mode of the individual heating mod-tem it would be possible to install aules needed to be optimized. The

cascade system as shown in the

Utilization of blower exhaust

entire system and the thermo-com-graphic “PM 3 heating system”.

for spray water heatingpressor operating modes were com-

Required investment: about 300,000

prehensively documented, paying

Optimization measures can also be

particular attention to aspects suchtaken on the hood supply air system.

as governor settings and definition ofThis is still connected to the 12-bar

Condensate heat utilization

the operating points in the compres-high-pressure steam line, but it could

Two alternatives:

sor characteristics curves. It was also

be connected instead to the 3.5 bar● Utilization for machine hall heating

found that savings could be achieved

low-pressure steam network.

● Utilization for whitewater heating.

These two measures – using a cas-

The results were as follows:

Euro. Payback time: 1.7 years.

by rebuild measures on the existing
siphon system.

cade system instead of thermo-com-● Machine hall heating –5. As mentioned above, a special as-pressors, and optimizing the hood

payback time 15 years.

pect at Hillegossen was that in 2005

supply air system – would save con-a new power plant went into opera-

siderable mill operating costs bytion. This raises the question as tousing all the energy-intensive 12-barwhether the existing 12-bar steam

steam for power generation (andThe mill management should, there-line is still required at all. Currently,

feeding surplus power to the grid!).

fore, find it easy to reach a decision.

36● Whitewater heating –payback time 0.96 years.

23 I 2007 I Voith Paper I twogether

TECHNOLOGY

Tank insulation

Further prospects

The investment required for insulating
the clear filtrate tanks will pay forThis study, carried out in teamwork

itself in 1.9 years.

between Mitsubishi Paper Bielefeld
and Voith Paper experts Martin

Heating system optimization

Dauner and Holger Funk, reveals sub-Savings can be achieved here on the

stantial energy-savings potential for

one hand without any investment, or

the PM 3 steam and condensate

on the other with investment costs.

system alone. However, the matter in
hand requires very specialized knowl-

Without investment costs:

edge not necessarily belonging toControl system optimization alone

everyday papermaking activities.

can save more than 100,000 Euro

Expert support in the relevant areasp.a. with the existing product range.

is, therefore, indispensable. For example, it is planned to hold a training

Off-line coater 3.

With investment costs:

course for the Hillegossen mill opera-● Siphon rebuild. Replacing thetors under Voith specialist leadershipsiphons and steam heads will pay

so that the findings of this study can

off in 1.25 years.

be implemented as far as possible in● Thermocompressor system rebuild

day-to-day production.

to a cascade system. The payback
time here is 3.8 years.

In the end, however, this study has● Hood supply air steam pressure re-only focused on a small part of theduction from 12 bar to 3.5 bar. The

overall energy-savings potential in apayback time here is only 0.8 years.

paper mill. All the individual plantcomponents and their networking

Overall payback time for the last two

play an important role in optimallymeasures together is 2.3 years, withefficient energy utilization.

the aforementioned advantage that
more high-pressure steam is available for power generation.
The overall savings potential revealedby this study – under the given circumstances – is almost 1 million Europ.a. Both from the economical andecological viewpoints, this is verysignificant. Bearing in mind the fairly
steep rise in energy prices forecast in
the medium term, the paper industry

Contact
Dipl.-Ing. Gerd Finkenhofer
Mitsubishi HiTec Paper BielefeldGmbHgerd.finkenhofer@mitsubishipaper.com
Klaus Schmidt
Paper Machines Graphic
klaus.schmidt@voith.com

would certainly have to pay more
attention to this aspect in future.

23 I 2007 I Voith Paper I twogether

37

TECHNOLOGY

Maxau PM 6 – the rebuilt VariTop.

Maxau PM 6 VariTop winder –All high-performance promises fulfilled!
Voith’s market leadership in SC paper technology has often been
proved in the past. Among the five SC production lines delivered
over the past ten years is PM 6 at the Stora Enso Maxau mill(see also twogether 19). After more than two years of excellent
results, it is now time to report on the VariTop winder and hispart to this success.

38

23 I 2007 I Voith Paper I twogether

TECHNOLOGY

Goals

Feasibility study

Solution

PM 6 was “modernized” – in actual

Voith experts teamed up immediately

Voith, therefore, proposed to Stora

fact an almost completely new paperwith the Maxau specialists to work

Enso the following rebuild solution:

machine was installed in the existingout the best alternative. The feasibility● Installation of a new parent rollbuilding – in order to boost annual

study primarily focused on three

production from 140,000 to 260,000

aspects:

t.p.a. as a first step and enable up to● How far could the existing maxi-

280,000 t.p.a. later on. This clearly

mum speed of 2,200 m/min be● A reel spool lifter systemincreased?

● A magazine for empty reel spools

meant upgrading the peripheral
equipment as well. Two alternatives
were considered:unwind● A fully automated magazine for
3 parent rolls● How to shorten the production out-

● Adapting the unwind splice to theage times (for set changes, etc.)?

new maximum diameter of the● Installation of a new VariTop winder● Which components of the 14-year-

in addition to the existing one, or

old winder would have to be re-● Modernization of the web severing● Upgrading of the existing VariTop

placed due to wear and in order tosystem and web tension relief roll,to meet PM 6 needs as far as

meet higher demands in future?

and of glueing at the sheet begin-possible.

parent rolls

ning and end
A detailed study of these questions

The customer’s desire to produce in

led to unanimous agreement: thefuture 5 m wide jumbo rolls had also

rebuild alternative would be by far the

to be considered.

best solution!

● Modification of the winder drum
drive mechanism● Special ElaGrip coating on thewinder drum for improved winding● Two heavy-duty stations for parent
rolls up to 5 m wide
● Installation of a new cores table● Replacement of the winder PLC
controls and production parameter
control system● Siemens SPS system conversion
from S5 to S7 technology● General overhaul of the VariTop● Dynamic balancing of all rolls forthe higher operating speed of
3,000 m/min.
Project implementation
Fully satisfied with results of the project studies by our specialists, Stora

Carsten Wenk, Stora
Enso, congratulates
Dirk Cramer of Voith
Paper Finishing:“Engineered reliability –all promises kept!”

23 I 2007 I Voith Paper I twogether

Enso entrusted Voith with upgrading
the VariTop as proposed. Having
determined the scope of supply andperformance, it “only” remained to
execute the project with due care and39

TECHNOLOGY

VariTop after rebuild (blue = new or rebuild).

Customer Comment
Carsten Wenk
Stora Enso Maxau

punctuality. Clearly, this was not

Results

going to be an easy job. But thanks
to scrupulously detailed schedulingIn response to this exemplary start-

and continuous planning coordination

up, Stora Enso notified the author as

between the partners, all the manu-

follows: “Having so quickly attained

facturing and shipping, erection andsaleable paper production at the“We had always been fully satisfied withcommissioning went ahead without aagreed speed of 3,000 m/min with

our VariTop built in 1990, but were surehitch. Naturally there were some sur-our rebuilt winder – the world’s fast-that it could achieve more. With Voith asprises during the erection procedure

est VariTop – we take this opportunity

our project partner, we were able to mini-– with a 3-shift team of 20 men work-of sincerely thanking you and yourmize the winder rebuild costs required foring around the clock – such as theteam for such excellent partnershipincreasing production of our PM 6. Basedmuch more complicated tubes andwith our Project 3000”.

on a joint feasibility study of the existing

pipes installation than expected.
However, all erection work was nev-

winder, a custom-tailored rebuild andCurrent status

ertheless completed punctually

modernization project was worked out
and fully implemented. Thanks to ourthanks to the concentrated efforts of

For more than two years now, a sin-

partner’s outstanding teamwork also in

all concerned. In order to eliminate

gle upgraded VariTop winder handles

the commissioning and optimization

any start-up troubles with PM 6 as far

all designated paper produced byphases, the result was an exemplary

as possible, the rebuilt VariTop was

PM 6. To accomplish that it has tostart-up. Voith engineering and our com-

first tested and commissioned with

operate continuously at extremely

mon know-how in SC jumbo roll technol-

parent rolls from PM 8. And this paid

high speeds of 2,900 to 3,000 m/min,ogy have transformed our PM 6 VariTop

off in full: right after starting up PM 6,

but paper roll quality is neverthelessinto the world’s highest capacity SC wind-production went ahead smoothly with

first class. Carsten Wenk, Stora Enso,

er. All project goals were attained in full:

the rebuilt VariTop.

sums up as follows:a superlative achievement!”

Project 3000 –the world’s
highest capacity
SC winder.

40

Contact
Dirk Cramer
FinishingDirk.Cramer@voith.com

23 I 2007 I Voith Paper I twogether

TECHNOLOGY

Handling bigger and heavier rolls –No problem with Voith Finishing logistics
Wound paper rolls – also called parent rolls or full reel spools orjust rolls – are getting much bigger and heavier these days.
Weights of 125 t have already been reached (160 t will be attainedin future), with web widths up to 11 m and roll diameters up to
4.5 m (or even 5 m in future). Such large rolls must be kept underprecise control during handling and transport.
As explained in this article, Voith

The situation so far

solves these problems by focusing
in particular on the following:

Paper roll magazines serve as a

● Paper roll handling (transportbuffer between production stages.

tractor, rails and switches,

Rolls are stored there between theroll magazine, roll turning)

paper machine and offline coaters,● Paper roll trolleys.

offline calenders and winders if thesePaper rollmagazineahead of the
VariFlex
winder.

23 I 2007 I Voith Paper I twogether

41

TECHNOLOGYLine withconventional rollmagazine.

are all situated in the mill. So far thewell-aligned guide rails, perfect con-Voith paper roll storage concept hasdition of the roll spindles, and clean

comprised two sets of rails installed

guide surfaces.

in parallel, with a slight downward

Schematic
view ofroll tractor.

The solution
This challenge was met with a newconcept. Although the paper rolls still

gradient in web run direction. The

Roll trolleys transport the rolls at right

run on rails, these are not inclined.

rolls travel down these rails as far as

angles to the web run direction, either

The rolls are subjected only to pre-the next storage location or paper

between two lines operating in paral-

cisely applied forces.

processing station. At the storagelel, or between separate magazines.

stations they are caught and held by

They also run on sloping rails, with aInstead of descending by gravity, thea damping lever system until they

lever system to catch the rolls androlls are moved by a rail-mounted

are released afterwards for further

rail switches for accepting or passing

trolley – also known as a “roll tractor”

transport.

on rolls.

– on each side. The guide rails for thetractor are incorporated in the roll

Each magazine also has rail switches

The challenge

guide-rail structure.

or transferred to upline or downline

The current state of technology had

Each roll tractor has a centrally

systems respectively. They also allow

to be improved to ensure the con-pivoted rocker beam, which in theoperator access to certain magazine

trolled transport particularly of large

horizontal position can be moved

zones.

heavy rolls, smoothly and well aligned

underneath a roll. The ends of thisto the guide rails. This requires therocker beam extend out of the

In these present systems the paper

systematic application of controlled

tractor on both sides, and can, in its

rolls move freely from one storage

horizontal transport forces, precisely

tilted up position, pick up and movepoint to the next, the only form ofpredictable and repeatable under all

the parent roll. The beam projects

control being lateral restraint by theoperating conditions. The principle ofenough for the tractor to transfer

guide rails. Once a roll has been re-using a descending plane for moving

rolls to or from neighbouring systems

leased by the lever system, it cannot

the roll therefore had to be aban-

without actually entering them.

be stopped until it reaches the next

doned in order to eliminate uncon-

This greatly simplifies the interfaces

position. This freedom of motion cantrolled roll motions.

between systems.

spindle ends impact the guide rails so

Another requirement was restriction

The tilting rail switches for roll accep-

heavily that the rails and spindle ends

to a single form of applied energy astance, handing over and transfer

are subject to considerable wear andfar as possible, but at any rate to use

are retained. They enable the connec-

tear. Dependable operation of suchless maintenance-intensive systems

tion of neighbouring systems to thea roll transport system depends onthat are also easier and faster to install.

roll magazine, and provide accessenabling rolls to be taken over fromresult in oscillations whereby the roll42

23 I 2007 I Voith Paper I twogether

TECHNOLOGYLine with
new-generation rollmagazine.
System 1

Parent roll magazine

System 2

for maintenance and setup work prior

the same way as in the magazine,● All interfaces are clearly defined.

to the further processing of paper

and they are received or passed on● The dependable mechanicalrolls.

by the roll tractor. These changes

mechanisms used reduce systemeliminate many of the elements pre-vulnerability.

There are two ways of fixing rolls inviously required on the lateral trans-

the magazine. In the intermediate

port trolley, and no energy input isstorage positions, a purely mechani-

required except for actually moving

cal braking device stops even eccen-

the trolley. Communication with the

By developing this new-generation

trically wound rolls from moving.

neighbouring systems is by dataroll storage magazine and transport

At other storage points where theinterchange line.

trolley system, Voith Paper has notrolls have to be rotated e.g. for wind-

Summary

only met today’s demands for han-ing off scrap paper, an adjustable

Benefits of the new logistics

dling bigger and heavier parent rolls,

wedge keeps them precisely posi-

systembut also set another milestone towardtioned.

the complete automation and optimi● The fundamental advantage is

A new generation of roll turning

precise system control, the basis

devices has also been developed

for automation of the roll magazine

whereby the roll is rotated by a driverstorage system. And since rolls

meshing with the teeth inside the reelin the magazine can be transported

spool. This ensures a fixed connec-

in both directions if required, thetion between the drive mechanism

storage logistics are much more

and the reel spool (instead of a fric-flexible.

tional drive as previously). Rotation● Without the need for a hydraulics

is kept under control by a disk brake,

system, roll magazine installation

also mounted on the driver, that iscosts are significantly reduced.

much more effective than the friction

This also saves planning and com-brake used so far.

missioning time, as well as mainte-zation of finishing logistics.

nance costs later on (the entire
The trolley for transporting paper rolls

hydraulics group on the roll trans-

between lines has been greatly sim-

port trolley has been eliminated).

plified, and the receiving and transfer● Smoother motion of the rolls in theswitches are now installed on the rollmagazine saves wear and tear.

magazine. Rolls are fixed to the trol-● The roll transport trolley has been

ley by a purely mechanical device, in

23 I 2007 I Voith Paper I twogether

Contact
Henning Gugel
Finishinghenning.gugel@voith.com

greatly simplified.

43

TECHNOLOGY

Voith DriveCommand – a major spin
to totally integrated paper machine automation
Paper machines, satisfying recent standards in terms of productquality and productivity, become increasingly complex due to theinstalled subassemblies as well as the required precision-control.
Voith has now the answer to the increased complexity of operationand maintenance of modern and high-capacity paper machines:
Thanks to Voith DriveCommand the control of a paper machine will
get quite simple. For the first time Voith realizes the total integration of the drive control. This is seen as an innovative solution for
Solikamsk and VDC teamduring Final Acceptance Test
at Voith prior to delivery of theVoith DriveCommand.

the needs of paper makers.

In the past machine motions and drive

Voith. On the one hand unnecessaryfunctionalities at a paper machineinterfaces in the program are elimi-

have been considered separately,nated and on the other hand the real-

although they influence each other.

ization of the project is much more

The Voith DriveCommand developed

comfortable for the customer, be-by Voith Paper Automation eliminatescause there is one overall responsible

this separation by integrating the

supplier.

drive control into the process control

44

system. Based on the process know-

Voith DriveCommand can be installed

how for the whole papermaking

in new plants as well as used forprocess, which Voith has contrary tomodernizations for automation andmany other automation suppliers, adrive systems. The strengths of Voith

comprehensive and coordinatedDriveCommand are very effective at

system has been developed. The

modernizations, because the auto-

Voith DriveCommand functions aremation solution can be chosen inde-combined with machine and process

pendently from the drive solution

control functions for a higher perfor-(converters and drives). This allows

mance control. The customer benefits

the integration and control of drives

from the single-source solution oforiginating from different suppliers

23 I 2007 I Voith Paper I twogether

TECHNOLOGY

Drive Control without Voith DriveCommand
Drive Control

Machine Control
Control Room

ServerDrive Control with Voith DriveCommand

Local Operation

Local Operation

Drive Control

Machine Control
Control Room

Local Operation

ServerServerServerVoith
DriveCommand

MCS

MCS

Local Operation

MotorsMotorsVoith has filled the gap in paper machine automation. In future the drive controls will be integrated in the machine control system.

and having different ages. Voith Drive-

types of programmable logic control-

Voith DriveCommand unique: The

Command integrates the complete

lers and put themselves into various

testing on a comprehensive process

speed control and monitoring of the

programming philosophies because

simulation prior to delivery. This

paper machine from the wire section

the Voith platform (PCS 7) will be

paper machine simulation calculates,to the reel into the standard Voith

used exclusively. This reduces differ-based on the received nominal

process automation platform. Voith

ent hardware components andspeeds and torques from the Voith

closes the technological gap in paper-

demands for maintenance will be

DriveCommand, the full dynamic

making automation, which up to now

minimized.

reaction of the drives with the con-required the integration of a third par-nected gearboxes, rolls and fabrics.

ty control, the drives supplier. Voith

Voith DriveCommand comes with a

DriveCommand includes general

rapid data acquisition system for aSpecial care was taken to the accu-

functions such as jogging, crawling,

fast and time-synchronous recording

rate simulation of the paper behav-

normal run, stopping of individual PMof drives data and other relevantiour during threading and normal run

sections or the entire production line

process parameters. Due to the highto identify the paper’s influence on

as well as technological features such

resolution of the data acquisition sys-

the drive dynamics. A highlight ofas tension control and load-sharing.

tem and via optimization algorithms

Voith DriveCommand is the possibil-

based on Voith Paper’s technology

ity to simulate changing production

With Voith DriveCommand, the op-

know-how papermakers will have a

conditions such as changes of vacu-

erators benefit from the same visual-

deeper insight in the process. Thisum levels in the wet end, change inization platform and a uniform ma-gained knowledge is the essential

press-nip loads as well as variations

chine operation because all controls

basis for trouble-shooting: It can bein web tension or sheet breaks.

can be operated through one auto-used by the paper or board producer

mation platform. In addition to this,for production analysis and for theThus, it allows Voith to analyze inthe homogeneous process control

tracking of quality fluctuations caused

detail the dynamic behavior of theand programming structure is veryby drives allowing countermeasurespaper machine and to tune the reac-

useful for the maintenance crew due

to be initiated. This leads to a con-tion of the Voith DriveCommand

to a simplified maintenance of thetinuous process improvement.

already prior to start-up. This ensures

soft- and hardware. Thanks to Voitha smooth installation of the Voith

DriveCommand the service teamCompared to existing drive control

DriveCommand and simplifies thedoes not have to maintain different

solutions another feature makes thestart-up.

23 I 2007 I Voith Paper I twogether

45

TECHNOLOGYVDC Control

Permanent Data Recording

Engineering Screen Visualization Screen

OnView PDA

VDC PM– Wire– Press– Dryer– ReelTypical visualization screen of VDC.

Connection of VDC to simulation for testing of individual
VDC functionalities.

Benefits of Voith DriveCommand forof the drives just by clicking on the

Safety Control for Accident

the paper makers can be realized

drive icons displayed. All relevant

Prevention

through the following components:

status and alarm information required

Voith DriveCommand reflects thefor safe machine run are shown.

high Voith standards to insure humanProcess Control

safety. Voith DriveCommand inte-

The application software calculates

Rapid Data Acquisition System

grates the whole engineering of drivefor each individual drive the nominal

This system, specially designed withalarming and the required equipment

speed/load, which is typically trans-

open interfaces to various kinds ofsuch as signal horns and flashlights.

mitted to the drive system via Profi-

bus communication, traces the actualbus. In return, the individual drives

parameters such as speeds, loads,

Optionally, the whole emergency stop

send the actual load and speeds as

status information with a time resolu-

concept of the production line iswell as the information of the actualtion down to 1 ms.

supplied, including the required local

drive status and alarms. This informa-

emergency stops and the safetytion, permanently monitored by Voith

Additionally, the system permanently

DriveCommand, is used in the inter-records the internal parameters of thenal control as well as for display on

Voith DriveCommand and the con-First Application for

the visualization stations.

nected machine control system. That

Solikamsk PM 1

control cubicle.

means that permanently about 200 to
Visualization

800 parameters are recorded at the

The first application for the paper mill

As mentioned before, Voith Drive-

same time and with high time-resolu-

JSC Solikamsk Bumprom in Soli-

Command is based on the PCS 7

tion. The analysis of the acquired

kamsk, Russia reveals the potential of

platform. The visualization will bedata is the basis for tuning of thethe Voith DriveCommand especiallydirectly integrated into the processcontrol system as well as the devel-

for modernization of drive systems.

control system. Voith’s special drive

opment of new technological func-

The drive system of the paper mill is

faceplates allow a direct examination

tions.

very heterogeneous with partly re-46

23 I 2007 I Voith Paper I twogether

TECHNOLOGY

Simulation of complete PM 1
Simulation PC

Simulation of:– complete dynamic
behavior– exact drive interface

In future all controls
including drive control
will be integrated in thesame operating system.

maining ABB drives, which have todrives. The visualization includes

Single automation platform for pro-interface with a special adapter

equally overviews of drive status,

cess, machine and speed control with(serial <> Profibus) and new Voith

load and speed in graphic form as● unified machine handling (HMI) in

supplied drives with a standard

well as the visualization of the emer-

Profibus interface.

gency stops in the production line.

one system● simplified maintenance of softwareand hardware● minimized spare parts requirement.

As Voith DriveCommand is open toDuring the factory acceptance test

diverse interfaces, such configura-at Voith an intensive test of the Voith

tions are no handicap, open the cus-

DriveCommand has been carried out

Improved machine control and auto-

tomer economic modernization pos-by combining the system with anmation systemsibilities and allow to choose his pre-extensive simulation of the real PM 1.

● through the combination of

applied automation solution. Inside

Coupling the Voith DriveCommand● due to increased process transpar-

the Voith DriveCommand, the control

with the simulation makes an inten-

ency because of the high resolution

takes care that varying reaction times

sive training of the operators possibleof the data acquisition systemof drives due to different age andto prepare themselves perfectly for● via optimization algorithms based

manufacture are compensated.

the start-up of the new system.

ferred drives independently from themachine and speed control

on Voith Paper’s technology
know-how.

Visualization was designed with theSummary

objective to allow intuitive and self-

Contact

explaining handling. A typical HMI

Voith DriveCommand – the integra-

screen, as shown in the figure above,tion of the speed control into therepresents a clear overview of theVoith automation platform – allows

actual drive status, with details avail-the paper industry customer to ben-able just by clicking on the individual

efit from:23 I 2007 I Voith Paper I twogether

Dr. Markus Schoisswohl MBA
Automation
markus.schoisswohl@voith.com

47

TECHNOLOGY

1

2

3

Fabric cross-section
1 Compressible top layer (fine)
2 Incompressible basic weave structure (here woven)
3 Compressible bottom layer (coarse)

PrintFlex PRO – For the finest possible pressing
As a member of the Voith Paper group, Voith Paper Fabrics is the
only machine clothing supplier to offer the enormous advantage
of in-house synergies covering the entire spectrum of papermaking
technologies. This greatly benefits fabric research and development.

48

23 I 2007 I Voith Paper I twogether

TECHNOLOGY

Voith Paper Fabrics’ products can be

useful fabric life. In other words,

PrintFlex PRO, our latest develop-

tested from initial concept to com-some innovations are simply not cost

ment for the European and Asian

mercial maturity under realistic oper-

effective.

markets, carries us further on our

ating conditions at the new Paper

journey to complete customer satis-

Technology Center (PTC) in Heiden-

The short life of such highly special-faction. The ongoing analysis ofheim. Because of this, Voith Paper

ized fabrics reduces their cost-effec-

customer demands on paper surface

Fabrics’ customers have the benefit

tiveness because of the additional

quality led to a more intensive exami-of optimal security and testing before

outage time needed for more fre-nation of each press fabric during

trialing new products.

quent fabric changes, often cancelingthe manufacturing stage.

out the potential profitability of paper
In the papermakers’ never-ending

quality improvements. A lot of fabric

The main findings were that non-quest for ways to improve their pro-producers, therefore, have no other

woven production, the weaving

cesses, 2-sidedness, printability andchoice with new developments but

process and the fixing procedureenergy consumption are at the fore-

to meet papermakers’ requirements

have the greatest affect on the fabricfront of their mind. Fabric character-increments at a time – always at thesurface and the end product.

istics play an important role in thisrisk of neglecting one of the key

connection and innovative fabricaspects mentioned above.

designs can address these concerns.

● Nonwoven production: selection,fineness and fiber combination● Weaving process: speed, density/

Fabric designs can be made to meetWith innovative machine clothing,or even exceed these improvement

Voith Paper Fabrics has proved that

requirements. As with many ad-

they can significantly improve paper● Fixing procedure: speed, tempera-

vanced technologies, however, thisquality and machine runnability while

ture and type/method of fixing.

sometimes comes at the expense ofmaintaining cost effectiveness.

designNeedling.

Press Fabrics
As shown in the Fig. “Fabric cross-section,” press fabrics
comprise a compressible layer (non-woven) and an incompressible basic weave structure. The non-woven layer ismade up of polyamide fibers with various diameters andproperties, and serves mainly for paper sheet dewatering.
The basic weave structure provides mechanical strength(e.g. tensile strength) and water storage volume.
As shown in the Fig. “Needling,” during fabric production the
non-woven layer is laid loosely on the basic weave structure
and then fixed to it by needling.

23 I 2007 I Voith Paper I twogether

49

TECHNOLOGY

PrintFlex PRO advantages

paper. As a result, the fine fibers in-

so that fabric startup times are con-corporated in PrintFlex PRO fabrics

siderably reduced. The optimal, ho-

Problems have arisen when using the

do not penetrate the paper surface.

mogeneous press fabric structurefinest fibers for press fabric produc-

And the finer the fibers, the less risk

gives the finely pored surface on thetion, because they did not haveof sheet marking. PrintFlex PRO

paper side a strong supporting layer

enough abrasion resistance during

fabrics are particularly beneficial onthat immediately absorbs drainage.

machine operation. This was not only

the last presses, where the web

This prevents the air pockets that

evident from the small fiber particles

dryness is already so high that paper

otherwise cause bubble formation in

found in the paper surface, but also

fibers are no longer likely to be dis-the paper sheet at nip entry.

from the unequal substance losses

placed.

that interfered with drainage behav-

Furthermore, the aforementioned

ior. On the one hand abrasion has

Thanks to a far greater number ofstructural characteristics of this fabricsomething to do with the fiber diam-

contact points, the PrintFlex PRO

ensure trouble-free sheet threading

eter, but on the other hand – and ver-fabric surface is consistently homo-and eliminate the problem of edge

ifiably to a greater extent – also withgeneous. This results not only incurling.

the way the fibers are bonded into

excellent fabric startup behavior andthe fabric structure: the smoother theuniform drainage, but also in deci-

The illustrations above clearly show

surface, the lower the wear tendency.

sively better sheet quality.

the superior surface quality attained

Thanks to innovative developmentwith PrintFlex PRO compared to aand optimization steps in press fabric

By incorporating the finest fibers, astandard press fabric. Above all,

production, Voith Paper Fabrics hascompact non-woven layer is gener-

thanks to optimal fiber bonding on

successfully bonded the finest fibers

ated. The resultant micro-pore struc-the fabric surface, marking is mini-in the fabric surface contacting theture hardly changes under pressure,mized and fiber losses are reduced.

Topographical surface of a standard press fabric compared with that of PrintFlex PRO fabric (on the right).

50

23 I 2007 I Voith Paper I twogether

TECHNOLOGY

Paper-side surface of a standard press felt compared with that of PrintFlex PRO felt (on the right).

Measurements of the surface charac-

further proof that both the smootherteristics (below on the left) clearly

fabric surface and the better fiber

show the comparative topographicalbonding consistently reduce sheet

improvements attained. While the oldmarking in the press.

standard fabric exhibits significant
indents on the paper side that cause

As confirmed by pilot tests at themarking on the sheet surface in the

Heidenheim Paper Technology

press nip, the new fabric has a great-

Center as well as by market feed-

er support surface area thanks to sur-back, the PrintFlex PRO development

face displacement in the z-direction

has met its claim and is the optimal

toward the paper web. This provides

fabric to achieve sheet smoothness

much more homogeneous sheet sup-in press positions.

port. As a result, the printability of
paper dewatered with PrintFlex PRO

Summary

is significantly improved.
The new PrintFlex PRO, available in
The illustration below on the right

Europe and Asia, provides customers

shows a horizontal cross-section

with a press fabric that is able tothrough the topographical surface

achieve the most demanding require-profile, 30 μm below the highest mea-

ments on graphic machines. PrintFlex

sured peaks. Far more peaks (white

PRO combines the advantages ofdots) are visible in the standard fabricquick startup times and significant

than in the new PrintFlex PRO. This is

improvement in paper surface quality.

Topographical cross-section of a standard press fabric compared with that ofPrintFlex PRO fabric (on the right) at a depth of 30 μm.

Contact
Arved H. Westerkamp
Fabrics
arved.westerkamp@voith.com

Peter Mödl
Fabrics
peter.moedl@voith.com

23 I 2007 I Voith Paper I twogether

51

TECHNOLOGY

SSB forming fabric production.

Effective forming fabric concepts –for economical paper and board production
Energy consumption is an increasingly important point of attention
within the paper industry. Oil prices have reached all-time highs,
driving up in turn the cost of energy, raw materials and additives.
And at the same time, paper and board prices are under pressure.
Rising costs and falling prices clearly mean less profitability. This
article touches on some aspects where forming fabrics, especially
SSB designs*, are able to help in reducing papermaking costs.
* SSB fabric concepts
SSB stands for Sheet Support Binder– the latest technology in forming
fabric production. In contrast toconventional 3-layer forming fabrics,
separate binding threads for holding
together the individual layers are notrequired.

52

Forming fabrics

quality and achieve the highest paper
machine runnability. Within time,

Forming fabrics are technical con-constant innovations in forming fabricsumables in the process of making

designs have helped make paper

paper and board. The function ofmachines wider and faster while

a forming fabric is to help the mills

improving the quality and runnability

reach the required paper/board

requirements.

23 I 2007 I Voith Paper I twogether

TECHNOLOGY

Forming fabric cost-comparison

sumption (m2/1,000 tons of paper

Forming fabrics cost-savings

produced) by the forming fabric pricepotential

The contribution of forming fabrics to

per m2 (Euro/m2). Working with the

reducing costs can be viewed from

specific forming fabric price has been

Apart from the specific forming fabric

two sides. There is, of course, thea real eye opener for many people

price, the savings that can be at-

price of the forming fabric itself. The

who often come to premature conclu-

tained by applying the most suitableprice is normally dependent on thesions based merely on the price offorming fabric design are far moredesign, the dimensions and the pos-

the fabric.

interesting. Optimally fulfilling the twosible options applied. Secondly, there

main functions of a forming fabric

are costs that can be reduced bySpecific forming fabric(paper quality compliance and PM

applying a particular forming fabricconsumption

efficiency) not only brings substantial

design. A forming fabric is a technicalsavings thanks to higher paper ma-

product that has a big influence on

Modern SSB concepts have signifi-chine efficiency, but also reduces

runnability, energy, raw material andcantly decreased the specific forming

energy, raw materials and additives

additives costs.

fabric consumption. The share of

consumption.

SSB concepts has increased from
A good way to judge the forming fab-just below 10% to over 50% from

SSB fabrics –ric price is to use the specific forming

2001 to 2005. At the same time, thethe optimal solution

fabric cost in Euro/1,000 tons ofspecific forming fabric consumption

paper produced. The specific cost

for all designs has decreased overall

Contradictory needs and wishes

can easily be calculated by multiply-from 14.3 m2/1,000 tons to 13.0 m2/

regarding the wet end of a paper ma-

ing the specific forming fabric con-1,000 tons, a reduction of nearlychine often mean making a compro-

10%**.

mise. Currently, the SSB designs holdthe lowest concessions and the high-Forming fabrics total deliveries in Western Europe (Plastic only 1,000 m2)**

est possibility of helping paper mills
reach the required paper/board qual-

1200

ity, achieving the highest paper machine runnability and most economical production. SSB fabrics with their

Forming fabrics [1,000 m2]

1000

800

New technologies(ex. SSB)

600

Triple layer-2.4% p.a.

400

Double layer-6.3% p.a.

200

Single layer-9.0% p.a.

special advantages optimally support
our customers in reaching their requirements, and, therefore, bring thehighest potential cost savings for the
wet end.

% p.a. 05/95

Introduction of the SSB concept haslead to an increase in paper andboard quality and better machine runnability. In the graphics sector, where
there is a high percentage of recov-

085 86 87 88 89 90 91 92 93 94 95 96 97 98 99 00 01 02 03 04 05
Yearered paper, the conventional threelayer designs cause quality problems,** Source: PCA, statistics bulletin no 12 – September 2006 – Western Europe only

23 I 2007 I Voith Paper I twogether

53

TECHNOLOGY

i.e. marking and roughness, andand other operating media. The dif-stimulate homogeneous sheet forma-sometimes lead to poor runnability

ferent types of energy and media

tion during the dewatering process,through delamination problems andconsumed on and around a wire sec-

thanks to their surface design andlimited life potential. Therefore, thistion are electricity, vacuum, hydraulic,pulse transmission, are likely to needpart of the industry was more or lessair, water, and sometimes steam.

less vacuum. During sheet formation

forced to stick to double-layer de-Significantly influenced by the ap-

the open sheet structure is retained insigns. The SSB designs are now able

plied forming fabric design are thethe forming section and facilitatesto eliminate these negative effects

consumptions of electricity, vacuum

dewatering through the suction couch

while improving formation, Z-direc-

and water. Electrical power is re-roll. A forming fabric with a fine papertion fines/filler distribution and run-quired for driving the fabric, vacuumside and a high open surface area

nability.

is required for dewatering and sheetwith the right air-permeability range

transfer, and water is used to clean

will help with this aspect. An addi-

Other cost parameters

the fabric or for sheet knock-off.

tional advantage of such a design is

SSB designs have made it possible to

The right choice of a fabric can sig-

boost machine runnability and reduce

nificantly decrease power consump-

the amount of costly raw material andtion. A fabric design with an open

Water is used among other purposes

additives. Machine efficiency is in-machine-side structure undergoes

for keeping the fabric clean and forcreased as a result of cleaner run andless resistance from the dewateringknocking off the sheet. If the forming

better water handling. Formation iselements, and, therefore, consumes

fabric is designed in a way that allows

improved due to the ability to apply

less operating power. As a rule ofit to run cleaner, then naturally lessless retention aid, run at higher

thumb: the percentage decrease incleaning is required. High-pressure

speeds without risk of marking, andnumber of wear side cross direction

spray pipes with smaller holes canensure a more controlled water han-yarns corresponds to the amount ofthen be used, and in many cases theydling. Smoother paper and board sur-electrical energy saved. Optimal

are even replaced with periodic use

faces and more uniform Z-directionenergy savings are achieved here byof e.g. a Voith DuoCleaner. Thin form-

filler/fines distribution has led to sav-using modern SSB designs withing fabrics with low internal volume

ings on coating/starch consumption,

paper side versus machine side weftrequire less water to knock off theand less waste due to blackening.

yarn ratios bigger than 1.

sheet. In both cases less fresh waterthat less power is required for driving
the fabric.

is used, thus enabling significant
Vacuum is used for dewatering andcost-savings potential. As mentioned,

for transferring the sheet. The major-

fine forming fabrics with high paper

Apart from raw material and additives,

ity of the energy is consumed by theside support and open wear sides

paper machines also need energy

high vacuum elements. Fabrics thatoffer the best savings potential.

Operating media consumption

Binding weft thread patternin an SSB fabric design*.

CD

54

23 I 2007 I Voith Paper I twogether

TECHNOLOGY

PrintForm HQ.

Well-proven products

PrintForm HR.

tremely good sheet support. The HQ

Summary

designs have a relatively coarse maVoith Paper Fabrics has a strong newchine side with high shear and cross

SSB forming fabrics offer huge sav-

SSB product range known under the

directional stability, which makes

ings potential in the wet section. The

names PrintForm H and MultiForm H.

for long life potential. The applied

somewhat higher price of SSB fabrics

Within this range we have two uniquehigh shed weaving technology (seesoon pays off thanks to the resultant

products: the PrintForm / MultiForm

twogether 21, p. 58 ff.) gives a mark-savings in and around the forming

HQ and HR. The PrintForm HQ can

free structure. By selecting the opti-

section. These savings are due not

be placed in the “fine” segment ofmal design, cost savings can be

only to the higher machine efficiency,

SSB designs. It is a design appliedachieved in clean running, additives

but also with regard to raw materials

typically in the graphics area for high-use, vacuum, water and power con-use, additives consumption and pow-

quality grades.

sumption.

er consumption.

The MultiForm HR is a somewhat

PrintForm HR, MultiForm HR

more robust forming fabric design,specially conceived for high-quality

An important advantage of MultiForm

packaging grades (corrugated board).

HR and PrintForm HR forming fabrics

They both provide the ultimate sup-lies in their open warp density, result-port for our customers’ requirements,

ing in the same advantages as withand offer a high cost-savings poten-

the HQ fabrics. Another advantage oftial thanks to their fabric design.

this design is that the wear side holds
long cross directional weft flotations,

PrintForm HQ, MultiForm HQgiving the fabric long life potential.
The floats go over 8 instead of the

The distinguishing characteristic ofmore usual 6 or 5 warp threads. Here

Voith PrintForm HQ and MultiForm

again, selecting the optimal fabric

HQ forming fabrics is their low warp

design brings cost savings in cleandensity and high number of crossrunning, additives use, vacuum, water

directional yarns. This results in ex-

and power consumption.

23 I 2007 I Voith Paper I twogether

Contact
Johan Mattijssen
Fabrics
johan.mattijssen@voith.com

55

TECHNOLOGY

NipMaster and NipSense
help papermakers improve machine runnability
The importance of roll covers on paper machine efficiency andpaper quality has already been extensively reported in previous
issues of twogether Magazine. Voith Paper Rolls is developing
new covers fulfilling future requirements (higher machine speed,
reduced energy consumption, better paper quality, ...)of the paper makers.

Strong application expertise in cover

Therefore it is of prime importance toselection, design and on-site support,

understand and predict the process

is required to obtain the expectedin the nip: peak pressure in the nip,

performance and all potential benefits

nip width, heat generation, coolingfor the papermaker, in term of ma-requirements, absence of non-unifor-chine efficiency, total cost of owner-

mity in cross machine direction, andship and paper quality.

absence of overloads to avoid cover
failure.

Application know-how includes paper
making process understanding, roll

Soft press and suction roll covers

cover properties and their impact on

have to be designed to offer thethe paper making process, as well as

required storage volume for nip

calculation and measurement tools.

dewatering, at the end of the felt
life and after several regrinds. The

The purpose of this article is to reportpressing has to be uniform in theon NipSense and NipMaster, some ofcross-machine direction for uniformthe major tools used by the applica-

dryness.

tion engineers of Voith Paper Rolls for
ensuring successful operation of rollMichael Weinzettl and Mike Radtke,

covers.

polyurethane roll cover product managers and specialists of nip dewater-

56

The key applications of roll covers

ing, report how a suction press rollare pressing the sheet for dewatering,cover is designed and optimized with

apply starch or colour, and calendering.

NipMaster in its operation.

23 I 2007 I Voith Paper I twogether

TECHNOLOGY

Nip Calculation.

Surface Design.

Step 1: assess the type of paper

Step 5: define limits of safe opera-

continue with start-up support andproduced, operating conditions,tion. The calculation engine devel-

follow-up of operation.

press configuration, type of felt used,

oped by Dr. José Rodal, VP R&D

felt and roll conditioning, moisture in

North America, to solve the nonlinear

Key activities include:

the felt.

contact problem of dissimilar multi-● Assessment of nip conditions

layer viscoelastic covered rolls is run● Checking roll and felt conditioning

Step 2: with NipMaster, our new

for the assessment of the stresses,● Checking operation temperaturesroll cover design, calculation andstrains, temperatures and other im-● Checking doctoring.

measuring software assess theportant press roll engineering param-

current operating situation using as

eters under current or future condi-

A key tool and new development for

input those parameters.

tions of paper machine operations.

assessing the nip conditions is theReports on some of the capabilities

NipSense instrument for electronic

Step 3: define most appropriate rollof the computing program has been

nip measurement, which uses a new

surface design for customer expecta-

given at the 2005 TAPPI Papermak-

generation of sensors and intelligent

tions (uniform dewatering, increased

ers Conference.

microchips to achieve superior

dryness, elimination of shadow mark-accuracy.

ing by reducing hydraulic pressure

Step 6: give a final recommendationin the nip or allow higher machineand cover argumentation. It is known

Because Voith designs and builds

speed without loosing dryness).

that two identical paper machinespress sections, Voith Engineers have

may not always produce the same

unmatched expertise in the optimiza-

Step 4: make a water balance calcu-

end result. Therefore the task of thetion of nip profile. NipSense comple-

lation and define improvement poten-

application engineering can not end

ments this expertise with patented

tial in dewatering.

with design calculations and mea-

technology that provides the same

surements, but it is very important toresolution in the Cross-Machine

23 I 2007 I Voith Paper I twogether

57

TECHNOLOGY

designed pattern with 41.5% openarea.
Immediately after start-up, the average press section draw came downfrom 2.7-2.8 % to 2.3-2.4%. An extra
bonus with the Aqualis was that themill was able to significantly shorten
their felt break-in time. The machineis speed limited at 1,275 m/min(4,186 fpm) because of the suction
Nip profile resulting from a miscrown.

couch roll drive, but with conditioned
felts, they have seen their steam

Direction as prescale film scanning,

Before deploying this new electronic

consumption reduced between 4-7%

but in real time. Real-time display

nip measurement device around thedepending on the days. This repre-

technology shows actual nip-width

world, extensive field trials have been

sents approximately 2,000-3,000 kg/h

variation with time as load is applied

conducted with great success.

of steam savings (at a value of overon rolls. NipSense systems have a

200,000 € / $ 250,000 per year).

minimum of 32 sensors in the cross-

The NipSense measurement is cou-

machine direction but NipSense canpled with the NipMaster computer

Contact Voith Paper Rolls for details

also be deployed with 64 or moreprogram, allowing to use the sameand starting a program for optimizing

sensors in the cross-machine if de-set of parameters for both measuring

the runnability of the roll covers insired. This greater resolution allows

and calculating the nip situation.

your machine, increase your efficien-precise solution of nip profile prob-

Effect of overload can be computed.

cy, reduce the unplanned shut-downlems. Wireless connectivity allows

The calculation engine is able torisk and costs or improve your paper

you to make load adjustments while

calculate the stress distribution within

quality combining your paper making

you look at the resulting nip profile.

the cover in case of overload andknow-how with our applicationassess the risk of cover damage, andexperience.

NipSense proprietary technology

also to compute the pressure distri-involves intelligent microchips thatbution in cross machine direction andmonitor the health of the sensor andthe effect on sheet pressing and de-connections, as well as eliminatingwatering in cross machine direction.

the need for calibration.
The successful optimization of a press
NipSense allows measurement of

was demonstrated at a producer of

3 nips simultaneously. The ability tonewsprint. The producer installed an

measure on-line 3 nips is a great way

Aqualis suction roll cover (blind drilled

to visualise the very complicatedand grooved) on the DuoCentri II-type

influence of one nip to the other in apress. This replaced a grooved suc-cluster press in a minimum amounttion roll that needed recovering. Theof time.

cover was 5 P&J and had a custom

58

Contact
Dr Michel Beltzung
Rolls
Michel.Beltzung@voith.com

Dr José Rodal
Rolls
Jose.Rodal@voith.com

23 I 2007 I Voith Paper I twogether

TECHNOLOGYProfile Maintenance Program utilizing
Virtual Reference Grinding (VRG)
The recent development by Voith Paper’s Tissue Cylinder Services
group of its Virtual Reference Grinding (VRG) technology has truly
revolutionized the way Yankee and MG cylinders are ground. By
combining scanning lasers with computerized control of grinding
forces, the VRG has set a new standard for speed and accuracy
in the grinding of crowned or profiled cylinders in the field.

23 I 2007 I Voith Paper I twogether

59

TECHNOLOGY

VRG system.

Helix surface measurement.

This technology has led to a re-exa-

based on the amount of time the ma-

which utilized a heavy platform bed

mination of the practices concerning

chine could run before problems withthat weighted 14,000 lbs!

the planning of Yankee profile grin-moisture control, edge breaks and pi-

ding. The new paradigm is the Profile

cking made a significant impact uponA typical mill can save 12-24 hours

Maintenance Program (PMP). PMP

the machines efficiency. The focus

of pre and post grind machine prepa-

takes advantage of other planned

was on extending the runtime as longration work when using the VRG for amaintenance outages to complete

as possible to avoid the 2-3 days

typical grind. Another advantage ofa profile maintenance grind in 24-

downtime required to complete a fullthe VRG is the unparalleled level of

32 hours. By adopting this program

profile grind. A typical grind removes,documentation included in the grind

tissue companies are embracing the

on average, 0.030” from the radius ofpackage.

philosophy of preventive mainte-

the cylinder. Often mills over estimate

nance. This as opposed to the run to

the amount of run time required to

The VRG system gives complete top-

“failure” practice currently used by

get to the point of significant machine

ographical scans of the drying cylin-

many in the industry with regard to

impact caused by poor conditions ofder before, during and following thethe condition of their most important

the Yankee’s profile. This can result

grind. This allows the mill to evaluate

assets.

in weeks or even months of reduced

the condition of the cylinder before

paper machine efficiency and off

the grind to determine any unusual

quality production.

wear conditions which might indicate

The Yankee dryer is the heart of conventional tissue machine. Its crown ora problem with the condensate remov-

profile is critical in establishing theWith the development of the VRG,

proper geometry between the pressu-

crown profiles can ground by a sys-

re/dewatering rolls and the Yankee

tem that mounts directly on an exis-

Experience has shown that the wear

when it is under a full condensing

ting doctor blade holder. This doctor

rate overtime for the Yankee surface

load. The Yankee profile degrades

mounting eliminates the need to re-is not linear. As the miss-crownover time due to the cumulative effectmove pressure rolls and other heavy

condition increases between pressu-

of process upsets. Yankees have be-paper machine components. Thisre rolls and the Yankee and as

en typically ground on a cycle thatcompares to the efforts required tooperators make doctor blade adjust-has been established with experience

prepare a machine for the previous

ments to cope with low/high moisture

over time. Normally this cycle wasTangential Grinder (TG) technology

areas, the wear rate accelerates.

60

al system or the coating sprays etc.

23 I 2007 I Voith Paper I twogether

TECHNOLOGY
Number Downtime Total downtime Materialof grinds hours
for profile grind removal
per grind/grind0

Total
removed

$ per
grind

Total $

0.090“$ 50,000$ 150,000

New
4
30
120
0.015“
0.060“
18 month cycle
Hours saved
60
Increased grind cost
Machine time ($/hour)
Based metal savings
0.030“Total downtime savings
Efficiency savings in last 90 days before grind$ 2,400 (per day) x 90 (days) = 216,000 x 3 (regrinds) = $ 648,000$ 57,500$ 230,000

Material loss in inch

-0.005Current
3
24 month cycle

-0.01
Loss
-0.015-0.02-0.025-0.03-0.035
4

8

12

16

20

24

Months from profile grind

60

180

0.030“$ 80,000$ 5,000$ 300,000

Total 6 year savings$ 648,000$ 868,000

Yankee Wear Rate.

Profile Maintenance Program savings. Time frame 6 years, 72 months.

As shown in the graph, the wear rateaching the accelerated portion ofa PMP. This reduction in base metal

accelerates as the radial loss passes

their machines wear curve. In theloss can considerable extend thethe .012’’ point in the low areas. Du-

example from the graph, a grind isuseful life of the Yankee.

ring the final 6 months of operation

indicated at or before 18-19 months

prior to grinding, the tissue machine

versus the previous practice ofIn summary, by adopting Voith’s

usually experiences an increase in

24 months. The actual wear curve va-

Profile Maintenance Program philoso-

breaks and quality issues that areries for each machine. But a rule ofphy for your conventional Yankee

gradual but very persistent. Efficiency

thumb is that a grind is most likely in-dryer you can substantially reduce

losses during this period which candicated at the 2/3 point of the histori-

downtime associated with profile

have significant economic impact on

cal grind cycle for each machine.

grinding, avoid efficiency/quality losses associated with miss-crowning,the mills results. Due to the gradualnature of this degradation it may go

The table gives an example of theand extend the lifetime of this criticalunnoticed until the operation of thepotential savings from adopting PMP

assets. At the same time you willmachine is effected to the point thepractices. More frequent grinds of areceive all the benefits of the VRG’s

mill can not longer put off the need toshorter duration result in significantly

accuracy, advanced mapping andgrind.

reduced downtime over the sample

documentation capabilities.

period. A net savings of $ 868,000
Many mills experience an increase inin downtime (minus additional grind

the amount of organic coating re-costs) was found in this example.

quired to keep their machine running

Efficiency losses were valued atwell during the final phase of the ex-$ 2,400 per day for the final 90 days

tended grind cycle. The additionalof the tradition grind cycle (including

cost of this chemistry can run several

breaks, chemical usage, machine

thousand of dollar per day when

speed, quality issues).

compared to usage rates just following the grind.

These saving figures do not attempt
to put a value on the savings of one

By adopting a Profile Maintenanceadditional grind worth of material base

Program (PMP) the mill can avoid re-stock left on the Yankee by adopting

23 I 2007 I Voith Paper I twogether

Contact
Ted Johnson
Rolls
Ted.Johnson@voith.com

61

TECHNOLOGYNew Service Center now also in Chile
The maintenance and optimization service offered by Voith to thepaper industry worldwide is highly appreciated and sets thestandards in quality and reliability. Chile will now also have a new
Service Center to help local paper and pulp producers to maximize
their productivity, lengthen the intervals between maintenanceworks and optimize machine availability.
Investment in new paper and pulp

ization acquired in other Voith units in

Association and local authorities.

mills in Chile has grown substantially

Brazil now share their knowledge with

After that, cocktails with a Brazilian

in recent years. Realizing the need

the Chilean technicians, building withand Chilean atmosphere and a delight-

for high-quality service, Voith in-them a strong experts team. Besides

ful lunch were offered. The customers

stalled in early 2006 a new Service

that, the local team can easily con-left the place with confidence that

Center in Concepción, Chile.

nect with Voith’s global specialists

Voith is now really rooted in Chile.

network to provide solutions for the
Until then, no OEM service units werecomplete paper making process.

The Voith Service Center in Chile will
fulfill the customers’ needs, ensure

available in the country and paper
mills were forced to have the mainte-

Almost 2 years ago Voith started tothe supply of services with the samenance services of their equipment

look for a proper area in Concepción

quality found in more than twenty

carried out internally or through small(530 kilometers south of Santiago) to

Voith Paper Rolls service units spread

local workshops or done in foreign

built a new service unit. On Octoberover the five continents, to support

countries.

26th, 2006 the opening ceremony forpapermakers to be more competitive

the new center finally took place. In-

in the global market.

The new service unit, the fifth of thevited customers were informed about

Voith Group in South America, offers

the extent of the available services

to the Chilean market Voith’s know-

in a nearby golf club. A tour throughhow in the design, manufacture and,the Service Center was followed

particularly, maintenance of equip-

by a short inauguration ceremony inment. Technicians with several years

the presence of many customers,of experience, training and special-members of the Chilean Pulp & Paper

64

Contact
Cesar Schneider
Rolls
Cesar.Schneider@voith.com

23 I 2007 I Voith Paper I twogether

SEMINAR“Life Cycle Partnership” presented in China –High interest in lasting partnership
In late September / early October 2006 Voith Paper China held
three seminars in Qingdao, Shenzhen and Shanghai for paperindustry customers in these regions. The interest was so highthat 250 customers from 60 large and medium size companies
attended these events. Among the leading Chinese papermakers
welcomed by Voith Paper China were Hua Tai, Gold East, Sun
Paper, Nine Dragons, Lee & Man, Hong Ta and Gold Huasheng.
For these seminars Voith Paper China

70 million Euros had been invested

And as a new development: in future

had put together a first-class team ofin the new Paper Technology Center

the Voith Paper China headquarters

its own specialists, supported by ex-

at Voith headquarters in Heidenheim.

will be in Kunshan, just outside

perts from Voith Technology Centers

President Ming Ming Lou pointed

Shanghai. Among other departments

worldwide.

out how Chinese customers can also

located here will be sales and mar-benefit from this R&D center byketing, development and engineering,

The seminar was led by Ming Ming

having trials carried out there underspare parts logistics, project man-

Lou, President Voith Paper China.

realistic conditions.

agement, and automation. Voith

She began by introducing Voith

Paper Fabrics and Rolls Service divi-

Paper as a supplier and partner cov-

Life Cycle Partnership, the theme ofsion plants were already establishedering the entire papermaking processthese seminars, is an all-embracingin Kunshan some years ago. Voith

from stock preparation and sheet

approach covering technical service

Paper China also has state-of-the-art

formation to finishing and slitter-for paper production lines rightmanufacturing facilities and service

winding. Voith Paper also supplies

through their operating life time. Thiscenters in the Chang Jiang Delta andthe entire web transfer system andalso includes technical consulting, re-Round-Bohai regions, where a large

components such as rolls and fab-build concepts, spare parts supplies,

part of China’s paper industry is con-rics, she explained, as well as theongoing process optimization andcentrated.

complete automation. This enables

comprehensive after sales service

single-source delivery of complete(AMB products). “We offer all-inclu-“Process Line Package” (PLP) pro-sive service and support for the entire

duction lines comprising optimally

production line right through its oper-

matched modules and components.

ating life”, explained Ming Ming Lou,

To further consolidate Voith Paper’s“and that is why we aim for life-cycle

reputation for innovation leadership,partnership with our customers”.

23 I 2007 I Voith Paper I twogether

Contact
Susan Zhao
Voith Paper China

65NEWS FROM THE VOITH GROUP

Energy from active breakwaters
Wave power is one of the largest global energy resources, but isinnovative technology in existing or

also one of the most difficult to harness. Wavegen, a wholly owned

new port facilities and breakwaters,

subsidiary of Voith Siemens Hydro Power Generation, started tap-

etc. to make the most of synergies:

ping wave power at the westernmost point of Islay in the Hebrides.

construction costs can be shared between the power plant and port facility operators. In nearly all cases com-

This system utilizes wave power indi-

the airflow direction keeps changing,missioning and maintenance work

rectly through the oscillations inside

the turbine always drives the genera-

can be carried out entirely on shore

an onshore chamber connected un-

tor in the same direction – thanks

without incurring any costs for spe-

derwater to the sea. When the water

to the ingenious turbine blading

cial marine infrastructures or vessels.

level in this chamber rises with anconcept.

Furthermore, grid connections fromincoming wave, the air column above

this onshore system are far easieris forced out through a turbine, andAs nearly always, this concept was

and much less expensive. And very

when the level falls again, air isderived from Mother Nature. Appar-

importantly: the Wavegen system has

sucked in through the turbine (seeently the inventor Alan Wells was in-

no impact on coastal environments.

diagram). In other words, the systemspired by the way the birds’ up and“breathes” through the turbine indown wing strokes propel them in

Based on operating experiencerhythm with the waves. But although

only one direction. So his Wells tur-gained in the Hebrides, the firstbine does exactly the same thing the

Wavegen plant is now planned inother way round: the turbine rotates

Germany as a joint venture between

in the same direction whichever way

Lower Saxony Land and the EnBW

the air flows through it.

power utility. Here again, the rated
output will be 250 kW. A much larger

The oscillating water column pushes andsucks air through a Wells turbine.

66

According to Voith Siemens Hydro

Wavegen project with 3.5 MW rated

estimates, global wave energy utili-

output is currently under study for thezation potential amounts to at least

Hebrides island of Lewis. This would

100 GW. As a next step, Voith

supply enough renewable energy for

Siemens Hydro plans to install thisabout 2000 households.

22 I 2006 I Voith Paper I twogether

Photo: Stora Enso Baienfurt

NEWS FROM THE VOITH GROUP

Voith Industrial Services Voith Water Tractors will soon escort the biggest
implements OPM
cargo vessels into the world’s largest container port
Operator Maintenance atShanghai Deepwater Port, currently under construction,

Stora Enso, Baienfurt

will be the world’s biggest container port when completed.

OPM is an innovative maintenance

The location of Shanghai’s new deep-

22 km/h). They are also equipped

concept to ensure optimal plant avail-water port – 32 kilometers off thewith state-of-the-art firefighting sys-ability. It covers not only mainte-

coast – reflects the enormous dimen-

tems. These two Voith Water Tractors

nance, but also inspection and trou-sions of this infrastructure project.

will be equipped with the four Voith

bleshooting.

With a mean depth of 15 meters,

Schneider Propellers for decisive rea-This concept enables the operator

Shanghai Deepwater Port will accom-sons: their safety and reliability, ma-

to take over certain maintenance,

modate the largest container vessels.

noeuvrability and precision in tug andinspection and troubleshooting activi-

As of October 2007 Voith Water Trac-

escort duty as well as for firefighting.

ties, thereby improving working

tors (VWT) will assist them in safely

methods, reducing repair costs andentering the harbor and tying up at

In October 2007 both Voith Water

increasing machine efficiency.

their terminals.

Tractors will go into service after

For OPM implementation, the Voith

completion in only one year. By thenIndustrial Services team divided the

For these two new VWT, built at San

some of the 50 container terminals

project into three phases over a one-Lin Shipyard, Voith Turbo Schneider

will be ready, and it is already clear

year time span. A special training

Propulsion is supplying four Voith

that several more Voith Water Tractors

program was developed to prepare

Schneider Propellers size 28 (28 R5/will be required by the time Shanghai

the Stora Enso production and logis-210-2), four Voith 1330 DTL fluid cou-

Deepwater Port is completed.

tics people for their new tasks.

plings, and two control stands. Crew

The OPM activities will be analyzed

instruction will be taken over by aMore than 800 Voith Water Tractors

in working groups and divided there-

Voith training captain, and the Chi-

are currently in service at over 120

by into maintenance task packages

nese shipbuilder will also benefit fromports worldwide. The long-standing

with a view to activity planning by

Voith Turbo Schneider Propulsion

success of this concept is proved by

SAP in future. The goal of this OPM

design and construction know-how –the Alaskan Environmental Ministry’s

project is to create an innovative andafter all, these 30 m long and 11.2 mclassification as “Best Available

modern working concept for the pa-

wide VWT are custom-made for theTechnology” (BAT).

per industry that will set benchmarks

new deepwater port. Powered by twoin the Stora Enso Group, when fully

1,940 kW Yanmar diesel engines,

implemented.

their rated speed is 12.5 knots (about

22 I 2006 I Voith Paper I twogether

67

68

23 I 2007 I Voith Paper I twogether

CULTURE

Paper bridge
supports Chinese clay soldier
It sounds improbable at first, bearing in mind that a clay soldierof this sort weighs around 300 kg (661 lbs). At the 6th paper bridgecompetition held in 1999 in Mecklenburg-Western Pomerania,
Germany, it was however proved that such a load could be borne,by a 40 cm (15.75 inches) span, by a paper bridge. Every year
since, students from elementary school to college have been
striving to beat this record.
The Mecklenburg-Western Pomerania

pacities are determined using a test-

paper bridge competition has been

ing machine. A single load is placed

held at the Institute of Industrial

on the center of each bridge. The aim

Engineering at Rostock University forof the paper bridge competition is to

13 years now. The aim is to build as

get students from elementary/highstrong a bridge as possible with aschool to college thinking both cre-clear span of 40 cm (15.75 inches)

atively and technically.

using a maximum of 150 g (5.3 oz)of standard Bristol board and glue

The hordes of participants, especially(UHU, Pritt, etc). The amount ofin the elementary/high school stu-

paper permitted is roughly equal todents category, span all ages. The

30 sheets of normal printing paper

youngest are aged around nine and(80 g/m2). The competition features

the oldest 17 to 18. The competition

two categories: ‘elementary/highis especially popular with thoseschool students’ and ‘college stu-around the age of 12/13, because

dents/staff’. The bridges’ load ca-

they have the chance to try out their

The most stable
paper bridge
to date bore
304 kg, whichis equal to theweight of a
Chinese clay
soldier.

23 I 2007 I Voith Paper I twogether

69

CULTURE

Different paper constructions.

designs in physics lessons and putof physics. If you look at a piece ofhigh pressure should have solid pa-

their bridges to the test in a real com-paper, it’s fairly obvious that based

per tubes beneath them, for example,

petition. But also among college stu-

on its geometry, it’s not suitable forwhile strips of paper are sufficient fordents, interest has been expressed

absorbing compressive forces. Wereareas subjected to pulling forces.

by mechanical engineers, civil engi-

the paper to be rolled into a tube,

It is also worth noting that long, thinneers and even a group of female

however, it would be able to with-sticks kink very easily (see kebab

economists who won the competition

stand a fair amount, and halving the

stick), whereas shorter sticks are

in 2004.

length of the tube with the same

much more stable (such as matches).

amount of paper doubles this load
If you were to hold the specified

capacity. If, on the other hand, you

When choosing the optimum struc-quantity of paper in your hands, youwanted to tear the same sheet ofture, it is worth looking back to thewould ask yourself how on earth thispaper by applying a pulling force atreally early days of bridge building.

could support a Chinese clay soldier.

the ends, you would need a consider-This may not seem particularly logi-

This is where the creative thinking

able force. It is through the combina-cal, since the first big bridges werecomes in: the idea is to find the besttion of these two properties that the

all arched stone bridges, but even

way of bringing out the paper’s con-strongest bridge is made. This means

these needed adapting to construc-

structional properties using the lawsthat the areas, which are subjected totional properties. The stones used
could indeed cope well with compressive forces, but they were also

Checking the overall weight.

Testing the load capacities.

very susceptible to pulling forces. An
arched structure is ideal when using
this type of material, because when
the load is central, only compressive
forces are applied. If you are to adapt
this principle to a paper bridge, thearch must be reproduced using short,tightly rolled tubes stuck together atthe ends. Since this type of construction is not one single, constant arch,
compressive forces will be directedto the joints, causing the structure tobuckle. This is where the paper’s
good resistance to tension comes into its own, using straps at the points
where the paper tubes meet to pre-70

23 I 2007 I Voith Paper I twogether

CULTURE

vent buckling. Cleverly redirecting thegram. Despite these considerable

mutually exclusive, as shown by thepulling forces enables you to balance

efforts, however, a number of compe-

skeletal bridge mentioned above. Not

out the two halves of the bridge. The

tition entries were needed before get-only was it a realistic replica of exist-

resultant bridge construction can alsoting the load capacity of his bridge

ing steel framework bridges; it also

be seen as a ‘truss construction’.

design over 237 kg to the record level

achieved a respectable load capacity

This design is sometimes used forof 304 kg (670 lbs). This was in partof 81.9 kg (180.5 lbs).

modern concrete and steel compos-

due to the impact the joints had on

ite bridges too, whereby the concreteload capacity, which could only be

The organisers are eagerly anticipat-

absorbs the compressive forces andaccurately determined when put to

ing the competitions to come, which

the steel absorbs the tensions.

the test. It was also because theare sure to produce yet more innova-

strength values of the paper and thetive and impressive bridge construc-

Of course, other bridge designs arejoints were hard to pin down andtions and designs.

also possible, such as the skeletal

subject to certain random variables.

structure, which, as a design by high

Dr Olaf Mertzschschool students, demonstrated a highEach year though, the results of the

Rostock University

load capacity of 81.9 kg (180.5 lbs).

high school student’s competition

Area of expertise:

Experience suggests, however,prove that high load capacities cansolid constructions

that the largest load capacities are

be achieved without sophisticatedachieved using an arch truss con-analyses. This year’s school bridge

struction, or at least they have been

was carrying a good 118 kg (260 lbs)

so far. The maximum load capacity ofwhen it went down with a loud crash.

this type of bridge, with a 40 cm span

The record in this category currently

and no more than 150 g (5.3 oz) ofstands at 198.1 kg (436.7 lbs), underpaper, is currently 304 kg (670 lbs).

the same conditions as previously

In 1998, a similar bridge earned itself

described.

Entryin theGuinness
Book of
Records.

a place in the Guinness Book ofRecords for its 237 kg (522.5 lbs) load

So as to keep the Olympic ideal alive

capacity. It’s worth noting that thewithin the competition, there is aperson who built this bridge not only

prize each year not only for the stron-

followed a logical thought process,gest bridge, but also for the prettiest,

but also carried out a whole range of

normally going to someone from apreliminary investigations. He studied

high school. With this prize it’s all

the paper’s tension resistance andabout the multitude of tiny details.

perfected the load-bearing structure

When it comes to paper bridges, how-of his bridge using a computer pro-

ever, strength and beauty are not

23 I 2007 I Voith Paper I twogether

71

HIGHLIGHTS

Startup highlights 2005/2006
Fiber Systems
Stock preparation systems
and sub-systems for graphic
papersBowater Newsprint, Calhoun,
TN, USA.
Weyerhaeuser, Hawesville, USA.
International Paper, Eastover,USA.
Bowater Canadian Forest,
Dolbeau-Mistassini, Canada.
INPACEL, Arapoti, Brazil.
Guangzhou Paper, Guangzhou,
China.
Shandong Huatai Paper, Dongying,
China.
Sappi Ehingen, Ehingen,Germany.
Holmen Paper, Madrid, Spain.
Metsä Tissue, Katrinefors Mill,
Sweden.
Papierfabrik Hermes, Düsseldorf,
Germany.
UPM Nordland Papier, Dörpen,
Germany.
Australian Paper, Burnie,
Australia.
Arkhangelsk Pulp and Paper Mill,
Novodvinsk, Russia.
Voith Paper Technology Center,
Heidenheim, Germany.
Norske Skog Parenco, Renkum,
Netherlands.
Mondi Paper, Durban,
South Africa.

72

Stock preparation systems
and sub-systems for board
and packaging papers
Greif, Riverville, USA.
Republic, Lawton, USA.
CMPC Procor, Puente Alto, Chile.
ORSA, Nova Campinas, Brazil.
CMPC, Valdivia, Chile.
OAO Kiev Cardboard and Paper Mill,
Obukhov, Ukraine.

Stock preparation systems
and sub-systems for tissue
papersSCA South Glens Falls, USA.
Papeles Higienicos de Mexico,Col. Cuauhtemoc, Mexico.
Georgia-Pacific, Rincon, USA.
Georgia-Pacific, Muskogee, USA.
Fabrica de Papel San Francisco,
Mexicali, Mexico.
Wausau Paper, Rhinelander, USA.
Coastal Paper, Wiggins, USA.
Kimberly-Clark de Mexico,
Ecatapec de Morelos, Mexico.
PSA, São Leopoldo, Brazil.
CMPC Tissue, Talagante, Chile.

Paper Machines

Veracel, Eunápolis, Brazil.

Dresden Papier, Heidenau,
Germany.
Mondi Business Paper, Ruzomberok,
Slovakia.
Moorim Paper, Jinju, Korea.
Mondi Business Paper, Szolnok,
Hungary.
Bowater, Calhoun, USA.
JSC Solikamsk Bumprom, Solikamsk,
Russia.
Pan Asia Paper, Jenjou, Korea.
Norske Skog Tasman, Kawerau,
New Sealand.
Norske Skog, Albury, Australia.
CMPC, Valdivia, Chile.
Celulose Nipo Brasileira, Cenibra,
Belo Oriente, Brazil.
Aracruz Celulose, Guaíba, Brazil.
International Paper, Eastover,USA.
Visy Pulp and Paper PTY, Tumut,
Australia.
Orsa Celulose, Papel e Embalagens,
Nova Campina, Brazil.
Klabin, Angatuba, Brazil.

Installation and rebuilds

Coating technology

Goricane Tovarna Papirja Medvode,
Medvode, Slovenia.
Dunafin, Dunaujvaros, Hungary.
Sappi Ehingen, Ehingen,Germany.
OAO Nemanski Cellulosno-Bumashni
Savod, Neman, Russia.
UPM Papeteries de Docelles,
Docelles, France.

Norske Skog, Walsum, Germany.
Delfortgroup, Dunaujvaros,
Hungary.
Mitsubishi HiTec Paper, Bielefeld,
Germany.
Mondi Business Paper, Szolnok,
Germany.
Mondi Business Paper, Merebank,
South Africa.

Graphic papers
Shandong Huatai Paper, Dongying,
China.
Voith Paper Technology Center,
Heidenheim, Germany.

Board and packaging papers
Atlantic Packaging Products, Union,
Scarborough Mill, Canada.
Saica, El Burgo de Ebro, Spain.
Zhuhai Hongta Renheng Paper,
Zhuhai, China.

Tissue
CMPC, Talagante, Chile.
Shandong Hengan Paper Products,
Weifang, China.
Hengan Paper, Jinjiang, China.
Productos Familia, Cajicá,
Columbia.

Dewatering machines

23 I 2007 I Voith Paper I twogether

HIGHLIGHTS

Papel Aralar, Aralar, Spain.
Perlen Papier, Perlen, Switzerland.
Burgo Marchi, Villorba, Italy.
Burgo Marchi, Verzuolo, Italy.
Bowater, Calhoun, USA.
ShinMooRim Paper, Jinju, Korea.
VPK Packaging Group, Oudegem,
Belgium.

Winding technology
Shandong Huatai Paper, Dongying,
China.
Sappi Ehingen, Ehingen,Germany.
MD Papier, Plattling, Germany.
SCA Graphic Paper, Laakirchen,
Austria.
Koehler Kehl, Kehl, Germany.

Holmen Paper, Madrid, Spain.
Shandong Huatai Paper PM 11 (2)Dongying, China.
Weyerhaeuser Pulp & Paperboard
Division, Longview, USA.
Mudanjiang Hengfeng Paper,
Mudanjiang, China.
3M Canada, Brockville,
Canada.
Trois Rivieres Centre Intégré enPates et Papiers, Trois Rivieres,
Canada.

Janus Concept
Perlen Papier, Perlen, Switzerland.
Papel Aralar, Amezketa (Guipúzcoa),
Spain.

Ecosoft calender
Zhangqiu Huashi Paper, Zhangqiu,
China.
Zhejiang Xianhe Special Paper,
Quzhou, Zhejiang, China.
Sappi Ehingen, Ehingen,Germany.
Vipap Videm Krsko, Krsko,
Slovenia.

Parent reel cart
Sappi Ehingen (2), Ehingen,Germany.
Shandong Huatai Paper, Dongying,
China.

Laborkalander, Krefeld, Germany.
Koehler Kehl, Kehl, Germany.
Weyerhaeuser Pulp & Paperboard
Division, Longview, USA.

Norske Skog, Albury, Australia.
Klabin, Angatuba, Brazil.
Hangzhou Tongda Paper, Fuyang,
China.

Roll cutting machines
Cartiere del Garda, Riva del Garda,
Italy.
Cartiere Burgo, Duino, Italy.
Oji Paper, Fuji, Japan.
Shandong Huatai Paper (2),Dongying, China.
UPM-Kymmene Papier, Schongau,
Germany.
Stora Enso Kabel, Kabel,
Germany.

23 I 2007 I Voith Paper I twogether

Mondi Business Paper, Merebank,
South Africa.
North-West Timber, Neman,
Russia.
Holmen Paper Madrid, Madrid,
Spain.
Saica, Zaragoza, Spain.
Cartiere Marchi, Toscolano, Italy.

Twister/Roll Handling
Roto Smeets, Deventer, Netherlands.
Shandong Huatai Paper, Dongying,
China.

NipcoFlex calender

Calenders
Finishing

Sappi Ehingen, Ehingen,Germany.

Automation
Sappi Alfeld, Alfeld, Germany.
UPM Nordland Papier, Dörpen,
Germany.
Norske Skog Walsum, Walsum,
Germany.
Stora Enso Kabel, Kabel,
Germany.
Munksjö Paper, Unterkochen,
Germany.
Stora Enso Baienfurt, Baienfurt,
Germany.
UPM Papeteries de Docelles,
Docelles, France.
Bowater Canadian Forest Products,
Donnacona, Canada.
Steinbeis Temming Papier,Glückstadt, Germany.
Shandong Huatai Paper, Dongying,
China.

Voith Fabrics
Nine Dragons PM 16, 17, China.
Lee&Man, China.
Zhangjiagang Huaxing PM 1, 2,
China.
Sea Dragon, China.
YFY Yangzhou PM 1, 2, China.
Mudanjiang Hengfeng, China.
Guangzhou Paper, China.
Gold Huasheng, China.
Sun Paper, China.
PT Fajar Surya Wisesa, Indonesia.
Hiang Seng Fibre, Thailand.

73

HIGHLIGHTS

Recent large orders
Fiber Systems
Stock preparation systems
and sub-systems for graphic
papersInternational Paper, Cantonment,
USA.
Bowater Canadian Forest,
Dolbeau-Mistassini, Canada.
Abitibi-Consolidated, Mackenzie,
Canada.
Propal, Cali, Columbia.
Daio Paper, Mishima, Japan.
Thai Paper, Khon Kaen, Thailand.
Stora Enso Publication Paper,
Hyltebruk, Sweden.
Emami Paper Mills, Kolkata, India.
Sappi Ehingen, Ehingen,Germany.
Rama Newsprint and Papers, Surat,
India.
EN Paper Jinju Mill, Jinju-City
Kyungnam, Korea.
JSC Solikamsk Bumprom, Solikamsk,
Russia.
Nampak Paper, Kliprivier,South Africa.

Stock preparation systems
and sub-systems for board
and packaging papers
Republic Paperboard, Lawton, USA.
International Paper, Mansfield, USA.
Klabin, Monte Alegre, Brazil.
São Carlos, São Carlos, Brazil.
PCE, Manaus, Brazil.

74

ZAO Proletariy, Surazh, Russia.
St. Regis Paper, Kemsley,
Great Britain.
Cartiere Villa Lagarina, Villa Lagarina,
Italy.
Delkeskamp Verpackungswerke,
Nortrup, Germany.
OAO Kiev Cardboard and Paper Mill,
Obukhov, Ukraine.
Papierfabrik Adolf Jass, Fulda,
Germany.
Feinpappenwerk Gebr. Schuster,
Hebertshausen, Germany.

Stock preparation systems
and sub-systems for tissue
papersSCA Tissue, Alsip, USA.
SCA Tissue, South Glens Falls, USA.
Wausau Paper, Rhinelander, USA.
Coastal Paper, Wiggins, USA.
CMPC Tissue, Talagante, Chile.
SCA Hygiene Products,
Mainz-Kostheim, Germany.
Metsä Tissue, Katrinefors Mill,
Sweden.

Stock preparation systems
and sub-systems for dewatering machines
Riau Andalan, Kerinci, Indonesia.
Fox River, DePere, USA.

Paper Machines
Graphic papers
Century Pulp & Paper, Lalkua, India.
Johns Manville, Etowah, USA.
Sun Paper Shandong, Yanzhou,
China.
Phoenix Pulp & Paper, Khon Kaen,
Thailand.
Daio Paper, Mishima, Japan.
Packages, Kasur, Pakistan.

Board and packaging papers
Klabin Monte Allegre, Telemaco
Borba, Paraná, Brazil.

Dewatering machines
Riau Andanlan, Indonesia.
CMPC Celulosa, Santa Fé,
Nacimiento, Chile.

Installation and rebuilds
Kimberly-Clark, Corinth, USA.
Mauduit Tobacco Paper, Jiangmen,
China.
Packages, Kasur, Pakistan.
Oji Paper, Tomioka, Japan.
Hokuetsu, Niigata, Japan.
Coastal Papers, Rajahmundry, India.
Munksjö Paper, Unterkochen,
Germany.
Shinho Paper, Daejeon, Korea.
Genting Sanyen, Selangor,
Malaysia.
UPM-Kymmene, Tervasaari, Finland.
Daeyang Paper, Ansan, Korea.

Lecta Condat, Condat, France.
Neenah Paper Lahnstein, Lahnstein,
Germany.
Nippon Paper, Ishinomaki, Japan.
Shandong Huatai Paper, Dongying,
China.
Jinju, Jinju, Korea.
Holmen Paper, Braviken, Sweden.
JSC Solikamsk Bumprom, Solikamsk,
Russia.
Nippon Paper, Japan.
Sappi, Skowhegan, USA.
Papresa, Renteria, Spain.
CMPC Celulosa, Santa Fé,
Nacimiento, Chile.
Productora de Papeles Propal, Cali,
Colombia.
Trombini Embalagens, Curitiba,
Brazil.
Inpa Ind. de Embalagens Santana,
Pirapetinga, Brazil.
Amcor Cartonboard, Petrie,
Australia.
Kimberly Clark, Mogi das Cruzes,
Brazil.
Botnia, Rio Negro, Uruguay.
VPK Packaging Group, Oudegem,
Belgium.
Pro-Gest, Villa Lagarina, Trient,
Italy.
Ningbo Zhonghua Paper, Zhejiang,
China.
Mondi Packaging, Springs,
South Africa.
SCA Packaging, Aschaffenburg,
Germany.

23 I 2007 I Voith Paper I twogether

HIGHLIGHTSSCA Packaging, Witzenhausen,
Germany.
Les Papeteries de Champagne,
Nogent-sur-Seine, France.

Coating technology
Dongguan Sea Dragon Paper,
Dongguan, China.
Shandong Sun Paper, Yanzhou,
China.
Klabin Monte Allegre, Telemaco
Borba, Paraná, Brazil.
Torraspapel, Sant Joan Les Fonts,
Spain.
Torraspapel, Leitza, Spain.
Mondi Packaging, Springs,
South Africa.
APP, Ningbo, China.
Burgo Marchi, Villorba, Italy.
Phoenix, Khon Kaen, Thailand.
Daio Paper, Iyo-Mishima, Japan.
Packages, Kasur, Pakistan.

Winding technology
Nine Dragons Paper Industries,
Jiangsu, China.
SCA Packaging, Aschaffenburg,
Germany.
Klabin Monte Allegre, Telemaco
Borba, Paraná, Brazil.
Thai Paper, Khon Kaen, Thailand.
Daio Paper Corporation, Mishima,
Japan.
VPK Packaging Group, Oudegem,
Belgium.
Soporcel, Figueira, Spain.

FinishingJanus Concept
Boise Cascade, Wallula, USA.
Daio Paper, Mishima, Japan.
Stora Enso Huatai (Shandong) Paper,
Dawang, China.

Ecosoft calender
Dongguan Sea Dragon Paper
Industry, Dongguang, China.
Yanzhou Zhongtian Paper Industry,
Yanzhou, China.
Thai Paper, Khon Kaen,Thailand.
Laborkalander, Krefeld,
Germany.

Thai Paper, Khon Kaen,Thailand.
Hokuetsu Paper Mills (2), Niigata,Japan.
SCA Packaging, Aschaffenburg,
Germany.

Twister/Roll Handling

Dongguan Sea Dragon Paper,
Dongguan, China.
Mondi Packaging, Springs,
South Africa.
Klabin Monte Allegre, Telemaco
Borba, Paraná, Brazil.
Chuetsu Pulp & Paper, Nohmachi
Mill, Takaoka, Japan.
Sonoco, Hartsville, USA.
IP Pensacola, USA.
Oji Specialty Paper, Nakatsu,
Japan.
Thai Paper, Banpong, Thailand.

Klabin Monte Allegre, Telemaco
Borba, Paraná, Brazil.
Stora Enso, Fors, Sweden.

Voith Fabrics

Parent reel cart
Daio Paper, Mishima, Japan.
Stora Enso, Fors, Sweden.
SCA Packaging, Aschaffenburg,
Germany.

NipcoFlex calender
Koehler Kehl, Kehl, Germany.

Automation

Calenders

Norske Skog Walsum, Walsum,
Germany.
UPM Schwedt, Schwedt, Germany.
Steinbeis Temming Papier,Glückstadt, Germany.
Sappi Alfeld, Alfeld, Germany.
Perlen Papier, Perlen, Switzerland.
Nine Dragons, Guangzhou,
China.
JSC Solikamsk Bumprom,
Solikamsk, Russia.
Holmen Paper, Braviken, Sweden.
Shandong Huatai Paper, Dongying,
China.
SCA Packaging, Aschaffenburg,
Germany.

Dongguan Sea Dragon Paper
Industry, Dongguang, China.
Hansol Paper, Taejon, Korea.
Klabin Monte Allegre, Telemaco
Borba, Paraná, Brazil.
Daio Paper, Mishima, Japan.
Wuxi Long Chen Paper, Wuxi
Jiangsu, China.

Roll cutting machines
Koehler Kehl, Kehl, Germany.
Daio Paper (2), Mishima, Japan.
Klabin Monte Allegre, Telemaco
Borba, Paraná, Brazil.
Stora Enso, Fors, Sweden.

23 I 2007 I Voith Paper I twogether

Chung Loong Shanghai, China.
Lee & Man PM 3, 4, 5, China.
Nine Dragons PM 1, 2, 3, 4, 5, 6, 7,
8, 9, 10, China.
Shandong Asia SSYMB, China.
Guangxi Jindaxing, China.
PT Indah Kiat Pulp & Paper,
Perawang Mill, Indonesia.
PT Aspex Kumbong, Indonesia.
St. Regis Kemsley Mill,Great Britain.
NewPage Escanaba, MI, USA.
Weyerhaeuser Dryden, Ontario,
Canada.
Stora Enso Kimberly, WI, USA.
Boise Paper International Falls,
MN, USA.
Stora Enso, Kvarnsveden, Sweden.
Holmen Paper, Braviken, Sweden.

75

Newsmagazine for theinternational clientele,
partners and friends ofVoith Paper“twogether” is published twice annuallyin German, English, Chinese, Russian and
Finnish. Contributions by independent
authors do not necessarily reflect theopinion of the publisher. Please address
all correspondence and inquiries to theeditor.
Published by:Voith Paper Holding GmbH & Co. KG
Editor:Dr. Wolfgang Möhle, Corporate Marketing
Voith Paper Holding GmbH & Co. KG
Tel. (++49) 07 51 83 37 00
Fax (++49) 07 51 83 30 00
Escher-Wyss-Straße 25
88212 Ravensburg, Germany
wolfgang.moehle@voith.com
http://www.voithpaper.com
Design, layout and typesetting:
Manfred Schindler Werbeagentur
P.O. Box 1243, D-73402 Aalen
www.msw.deIssue 23, March 2007

Copyright 3/2007: No part of thispublication may be reproduced or copied
by any means whatsoever without theexpress permission of the editor.

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